Shubham's Bajaj project

Shubham Bhandari (Department Of Mechanical Engineering)

NORTHERN INDIA ENGINEERING COLLEGE

SUMMER INTERNSHIP

(JUNE-JULY 2015)

AN INTERNSHIP PROJECT REPORT BY:

SHUBHAM BHANDARI

B.TECH. (MECHANICAL ENGINEERING)

BATCH 2012-2016

INTERNSHIP WITH:

BAJAJ AUTO PRIVATE LIMITED

UNDER THE GUIDANCE OF:

Mr. Anirudh Joshi

(Assembly Head)

VEHICLE ASSEMBLY


VEHICLE ASSEMBLY

LINE BALANCING

AND

IDENTIFICATION OF UNDERUTILIZED STAGE

SUBMITTED TO: SUBMITTED BY:SUBMITTED TO: SUBMITTED BY:

SHUBHAM BHANDARI SHUBHAM BHANDARI

HUMAN RESOURCE MANAGER B.TECH (MAE) HUMAN RESOURCE MANAGER B.TECH (MAE)

BAJAJ AUTO PVT LTD. NIEC, IPUBAJAJ AUTO PVT LTD. NIEC, IPU

NEW DELHI NEW DELHI

VEHICLE ASSEMBLY


CERTIFICATE

This is to certify that SHUBHAM BHANDARI, student of B.Tech(Mechanical

Engineering) has undergone industrial training with this company (Bajaj Auto Pvt.

Ltd.) under my supervision and guidance. During the internship he was assigned the

under mentioned tasks:-

Which he …………… (Please write few lines on how the student performed the task,

his conduct and any special contributions)

Date:

Name and Designation:

Signature

Seal/Stamp of the Organization

VEHICLE ASSEMBLY


Acknowledgement

It is a great pleasure to present this report of summer training in BAJAJ AUTO Pvt. Ltd.,PANTNAGAR in partial fulfillment of B.Tech programme under NORTHERN INDIA ENGINEERING COLLEGE, IPU. At the outset, I would like to express my immense gratitude to my training guide, Mr. Anirudh Joshi (Assembly Head).

And my heartiest thanks to Mr. Ashish Pundora (Assistant Manager Vehicle Assembly) for guiding me right from the inception till the successful completion of the training. I am falling short of my words for expressing feelings of gratitude towards him for extending his valuable guidance about “VEHICLE ASSEMBLY STUDY” & support for critical reviews of project & also moral support he had provided me throughout the training.

Besides, I would like to extend thanks to Mr. Rahul Bhatt(Vendor Quality Control) and Ms. Priya Pundir(Senior Engineer) for lending their time and support whenever asked.

Training guide: Trainee:

Mr. Anirudh Joshi Shubham Bhandari

VEHICLE ASSEMBLY


PREFACE

The four year B.Tech Programme is a full time technical course which helps in immense learning of technological aspects, similarly the project helps us in enhancing our learning by adding more to our world of knowledge & summer training is the part of B.Tech to nurture our technical skills.

Bajaj Auto Pvt. Ltd., Pantnagar gave me the chance for exposure to the industrial practices and techniques. Here I got the practical knowledge of many theoretical concepts.

I worked under ENGINEERING DEPARTMENT (VEHICLE ASSEMBLY)

It was a life time experience for which I thank all the staff members of Bajaj Auto Pvt. Ltd., Pantnagar.

VEHICLE ASSEMBLY


ABSTRACTIndustries that utilize the assembly line to obtain their products currently go through great challenges. The first is the need to assemble a large number of product models and their variants in their lines, due to the variety required by the market. Another challenge is the need to maintain an adequate level of manpower occupation and other utilized resources. In this scenario the activity of balancing operations appears. In order to increase the efficiency and reduce the operating costs of the line, balancing activities among workstations are performed. They can be done by different methods, such as: exact, heuristics, meta-heuristics methods, or simulation. In assembly lines that produce more than one model, total and individual assembly times are often different among models, so the operation time of each station varies from model to model. The balancing in lines that produce more than one model can be performed by using the weighted averages of the times of the different models. Another possibility is to use an objective function that considers the imbalance among the models and try to minimize it. Using real data from an assembly line meets the need of a greater amount of practice research in

VEHICLE ASSEMBLY


assembly line’s balancing, because according to Boysen, Fliedner and Scholl, researches using real data represented only 5% of the work on assembly lines balancing. A well-balanced assembly line reduces wastes, such as operator idleness, the need of fluctuating operators, stock, and faulty products, it also decreases the production costs of the unit for the company and allows the company to reduce the price of their products. The objective of this study is to evaluate eight methods of mixed model assembly lines balancing, by applying them to an assembly line of a large-scaled enterprise in the automotive industry. The limitation of this study was the inability to access the real balancing method used by the enterprise, which uses the Maximum Task Time method, however it was not possible to make a comparison between it and the theoretical result.

TABLE OF CONTENTS

Certificate

1. Acknowledgement2. Abstract3. Table Of Contents4. Company Profile

a. Bajaj Company Profile b. Pantnagar Plant

5. Vendor’s List6. Vehicle Assembly7. Line Balancing 8. Revised Balancing of Discover 125 in Conveyor D9. Summary

VEHICLE ASSEMBLY


VEHICLE ASSEMBLY


COMPANY PROFILE

BAJAJ – Company Profile

History

Bajaj Auto came into existence on November 29, 1945 as M/s Bachraj Trading Corporation Private Limited. It started off by selling imported two- and three-wheelers in India. In 1942, his son Kamalnayan Bajaj took over the charge, he not only consolidated the group, but also diversified the group into various manufacturing activities.The present Chairman of the group, Rahul Bajaj, took charge of the business in 1965. Under his leadership, the turnover of the Bajaj Auto the flagship company has gone up from INR.72 million to INR. 120 billion, its product portfolio has expanded and the brand has found a global market of Bajaj Auto Limited is a major Indian automobile manufacturer having a turnover of 120 billion rupees.

