Professional Documents
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Types of Shock Absorber
The shock absorbers are of many types. It may by operating on friction,
compressed air and hydraulically. Of these, the hydraulic type shock absorber is
commonly used several designs of hydraulic shock absorber have been used such as
direct acting, parallel cylinder shock absorbers are called hydraulic dampers because they
hydraulically dump extra movements on the wheels. The vane type shock absorber has
vanes that rotate in the cylindrical chamber filled with fluid. The direct acting shock
absorber are mostly widely used and it consist of three concentric tubes ie. Cylinder tube,
reservoir tube and dust tube and a piston together with valves, seals gaskets etc.
In the case of mopeds and motorcycles, the front wheel has fork fronts in lieu of
shock absorber. Functionally both of them are used for the same purpose but since
technology differs in the manufacture of each, they are classified as forks and shox
respectively. However in India most of the shock absorber manufacturers fork fronts.
As strut is suspension link between the chassis of a car and wheel assembly. It
comprises of coil spring and shock absorber. Being a load bearing member, it basically
acts as safety item last longer and cost more than shock absorber as it can withstand a
higher load it is basically used in passengers cars, jeeps, and LCVs.
Working of Shock Absorber
Shock absorber work on the principle of ‘Compression/Expansion of cylinder and
piston to provide comfortable ride.’ As the shock absorber moves on the odd/even
surface, it will shorten or elongate and compress filled fluid ie shock absorber oil. When
shock absorber shortens, piston rod forces the piston down into the cylinder tube, thereby
putting the fluid below the piston. At the same time, it creates vacuum in the cylinder
tube above the piston. The fluid is forced through small orifice, or opening in the piston,
and into upper part of the cylinder tube. On the rebound when the wheel moves
downwards after passing into a hole or bumb road, shock absorbers extended. As this
happens the piston moves into upper part of the cylinder tube, thereby forcing fluid from
upper into lower part of the tube.
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Functions of Shock Absorber
A shock absorber is a device that resists motion. Because it does that, it is used in
a wide variety of applications to stop unwanted motion to provide safe control of a
necessary motion to provide a measured response to a given energy input.
The most common application of shock absorber is in a vehicle suspension, where
pumps in the road start a bouncing motion in the wheels (unsprung mass) and the body
(sprung mass). While the suspension motion required to negotiate the bump is allowed by
the springs subsequent oscillation of the wheels and body are unwanted. Therefore, a
shock absorber is connected between the axle and the body to minimize the extra body
bounces or wheel hops. In this application it is often called a spring damager.
There are sizes for any suspension from gold carts to heavy duty trucks. Trucks
cab suspension and seat suspension are called upon to provide further isolation for the
driver from road (or off-road) bumps and these, too use shock absorbers to damp out
unwanted extra oscillations. Steering inputs from the driver to the road wheels are
necessary to control the direction that a vehicle will move, but sudden impacts from the
road feeding back to the steering wheel can tire the driver and jeopardize the safe
progress of the vehicle. A shock absorber, called a steering damper, connected between
the frame and the steering linkage, can permit the necessary slow steering motion with
little extra effort and yet respond strongly to control sudden feedback from the road
thereby helping to keep the vehicle safely on course. When a spring loaded device is
unlatched it may tend to pop into a new position very rapidly, like a jack-in-the-box. A
shock absorber is sensitive to stroking speed and this makes it useful in exercise slowly
with only a slight effort, but as the tempo increase so the shock absorb resistance increase
providing a measured response to the energy input.
A shock absorber is in fact an energy absorber because it absorb the excess energy
in system to stop the motion or control the action. This energy show up as heat in the
shock absorber, causing its temperature to rise until heat dissipates into the atmosphere.
6.2 Description of Existing Production System
After buffing piston rods are 100% inspected for surface defects i.e. free from
dents, scratch marks, grinding marks, material defects. The inspection is carried out
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visually. Surface roughness is also inspected once/shift on surface tester (0.08 to 0.2
microns)
After inspection, piston rods are sent for assembling the shocks in various cells.
