SYNOPSIS

DESCRIPTION

PAGE NO

1) Title of the project

2) Objectives of the study

3) Rationale for the study

4) Detailed methodology to be used for carrying out the study

5) The expected contribution from the study

6) List of activities to be carried out to complete the project

(With the help of a Gantt chart showing the time schedule)

7) Lab/equipment and tools to be used

8) Problems envisaged in carrying out the project

9) Theme and target of the project

PREPARED BY: -

G DILEEP KUMAR
Membership no: ST 489009-5
Mechanical Engineering
THE INSTITUTION OF ENGINEERS (INDIA)

APPROVED BY: -

MR. M. Venkata Raju, B.E., F.I.E.

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TITLE OF THE PROJECT

Increase the productivity, safety & reduce human fatigue

during maintenance activity in Sintering Furnace.

Through

PROCESS ANALYSIS & KAIZEN

At

M/s Taegu Tec India Ltd,

(IMC Group)
Cutting tools manufacturing unit,
Bangalore.

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OBJECTIVES OF THE PROJECT

The main objective of this project is to design a trolley for maintenance
activity in Sintering Furnace.
To reduce the maintenance time of furnace & increase productivity
To reduce human fatigue during maintenance activity
To improve safety during maintenance activity
To Improve morale of the people

RATIONALE FOR THE PROJECT

The following are motivating factors for this project:

The Vacuum line through ROUGH VALVE and the MODULATOR

VALVE was getting clogged with wax over a frequency of 10 - 12 batches.
While cleaning the wax in this line it was difficult for the people to handle the
PIPE LINE as it was approximately 50 - 60 kg. In the 5-6 hrs of the
maintenance activity removing and fixing the pipe line would take 1 - 1.5 hrs
and total of FOUR people were required to do this activity.

At present cycle time for this maintenance activity is ~ 5-6 hours

Due to this problem, we are unable to achieve the required production. At

present we require 4 peoples to finish this maintenance activity. We aim to do
the same job with one person, that to with less human fatigue.

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METHODOLOGY
Methodology or procedures followed for developing new trolley for sintering
furnace maintenance activity are as follows

1. Identification of maintenance persons: Receiving the input data from

sintering department people about the routine maintenance activity of
furnace requirement for production, which originally comes after
completing every 10-12 batches.

2. Ideation:
a. Plan for a flexible system which satisfies majority of shop floor
production requirement.
b. Studying the feasibility of concept design for maintenance activity.
c. Analyzing the existing method carried during the maintenance activity in
the production line
d. Confirming the safety requirement of the shop floor
3. Refinement: Selecting suitable optimum cost design

3. Concept design: Establishing geometric model. Preparing solid models

and drawings using CAD system (CATIA V5)

4. Analyze: Performing engineering calculations to refine the design

5. Implementation: Building. Conducting field and life test runs

6. Conclusion and recommendations

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EXPECTED CONTRIBUTION FROM THIS PROJECT

1. Meeting the daily and peak production requirement

2. Establish a safe working environment
3. Develop a user friendly system
4. To reduce the maintenance time of furnace & increase productivity
5. Increase in production
6. To Improve morale of the people

LIST OF ACTIVITIES
Gantt Chart

Sl.no. Activities
1
Selection of Project
Analysis of Problem in
Project
2
Submission /Approval of
3
Synopsis
Study of Furnace /
4
Maintenance activity
5
Concept Design of Trolley
6
Check for Feasibility
7
Final Design
Quotation and Order at
8
Supplier
9
Inspection and trails
10
Process Capability study
Final Conclusion and
11
submission of project

December
Dates
12 ~
19 ~
26 ~
18
25
31

Page 5 of 7

1~
8

January
Dates
9~
16 ~
15
22

23 ~
29

LAB/EQUIPMENT AND TOOLS TO BE USED

1. Sample acme thread bolts and nuts for development of trolley design to
do trails.
2. CATIA V5 software for preparation of 3D models and 2D
manufacturing drawings.
3. Vendor fabricates the parts and assembly done in house for model
building and testing.

MEASURING TOOLS TO BE USED

1. Digital Vernier Caliper

2. Measuring Tape
3. Stop watch

PROBLEMS

ENVISAGED

IN

CARRYING

OUT

THE

PROJECT

Finalizing guide pillar for design of a trolley is the key element in this
project, from initial concept to final concept is done thru trial and error method
which was difficult.

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THEME & TARGET

Reduce the cycle time of rough line cleaning activity by introducing the
new trolley through process analysis and kaizen.

Maintenance Activity Cycle Time

Time ( hours)

6
5
4
3
2
1
0
Series1

Series1

5
1
Before

Target

After

KEY REFERENCES
Cemented Tungsten Carbide - By Gopal S. Upadhyaya
www.diliplifttruck.com
Cranes and Derricks, Fourth Edition by Jay Shapiro.
http://en.wikipedia.org/wiki/Material_handling_equipment
http://www.lightlift.com/
Total Quality Management - By Subburaj Ramasamy
Introduction to Ceramic - By W.D. Kingely
Mechanism of Sintering bonds By Dr. R.H. Thupkay
Solid State Sintering By O.P. Khanna
Powder manufacturing, compacting & sintering process By P.C.
Sharma

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