The Bajaj Group is amongst the top 10 business houses in India. Its footprint stretches over a wide range of industries, spanning automobiles (two-wheelers and three-wheelers), home appliances, lighting, iron and steel, insurance, travel and finance. The group's flagship company, Bajaj Auto, is ranked as the world's fourth largest two- and three- wheeler manufacturer and the Bajaj brand is well known across several countries in Latin America, Africa, Middle East, South and South East Asia.

VEHICLE ASSEMBLY


Manufacturing Location Bajaj Auto’s has in all three plants, two at Waluj and Chakan in Maharashtra and one plant in Pantnagar in Uttrakhand. Waluj – Bajaj range of Motorcycles and three-wheelers. Chakan – Bajaj range of Motorcycles. Pantnagar – Bajaj range of Motorcycles.

Key Milestone

1945 – Bajaj Auto comes into existence as M/s Bachraj Trading Corporation Private Limited.

1948 – Sales in India commence by importing two- and three- wheelers. 1959 – Bajaj Auto obtains license from the Government of India to

manufacture two- and three- wheelers. 1960 – Bajaj Auto becomes a public limited company. 1970 – Bajaj auto rolls out its 100,000th vehicle. 1971 – The three-wheeler goods carrier is introduced. 1972 – The Bajaj Chetak is introduced. 1975 – BAL & Maharashtra Scooters Ltd. Joint venture. 1976 – The Bajaj Super is introduced. 1977 – The rear engine Auto rickshaw is introduced. Bajaj Auto achieves

production and sales of 100,000 vehicles in a single financial year. 1981 – The Bajaj M-50 is introduced. 1984 – Foundation stone laid for the

new plant at Waluj, Aurangabad. 1985 – Production commences at Waluj, Aurangabad. 1986 – The Bajaj M-80 and the Kawasaki Bajaj KB100 motorcycles are

introduced. 1986 – The Bajaj Sunny is introduced. 1991 – The Kawasaki Bajaj 4S Champion is introduced. 1994 – The Bajaj Classic is introduced. 1995 – Agreement signed with Kubota of Japan for the development of

diesel engines for three – wheelers and with Tokyo R&D for ungeared Scooter and moped development.

1997 – The Kawasaki Bajaj Boxer and the RE Diesel Auto rickshaw is Introduced.

1998 – Production commences at Chakan and India First Four Stroke scooter rolls out of Akurdi.

1999 – Caliber Motorcycle notches up 100,000 sales in record time of 12 months.

VEHICLE ASSEMBLY


2000 – Bajaj Saffire is introduced. 2001 – Bajaj Auto Launched its Premium Bike Segment ‘Pulsar’. 2003 – Bajaj Pulsar DTS-I is launched. 2004 – Bajaj Discover DTS-I and New Bajaj Chetak-4 Strike with wonder

Gear Launched. 2005 – Bajaj Avenger DTS-I launched. 2006 – Bajaj Platina launched, Foundation stone laid for the new plant at

Pantnagar, Uttrakhand. 2007 – Bajaj XCD 125 DTS-I, Bajaj Pulsar 220 DTS-Fi, 200 cc Pulsar

DTS-I launched and Production commences at Pantnagar. 2008 – Bajaj Platina 125 DTS-I and Bajaj Discover 135 DTS-I Upgrade

launched. 2009 – Bajaj Pulsar 150 & 180 upgrade launched. 2010 - BAL achieves BS III norms on entire 2-wheeler range.

Pantnagar Plant VEHICLE ASSEMBLY


HISTORY

Foundation stone- April 2006 Plant Inauguration- 9th April 2007 Commercial Production Start- 9th April 2007

INVESTMENTS

Total investments made into this factory- Rs.1.73billlion (Rs. 173 Corers).

AREA

BAL-Pantnagar Plant Area-60 acres And 180 acres of the plant area has been taken up by 16 vendors to set up a dedicated facilities-and thus ensure seamless integration with the mother plant.

DEPARTMENTS 1. Vehicle Assembly

2. Engine Assembly

3. Paint Shop

4. Production, Planning and Control (PPC)

5. Vehicle Dispatch

6. Utility & Services

7. HR & Admin.

VENDOR’S LIST

S.NO Vendor's S.NO Components VEHICLE ASSEMBLY


Name

1 Varroc 1 Seat

2 R. R. Unit

3 C D I

2 Badve 1 Frame Assembly

2 Silencer

3 Gear Shift Lever

4 Hanger Bracket

5 Engine RH Bracket

6 Engine LH Bracket

3 Pricol 1 Speedometer Assembly

2 Fuel Gauge

4 AEL 1 Front Brake Assembly

2 Rear Brake Assembly

5 Roop Polymers 1 Battery Arrester or Band

2 RR Cover

6 Minda Corp. Ltd. 1 Lock Set

VEHICLE ASSEMBLY


2 Handle Holder

3 Fuel Cap

7 Advik 1 Fuel Cock

8 Minda Industries 1 Handle Bar

9 Lumax 1 Fairing

2 S.P.M. Flap

10 Endurance 1 Front Fork

11 NAPL 1 Frame Assembly

2 Chain Case

12 MMT 1 Frame Assembly

2 Silencer

Vehicle Assembly

Conveyor D Layout :-

VEHICLE ASSEMBLY


Basic Information :-1 Length Of Conveyor 90 m

2 No. of Conveyors 4

3 Pitch time 26.08sec

4 Ideal Production/hr 138

5 Ideal Production /shift 1104

Basic Layout For Vehicle Assembling

Paint shop

PPC Logistics Final Product Dispatch

VEHICLE ASSEMBLY


Assembly Verification

Account Line ENGINE Static test Dynamic test Handling Feeding ASSEMBLY

Material Inflow

STAGES FOR VEHICLE ASSEMBLY

There are mainly 56 stages in Vehicle Assembly, 28 in both Right hand (RH) side & Left hand (LH) side each. They are divided in four zones, namely, Zone1, Zone2, Zone3 and Zone4. Sometimes sub stages are made to distribute the work.

