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    Initially Front and Rear dowel holes were made on machines no. 1828 (Drilling) and 1731 (Finishing). From past few months deviation of dowel hole w.r.t crank bore was occuring on machine 1828 as the machine life was ending. So new machine were installed 7110 and 7111 both are CNC machines with automated conveyor. The cycle time for the line should be 136 secs as per tact time as against machine cycle of 146 secs.

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    Initially Front and Rear dowel holes were made on machines no. 1828 (Drilling) and 1731 (Finishing). From past few months deviation of dowel hole w.r.t crank bore was occuring on machine 1828 as the machine life was ending. So new machine were installed 7110 and 7111 both are CNC machines with automated conveyor. The cycle time for the line should be 136 secs as per tact time as against machine cycle of 146 secs.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
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    19 views16 pages

    Project 1

    Uploaded by

    Nikita Awasthi
    Initially Front and Rear dowel holes were made on machines no. 1828 (Drilling) and 1731 (Finishing). From past few months deviation of dowel hole w.r.t crank bore was occuring on machine 1828 as the machine life was ending. So new machine were installed 7110 and 7111 both are CNC machines with automated conveyor. The cycle time for the line should be 136 secs as per tact time as against machine cycle of 146 secs.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    of 16

    Mahindra & Mahindra Ltd.

    - Kandivali

    CHAPTER 2

    DE-BOTTLENECKING OF 7111 MACHINE

    M.H.S.S C.O.E- Byculla

    Page 30

    Mahindra & Mahindra Ltd. - Kandivali DE-BOTTLENECKING OF 7111 MACHINE


    2.1PROBLEM: - Identification & Definition Problem Selected:
    Reduction of Cycle time of TAL (7111) Machine (CNC).

    Project Title:
    To reduce the machining time of TAL machine by more than 10 secs to balance the line.

    Project Need:
    Initially Front & Rear dowel holes were made on machines no. 1828 (Drilling) & 1731 (Finishing). From past few months deviation of dowel hole w.r.t crank bore was occuring on machine 1828 as the machine life was ending. So new machine were installed 7110 & 7111 both are CNC machines with automated conveyor. The problem of deviation was solved but the cycle time was more compared to old machine. The cycle time for the line should be 136 secs as per tact time as against machine cycle of 146 secs.

    Project Target:
    To reduce the Cycle time from 146 secs to 136 secs. To improve O.E.E.

    M.H.S.S C.O.E- Byculla

    Page 31

    Mahindra & Mahindra Ltd. - Kandivali


    Operation Performed:

    Front face dowel hole 9.42/9.38

    Rear face dowel hole 7.8/7.84 Rear face dowel hole 12.564 0.019 Rear face dowel hole 20.0 0.033

    M.H.S.S C.O.E- Byculla

    Page 32

    Mahindra & Mahindra Ltd. - Kandivali


    Initial sequence of operation:-

    Operations
    Tool change & Rotation of pallet by 90 Drilling on front face dia. 9 Tool change Hole milling on front face dia. 9.4 Tool change Delay due to fixture index 180 Drilling on Front & Rear face dia. 7.5 Tool change Hole milling on Front & Rear face dia.7.8 Tool change Drilling on Rear face dia. 11.5 Tool change Hole milling on Rear face dia. 12.5 Tool change Drilling of dowel hole on Rear face dia.20

    Speed (RPM)
    5299 2030 6359 1830 4500 1650 2200

    Feed (MM/Min)
    1060 609 1145 457 800 495 176

    Time (Secs)
    4.5 11.21 4.5 9.37 4.5 17.49 9.34 4.5 11.13 4.5 10.26 4.5 12.8 4.5 12.36

    M.H.S.S C.O.E- Byculla

    Page 33

    Mahindra & Mahindra Ltd. - Kandivali

    2.2 ANALYSIS: - Discovery of Main Root Causes


    Possible causes: -

    Brainstorming: - 4 causes were identified


    Cause & Effect Diagram - (All relevant brainstormed causes)

    Probable causes found in brainstorming session:Loading & unloading time. Operator control. Cutting parameters. Tools used.

