CHAPTER 5

DEVELOPMENT OF NEW PROCESS

5.1 Introduction
From the study conducted on existing process revels it has identified several things, important are, the cycle time for the production of cub-frame and coolant channel are 1.75 Hrs/component and 1.25 Hrs/component respectively, manual strain of the labors are more because marking time more for the guarding and also the quality of the components produced in the existing process is less and the cycle time can be reduced by adopting the following methods (i) Modification of production process of cub-frame will results in decreases the cycle time and inventory cost materials. (ii) Modification of production process of coolant channel will results in decreases the cycle time and inventory cost of the materials.

5.2 Cub-frame Production Process

Cub-frame manufactured at SMD is depicted in the Figure 5.1. The various operations involved in the manufacturing of cub-frame are cutting, bending, welding and finishing. The sequences of operations in cub-frame production process are depicted in Figure 5.2.

Raw materials for Cub-frame manufacturing: High carbon steel contains from 0.7 to 1.00% C with manganese ranging from 0.5to 0.9% this steel commonly known as spring steels. These steels are generally operated at very high stress and heat treated to obtain the maximum elastic limits and fatigue resistance without becoming sufficient brittle to cause sudden failure in services. Harden ability of spring steel is very important because only fully hardened spring have the maximum resistance to take a permanent set (sagging).

Figure 5.1 Finished Cub-frame

CNC Laser cutting of Cub frame parts

C\T for cutting= 10min Bending of Cub frame parts

C\T for Bending 15min Welding of Cub frame parts

C\T for welding= 20min

C\T for Inspection is 5min

Inspection of cub frame

C\T for Finishing =10min Finishing of Cub frame parts

Figure 5.2 Proposed Cub-frame Production Process

CNC Laser Cutting operation: FANUC- CO2 CNC laser cutting machine is used to cut the sheet metal for the production of cub-frame components. Each cub-frame component consists of cutting operations of different lengths and the total cutting involves 5875 mm in length. The laser cutting operation is computer controlled which gives high production rates and also high accuracy of 0.025 mm. The cycle time required for this operation is 10 min.

Bending operation: CNC bending is a process where cub-frame is bent to an angle using, typically a V shaped punch and die. The sheet is placed between the punch and die which presses down on the sheet. It provides a low cost method to product 3D shapes from 2D sheets and it is a suitable for processing most ductile metals and primarily for sheet metal designs with one or more bends. A large percentage of sheet metal parts are bent along some lines to get them into the desired shape for use. The sheet metal part before it is bent is called a blank. The cycle time required for this operation is 15 min.

Welding operation: Spot welding process is used for Cub-Frame welds in SMD and the different parts of cub-frames are welded with the help of welding fixture. The cycle time required for this operation is 20 min.

Finishing: Hand grinders are used for final finishing operation process for cub-frame, accompanied by a certain amount of metal removal and high surface finishing. The cycle time required for this operation is 10 min.

Inspection: Inspection is carried out to check for the required dimension on all the cub-frame components, after the completion of all the above process. In case of any deviation in the dimensions frames will be sent back for rework. If the required dimensions are achieved it will further sent to the painting division. The cycle time for the inspection process is 5 min. Figure 5.4. The cycle time analysis for the production of Cub-frame components are given the Table 5.1 and the graphs of cycle time verses processes are show in the Figure 5.5.

5.2.1 Operating cycle time of cub-frame

Basically, there are five processes are involved in the production process of cub-frame Sheet metal guarding for a CNC Machine centers. Cycle time presently used in all the production processes were noted which are given in the Table 5.1. The cycle time required to complete one component of cub-frame is 60 min/ 1.00 Hrs and bar chart of cycle time is depicted in Figure 5.3. It is observed that the cycle time required for manual drilling and tapping operation is completely eliminated and it is adopted with the laser cutting machine by taking the advantages of laser cutting and high accuracy.

5.3 Coolant channel Production process in proposed method

Coolant channel manufactured at SMD is depicted in the Figure 5.4. The various operations involved in the manufacturing of coolant channel are cutting, bending, welding and finishing. The sequences of operations in Coolant channel production process are depicted in Figure 5.5.

Raw materials for Coolant channel manufacturing: High carbon steel contains from 0.7 to 1.00% C with manganese ranging from 0.5to 0.9% this steel commonly known as spring steels. These steels are generally operated at very high stress and heat treated to obtain the maximum elastic limits and fatigue resistance without becoming sufficient brittle to cause sudden failure in services. Harden ability of spring steel is very important because only fully hardened spring have the maximum resistance to take a permanent set (sagging).

CNC Laser Cutting operation: FANUC- CO2 CNC laser cutting machine is used to cut the sheet metal for the production of Coolant channel components. Each Coolant channel component consists of cutting operations of different lengths and the total cutting involves 1206 mm in length. The laser cutting operation is computer controlled which gives high production rates and also high accuracy of 0.025mm. The cycle time required for this operation is 5 min.