RH SIDE LH SIDE

Loading Kitbin Unloading of Kitbin

Rear Wheel Matching Frame Loading

Carburetor Sub Assembly Flag Loading

Rear Brake Connections Horn Prefitment

Front Fork Tightening Lockset Fitment

Front Fender Prefitment and Tightening

Engine Rear Mounting

Engine Loading and Engine Bracket Matching

Engine Bracket Matching

Front Wheel Fitment Chain Slack Adjustment

Engine Tightening Chain Case Fitment

Front Wheel Tightening and Rear Chain Case Tightening

VEHICLE ASSEMBLY


Wheel Alignment

Silencer Fitment Stem Nut Tightening

Torque Rod Tightening Handle Bar Tightening

Carburetor Tightening Silencer Front Tightening

Cable Routing GSL and Engine Rear Cover Fitment

Clutch Wire Tightening Battery Fitment

Throttle Connections Seat Cowl Fitment

Throttle Lock Connections Battery Connections

Silencer Lower Tightening CDI Fitment

Clutch Connections Relay Connections

Fairing Fitment Fairing Fitment

Fairing Tightening Fairing Tightening

Seat Cowl Front Tightening Petrol Tank fitment

Grab Handle Tightening Front Number Plate Fitting

Kick and Side Panel Tightening Front Brake Connections

Online Inspection Visual Inspection

Vehicle Scanning

PROJECT OBJECTIVE:

1) CREATION OF BALANCING FOR DISCOVER-125 MODEL.2) IDENTIFICATON OF UNDERUTILIZED STAGE OF

CONVEYOR D OF VEHICLE ASSEMBLY OF PHASE 2. VEHICLE ASSEMBLY


BASIC KNOWLEDGE:

UTILIZATION OF STAGE CAN BE CALCULATED BY THE FOLLOWING FORMULA,

UTILIZATION (%) = TIME TAKEN BY STAGE X 100 CYCLE TIME (PITCH TIME)

If the Utilization comes out to be less than 80%, stage is termed as an Underutilized stage.

CYCLE TIME (SEC) = (NO. OF HOURS OF SHIFT) X 60 X 60 IDEAL PRODUCTION PER SHIFT

VEHICLE ASSEMBLY


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LINE BALANCINGProductivityProductivity is the average measure of efficiency of production. Efficiency of production means production’s capability to create incomes which is measured by the formula real output value minus real input value. In simple terms, it is the ratio of outputs to inputs in production. Line Balancing plays a salient role in productivity improvement of assembly line. Assembly line is a sequential progression of the input material that comes with one particular point and one edge. Then it goes to different workstation where operator performs those operations which are required and so on. So at the end, the final assembled product comes out of the line. Thus, balanced assembly line helps the organization by increasing its efficiency, productivity and potential increase in profits & decrease in costs.

Line Balancing Line Balancing is leveling the workload across all processes in a cell or value stream to remove bottlenecks and under capacity stages. A constraint slows the process down and results if waiting for downstream operations and under capacity results in waiting and absorption of fixed costs.

Objective of balancingMatch the production rate after all wastes have been removed from the takt time at each process of the value stream.

TAKT TIME Takt time is the rate at which products or services should be produced to meet the customer demand. The value, in conjunction

Vehicle assembly line balancing And

Identification of underutilized stage


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with current loading (production) rates, is used to analyze process loads, bottlenecks, and excess capacity. The study will indicate which operations are ahead of the demand rate and others that are not, both indicating opportunities for improvement. This is strictly a formula and calculation. Use it to compare your measured "loading" to quantify whether an operation meets, exceeds, and by how much.

The unit of time in the numerator & denominator must be the same.

The numerator, Available Work Time, is often expressed as Minutes/Shift, Seconds/Day, Minutes/Day and so on.

The denominator, Customer Demand R ate, is often expressed as Parts/Min, Units/Shift, Pieces/Day, and so on.

Approach for Balancing of Assembly line:-

1. List the sequential relationships among tasks.

2. Calculate the required workstation cycle time, if it is kept to be constant and then theoretical number of workstations are calculated

3. Choose a primary rule that will determine how tasks are to be assigned in work station.

4. Beginning with the first work station, assign each task, one at a time until no other tasks can be assigned due to sequence or time restriction.

5. Repeat the above step for remaining workstation until all the tasks have been assigned to each workstation.




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6. Evaluate the efficiency of the line balance.

7. Rebalance, if necessary

BALANCING, WITH CYCLE TIME OF CONVEYOR D

(DISCOVER 125 MODEL)




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S.NO

STAGE NAME S.NO

STANDARD OPERATING PROCEDURE (ACTIVITY)

AVG. TIME (IN SEC)

