centralized system for traffic control

7/27/2019 Centralized System for Traffic Control

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By: Ashish Sinha Nithin H S Pratik Tilak Ramakrishna Anantha


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Objectives of Our ProjectReducing Traffic density in GangwaysCreating a centralized system in order to improve

traffic condition.


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Root causes for Traffic Jam


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Problem 1Under utilized gangway between engine Jundate and

engine sub assembly lineRoot Cause:Tow motor is being parked in that gangway, whiledriver is fixing hose pipes for engine.

Solutions:Shifting the parking place and inventory shelf

towards engine sub assembly line.Benefits:Diversion of Chassis frame tow motor and engine sub

assembly line supplies to weld shop gangway throughthis route.


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36503900

Present Situation

Gangway is blocked by the parking of Tow motor

Engine Jundate

Tow motor with engine

chorokyu

Pneumatic cylinder


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Tow motor with engine

chorokyu

Proposed Idea

Pneumatic cylinderEngine Jundate


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Problem -2Parking of Dollies near IP Sub assembly line obstructing the

gangway 1Root CauseThere is no space available for dollies while

replenishing the stock.SolutionIntroducing Set Pallet System for IP sub assembly line.BenefitsIt will remove traffic congestion near IP sub assembly line.


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Problem - 3Parking of Dollies near Engine Sub assembly line

obstructing the weld shop Gangway Root CauseThere is no space available for dollies while

replenishing the stock.SolutionIntroducing Set Pallet System for Engine sub assembly line.

BenefitsIt will remove traffic congestion near Engine subassembly line.


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Kaizen -1

Increasing the Rear Axle lot size from 4 to 5

Number of movements can be reduced are - 19

Increased movement of Assembly line employee is- 30 cms


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Kaizen -2Shifting the tow motor parking place which is

obstructing the traffic in the junction


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Problem - 4Traffic Jam at JunctionsTo many tow motors are coming from differentdirection at the same time causing an average traffic

jam of 1.2 mins.


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Centralized Inventory and Traffic monitoring system

Based on the real time inventory at assembly line each tow motor agent is assigned dynamically with a priority.The priority is completely automatic and it can be setmanually in the master centralized control unit by usingthe key pad and an LCD display.IR transmitter is installed on each Tow motor and IR receiver is installed on each road near the common

interface.The agent continuously transmits its ID code and when thetow motor approaches the common interface IR signalfrom the agent is detected by the road unit.


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R l i I i l


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Real time Inventory manipulator


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Sensors used for finding out inventory at Assembly line

Ultrasonic SensorError 0.5 cms

Bending Beam Load SensorError 1% of its capacity

Motion sensor

Long range IR Proximity sensor


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Ultrasonic sensor: List of workstationsFortuner SPS dolly

CarpetRoof mouldWeighing sensor: List of workstations:Stabilizer barRear axle

Propeller shaftExhaust center pipeRadiatorProximity sensor: List of workstation:Tyre LHTyre RHMotion sensor: List of workstation:Modular dolly IP dolly Engine


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Ultrasonic Sensor working Principle

Centralized system


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-- Tow motor

-- Base station

-- Zig bee Transreceiver

-- Micro processor

-- EEPROM

2 0 m

t s Real timeinventory data


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Centralized system

Real timeinventory data

Inventory atassembly line


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1 234



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SPS

1. Tow motor moves from SPS to A/S line for part delivery,

2. Tow motor waiting in A/S line for part delivery ,

3. First tow motor inform the Second Tow motor to stop nearSPS until it inventory get consumed to fixed quantity ,

The parking of Tow motors can be eliminated with propercommunication between two tow motors.

Proper Communication Between tow motors


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BenefitsLow cost and efficient systemLong range sensors

Reprogrammable cmosIt can minimize traffic Jam with real time dataReduction of traffic congestion at each junction.Proper information sharing between tow motors.


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Estimated project cost for one junction

Centralized Unit:Cost: Rs.15,000/unit

Vehicle Unit:

No. of tow motors: 14Total cost per unit :Rs.7,000Total cost : Rs.98,000

Road Unit:

No. of road units required=3Total cost per unit= Rs.4,500Total cost: 4500*3= Rs.13,500

Total cost for this junction= Rs.1,26,500


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a) Ultrasonic sensor: List of workstations:Fortuner SPS dolly CarpetRoof mould

Estimated cost for using Ultrasonic sensor:No. of sensors= 3Cost per sensor= Rs.1,100Total cost= 1100*3= Rs.3,300

Estimated cost of Real Time Inventory system


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b) Weighing sensor: List of workstations:Stabilizer barRear axlePropeller shaft

Exhaust center pipeRadiator

Estimated cost for using Weighing sensor:No. of sensors per workstation= 4Cost per sensor= Rs.5,000

Junction box= Rs.6,000Total cost per workstation= Rs.26,000

Total no. of workstations= 5

Total cost required= 5 * 26000= Rs.1,30,000



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c) Motion sensor: List of workstation:Modular dolly IP dolly

Engine

Estimated cost for using Motion sensor:No. of sensors per workstation= 2Cost per sensor= Rs.2,500

Total cost per workstation= 2*2500= Rs.5,000

Total no. of workstations= 3

Total cost required= 3*5000= Rs.15,000



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d) Proximity sensor: List of workstation:Tyre LHTyre RH

Estimated cost for using Proximity sensor: No. of sensors required in each workstation : Tyre LH= 15Tyre RH= 10

Cost per sensor= Rs.500No. of sensors required= 25

Total cost required= 25*500= Rs.12,500



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Thank you

centralized system for traffic control

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