For assembling the shocks, there are three cells in Gabriel –
a. B Cell
b. NB Cell
c. E Cell
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action also tend to improve the physical property of the surface by compressing its grain
structure, thereby increasing its tensile strength. Burnishing does not remove the metal.
In Gabriel, burnishing carried out is hydraulic ball burnishing. It is carried out for
straightening the inner tube, in which piston can move easily without objectionable
irregularities. It consist of a hydraulic cylinder which can generate pressure upto 25 bar.
The motion of hydraulic assembly is transferred to quick change pusher rods which
pusher the standard ball into the hollow tube for burnishing. Burnishing machine frame is
also provided with guide rods, whose function is to guide the motion of pusher rod, else it
may not move straight. Also we have V-block with square magnet to hold inner tube acts
as further and inductive proximity switches which controls the lengths or motion of
pusher rod.
4. Ultrasonic Washing Machine
Ultrasonic washing is a process of removing material by the action of abrasive
particles vibrating in a liquid slurry which circulates through a narrow gap b/w the work
piece and a tool. It is used for washing in a tube and piston head, thus, removing
unwanted material so that the movement of piston head in a inner tube is smooth.
Chemical used for washing Trichloro Ethylene, machine used in Gabriel has a capacity 6
buckets, each buckets has a capacity of 45 tubes. At a time, 3 buckets can be washed.
Motion of buckets is through chain drive.
5. Piston Swedging
Piston Swedging is hydraulically operated through which piston head is
assembled with recoil spring by applying the pressure of 100 – 120 Kg/Cm2
1. Protector : It distributes the damping force equally on piston head
2. O- ring / Piston ring : According to the product specification we can have any
one of them. It prevents leakage.
3. Carrier : Carrier protector and O-ring. It also carries the slot for the fluid flow.
4. Valve spring : It helps in flow of fluid during compression.
6. Marking Machine
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Through hydraulic press, inter tube marking is done. Product no., licence no.,
trade mark etc. are marked on inter tube. System pressure for hydraulic press is 40-50
Kg/Cm2
7. Inter Seam Welding
Resistance welding produces a series of overlapping spot welds on work pieces.
The work is gripped b/w two narrow wheels that serve as electrodes. The current passes
and flow is interrupted to form a distinct line of weld nuggets. Wheel rotational speed,
pressure and current flow are carefully regulated to produce the desired weld pattern.
Seam welds generally overlap to create a water or airtight joint. Through this process,
inter tube cap is welded with inter tube.
8. Lower Mounting Projection Welding
Resistance projection welding employs special spot welds in which the placement
of the weld nuggets is controlled by projection on one or both of the work pieces. The
parts to be welded are held under pressure b/w electrodes, but contact each other only at
projections. The metals of area of contact are melted to form the weld nuggets. This
welding enables two or more spot welds to be made at the same time with one pair of
electrodes. In this plant, according to product specification, either stud or eyering is
welded on the inter tube cap.
9. Lower Mounting Arc Welding
To provide additional strength and toughness to the joint made by projection
welding metal inert gas welding is carried out. This employs the heat of an electric arc
b/w the work piece and a consumable electrodes that supplies the filler metal. It is type of
gas shielded arc welding and consequently no flux or coating is used on the filler
material. Welding take place in an atmosphere of gas that shields the metal from the air.
Gas used here is Co2
Flow rate with Co2 – 10 – 14 LPM
Wire feed rate – 3.0 – 4.0 M/Min
Current – 180 – 260 Amp
Voltage – 22 – 30 Volts
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10. Inter Tube Leak Testing
During the operation, inter tube is filled with air, while it is submerged in water,
hence this process shows presence of any holes or cracks in the tube through which
leakage can occur.
11. Compression Head Pressing
Compression head is press fitted with inner tube through hydraulic press. Later it
is put in the inter tube.
12. Oil Filling
Servo shocam is filled inside assembly of inner and inter tube. The volume to be
filled varies according to be product specification and damping force that is to be
generated.
13. Upper Mounting Projection Welding
This weld joint is made to join dust tube cap, eyering/stud and piston rod.