Sl no Sequence of Operations
1 2 3 4 5 CNC laser cutting Operation CNC bending Operation Welding Operation Finishing Operation Inspection Operation

Cycle Time in min

10 min 15 min 20 min 10 min 5 min 60 min/1 Hrs

Cycle per batch

1200 min 1800 min 2400 min 1200 min 600 min 7200 min/120 Hrs

Total Cycle Time for Cub frame

Table 5.1 Cycle Time in Proposed Production Process for Cub-frame

Cub-frame
25

20

Cycle Time in min

15

10

CT for Laser Cutting

CT for Bending

CT for Welding

CT for CT for Finishing Inspection

Processes
Figure 5.3 Proposed Process Cycle Time for Cub-frame

Figure 5.4 Photo Graph of Coolant Channel

CT for cutting =10min CNC Laser cutting operation Bending of Coolant channel parts

CT for Bending = 15min Welding of Coolant channel parts

CT for Welding 10min

CT for Inspection =5min

Inspection of Coolant channel

CT for Finishing =5min

Finishing of Coolant channel

Figure 5.5 Proposed Process Flow Diagrams for Coolant Channel

Bending operation: CNC Bending machines are used for bending operation Coolant channel production involve any one bending operation. A large percentage of sheet metal parts are bent along some lines to get them into the desired shape for use. The sheet metal part before it is bent is called a blank. The cycle time required for this operation is 15 min.

Welding operation: Spot welding process is used for Coolant channel welds in this division with the help of fixture. The cycle time required for this operation is 20 min to completely weld.

Finishing: Hand grinders are used for final finishing operation process of Coolant channel accompanied by a certain amount of metal removal. The cycle time required for this operation is 5 min.

Inspection: Inspection is carried out to check for the required dimension on all the Cub-frame components, after the completion of all the above process. In case of any deviation in the dimensions frames will be sent back for rework. If the required dimensions are achieved it will further sent to the painting division. The cycle time for the inspection process is 5 min.

5.3.1 Operating cycle time for coolant channel

Basically, there are five processes are involved in the production process of coolant channel sheet metal guarding for a CNC Machine centers. Cycle time presently used in all the production processes were noted which are given in the Table 5.2. The cycle time required to complete one component of coolant channel is 45 min/ 0.75 Hrs and bar chart of cycle time is depicted in Figure 5.6. The flat piece is replaced by circular bush with the inner thread cut and the welding length is reduced.

Sl no
1 2 3 4 5

Sequence of Operations
CNC laser cutting Operation CNC bending Operation Welding Operation Finishing Operation Inspection Operation

Cycle Time in min

10 min 15 min 10 min 5 min 5 min 45 min/ 0.75 hrs

Cycle time per batch

1500 min 2250 min 1500 min 750 min 750 min 6750 min/112.5 Hrs

Total Cycle Time for Coolant channel

Table 5.2 Cycle Time for Production Process for Coolant Channel

coolant channel
12

10 10

10

Cycle Time in min

6 5 5 5

CT for laser Cutting

CT for Bending

CT CT CT for forWelding forFinishing Inspection

Processes

Figure 5.6 Cycle Time of Proposed Production Process for Coolant Channel.

5.4 Comparing the Cycle Time in Existing Process with the Proposed Method of Cub-frame Production Process
Comparing the cycle time and manufacturing cost of the cub-frame process in SMD were carried out, after incorporating the new production flow process and reported that there is a substantial improvement in the cycle time and also in the manufacturing cost of the component, by eliminating the drilling and tapping operation in the sheet metal division and the operation is incorporated with the CNC laser machine and the details is depicted in the Figure 5.11. The purpose of comparison of existing process with the new process development for the manufacturing cost reduction in this process, 66% of the cost is reduced with the new process and also the 45 min of cycle time is reduced, details of this as shown in the Table 5.7 and also product cost V/s batch size as shown in the Figure 5.12.

5.5 Comparing the Cycle Time in Existing Process with the Proposed Method of Coolant channel
Comparing the cycle time and manufacturing cost of coolant channel assembly in ACE designers Ltd were carried out, after incorporating the new production flow process and reported. There is a substantial improvement in the cycle time and also in the manufacturing cost of the component, details is depicted in the Figure 5.13 For the purpose of comparison of existing process with the new process development for the manufacturing cost reduction in this process 55% of the cost is reduced with the new process and also the 30 min of cycle time is reduced, details of this as shown in the Table 5.9 and also product cost V/s batch size is depicted in the Figure 5.14 show the cost comparison of Coolant channel the existing process consumes cost Rs 4050 and the new process consumes cost Rs 2700 with the reduction of cycle time 20 min and the elimination of the drilling time in the existing process of Coolant channel manufacturing and 60% of the cost is reduced and monthly saving is Rs 2847 and the details of about this is as show in the table, the table shows the elimination of flat piece welding length, drilling and threading operation by incorporating the circular bush with inner thread, the cost of the bush is low compare to the flat welding operation.