ZONE

1

1 ZERO STAGE 1 INSPECTION OF FRAME BEFORE LOADING.

Total Time

2 BARCODE SCANNING

1 SCAN THE BARCODES AUTOMATIC

2 MAKE PV CARDS(8 AT ONCE)

22

3 PUT PV CARD ON FRAME 3.19

Total Time 25.19

3 NO. PUNCHING ON FRAME

1 PICK UP THE FRAME FROM TROLLEY AND TAKE IT TO MACHINE.

9.2

2 PLACE BEARING RACE ON LOCATOR

3.12

3 PUT FRAME ON LOCATOR

AND CLAMP BY FOOTPADDLE

3.47

4 REMOVE A/C BOX 3.67




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POLYTHENE

Total Time 19.46

4 FRAME LOADING 1 PICK UP FRAME FROM MACHINE WITH TACKLE

5.09

2 LOAD THE FRAME ON CONVEYOR AND MATCH THE COUPLING WITH WHEEL

8.87

3 PICK REAR AXLE FROM KITBIN AND REMOVE CHAIN FROM REAR SPROCKET.

2.23

4 APPLY GREASE ON AXLE AND INSERT AXLE

3.69

5 REMOVE TACKLE AND MOVE BACK

2.25

Total Time 22.13

5 FLAG LOADING BLINKER FITMENT AND TIGHTENING

1 PICK LOADED FLAG WITH TACKLE FROM TROLLEY

3.89

2 PLACE FLAG ON FLAG HOLDER ON CONVEYOR

1.8

3 LOOSEN THE LH AND RH ADJUSTER NUTS

4.25

4 PUT THE BATTERY PAD IN POSITION

1.77

5 PUT THE BLINKER 10.30




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FITMENT AND TIGHTEN THE NUT IN BLINKER FITMENT

Total Time 22.01

6 PAINT AND HANDLE

HOLDER MOUNTING

1 PICK THE PAINT BOTTLE FROM BIN AND APPLY ON THE CHASSIS NO. AND WIPE THE EXTRA PAINT

3.67

2 PICK THE HANDLE HOLDER FROM FLAG AND INSERT THE BOLTS IN IT

8.53

3 PUT THE HANDLE HOLDER ON THE CHASSIS POINT BRACKET

2.40

4 PICK THE BATTERY DRAINPIPE AND POSITION IT WITH ROUTING THROUGH THE DRAIN PIPE BRACKET ON FRAME

7.39

Total Time 21.99

7 FAIRING FITMENT 1 MATCH FAIRING BY INSERTING FAIRING STUD INTO FORK BRACKET AND INSERT BELLOW IN IT.

7.93

2 PICK FAIRING UPPER 4.94




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BOLT FROM BIN AND PREFIT IT ON UPPER SIDE OF FAIRING

3 CONNECT THE TPS COUPLER

5.52

Total Time 18.39

8 ENGINE REAR

BRACKET MATCHING

1 PICK UP TWO BOLTS FROM KITBIN

1.04

2 PICK UP THE FENDER BOLT FROM BIN AND PREFIT ON FENDER

6.79

3 ROUTE THE HARNESS BELLOW

7.12

4 MATCHING OF ENGINE WITH RH MEMBER AND INSERTION OF TWO BOLTS

7.95

Total Time 22.9

9 ENGINE FRONT BRACKET MATCHING

1 PICK UP THE ENGINE FRONT BRACKET FROM KITBIN

1.92

2 PICK UP THE TWO BOLTS FROM SIDEBIN AND INSERT THE BOLTS ON FRONT BRACKET

4.25

3 MATCHING AND INSERTION OF THE

8.41




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FRONT BRACKET WITH THE HELP OF RH MEMBER

5 FITMENT OF BREATHER PIPE CLIP ON ENGINE HEAD

7.76

Total Time

22.34

10 ENGINE UPPER

BRACKET FITMENT

AND TIGHTENING

1 PICK THE ENGINE UPPER BRACKET FROM KITBIN

2.9

2 PICK UP THE TWO BOLTS FROM SIDEBIN AND INSERT

THE BOLTS ON UPPER BRACKET

3.55

3 INSERT THE UPPER BRACKET ON FRAME

3.73

4 PREFIT UPPER BRACKET WITH TWO BOLTS ONFRAME

3.98

5 TIGHTENING OF ENGINE UPPER BRACKET AND ENGINE REAR MOUNTING BRACKET

7.08

Total Time 21.21

11 HORN FITMENT

AND MAGNETO

1 PICK UP THE HORN FROM BIN

3.7




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CONNECTIONS 2 PICK UP HORN BOLT AND WASHER FROM BIN

6.1

3 REMOVE THE TAPE FROMMAGNETO CABLE ANDCONNECT WITH THE COUPLE ROUTING OF STARTOR MOTOR CABLE

14.54

Total Time 24.34

12 CHAIN SLACKNESS

ADJUSTMENT

1 ROUTING OF CHAIN ON ENGINE OUTPUT SPROCKET

2.71

2 ROUTING OF CHAIN ON REAR COUPING SPROCKET. ROTATE THE REAR WHEEL HALF TIGHTENING OF SLEEVE NUT BY GUN ADJUSTMENT OF CHAIN ADJUSTER PLATE AND CHAIN AND AFTER THAT FULL TIGHTENING OF SLEEVE NUT.

11.76

3 TIGHTENING OF LH CHAIN ADJUSTER NUT AND HOLDING OF REAR WHEEL WITH THE HELP OF HOLDING TOOL.

9.53

Total Time 24




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13 REAR WHEEL

HOLDING

1 SPARK PLUG CONNECTIONS

3.83

2 HOLDING OF REAR WHEEL WITH THE HELP OF HOLDING TOOL

4.22

3 MATCHING OF CHAIN ADJUSTER MARKING WITH RH MEMBER. REMOVE THE HOLDING TOOL

6.98

Total Time 15.03

14 CHAIN CASE

FITMENT

1 PICK UP THE CHAINCASE FROM TROLLEY

3.93

2 INSERT THE C/C UPPER SIDE ON SWING ARM

3.21

3 INSERT THE C/C LOWER SIDE ON SWING ARM ON FRAME

4.92

4 MATCHING OF UPPER AND LOWER C/C

5.53

5 PREFIT THE REAR LOWER BOLT OF C/C

4.35

Total Time 21.94

15 CHAIN CASE

TIGHTENING

1 PICK UP THE THREE BOLTS FROM BIN

4.27

2 TIGHTEN THE BOLTS WITH S.O.P BY GUN

15.92




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3 ENSURE MATCHING OF UPPER AND LOWER C/C REAR SIDE

2.23

Total Time 22.42

16 STEM NUT TIGHTENING

1 PICK UP TWO SIDE BOLTS FROM THE BIN.

3.55

2 PREFIT THE SIDE BOLT ON FORK LEG.

5.30

ENSURE PREFITMENT OF STEM NUT.

1.66

TIGHTEN THE STEM NUT BY D.N.R.

2.81

TIGHTENING THE FORK SIDE BOLT BY GUN.

4.48

PREFIT THE SILENCER NUT ON STUD OF ENGINE

5.78

Total Time 23.58

ZONE

2

1 REAR WHEEL

MATCHING

1 PICK THE REAR WHEEL AND

FIT IT ON CONVEYER FIXTURE.

3.19

2 FIX THE PANEL IN REAR FRAME ASSEMBLY

9.50




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3 REMOVE THE SWING ARM RUBBER.

