pg thesis presentation

PRODUCTIVITY IMPROVEMENT IN MANUFACTURING DIVISION OF SHEET METAL INDUSTRY

Guided by : Dr. Gukan Rajaram

KANNAN P

Roll No : 13MM09

E-mail : Kanna1140@gmail.com

Mobile No : 9500254280

PROJECT WORK REVIEW : Phase 2 TITLE

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 1 P S G T E CH

LITERATURE REVIEW

IMPROVING PRODUCTIVITY OF MANUFACTURING DIVISION USING LEAN CONCEPTS AND DEVELOPMENT OF MATERIAL GRAVITY FEEDER

• Productivity improvement is achieved by optimizing the layout.

• Distance travelled by the material in the Proposed layout is compared with current

layout.

• Simulation of current and proposed layout is done by using Witness software to

identify the efficiency of each layout

PROJECT WORK REVIEW : Phase 2 LITERATURE REVIEW

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 2 P S G T E CH

OBJECTIVES

• To achieve reduction in material movement distance for Gilbargo’s CE Carrier

assembly by 20%.

• To identify new spaces for Drilling station and Paint touch up station in powder

coating area instead of the packing area.

• To increase the utilization of resource by availing the suitable scrap sheets for

Punching operation.

• To introduce Multi hoist-Electrically operated overhead crane to load/unload

the part into pre-treatment process to reduce the waiting time

PROJECT WORK REVIEW : Phase 2 OBJECTIVE

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 3 P S G T E CH

METHODOLOGYPROJECT WORK REVIEW : Phase 2 METHODOLOGY

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 4 P S G T E CH

Implementation and Follow-up phase

Proposed Layout

Analysis of results

Comparison of Layouts

Estimation of Performance

Simulation study

Redesigning of Layout

Problem identification

Collection of Data and Time study

Plant study

CATIA DIAGRAM OF PRODUCT

PROJECT WORK REVIEW : Phase 2 CATIA DIAGRAM OF PRODUCT

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 5 P S G T E CH

PRODUCT DETAIL

• Product name - CE Carrier Assembly• Customer - Gilbargo• Demand

• Average demand - 450 products• Lead time to delivery - 15 days• Application - Fuel dispensing pump

PROJECT WORK REVIEW : Phase 2 PRODUCT DETAIL

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 6 P S G T E CH

S.No Product name Demand

1 Aug2014 480

1 Oct2014 400

2 Dec2014 400

3 Jan2015 520

PROCESS MAP

PROJECT WORK REVIEW : Phase 2 DETAILED PROCESS MAP

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 7 P S G T E CH

Punching Part removal Filing

DeburringWelding/ fabrication

Pre-treatment

Powder coating Drilling Assembly/packing

TIME STUDY

PROJECT WORK REVIEW : Phase 2 TIME STUDY

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 8 P S G T E CH

DETAILS OF TIME STUDY

operation

numberMachine type

Number of

operators

Number of

component

Loading &

unloading time

(s)

Value added

time per compone

nt

Total cycle time per compone

nt (s)

setup time cycle time allowance inventory

Material movement distance

1 Punching 1 1 70 850 920 54000 22

2 Part removal 2 6 40 200 240 0 2550 382.5 2932.5 10

3 Filling 2 6 50 27 77 0 600 90 690 11.1

4 Deburring 2 6 80 62 142 180 480 72 732 10

5 Pressing 2 6 50 150 200 300 1110 166.5 1576.5 14.3

6 Welding 6 6 100 600 700 1200 2700 405 4305 84.1

7 Pre-Treatment 3 12 720 3000 3720 4200 5400 810 10410 54.5

8 Powder coating 5 6 100 2000 2100 1600 6480 972 9052 81.3

9 Drilling 1 6 120 40 160 120 10500 1575 12195 35.4

10 Inspection 2 6 40 100 140 60 720 108 888 16

CURRENT LAYOUTPROJECT WORK REVIEW : Phase 2 CURRENT LAYOUT

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 9 P S G T E CH

PROJECT WORK REVIEW : Phase 2 MATERIAL MOVEMENT

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 10 P S G T E CH

MATERIAL MOVEMENT

PROJECT WORK REVIEW : Phase 2 CSVSM

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 11 P S G T E CH

CURRENT STATE VALUE STREAM MAPPING

PROJECT WORK REVIEW : Phase 2 PROPOSED LAYOUT

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 12 P S G T E CH

PROPOSED LAYOUT

DISTANCE TRAVELED BY OPERATOR WITH MHS

S.NO StationDistance traveled

with MHS (m)

