JCB INDIA LTD

Robin Singh Bhinder

40707028

INE-MBA 3rd Year

Projects Undertaken Project 106 (A new backhoe loader designed in India

for India) Introduction of Health Cards/ Health Management

System in JCB Introduction and Implementation of ANDON System

based on supervisory control and data acquisition (SCADA)

Designing and commissioning of a new King Post Carriage assembly line

Kaizens/ Improvements

Project 106

• Preparation of Elementary Process Sequence sheets for every part of the machine

• Preparation of Standard Operation Procedures for every part of the machine

• Fixture/ tackle design, testing and installation• Tool identification and commissioning of the

same

Elementary Process Sheet - EPS

• I was involved with the formulation of the Elementary Process Sheet (EPS) of P-106.

• It states the smallest possible amount of work done during the process• It deals with part numbers, quantities of the parts, TAKT times, method of

operation and the process of production being followed.• It lays down the basic procedure of production. • It also gives details about the tooling required for the process.• Used only for reference at managerial level• The details of EPS are very helpful for formulation of Standard Operation

Process , Work Combination Charts and in time studies.• It is also very useful in dividing the work content between the workers at

a stage

Standard Operation process-• I formulated the Standard Operation Process (SOP) for P-106• Standard Operation Process gives the exact step by step procedure to be

followed by the workers during a procedure/process• It is formed by analyzing the drawings of various assemblies • It gives all the details like part names, numbers, their quantity• It also gives various key points to be followed during the process like use

of proper safety equipments, proper handling and quality issues.• It gives the critical torque values to be used in the process (if any)• It reduces the time required for a new worker to get accustomed to his

work.• The visitors can use this sheet to understand the process without any

enquiry• An example of SOP is shown in the next slide.

Fixture Design, Testing & Installation

• The P106 is a compact machine as compared to the normal 3DX machine . Therefore all the dimensions are different.

• Thus all the fixtures, tackles and trolleys to be used on M Line, Assembly Line and paint shop were to be designed.

• In all a total of 6 Tackles, 3 Sub Assembly Trolleys and 5 component Trolleys and 4 Fixtures were designed

• I was involved in the designing and testing process of all the fixtures, tackles and trolleys.

• This was done with the help of drawings of different components. • The software used was AUTO CAD 2010.

BOOM DIPPER SUB ASSEMBLY FIXTURE

Tooling Analysis• I analyzed the EPS and SOPs made previously to find

out the types and quantity of tools required.• Ergonomic and safety points were also considered

during selection of tools so that human effort is minimized

• State of the art DC tools and Oil Pulse tools were procured where the torque values were critical like Rear Axle to Mainframe mounting, Yoke Plate mounting, Cab Fitment and Tyre mounting.

• In case of bulky tools gravity balancers were employed to reduce the amount of force required to carry/ lift the tool

Health Management System• I was involved in the process of improving the health

of the workers.• The basic aim of this system was to reduce the

complaints regarding high fatigue levels• For this movement of every worker was captured

along with the amount of weight and the amount of bending he has to do using a Health Card and Movement Chart

• Stage wise concerns were then developed and actions taken through Problem Counter Measure approach

Sr. No. Description Permissible Actual

1 Maximum Lifting of Weight 8 Kg.  

2 Body Posture while working    

  Walking    

  Sitting Nil  

  Bending < 60 Deg  

  Stretching    

3 Working Temp. 32-35 Deg. C  

4 Drinking Water Access Point 25 Mtr  

5 Kaizen Cell Point 25 Mtr  

Health Card

Movement Chart

Assembly Line - Movement Chart (Feb'10)

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

Stages/Operator

Dis

tanc

e (m

m)

Health Card Summary A Line

0

100

200

300

400

500

600

700

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Stages

Sco

re

January

February

March

• The health cards were then analyzed and the stages with high values were tackled first

• For example-

ANDON System

• I was involved in implementing and installing the new ANDON system which unlike the previous system is based on Supervisory Control and Data Acquisition (SCADA)

• That is anyone at any place in the plant can find out about the production status instantly using his workstation or by looking at the display board

• Thus any kind of problem is notified instantly thereby decreasing the time required to rectify the problem

ANDON Work Station

King Post Coupling (KPC)• Since the demand of JCB 3DX model has been

increasing continuously, therefore to meet the demand a new KPC assembly area is required.

• The new assembly area is designed while keeping in mind that the amount of manual lifting required is minimum and that the problems faced in the current system are not present

• Special care has also been given to the fact that the worker does not have to bend in order to reach the tools, parts

• The new system is designed to be safer and is easy to maintain

• To make the system easier to maintain, the cranes are only eight feet above ground level

• The whole conveyor set up is on ground level. Thus the breakdown time is considerably reduced

• The new system is more spacious, thus there is more room for the worker to maneuver in and the various tools to be used can be placed within the reach of the worker

KPC Layout

Kaizens & Improvements

• Improvement is a continuous process in JCB• I was involved in various kaizens implemented

in the company• Some of the Kaizens implemented are-

1. Installation of new axial fans on the shop floor

Advantage- Better air circulation and flow on the shop

floor. Eliminates the problem of low air pressure in

the ducts

Axial Fan

2. Developed new light weight tackle to lift king post

Advantage- Reduces operator’s fatigue level while lifting

the king post