1.20

4 ALIGN THE FRAME ASSEMBLY AND FIT THE ADJUSTER.

4.86

5 PUT THE SPACER AND HELP THE L.H. MEMBER TO FIT THE AXLE AND TIGHTEN THE NUT OF ADJUSTOR.

3.88

Total Time 22.63

2 REAR BRAKE AND CARBURATOR FITMENT

1 PICK THE CLIP FROM THE KITBIN AND PUT IT ON CARBURATOR SPACING

4.48

2 PICK CARBURATOR FROM FLOW RACK AND ATTACHN IT AFTER ROUTING THE CABLES

2.86

3 PICK UP THE SPRING AND WASHER AND FIT IT ON BRAKE ROD

8.72

4 PICK THE DRUM AND FIT IT IN REAR BRAKE ASSEMBLY

4.51

5 PICK A NUT AND TIGHTEN THE BRAKE ROD

4.25

Total Time 24.82




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3 FORK FITMENT AND

TIGHTENING

1 LIFT THE FORK FROM TROLLEY USING THE TACKLE

4.73

2 PUT WALL GUAGE ON FORK AND FIT IT INTO THE FRAME

2.34

3 PUT ANOTHER GUAGE ON TOP

2.36

4 PICK BUST CAP AND LOCKNUT FROM KITBIN

4.67

5 FIT THEM ON FORK AND TIGHTEN THE NUT USING A GUN

5.99

Total Time 20.09

4 BLINKER FITMENT 1 PUT HE BLINKER IN POSITION

5.67

2 PICK THE NUT AND PLACE IT ON GUN

3.62

3 TIGHTEN THE BLINKER TO FORK

4.15

4 ROUTE THE CARBURATOR CABLE AND CONNECT THE

9.48




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SWING ARM WITH NUT

Total Time 22.92

5 FRONT FENDER FITMENT AND

FOCUS PREFITMENT

1 PICK THE FRONT FENDER FROM FLAG AND ALIGN IT IN POSITION

8.53

2 PICK 2 BOLTS FROM SIDEBIN

AND PREFIT THEM IN ODER

TO TIGHTEN THE FENDER

6.86

3 PICK THE NUT BOLT FROM SIDEBIN AND TAKE IT TO FOCUS POSITION

4.43

4 PUT THE BOLT IN HOLE AND TIGHTEN THE NUT

5.78

Total Time 25.6

6 ENGINE MATCHING

AND INSERTION.

1 PICK THE ENGINE FROM TROLLEY USING A TACKLE AND TAKE IT TO THE POSITION

8.19

2 HELP THE LH MEMBER TO FIT THE ENGINE

6.41

3 PICK THE BOLT AND INSERT IT IN THE REAR BRACKET AND PREFIT IT

8.40




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Total Time 23

7 FRONT AND UPPER

BRACKET MATCHING

1 PICK THE FRONT BRACKET FROM KITBIN AND FIT IT. INSERT THE BOLTS TO PREFIT IT

9.45

2 PICK THE UPPER BRACKET AND INSERT IT

7.82

3 PICK BOLTS AND NUTS FROM SIDEBIN AND PREFIT IT

6.61

Total Time 23.88

8 FRONT WHEEL

FITMENT

1 PICK THE FRONT WHEEL FROM TROLLEY AND PLACE IT IN THE POSITION

3.90

2 PICK THE SIDEWAY SPACER AND GUAGE FROM KITBIN AND INSERT THEM

5.60

3 PICK THE FRONT AXLE AND INSERT IT AFTER GREASING

8.61

4 PICK THE WASHER AND NUT AND PREFIT THE WHEEL

5.08

Total Time 23.19




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9 ENGINE TIGHTENING

1 HOLD THE GUN AND TIGHTEN THE ENGINE BOTTOM NUT

4.25

2 TIGHTEN THE REAR BRACKET NUTS WITH THE GUN

7.66

3 TIGHTEN THE FRONT BRACKET NUTS

6.18

4 TIGHTEN THE UPPER BRACKET NUTS

7.77

Total Time 25.86

10 FRONT AND REAR WHEEL TIGHTENING

1 TIGHTEN THE FRONT WHEEL USING THE GUN

6.12

2 PICK UP A BOLT AND WASHER AND PREFIT THE STAY

6.93

3 HOLD THE REAR WHEEL ALIGNMENT GUN AND TIGHTEN THE REAR WHEEL

7.85

Total Time 20.19

11 RIDER STEP FITMENT

1 PICK UP THE RIDER STEP FROM KITBIN AND INSERT TWO BOLTS SET IN IT ON EITHER SIDE

6.52

2 PREFIT THE SIDE STEP IN 8.42




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FRAME AND TIGHTEN THE NUTS USING THE GUN