14. inside Arc Welding
This joint is make the above mentioned joint more tough and impact proof. This
welding is done on the inner surface b/w dust tube and piston rod.
15. Upper Mounting Arc Welding
Again to make the above mentioned joint strong, arc welding is carried on the
outside surface b/w dust tube cap and eyering or stud.
16. Piston Rod Assembly
After joining piston rod with dust tube capo. It is assembled with piston head
coming from piston swedging machine, as shown in the layout. During this assembly
following components are assembled, beginning from piston head end.
a. Inter cylinder head
b. Vilton / Nitrile seal – to prevent oil from leakage
c. Packing washer and packing spring – to protect the seal.
d. Inner cylinder head + oil seal
e. Piston stop – aiding compression spring
f. Piston head, it is tightened through biding agent 638 lock tight.
17. Torquing
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After assembling piston head with rod, torque is carried out. This ensure further
fixing of piston head with piston rod by applying torque.
Hydraulic system pressure
6 lac 20 – 26 Kg/Cm2
7 lac 26 – 30 Kg/Cm2
4 lac 30 – 36 Kg/Cm2
8 lac 35 – 40 Kg/Cm2
18. Inter and Piston Rod Assembly
After torque, inter tube assembly is combined with piston rod assembly shown in
layout.
19. Damping Force Testing
This machine is known as mytimaster, it is used for resistance checking during
rebounce and compression. The assembled shox is held b/w fixtures and then hydraulic
pressure of 100 – 140 Kg/Cm2 is applied, stroke length is 40 – 50 mm, to get a plot b/w
displacement and force as shown. Velocity is also calculated. Thus plot made should be
within the given standards.
20. Spinning
Vertical spinning machine is used for closing inter tube with the help of roller, the
spinning shox inter tube is bent on inter tube cap, thus enclosing inner and inter tube
assembly. For this system pressure 18 – 25 Kg / Cm2 and job holder pressure is
18 – 22 Kg/Cm2
21. Dust Tube Cap Seam Welding
In this last assembly operation, dust tube is welded with dust tube cap, hence
completing the assembly.
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6.3 Implementation of CONKAN System
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6.3.1 Collecting of Data from shop floor
In this step firstly we prepared the detailed operational Process chart and also
collect the information regarding production per shift.
Operation Process Chart
An operation process chart shows only the operations and inspections performed
during a Process. The process is not difficult, however it is time consuming. It provides a
step by step image of work flow, systems, procedures, and volumes. It reveals the
relationships between the tasks. Extending this approach to the entire production system
and focusing in on the mainstream activities that add value is key. Each of the steps can
be further decomposed into smaller activities. By providing the output, such as
transferring information, from smaller activities much sooner to the subsequent smaller
activities, time can be compressed. The greatest advantage of an operation process chart
is its simplicity; it enables the methods to visualize the relationship between operations or
processes without showing the sometimes confusing material handling activities. Firstly
we converted the existing production system into operation process chart as explained in
figure 6.2
6.3.2 Calculation the KANBAN & CONWIP size for implementation of models
In this case study we implemented all the models into the same production cell
and for implementation of different model we prepared the process chart according to the
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proposed model and then with the help of proposed calculation system ,we calculated the
card size according to the production line requirements.
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Figure 6.3: CONKAN COMMON CONWIP SYSTEM WITH LINE KANBAN
In assembly concepts, distinct part flows maintain at some point along the flow
path. These connecting points are assembling stations where two or more sub assemblies
are assembled or manufactured to form a whole product. In this form we utilized
CONWIP card for controlling on entire assembly line and KANBAN card for one-by-one
step.
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Figure 5.4 CONKAN COMMON CONWIP SYSTEM WITH LINE
KANBAN&CONWIP
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CONWIP, it needs to delay for the other pointer in alignment to release the raw material
into stage 1.