    M.H.S.S C.O.E- Byculla

    Page 34

    Mahindra & Mahindra Ltd. - Kandivali


    Testing of Hypothesis:SR. PROBABLE NO. CAUSES
    Loading & 1. unloading time.

    TESTING & OBSERVATIONS.


    As loading & unloading is done through automated conveyor its time cannot be reduced. As the machine is CNC so no manual control is required. No effect on cycle time. All cutting speed ,feed & depth of cut are made optimum. So parameters cannot be changed. The Drill & hole mill used for making dowel hole of dia. 7.8, dia 9.4 & dia 12.5 are used seperately for small causes more cycle time

    CONCLUSION
    Hypothesis Invalid

    2.

    Operator control.

    Hypothesis Invalid

    Cutting 3. parameters.

    Hypothesis Invalid

    4.

    Tools used.

    Hypothesis Valid

    Possible Root Cause (Probable cause where hypothesis proved valid):The tools used for making dowel hole of dia. 7.8, dia 9.4, dia 12.5 can be combined instead of using different tools for drilling & hole milling as it reduces the machining time.

    M.H.S.S C.O.E- Byculla

    Page 35

    Mahindra & Mahindra Ltd. - Kandivali


    2.3 ACTION: - to eliminate the loss The Why-Why Analysis was used to arrive at possible solutions.
    Why-Why Analysis:-

    SR. NO.
    1.

    ROOT CAUSES
    Tools used.

    WHY?
    As the tool used for drilling & hole milling can be combined.

    WHY?

    Recent tools used:-

    SOLID CARBIDE STEP DRILL DIA 7.5h8

    SOLID CARBIDE HOLE MILL DIA 7.8 / 7.84

    M.H.S.S C.O.E- Byculla

    Page 36

    Mahindra & Mahindra Ltd. - Kandivali

    SOLID CARBIDE STEP DRILL DIA 9.0 h8

    SOLID CARBIDE HOLE MILL DIA 9.38 / 9.42

    Development of Remedies:SR. NO. ROOT CAUSE REMEDIAL ACTION TARGET DATE

    1.

    The Drill & hole mill used for making dowel Tools can be combined into a hole of dia. 7.8, dia 9.4 & single tool dia 12.5 are used seperately for small causes more cycle time

    18th Feb - 09

    M.H.S.S C.O.E- Byculla

    Page 37

    Mahindra & Mahindra Ltd. - Kandivali


    Hence it was decided that in order to reduce cycle time the tools used for drilling & hole milling can be combined instead of using separate tools.

    Brief about Remedial Action:For combining tools the design was made & was given to vendor to make the tool as per requirement. Tools made:-

    COMBINATION TOOL CARBIDE 7.8*10*120

    COMBINATION TOOL CARBIDE 9.38*12*110

    M.H.S.S C.O.E- Byculla

    Page 38

    Mahindra & Mahindra Ltd. - Kandivali


    Problems for the remedies:Previous sequence of opeartion:Sr No.
    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

    Operations
    Tool change & Rotation of pallet by 90 Drilling on front face dia. 9 Tool change Hole milling on front face dia. 9.4 Tool change Delay due to fixture index 180 Drilling on Front & Rear face dia. 7.5 Tool change Hole milling on Front & Rear face dia.7.8 Tool change Drilling on Rear face dia. 11.5 Tool change Hole milling on Rear face dia. 12.5 Tool change Drilling of dowel hole on Rear face dia.20

    Limitations:No. of tools used more. Tool setting time more. Cycle time more.

    M.H.S.S C.O.E- Byculla

    Page 39

    Mahindra & Mahindra Ltd. - Kandivali


    Proposed sequence of operation:Sr No.
    1 2 3 4 5 6 7 8

    Operations
    Tool change & Rotation of pallet by 90 Front face dowel hole dia. 9.5 using combination tool Tool change & Rotation of pallet by 180 Rear face dowel hole dia. 7.8 using combination tool Tool change Rear face dowel hole dia. 12.5 using combination tool Tool change Drilling of dowel hole on Rear face dia.20

    Limtations:The combination tool for rear face dowel hole of size 12.5 is difficult to operate properly as dia 12.5 hole is on the weakest section of component. The tolerance on the hole i.e 12.564 0.019 is also strict so it is advisable not to use a combination tool for that operation. So it has not been used in actual practice.