3 TIGHTEN THE NUT ON TORQUE ROD

2.21

4 TIGHTEN THE NUT ON THE BRAKE ROD

2.45

Total Time 19.58

12 SILENCER FITMENT

1 PULL THE SILENCER ASSEMBLY FROM THE TROLLEY AND PLACE IT IN FRAME BY INSERTING THE SILENCER BRACKET IN STAY

7.89

2 PICK SILENCER REAR NUT AND BOLT

4.17

3 PREFIT THE STAY AND SILENCER TOGETHER

6.22

Total Time 18.28

ZONE

3

1 HANDLE BAR

FITMENT

1 PICK HANDLE BAR FROM TROLLEY

4.04

2 REMOVE RUBBER BAND AND ROUTE THE CABLES

3.85

3 INSERT HANDLE BAR INTO LOWER HANDLE

4.10




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HOLDER

4 PICK HANDLE HOLDER FROM REAR FENDER

5.96

5 TIGHTEN THE HANDLE BAR USING S.O.P GUN

5.87

Total Time 23.82

2 SILENCER FRONT

TIGHTENING

1 TIGHTEN HORN WITH THE HELP OF GUN

2.12

2 HOLD THE SILENCER IN ONE HAND, THEN HALF TIGHT THE SILENCER FRONT RH SIDE

4.26

3 THEN FULL TIGHTEN THE SILENCER LH SIDE

2.42

4 REMOVE TS BOLT FROM TS, INSERT TS WIRE, PREFIT TS BOLT.

12.51

Total Time 21.31

3 R.R COVER AND GSL

FITMENT

1 PICK R.R COVER AND GSL FROM KITBIN. PICK TWO BOLTS FROM SIDEBIN AND INSERT IN R.R COVER

4.64

2 MATCH THE R.R COVER INTO REAR ENGINE REAR

2.71

3 THEN TIGHTEN THE R.R COVER BOLTS

5.88




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4 TIGHTEN BOTH FENDER BOLTS

3.69

5 MATCH GSL INTO ENGINE OUTER SHAFT WITH GSL POSITION. THEN TIGHTEN GSL WITH THE HELP OF GUN.

7.64

Total Time 24.56

4 BATTERY FITMENT 1 PICK THE BATTERY ARRESTOR FROM KITBIN AND FLASHER FROM THE FLAG

2.22

2 INSERT FLASHER INTO BATTERY ARRESTER

2.59

3 PICK BATTERY FROM FLAG. KEEP BATTERY INTO BATERY BRACKET AND MATCH PROPERLY.

5.33

4 MATCH BATTERY ARRESTER INTO BATTERY

4.56

5 PICK 2 BOLTS FROM SIDEBIN AND TIGHTEN THEM.

5.54

Total Time 20.24

5 SEAT COWL FITMENT

1 INSERT FUSE INTO FUSE BRACKET (BATTERY ARRESTER)

3.59

2 PICK SEAT COWL FROM 3.33




`

FLAG

3 INSERT TAIL LAMP COUPLER AND CONNECT IT.

4.90

4 MATCH THE SEAT COWL WITH FRAME

5.64

Total Time 17.46

6 R.R UNIT FITMENT 1 PICK THE R.R UNIT FROM FLAG AND CONNECT ITS COUPLER

6.82

2 PICK 2 R.R UNIT BOLTS FROM SIDEBIN

5.88

3 PREFIT R.R UNIT WITH EARTHING CABLE

4.42

4 TIGHTEN THE R.R UNIT WITH GUN

5.22

Total Time 22.34

7 BATTERY CONNECTIONS

1 ROUTE THE LH BLINKER COUPLER

3.31

2 CONNECT BLINKER COUPLER WITH LH BELLOW

2.64

3 ROUTE THE BATTERY EARHING CABLE

4.55

4 LOOSEN BATTERY –VE TERMINAL AND CONNECT EARTHING

3.50




`

CABLE

5 REMOVE THE BATTERY BOLT

3.16

6 CONNECT THE TERMINAL WITH BOLT COMPLETELY

3.89

Total Time 21.05

8 C.D.I CONNECTIONS

1 TIGHTEN TS BOLTS WITH GUN

5.28

2 PICK C.D.I FROM FLAG 2.95

3 CONNECT C.D.I INTO HARNESS COUPLER COMPLETELY

9.17

4 INSERT C.D.I GOURMETT INTO C.D.I BRACKET

6.62

5 CLAMP IT 1.95

Total Time 25.97

9 BELLOW INSERTION

1 ROUTE HANDLE BAR COUPLER (SWITCH BASE AND CLUTCH SENSOR)

2.45

2 CONNECT BOTH COUPLER INTO LH BELLOW

6.11

3 COVER BELLOW COMPLETELY

4.3




`

4 INSERT BELLOW INTO FAIRNING GAP COMPLETELY AND CLAMP BELLOW

4.47

5 ROUTE THE CLUTCH CABLE

6.12

Total Time 23.45

10 CARBURATOR CAP

TIGHTENING AND

JELLY APPLICATION

1 CARB. CAP TIGHTENING WITH THE HELP OF SPANNER COMPLETELY

9.21

2 CONNECT THE FASHER COUPLE

4.61

3 PICK THE JELLY FROM JELLY BIN, APPLY IT ON BATTERY TERMINAL BOLTS

2.76

4 COVER BATTERY TERMINAL BY BOOT

1.12

Total Time 17.7

11 PETROL TANK FITMENT

1 PICK P.T FROM FLAG AND PLACE IT ON P.T DAMPER

7.91

2 CONNECT P.T COUPLER 2.26

3 MATCH P.T INTO P.T BRACKET

2.72




`

4 ROUTE TS, S.M WIRE, MAGNETO WIRE

7.91

5 CLAMP THE WIRE 2.56

Total Time 23.36

12 SIDE PANEL FITMENT

1 PICK SIDE PANEL FROM FLAG

3.30

2 PICK KEY POLYTHENE FROM KITBIN AMD EMPTY IT ON SIDE PANEL

3.71

3 INSERT SIDE PANEL LOCK INTO THE HOLE AND PICK THE LOCKOUT AND PREFIT IT ON THE LOCK AND TIGHTEN IT WITH SPECIAL TOOL

4.36

4 PICK AND INSERT THE RUBBER GOURMET IN LOCK

3.64

5 PICK THE P.T LOCK AND SIDE PANEL AND INSERT THE P.T LOCK INTO P.T CAP

5.20

6 REMOVE THE KEY AND INSERT KEY INTO SIDE PANEL LOCK AND MATCH THE SIDE PANEL ON FRAME AND LOCK IT

5.84

Total Time 26.05




`

13 FNP(FRONT NUMBER

PLATE) FITMENT

1 PICK FNP FROM KITBIN. MATCH IT WITH FNP BRACKET AND THEN TIGHTEN IT WITH GUN.

5.37

2 CLAMP SPM GOURMET INTO SPM BRACKET

5.17

3 PICK P.T WASHER FROM SIDE BIN AND PLACE IT ON P.T BRACKET

PICK P.T SNAP PIN FROM SIDEBIN AND INSERT IT INTO P.T BRACKET.