Sl no 1 2 3 4 5

OPERATIONS RAW MATERIAL COST CUTTING LENGTH IN MTS NO OF BENDS GRINDING LENGTH NO OF BUSHES

BEFORE

AFTER 0.5 2.693 2

DRILL AND TAPPING TIME IN Min 1 2 3 4 5 6 7 LASER CUTTING COST RAW MATERIAL COST BENDING COST

45 MIN

0.0 Rs 37.20 Rs 22 Rs. 4.00

Rs 88.00 WELDING COST LABOUR COST BUSH COST LABOUR COST PER DRILL AND TAP WITH SUITINGS TOTAL COST IN Rs. Rs 48 136.1 Rs. 0.00 Rs. 0.00 Rs. 10.00 0 74.0

TOTAL SAVING PER COMPONENT

Rs. 62.10

NO. OF COMPONENTS PER MONTH

120 COMPONENTS

SAVING PER MONTH

Rs. 7,452

SAVING PER YEAR

Rs. 89,424

Table 5.3 Cost comparison as per the company standards for Cub-frame production

Cycle TimeComparision for CubFrame

50 45 40 35 30 25 20 15 10 5 0 45

Cycle Time in min

2020 1515 1010 0 1010 5 5 Existing method of Cub frame Proposed method of Cub frame Manufacturing

Processes

5.7 Cycle Time Comparison for Cub-frame Production Process

Cost Comparision for Cub-frame

18000 16000 16332 13610 10888 8166 5444 4440 2722 1480 20 40 2960 5920 8880 7400 Cub frame before Cub frame after 14000 12000 10000 8000 6000 4000 2000 0 60 80 100 120

Product cost in Rs

Batch size 5.8 Batch Size Cost Comparison for Cub-frame Production Process

OPERATIONS Sl No 1 RATE/PIECE

FLAT WELD

Rs

BUSH WELD

Rs

7.6

7.6

5.2

5.2

WELD LENGTH IN MTS

52

5.2

25.12

2.5

DRILL TIME MIN

30 Min

14

Total

27

Total

SAVING PER COMPONENT NO. OF COMPONENTS PER MONTH SAVING PER MONTH PER YEAR SAVINGS

Rs 19 150 COMPONENTS Rs 2,847 Rs 34,158

Table 5.4 Cost comparison as per the company standards for Coolant channel Production

35 Cycle time in min 30 25 20 15 10 5 0 1010 5 15 1010

30

5 5 0

5 5

Existing method of Coolant channel Manufacturing Proposed method of Coolant channel manufacturing

Production process

5.9 Cycle Time Comparison for Coolant channel Production Process

Cost comparision for Cub-frame

4500 4000 3500 Product cost in Rs 3000 2500 2000 1500 1000 500 0 30 60 90 Batch size 120 150 810 540 1620 1080 1620 2430 2160 Coolant channel before Coolant channel after 3240 2700 4050

5.10 Batch size Cost Comparison for Coolant channel Production Process

5.6 Future State Mapping

Value stream mapping of the future state identifies the essential and non essential value added activities in the process. The plant works on a continuous basis for 16 hours a day for complete year except for major shutdowns and runs as 2 shift per day of 8 hours each. Figure 5.11 & 5.12 depicts the future state mapping of value stream related to complete production process for cubframe and coolant channel respectively. Small boxes in the map represent the process and each process has a data box below, which contains cycle time (CT), processing time (PT), changr over time (C/O), machines and equipments (MAE), overall equipment efficiency (OEE), number of operators (OP), number of shifts runs per day, production lead time (PLT) at each process. These data were collected by personal observation in the shop floor and talking to operators at each work station. The timeline at the bottom of the current state map has two components; first component is non-value added (NVA) activity, which is sum of each inventory triangle before each process. The NVA for one triangle is calculated by dividing the inventory quantity into daily customer requirements. The lead time for one inventory triangle is calculated by dividing the inventory quantity into the daily customer requirements. Operation wise analysis of NVA, VA, WIP inventory and other critical aspects are discussed.

5.7 Advantages of Proposed Method

5.7.1 Advantages of the Proposed Method of cub-frame manufacturing
Drilling and tapping is completely removed in Sheet metal department. Cycle time will be reduced with the availability of the new process. Manual strain of the labors will reduced in assembly with the elimination of the drilling and tapping. Quality of the materials produced in sheet metal department will be improved with accurate cutting of hole in the machines with the help of laser cutting machines. Manufacturing cost is reduced because of implementing the new process. Wastage of the materials will be less designs of drilling holes will be given by the designing department with that hole will be made according to the design. Drilling problems like over sized or under sized drill will be eliminated with usage of laser cutting machine.

 Labor cost also reduced and also highly skilled labors will be eliminated. Marking time for drill a hole will completely remove.

5.7.2

Advantages

of

the

Proposed

Method

of

coolant

channel

manufacturing
Cycle time will be reduced with the new process of coolant channel manufacturing. Marking and machining of rectangular plate will be completely eliminated. Welding and automation in welding for new process is less because welding length will be less compare to the old process and also the manufacturing time will be less. Manufacturing cost of the component produced is less compare to old process because of the machining cost of the rectangular plate will be more compare to the circular bush Wastage of the material will be completely eliminated with the help of circular threaded bush Quality of the manufacturing component will more compare to the old process Highly skilled labors are not required