    Actual sequence of operation:Sr No.


    1 2 3 4 5 6 7 8 9 10

    Operations
    Tool change & Rotation of pallet by 90 Front face dowel hole dia. 9.5 using combination tool Tool change & Rotation of pallet by 180 Rear face dowel hole dia. 7.8 using combination tool Tool change Drilling on Rear face dia. 11.5 Tool change Hole milling on Rear face dia. 12.5 Tool change Drilling of dowel hole on Rear face dia.20

    M.H.S.S C.O.E- Byculla

    Page 40

    Mahindra & Mahindra Ltd. - Kandivali


    2.4 Process comparison:The following table shows the operation time of 7111 (TAL) machine before combining tools:-

    Operations
    Tool change & Rotation of pallet by 90 Drilling on front face dia. 9 Tool change Hole milling on front face dia. 9.4 Tool change Delay due to fixture index 180 Drilling on Front & Rear face dia. 7.5 Tool change Hole milling on Front & Rear face dia.7.8 Tool change Drilling on Rear face dia. 11.5 Tool change Hole milling on Rear face dia. 12.5 Tool change Drilling of dowel hole on Rear face dia.20

    Speed (RPM)
    5299 2030 6359 1830 4500 1650 2200

    Feed (MM/Min)
    1060 609 1145 457 800 495 176

    Time (Secs)
    4.5 11.21 4.5 9.37 4.5 17.49 9.34 4.5 11.13 4.5 10.26 4.5 12.8 4.5 12.36

    Machining time:- 125.26. Loading & unloading time:- 21 secs. Total cycle time: 146.46 secs.

    M.H.S.S C.O.E- Byculla

    Page 41

    Mahindra & Mahindra Ltd. - Kandivali

    The following table shows the operation time of 7111 (TAL) machine after combining tools:-

    Operations

    Speed Feed Time (RPM) (MM/Min) (Secs)

    Tool change & Rotation of pallet by 90 Front face dowel hole dia. 9.5 using combination tool 5304 Tool change & Rotation of pallet by 180 Rear face dowel hole dia. 7.8 using combination tool 3260 Tool change Drilling on Rear face dia. 11.5 4500 Tool change Hole milling on Rear face dia. 12.5 1650 Tool change Drilling of dowel hole on Rear face dia.20 2200 176 12.36 4.5 495 12.8 4.5 800 10.26 4.5 392 11.29 22.59 1326 12.38 4.5

    Machining time:- 99.68. Loading & unloading time:- 21 secs. Total cycle time: 128.68 secs.

    M.H.S.S C.O.E- Byculla

    Page 42

    Mahindra & Mahindra Ltd. - Kandivali

    2.5 Results:Graph showing reduction in cycle time:-

    REDUCTION OF CYCLE TIME


    150 145 140 135 130 125 120 115 1

    146 128

    TIME (Secs)

    Before

    After

    M.H.S.S C.O.E- Byculla

    Page 43

    Mahindra & Mahindra Ltd. - Kandivali

    2.6 Benefits:The table shows the cost reduction sheet:-

    M.H.S.S C.O.E- Byculla

    Page 44

    Mahindra & Mahindra Ltd. - Kandivali


    Cost reduction by combining Drill (7.5) & Hole mill (7.8):COST REDUCTION

    14968
    16000 14000 12000 10000

    PRICE (Rs)

    8000 6000 4000 2000 0 1 2

    3724

    BEFORE

    AFTER

    Cost reduction by combining Drill (9.0) & Hole mill (9.4):COST REDUCTION

    15316
    16000 14000 12000 10000

    PRICE (Rs)

    8000 6000 4000 2000 0 1

    4925

    BEFORE

    AFTER

    Reduction in cycle time. Achieved line balancing. Cost saving through combining tools. Reduction in setup time as number of tools reduced. Less inventory of tools.

    M.H.S.S C.O.E- Byculla

    Page 45

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