10.50

TOTAL TIME 21.04

14 S.P.M TIGHTENING AND FRONT BRAKE CONNECTIONS

1 ROUTE THE SPM CABLE AFTER REMOVING RUBBER FROM IT

2.15

2 MATCH SPM CABLE INTO GUAGE METER

2.31

3 PICK SPM SCREW FROM SIDEBIN AND TIGHTEN SPM CABLE

3.25

4 FRONT BRAKE GOURMET,PIN AND NUT CONNECTIONS

11.2

5 FRONT BRAKE CONNECTIONS

6.8

TOTAL TIME 25.71




`

15 ONLINE INSPECTION

1 INSPECTION OF ALL CHECK POINTS AND DO OK

10.23

2 PUT THE REMARK ON PV CARD IF ANY DEFECT FOUND

3.25

TOTAL TIME 13.48

16 VEHICLE OFFLINE 1 UNLOAD THE FLAG FROM CONVEYOR USING ZIMMER MAN

4.16

PICK THE SCANNER AND SCAN THE ENGINE BARCODE AND VEHICLE BARCODE

5.25

TOTAL TIME 9.41

Zone

4

1 FRONT FENDER

TIGHTENING

1 MAKE THE BLINKER SDEEDOMETER HEAD LAMP CONNECTIONS.

18.03

2 TIGHTEN THE FRONT FENDER NUTS USING THE GUN.

3.54

TOTAL TIME 21.57




`

2 CARB. TIGHTENING

1 POSITION THE BELLOW CLIPS AND TIGHTEN THEM USING THE GUN (BOTH THE CLIPS).

10.64

2 MAKE THE IGNITION COUPLER CONNECTION.

5.71

3 TIGHTEN THE SILENCER REAR NUT IN STAY.

6.38

TOTAL TIME 22.73

3 BELLOW ROUTING 1 MAKE THE FBL AND SWITCH BASE CONNECTIONS.

15.46

2 ROUTE THE BREAK CABLES

3.23

TOTAL TIME 18.69

4 CABLE ROUTING 1 ACCELERATOR CABLE ROUTING.

8.73

2 DRAIN PIPE ROUTING 7.93

3 STARTOR MOTOR CONNECTION.

6.06

TOTAL TIME 22.72

5 CALLIPER FITMENT

1 PICK THE CALLIPER AND CABLE ASSEMBLY FROM FLOW RACK AFTER REMOVING THE GROUMET AND

4.38




`

STOPPER.

2 PICK TWO BOLTS FROM THE BIN AND INSERT THE CALLIPER IN DISK

4.96

3 PREFIT THE BOLTS 4.13

4 ROUTE THE HOSE PIPE AND CLAMP IT

5.54

5 MAKE THE COUPLER CONNECTION WITH BRAKE

3.99

TOTAL TIME 18.62

6 THROTTLE

CONNECTION

1 CLAMP THE ACCELERATOR TIE BAND IN BRACKET

5.43

2 REMOVE THE CAP OF CARBURATOR AND INSERT THE WIRE IN CAP.

10.90

3 PULL THE PLUNGER AND INSERT THE WIRE IN IT ALONG WITH SPRING

7.59

TOTAL TIME 23.92

7 THROTTLE LOCK

CONNECTION

1 INSERT THE PIN IN ACCELERATOR CABLE

8.74

2 INSERT THE CAP AND PLUNGER IN

13.44




`

CARBURATOR

TOTAL TIME 22.18

8 DISC GUARD

TIGHTENING(ONLY

FOR DISC BRAKES)

1 PICK DISC GUARD FROM KITBIN, INSERT CLIP IN IT AND FIT IT IN THE DISC.

5.95

2 PICK A NUT FROM SIDEBIN AND TIGHTEN

10.97

3 PUT A PIN IN THE RIGHT SWING ARM

3.58

TOTAL TIME 20.5

9 STARTOR MOTOR

TIGHTENING

1 COMPLETE THE HORN CONNECTIONS

10.05

2 PUT THE CABLE BOLT IN THE STARTOR MOTOR AND TIGHTEN IT USING A GUN

6.66

3 RVL CABLE CLAMPING BY ZIP TIE

5.59

TOTAL TIME 22.3

10 MASTER CYLINDER

CLAMPING

1 LOOSEN THE MASTER CYLINDER NUTS

5.81




`

2 FIT THE MASTER CYLINDER ASSEMBLY BESIDE THROTTLE

7.43

3 TIGHTEN THE NUTS USING THE GUN

6.15

TOTAL TIME 19.39

11 GRAB HANDLE

FITMENT AND

EARTHING

1 PICK THE GRAB HANDLE FROM FLAG. PICK THE 4 BOLTS FROM SIDEBIN AND INSERT THEM IN GRAB HANDLE

6.91

2 PLACE THE GRAB HANDLE ON SEAT COWL AND PREFIT IT

5.70

3 LOOSEN THE EARTHING SIDE BOLT OF STARTOR AND INSERT THE EARTHING WIRE

5.84

4 TIGHTEN IT USING THE GUN

6.96

TOTAL TIME 25.41

12 CLUTCH

CONNECTION

1 ADJUST THE CLUTCH CABLE AND LOOSEN THE NUTS IN END SIDE OF CABLE.

6.96

2 INSERT THE CABLE IN CLUTCH ASSEMBLY AND TIGHTEN THE RIGHT SIDE NUT. CHECK THE CLUTCH

7.92




`

CONNECTION.

