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SCRAP REDUCTION IN PISTON MACHINING SHOPGautham T.C1 , Akshay Kumar K.P2, Anurag S.Wallepure3 Mashahed Abdul Hameed4Rajesh S.M5, Srinivas Rao61Student, B.E in Industrial Engineering and Management-5600781, email: [email protected], B.E in industrial Engineering and Management-56007, email: [email protected],
3Student, B.E in industrial Engineering and Management-5600783, email:[email protected], B.E in industrial Engineering and Management-560078
5Asst. Professor of IEM, DSCE, Bangalore-560078
6H.O.D of Quality, Federal Mogul Goteze, Bangalore.AbstractThe resultant pistons are sent for cleaning up of surface of the piston from risers and runners and later, the strength, hardness and other foundry defects are evaluated. Then a bunch of piston is placed in piston blank for its machining operations.
From the initial study, it reveals that FEDERAL MOGUL is having a rejection rate of 8% overall of the products produced. Possible causes for higher rejection rate may be due to the process/ method used, failure in analysing the quality of raw material procured, on-job inspection in shop floor during production, damages occurred during finishing process or secondary production.
The aim of this project is to identify the possible causes for the above said rejection and reducing the rejection rate with the help of the quality techniques and the Quality Control tools.
I. INTRODUCTIONPiston is one of the most important parts in the reciprocating engine. With a huge development in the automobile industries, there is increased demand for the piston in the market.
Piston manufacturing involves various complicated process to produce a piston. The quality level set to ensure customer satisfaction has increased the degree of the precession for the manufacturing product, thus increasing the challenge for piston manufacturing industries.
To survive in tough competition in the market the piston manufacturing companies have to standardize the production system to ensure high quality product and high degree of customer satisfaction.
Due to very high rate of precision, various defects are observed in the out coming process, which indicates the nonconformity of product.II. Problem definition Rejection or the scrap is a threat to any manufacturing industries. In a mass production company which aims to produce around 800 per shift per line. Every single rejection accounts to the loss of efficiency.
As all products cannot be thrown out as scarp they are inspected again and rework is carried out to bring about difference in number of scrap thus bringing down of the quality of the product manufactured, consuming extra man and machine timeIII. METHODOLOGY
The Seven Quality (7 QC tools) Control tools include:
Check sheet
Stratification
Pareto diagram
Cause and effect diagram
Histogram
Control charts
Scatter diagram
III. DATA ANALYSIS
Figure.1: Pareto chart for cnc-1 lineXbar Chart:
X- Axis= Sample number
Y- Axis= Control limits Figure.2: X-bar Chart before implementation
Figure.3: R Chart before implementation
Figure.4: cause and effect diagram for compression height
Figure.5: cause and effect diagram for damage
IV. IMPROVEMENT PLAN
PROBLEMSPRESENT CAUSESSUGGESTIONSSTATUS
Chips gets embedded to fixtureManual cleaning of fixture in machineMotor will be put with the brush, use air compressorCompleted
Vibration in bed of machineTemporary packing was used Machining was given for maintenanceCompleted
Table.1: Improvement plan
Figure.6: X-Bar chart after implementation
Figure.7: R chart after implementation
Table.2: Implementation plan
Figure.7: before and after implementation
V. RESULTS AND DISCUSSIONS
Figure.8: % Improvement in compression height
Figure.9: % Improvement in damage
CONCLUSION
The project titled REDUCING PISTON REJECTIONS DURING MACHINING OPERATION IN MANUFACTURING is completed. And based on the observation and analysis, the following conclusions were drawn.
After providing the brush for cleaning machine fixture seat and providing training for the operator of machining process & Methodology, Rejection due to compression height has been reduced by 8.19 %.
After providing grooves & appropriate space in between the pistons and providing operative training on machine/ method, Rejection due to Damages has been reduced by 5.17 %.REFERENCES
1) Robinson, Harry (1977). Early detecting of defects poka-yokhttp//facultywebbery-ed/igrout/pokasoft.html.may2012.
2) Shingo Shigeo. Andrew P Dillon (1989) a study of Toyota production system for industrial engineering view point.3) Oregon productivity press Johan R Gorat production technology a brief tutorial on mistake proofing, poka-yoke, and 7QC.4) Manufacturing and processing system professor J S Colton Georige institute of technology (2009).5) Standard manufacturing process (piston) FMGIL manual.
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