Distance traveled without MHS

(m)

Distance traveled

in conveyor

(m)

1 Punching 0.73

2 Part removal 0.6

3 Filing

4 Deburring 2.45

5 Pressing 3.75

6 Welding 23.5

7 Pre-treatment 0.23 7.32

8 Powder coating 4.54 34.88

9 Drilling 7.55

10 Inspection 0.6

11 Assembly /packaging 0.83

DISTANCE CALCULATION FOR CURRENT LAYOUT

PROJECT WORK REVIEW : Phase 2 DISTANCE CALCULATION

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 13 P S G T E CH

DISTANCE TRAVELED BY MATERIAL

S.NO Station Distance traveled with MHS (ft)

Distance traveled without MHS (ft)

1 Punching 14 8

2 Part removal 10

3 Filing 11.1

4 Deburring 3 7

5 Pressing 14.4 0

6 Welding 62.8 21.3

7 Pre-treatment 33.6 20.9

8 Powder coating 17.4 64

9 Drilling 31.9 3.5

10 Inspection 16

11 packing 3

DISTANCE CALCULATION FOR PROPOSED LAYOUTPROJECT WORK REVIEW : Phase 2 DISTANCE CALCULATION

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 14 P S G T E CH

DISTANCE TRAVELED BY MATERIAL

S.NO Station Distance traveled with MHS (m)

Distance traveled without MHS (m)

1 Punching 14 8

2 Part removal 10

3 Filing 11.1

4 Deburring 3 7

5 Pressing 14.4

6 Welding 62.8 21.3

7 Pre-treatment 7.1 20.9

8 Powder coating 21 64

9 Drilling

10 Inspection

11 packing 31.9

COMPARISON OF CURRENT WITH EXISTING LAYOUTSPROJECT WORK REVIEW : Phase 2 COMPARISON WITH EXISTING LAYOUT

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 15 P S G T E CH

Welding Pre-treatment Powder coating Drilling paint touch up packing0

10

20

30

40

50

60

70

COMPARISON OF CURRENT LAYOUT & PROPOSED LAYOUT

EXPECTED RESULTS• Total distance travelled by a material in current layout

= 207.2 ft

• Total distance travelled by a material in the proposed layout = 165.3 ft

PROJECT WORK REVIEW : Phase 2 EXPECTED RESULTS

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 16 P S G T E CH

FUTURE STATE VALUE STREAM MAP

PROJECT WORK REVIEW : Phase 2 FSVSM

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 17 P S G T E CH

ARENA SIMULATION MODEL

PROJECT WORK REVIEW : Phase 2 Arena Model

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 18 P S G T E CH

PROJECT WORK REVIEW : Phase 2 KAIZEN

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 19 P S G T E CH

REAL TIME DATA TRACKING SYSTEM-FRONT END

PROJECT WORK REVIEW : Phase 2 Real time Data tracking system

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 20 P S G T E CH

REAL TIME DATA TRACKING SYSTEM-BACKEND

PROJECT WORK REVIEW : Phase 2 Database

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 21 P S G T E CH

PROJECT WORK REVIEW : Phase 2 KAIZEN

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 22 P S G T E CH

PROJECT WORK REVIEW : Phase 2 KAIZEN

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 23 P S G T E CH

PROJECT WORK REVIEW : Phase 2 KAIZEN

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 24 P S G T E CH

PROJECT WORK REVIEW : Phase 2 Multi Hoist-Electrically operated overhead crane

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 25 P S G T E CH

IMPLEMENTATION

PROPOSED LAYOUT:

Investment cost = Rs. 5000

Monthly cost saving = Rs. 500

Return Of Investment = 10 months

ROI calculation

PROJECT WORK REVIEW : Phase 2 Implementation

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 26 P S G T E CH

FUTURE WORK• Comparison of results for current and proposed layouts.

• Implementation of Visual studio application to store the necessary detail about

Scrap sheets.

• Implementation of Material Handling device to hold the material that is removed

from the conveyor.

• Design and development of Multi-Hoist Electrically operated overhead crane in

the pre-Treatment area.

PROJECT WORK REVIEW : Phase 2 FUTURE WORK

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 27 P S G T E CH

THANK YOU

PROJECT WORK REVIEW : Phase 2

Department of mechanical EngineeringDr.DRK- Prof.NGK- Prof.VVA ME : LM-4SEM13ML72 28 P S G T E CH