This way the customer demand information is moved upstream by KANBAN signal and
moved to the first stage by the CONWIP signal. If at some stage n a completed part is not
accessible in Bn, no card is moved upstream and the authorization for issuing a part
upstream is temporarily stopped; it is restarted when a part becomes available again in Bn
furthermore, this CONWIP control will limit the total WIP in the system because even if
there is a free card at the first stage, the raw material will not be issue except the total
work-in-process of the entire system is underneath the CONWIP limit.
This control is a hybrid control means that depends on parameter per stage,
namely kn, n = 1,…, N and one added parameter for the whole system, C and different
line card like C1,C2,..Cn. The number of KANBAN and CONWIP influence both the
transfer of completed components downstream through the system and the transfer of
parts upstream through the system.
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Figure 4.17: CONKAN WITH LINE CONWIP & LINE KANBAN
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6.4.4 Implementation of Model 4 (CONKAN MULTI CONWIP WITH LINE
KANBAN & LOOP CONWIP) into Existing production system
Figure 6.6: CONKAN MULTI CONWIP WITH LINE KANBAN & LOOP CONWIP
In this model we used Individual CONWIP card for each assembly line
separately. Single CONWIP C1 for one subassembly line with main assembly line other
C2( CONWIP card) for second sub assembly & Main Assembly line. In this Model on
the main subassembly line two CONWIP card will work simultaneously and by this
method we can provide the better control system in assembly line where the sub assembly
line is big and important. As shown In Figure 4.18 ,C1 & C2 providing the control on
subassembly line and main assembly line but by providing two extra CONWIP Card C3
& C4 we will also provide the control on sub assembly line separately.
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In the model of a CONKAN control principle having two subassemblies lines
,line B11…B1n & B22…B2n is the output buffers of stage n containing completed
components, stage n KANBAN’s and CONWIP cards(C1, C2, C3, C4,…,Cn). Line K1n
& K2n comprises stage n KANBAN’s and comprises CONWIP cards. When the system
is in its primary state, line B1n comprises k1n stage2 finished components, each part
having a stage2 KANBAN and a CONWIP card attached to it. Line B21 contains k2n
stage2 finished parts, each part having a stage2 KANBAN and a CONWIP card adhered
to it.
In this model also addition of all KANBAN card is larger than or identical to the
sum of CONWIP cards (C1, C2, C3, C4,…,Cn). Normally this control operates as
follows. When a customer demand arrives at the system it connects line D requesting the
issue of finished product from line B1n or B2n.
This way the customer demand information is moved upstream by KANBAN signal and
moved to the first stage by the CONWIP signal. If at some stage n a completed part is not
accessible in Bn, no card is moved upstream and the authorization for issuing a part
upstream is temporarily stopped; it is restarted when a part becomes available again in Bn
furthermore, this CONWIP control will limit the total WIP in the system because even if
there is a free card at the first stage, the raw material will not be issue except the total
work-in-process of the entire system is underneath the CONWIP limit.
This CONKAN model is a hybrid control means that depends not only on one
parameter per stage, namely Kn, n = 1,…, N and one added parameter for the different
line like C1,C2 ,C3,C4….Cn, The number of KANBAN and CONWIP cards influences
both the transfer of completed components downstream through the system and the
transfer of parts upstream through the system.
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Figure 6.7: System for New CONKAN System
In this System by the filling of data entry form, we can calculate the desired number of
cards.
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Figure 6.9: Identification form in System
In the CONKAN , system generated the report of KANBAN & CONWIP Card and the
inventory level.
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Once we calculated the quantities needed to support the production requirements, we
designed the CONKAN system .For designing of KANBAN & CONWIP card we used
the System the we selected the signaling mechanism for the CONKAN & Created a
visual management plan for the CONKAN Production system
In this case study we have focused on six factors i.e. production, rejection,
breakdown time, line inventory, throughput and OEE. This case study was conducted through
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a series of observations, in-depth interviews, and documentation reviews. We examined the
Production capacity, machine failure time, WIP both before and after the implementation of
the different CONKAN Models and then analyzed the impact that this model on existing
production system. In this section first of all we collected observation regarding existing
system. In this observation we have observed fifteen shifts in which each shift contains
four hundred and twenty minutes.
