OCTOBER 19-20, 2012 - YMCA University of Science & Technology

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Proceedings of the National Conference on Trends and Advances in Mechanical Engineering, YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012 VTM01 is 1526 sec. Due to variation in cycle time of both the machines; the component from the VTM 01 machine gets bottled up in the buffer station due to shorter operation time of the VTL machine From the existing line balancing chart it is clear that there is higher cycle time (918 sec) at second operation VTM 02 compared to customer takt time of 699 sec. To balance the line for customer takt time at VTM 02 machine two operations namely ID roughing and ID finishing are shifted to Horizontal Machining Centre A81 machine. The cycle time of each operation is given in the Table 1. From this change the cycle time at VTM 02 is brought down from 918 seconds to 676 seconds, which gets balanced with customer takt time of 699 seconds which is shown in fig 2. After shifting two operations from VTM 02 to HMC A81 the cycle time at HMC A81 gets increased to 863 seconds which is more than the takt time of 699 seconds. 1000 918 Cycle Time (seconds) 800 600 400 200 719 621 475 Takt Time= 699 0 1st 2nd 3rd 4th Operation Figure 1 Line Balancing Chart of OIB Axle Housing for Existing State Takt Time= 699 Cycle Time (seconds) Operation Figure 2 Modified Line Balancing Chart for OIB Axle Housing To balance the cycle time of HMC A81 machine with takt time four operations namely Dia 80 rough milling, Dia 63 fine milling, Dia 8 drilling and 3/8 turning operations are shifted to HMC A51 machine. After shifting these four operations to the HMC A51 machine the cycle time of machine HMC A81 comes down to 677 seconds which get balanced with customer takt time of 699 seconds. With these improvements waiting time for the material at HMC A51 machine gets reduced. Process inspection is performed at the end of machining work and time taken for process inspection is 60 seconds. 488
Proceedings of the National Conference on Trends and Advances in Mechanical Engineering, YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012 Standardized work for operators and estimation of number of operators Standardization of operations helps in the elimination of variability in the work. With this method each operator is doing the same amount of the work in a line leads better line balancing. The standard loading and un-loading procedures for the operators at OIB Axle Housing cell is provided. Number of operators required to meet the customer Takt time is determined as follows; Number of operators = Total work content in the cell is sum of the cycle time at each machine (Table 1) is 3453.5 secondsandcustomertakt time for OIB Axle Housing Components is 699 seconds Number of operators = = 5 operators 3.4 Line Balancing for IDB Axle Housing At IDB Axle Housing line machining work is carried out for three types of casting components. First operation for three casting components performed in three Horizontal Machining Centres (HMC A81) and second operation is performed in one machine of Horizontal Machining Centre (HMCA51). In order to scale the cycle time of each machine to the customer takt time, machining operations are equally divided in to three machines of Horizontal Machining CentresA81. The operations divided to the each machine are discussed here below. Horizontal Machining Centre [HMC A81/1] Seven machining operations are carriedout at this machine namely; Dia 80 Rough milling, Dia 80 Shell mill , Dia 25 end mill, Dia 63 fine milling cutter, Dia 32 finish end mill, Dia 298.5 rough boring bar and Dia 298.5 s/f boring operations. Time taken to perform these operations in HMC A81/1 machine is given in the Table 2. Horizontal Machining Centre [HMC A81/2] Nine machining operations are carriedout at this machine namely;Dia 40 milling ,Dia 32 3-lip end mill, Dia 25 L end mill, 65 & 71.5 rough boring bar, Dia 95 & 107 rough boring bar, Dia 72 chf, 99.75,112.1 chf , Dia 72 Fine boring, Dia 112.6 fine boring and Dia 250 mill cutter. Time taken to perform these operations in HMCA81/2 machine is approximately equal to the customer takt time of 638 sec. Horizontal Machining Centre [HMC A81/3] Total 13 machining operations are done on this machine namely;Dia 13.5 drilling, Dia 10.5 drilling, Dia 6.8 drilling, Dia 28 drilling, Dia 26.5 U- drilling, Dia 31.3 rough boring, Dia 31.9 fine boring, Dia 27 rough milling, Dia 28.8 rough milling, m12*1.5 taping, m8*1.25 taping, Dia 125 back facing milling and Dia32-42 chamfer. Time taken to carry out these machining operations is also given in the Table 2. Horizontal Machining Centre [HMC A51] Milling operations are performed in this machine and time taken to complete the machining operations in HMC A51 is 8 minutes. At the end of machining operations process inspection is performed on the component and time taken for inspection is 147 seconds. Fig 3 shows the line balancing chart for IDB axle housing. Standardized work for operators and estimation of number of operators Standardizing the workers movements in the cell can eliminates the variability in the process. For the purpose of loading and unloading of the components standard operating procedures are provided to the each operator working at IDB Axle Housing line. Number of operators required to meet the customer takttime; Number of operators = Total work content= 608.4+636.6+627+480= 2351 seconds and customer takt time for OIB Axle Housing Components is 699 seconds Number of operators = =3.6 operators = 4 operators 489
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NATIONAL CONFERENCE ON TRENDS AND A
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National Conference on Trends and A
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MESSAGE I am pleased to learn that
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Sr. No Proceedings of National Conf
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Proceedings of National Conference
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Akash Equipments & Machineries (P)
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3. MATHEMATICAL FORMULATION Proceed
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OUTPUT Proceedings of the National
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6.2 Effect of input factors on Surf
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1 Proceedings of the National Confe
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• Enhanced operational safety •
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3.2 Effect of Different Dielectric
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3. Results and Discussions Proceedi
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S. No. A= Handle B= Box size C= Wor
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II. III. IV. Proceedings of the Nat
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References Proceedings of the Natio
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Sl No. Sequence of operation Table
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‣ Maximize the degree of efficien
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OCTOBER 19-20, 2012 - YMCA University of Science & Technology

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