3 TIGHTEN THE LEFT SIDE NUT

3.15

TOTAL TIME 18.03

13 FOCUS TIGHTENING

1 TIGHTEN THE FOCUS NUT USING THE GUN

6.58

2 TIGHTEN THE ADJUSTER NUT

4.37

3 PICK SEAT COWL FRONT BOLTS AND WASHERS FROM SIDEBIN. INSERT THEM IN POSITION AND TIGHTEN THEM USING THE GUN.

11.57

TOTAL TIME 22.52


AND GRAB HANDLE

TIGHTENING

1 PLACE THE SIDE PANEL IN POSITION AFTER PICKING IT FROM FLAG

6.72

2 PREFIT THE SIDE PANEL 3.45

3 TIGHTEN THE FOUR BOLTS OF THE GRAB HANDLE

7.36

TOTAL TIME 17.53




`

15 SIDE PANEL

TIGHTENING AND

KICK FITMENT

1 PICK THE SIDE PANEL SCREW. INSERT IT IN THE SIDE PANEL AND TIGHTEN IT.

12.56

2 PICK THE KICK FROM KITBIN

3.31

3 INSERT IT IN THE POSITION AND PUT A BOLT IN IT. TIGHTEN THE BOLT USING THE GUN

5.85

4 TIGHTEN THE DISC GUARD NUTS(ONLY IN CASE OF DISC BRAKES)

3.51

TOTAL TIME 25.23

16 ONLINE INSPECTION

1 INSPECT ALL FITTED PARTS ONE BY ONE FOR ANY WORK UNDONE.

16-22

TOTAL TIME 16-22




`

WORK LOAD LEVELLING of Discover 125

STAGE 1

STAGE 5

STAGE 9

STAGE 1

3

STAGE 1

7

STAGE 2

1

STAGE 2

5

STAGE 2

9

STAGE 3

3

STAGE 3

7

STAGE 4

1

STAGE 4

5

STAGE 4

9

STAGE 5

3

STAGE 5

70

5

10

15

20

25

30

Cycle time of all the stages

Cycle time of all the stagesAxis Title

Summary:-Vehicle assembly line balancing

AndIdentification of underutilized stage


`

All the stages jotted down, with Percentage Utilization less than 80% can be termed as Underutilized stages. Certain activities from other stages can be shifted to these underutilized stages in order to utilize them well and reduce the work load of other stages.

Stages According To Cycle Time And Utilization

S.No

Stage Name

Cycle

Time(sec)

%Utilization

1 BARCODE SCANNING 25.19 96.58%

2 NO. PUNCHING ON FRAME

19.46 74.61%

3 FRAME LOADING 22.13 84.85%

4 FLAG LOADING BLINKER FITMENT AND TIGHTENING

22.01 84.39%

5 PAINT AND HANDLE

HOLDER MOUNTING

21.99 84.31%

6 FAIRING FITMENT 18.39 70.51%

7 ENGINE REAR 22.90 87.80%




`

BRACKET MATCHING

8 ENGINE FRONT BRACKET MATCHING

22.34 85.65%

9 ENGINE UPPER

BRACKET FITMENT

AND TIGHTENING

21.21 81.38%

10 HORN FITMENT

AND MAGNETO

CONNECTIONS

24.34 93.32%

11 CHAIN SLACKNESS

ADJUSTMENT

24 92.02%

12 REAR WHEEL

HOLDING

15.03 57.63%

13 CHAIN CASE

FITMENT

21.94 84.12%

14 CHAIN CASE

TIGHTENING

22.42 85.96%

15 STEM NUT TIGHTENING

23.58 90.41%

16 REAR WHEEL 22.63 86.77%




`

MATCHING

17 REAR BRAKE AND CARBURATOR FITMENT

24.82 95.32%

18 FORK FITMENT AND

TIGHTENING

20.09 77.03%

19 BLINKER FITMENT 22.92 87.88%

20 FRONT FENDER FITMENT AND

FOCUS PREFITMENT

25.6 98.15%

21 ENGINE MATCHING

AND INSERTION.

23 88.19%

22 FRONT AND UPPER

BRACKET MATCHING

23.88 91.56%

23 FRONT WHEEL

FITMENT

23.19 88.91%

24 ENGINE TIGHTENING 25.86 99.15%

25 FRONT AND REAR WHEEL TIGHTENING

20.19 77.41%




`

26 RIDER STEP FITMENT 19.58 75.07%

27 SILENCER FITMENT 18.28 70.09%

28 HANDLE BAR FITMENT

23.82 91.33%

29 SILENCER FRONT TIGHTENING

21.31 81.71%

30 R.R COVER AND GSL

FITMENT

24.56 97.30%

31 BATTERY FITMENT 20.24 77.60%

32 SEAT COWL FITMENT 17.46 66.94%

33 R.R UNIT FITMENT 22.34 85.65%

34 BATTERY CONNECTIONS

21.05 80.71%

35 C.D.I CONNECTIONS 25.97 99.57%

36 BELLOW INSERTION 23.45 89.91%




`

37 CARBURATOR CAP

TIGHTENING AND

JELLY APPLICATION

17.7 67.86%

38 PETROL TANK FITMENT

23.36 89.57%

39 SIDE PANEL FITMENT 26.05 99.88%

40 FNP(FRONT NUMBER

PLATE) FITMENT

21.04 80.67%

41 S.P.M TIGHTENING AND FRONT BRAKE CONNECTIONS

25.71 98.58%

42 ONLINE INSPECTION 13.48 51.68%

43 VEHICLE OFFLINE 9.41 36.08%

44 FRONT FENDER

TIGHTENING

21.57 82.70%

45 CARB. TIGHTENING 22.73 87.15%

46 BELLOW ROUTING 18.69 71.66%




`

47 CABLE ROUTING 22.72 87.11%

48 CALLIPER FITMENT 18.62 71.39%

49 THROTTLE

CONNECTION

23.92 91.71%

50 THROTTLE LOCK

CONNECTION

22.18 85.04%

51 DISC GUARD

TIGHTENING(ONLY

FOR DISC BRAKES)

20.5 78.60%

52 STARTOR MOTOR

TIGHTENING

22.3 85.50%

53 MASTER CYLINDER

CLAMPING

19.39 74.34%

54 GRAB HANDLE

FITMENT AND

EARTHING

25.41 96.39%

55 CLUTCH

CONNECTION

18.03 69.18%




`

56 FOCUS TIGHTENING 22.52 86.34%


AND GRAB HANDLE

TIGHTENING

17.53 67.26%

58 SIDE PANEL

TIGHTENING AND

KICK FITMENT

25.23 96.74%

59 ONLINE INSPECTION 16-22 61.34%-84.35%

Graphical Representation of Various Stages Vs Utilization

Stage

1

Stage

4

Stage

7

Stage

10

Stage

13

Stage

16

Stage

19

Stage

22

Stage

25

Stage

28

Stage

31

Stage

34

Stage

37

Stage

40

Stage

43

Stage

46

Stage

49

Stage

52

Stage

55

Stage

580.00%

10.00%20.00%30.00%40.00%50.00%60.00%70.00%80.00%90.00%

100.00%

% Utilization

% Utilization




`

THANKYOU



Shubham's Bajaj project

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