In this case study firstly we examined the existing system and after the analysis of the
same we have implemented the KANBAN Production System. In table 5.2 we discussed
the results of implementation of KANBAN System and concluded that there are some
difference in the results of the existing system and KANBAN System. In the KANBAN
System six factors are improved. The increased factors are Production, Throughput and
OEE and the factors decreased are Rejection, Breakdown Time and Line Inventory. The
comparison has been already showed in the tables _____ and ______.
The table 1 presents the results of production system from implementation of
KANBAN in the assembly area.
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Table 6.2: Summary Sheet of KANBAN production system
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Table 6.3: Summary Sheet of CONWIP Production system
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Implementation of CONKAN COMMON CONWIP SYSTEM WITH LINE
KANBAN (MODEL A)
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CONKAN COMMON CONWIP SYSTEM WITH LINE KANBAN (MODEL A) with
the existing system we have implemented CONKAN COMMON CONWIP SYSTEM
WITH LINE KANBAN&CONWIP (MODEL B) with the existing system. Now we came
to the conclusion that the results of implementation of KANBAN System, CONWIP
System and CONKAN COMMON CONWIP SYSTEM WITH LINE KANBAN
(MODEL A) respectively were found better but the results of implementation of
CONKAN COMMON CONWIP SYSTEM WITH LINE KANBAN (MODEL A) and
CONKAN COMMON CONWIP SYSTEM WITH LINE KANBAN&CONWIP
(MODEL B) were very similar. Some of the factors in the six factors we have focused
were increasing and some were decreasing, like Breakdown Time, OEE and Throughput
is low and production is high in CONKAN COMMON CONWIP SYSTEM WITH LINE
KANBAN&CONWIP (MODEL B) in comparison to CONKAN COMMON CONWIP
SYSTEM WITH LINE KANBAN (MODEL A). whereas rejection is almost similar in
both the models.
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Implementation of CONKAN WITH LINE CONWIP & LINE KANBAN
(MODEL C)
The table 2 presents the results of production system from implementation of
CONKAN WITH LINE CONWIP & LINE KANBAN (MODEL C) Production System
in the assembly area. If we compare this model with CONKAN COMMON CONWIP
SYSTEM WITH LINE KANBAN (MODEL A) and CONKAN COMMON CONWIP
SYSTEM WITH LINE KANBAN&CONWIP (MODEL B) we came to the conclusion
that Breakdown time in MODEL A is highest but it is lowest in MODEL B. but
production is high MODEL B but similar in MODEL A and C. Throughput is highest in
MODEL A, lowest in MODEL B but varying in MODEL C. OEE is highest in MODEL
C and Second highest in MODEL A. But in case of rejection all three models are almost
similar.
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Implementation of CONKAN MULTI CONWIP WITH LINE KANBAN &
LOOP CONWIP (MODEL D)
The table 2 presents the results of production system from implementation of
CONKAN MULTI CONWIP WITH LINE KANBAN & LOOP CONWIP (MODEL D)
Production System in the assembly area. When we compare the last three models with the
MODEL D we can conclude that the Breakdown Timing is highest in MODEL A,
Lowest in MODEL B but similar in MODEL C and D. Production is MODEL B & D is
high but results similar in MODEL C and A. Throughput is highest in MODEL A and D
and lowest in MODEL B but varying in MODEL C. In case of OEE results, MODEL D
is the highest, MODEL C is the second highest, MODEL A stands at the third highest and
MODEL B stands at the lowest level.
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6.7 Results and Discussion
We record & examined all the related data and after that we concluded that the
implementation of KANABN system is beneficial from existing but the CONWIP system
work better than KANBAN system.
In CONKAN system’s all models perform very well but no any one model is superior,
6.7.1 Production Comparison
We analyzed that in existing system the average production was 1107 units/ shift,
the minimum production was 1101 unit/ shift and maximum was 1115 unit/ shift. After
the implementation of KANABN it increased up to 1118 Unit/Shift and maximum
Production increased upto 1126 units/shift and minimum was 1107 units/shift.CONWIP
system also increased production upto 1137 units/ shift. After the analysis of figure 5.1
we can conclude that the average production per shift was maximum in CONWIP
system.
When we compared our Models A,B, C& D, We find that in average production in
Model A & C is 1183 units/shift , 1182 Units/shift and in Model B & D average
production was 1190 units/shift.but the maximum production 1193units/shift in model D.
After the analysis of Figure 5.2 & 5.3 we can say that the Model B& C perform well for
increasing in the production.
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Figure 5.13: Production Comparison between All CONKAN Models & Existing system
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6.7.2 Break Down Time Comparison
In existing system the average breakdown time was 69 minutes /shift and maximum
breakdown was 86 minute/shift. After the implementation of KANBAN &CONWIP
SYSTEM the minimum average breakdown time was 60 minute/ shift in CONWIP
system where as in KANABN the Breakdown time slightly increased.
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Figure 6.17: BD time Comparison between All CONKAN Models & Existing system
But when we compared Break down time with existing system, in Existing
system it was 69 Minutes/shift , whereas in Models it goes up to minimum level 61
Minutes/shift.
6.7.3 Throughput Comparison
When we compare between the existing system, KANBAN Production System and
CONWIP system, we came to the point that the throughput found in the existing system
is 3.15 parts/minute, in KANBAN Production System is 3.18 parts/minute and in
CONWIP System the throughput found is 3.25 parts/minute. The details shows the
regular improvement on the implementation of KANBAN Production system and then
CONWIP System.
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Figure 6.18: Throughput Comparison between Existing, KANBAN, CONWIP Models
When we compare the implementation of MODEL A then MODEL B then C and finally
D, we came to the conclusion that the highest throughput we got is from MODEL A i.e.
3.33 parts/minute, Model D also gives the good result as 3.32 parts/minute and is on the
second position, but MODEL B shows the worst result as 3.29 parts/minute.
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Now, if we compare all the four MODELS with the EXISTING System, we came to the
conclusion that all four MODELS gives the better performance then the EXISTING
System as Existing system gives throughput of avg. 3.15 parts/minute but all the four
MODELS gives avg. 3.33, 3.29, 3.31 & 3.32 parts/minute respectively.
Figure 6.20: Throughput Comparison between All CONKAN Models & Existing system
When we come to the comparison of WIP in all four MODELS, we came to the
conclusion that MODEL B & D gives 314 average readings per shift. But MODEL C
gives the highest WIP of 330 per shift and MODEL A gives the average of 328 per shift.
Then, when we talk about the comparison between the four MODELS and existing
System we found the difference, as about 120 per shift WIP found more in existing
System.
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Figure 6.21: WIP Comparison between All CONKAN Models
Figure 6.22: WIP Comparison between All CONKAN Models & Existing system
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6.7.5 O.E.E COMPARISON
The Overall equipment Effectiveness of the existing system is too low in comparison to
the KANBAN Production system and CONWIP system shows more effectiveness then
the existing and KANBAN system. the readings of existing, KANBAN and CONWIP
systems are 71.37%, 72.2% and 73.73% respectively.
The comparison between the four MODELS shows that in Model A it was 76.98 and in B
it increased upto 78.02.
Finally when we compared the all four models then we find out that the maximum O.E.E
in system was 78.04 in Model D and in Model B 78.02.
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Figure 6.24: OEE Comparison between Existing, & CONKAN Models
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Figure 6.25: Rejection Comparison between Existing, KANBAN, CONWIP Models
But if we compared the implementation of CONKAN system, then we find that the
average rejection is decreased up to 100 in Model A, where as in Model D it was 61.
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6.8 Conclusion
The goal of the case study was to implement CONKAN System in the Shock absorber
assembly line. The company has achieved tremendous benefits by implementing the
CONKAN System in the assembly area. It dramatically reduced the work in Progress (WIP),
break down time and rejection of parts. Whereas the throughput and OEE increased
significantly.
This case study showed that if we implemented the KANABN system & CONWIP system
then performance is increased but we implement the CONKAN system with all four models,
then the result showed that all models perform very well as compared to existing system and
all other control systems.
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