2

Summer Internship

By Rajat Saxena

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OVERVIEW

Make Vs Buy

ASSIGNMENTS MANAGER STATUS

Sop Design - Mast Assembly Ricky G. Completed

Plant Layout -fabrication shop Saul Completed

Time Study- EOS fabrication Afework Completed

Time- Kibo EM Kutty Completed

Design & Prototype for bench vise installation

Dinesh Completed

Design & prototype of Hose Support Yonas Completed

C.G.- Tilt Table Dinesh Completed

Make vs. Buy Yonas Completed

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Approach

Assignment-1 (Standard Operating Procedure- Mast Assembly)

Take pictures Use drawing Spec. from the drawing

Match the drawing part

nos. with B.O.M.

Check the parts no. with ASO

400

Updates the SOP with correct drawing no.

5

Sample SOP

No.

54

8 3

8 2

8 1

Qty No.

4

3

2

1

0 RS

CHG Init.

Legend: Visual Check Torque Requirement Critical DimensionQuality Control Special Requirement Jig/Fixture IndicatorSafety Environment Procedure Setup/Repeat

9421010912

9421010911

Part Number

9421111800

Mast Assembly- 5M25C37 1/6

6/11/2015

Date

Review for initial release

Description of Change

Document Name Page

N/A

EO - MO

Note

Shim T-0.5

For all three channels

Shim T-1.0

Roller Main

Part Name

Any shim can be used as per requirement

Bearing should have proper fit with item 2

Mitsubishi Caterpillar Production System Standard Operating Procedure

Procedure Quality Point

1 Placing shim(item 1) onto inner shaft 2 of middle and outer channel.

Lubricate no.2 before installations

2

Installing roller main (item 3) with the help of pnematic bering press(item4) onto inner shaft of outer and middle channel.

Step # 1 Step # 1

Step # 2 Step # 2

1

3

2

4

6

Suggestion1. Flow Diagram

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2. Control Plan

Prototype Prelaunch Model Document noPart name Person incharge Prepared byPart no. Customer name Checked byDrg. Name Supplier name Approved byDrg no. Core team

Size Freq. Y/N SIZE94111-07500 Shim - 0.5 0.1mm Filler guage 494111-07400 Shim - 1.0 0.1mm Filler guage 4

Line operatorInstalling the shim

onto the shaft1

CONTROL PLAN

Through hands

Sample ReccordingPart/

Process no.

Process name/ Operation description

M/C Jigs, Tools for

MFG

Part No. Product Name Process

Clas

s Product/Process specification

tolerance

Characteristic

Evaluation measurement

technique

Method

Photo

Insp

ecte

d By

Control Method

Reaction Plan

Revision no.Date org.Date rev.

ProductionMast Assembly

Page no

8

1. Layout of fabrication shop

Assignment-2 Fabrication Layout

9

Old Layout

Progress

10

New Layout

Progress

11

Approach Dimension of fabrication layout Studied the flow Studied the Constraints Layout Design

Constraints

Robots are fixed

Space

Conveyors are fixed

Space for fork lift movement

Magellan and Victoria should be

closed to Robot

One directional Flow

Electrical Connections

Budget

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Total Flow Dimension Required for each shop

Studies Required

ModelNo. of units produced

Total Flow

Magellan/Victoria 739 739Atlas/Kibo 124 124Centaur/EOS 80 80Mercury 79 79Apollo 23 23

Planned AreaVertical Horizontal Area Vertical Horizontal Area

EOS Weld 29 26 754EOS Fabrication 29 20 580Polaris 29 23 667 31 23 713Centaur 29 27 783 35 23 805Mercury/Mars 29 79 2291 66 35 2310Apollo 29 82 2378 29 83 2407Atlas 29 98 2842 30 100 3000Helios 29 28 812 29 30 870

30 23 69054 15 810

Total Area 12298 12991

Current DimensionShop Name

66 21 1386

Dashboard 29 41.06 1191

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Material Handling

Punch Press, Laser and plasma

Frame Fabrication

Robot StampingShot Blasting

Paint Storage

SchedulingMaterial HandlingPunch Press, Laser and plasma Frame Fabrication

Robot

Stamping

Shot Blasting

Paint

From

Atlas/ M

adge

lla/ V

ictoria

To

Material Handling

Punch Press,

Laser and plasma

Frame Fabricatio

nStamping

Shot Blasting

Paint Storage

SchedulingMaterial HandlingPunch Press, Laser and plasma Frame Fabrication

`

StampingShot Blasting

Paint

From

EOS/

POLA

RIS/

CEN

TAUR/

MAR

S & M

ERCU

RY/ A

POLLO/

HELIOS

To

From- To Chart Analysis

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Suggestion 3

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Creo Drawing Model

Assignment-3 Design Table for Bench-vise Installation

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Assignment-4 Time Study for EOS Mast (Sample)

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Time Measurement Used stop Watch to measure the time. Machine Time Loading & Unloading Time Average time

Challenges faced Shift Changes No specific schedule followed by the

supervisor Machining time is different for similar cut Operator has to wait for the forklift to flip the

part.

Approach

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Advantages

• Reduce waste of time• Forklift Operator can see the flag from

any part of the plant.• It is also helpful for the maintenance

department

Suggestion-4 Flag interpretation to call forklift operator to avoid time waste

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Formula Used Momentum M1R1 + M2R2 = (M1 + M2)R

R = M1R1 + M2R2/ (M1 + M2

Moment of body A Area of square / 2 * Area of triangle 10 *38.05/8 *38.08 = 5/4 Mass of rectangle = 5/9*500 =277 Mass of two triangles = 500- 277 =223Center of gravity with reference to plane A C.G. of the body A = (277 * 19.04 + 223 * 12.69)/ 500 =14.3 C.G. of the whole body (A and B) = (268 * 40.08 + 500 * 14.3)/768= 23.29 Center of gravity with reference to plane B C.G. of the whole system (A+B+C) = ((12+5)*4500 + (272+23.29)*(500+268))/ (500+268+4500) = 57.75

Drawing

Assignment-5 Center of Gravity of Tilt Table

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Challenges Faced

Hanging hoses create disruption during the processes.

Hose- Stand in not utilized well Existing are not perfectly aligned Hoses are entangle with each other

Assignment-6 Design for new Hose Support- Kaizen

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Creo Drawing Prototype

Design in Creo & Prototype

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TOTAL STUDY TIME:

Date:

Serial No. Process Start Time End Time Cycle Time 1 Gear oil (Differential) filling to the front axle 0:00:00 0:05:40 0:05:40

2 Engine Oil (Motor oil) filling 0:00:45 0:02:30 0:01:453 Coolant(ATF) filling to the radiator 0:02:10 0:04:30 0:02:204 Coolant(ATF) filling to the reserviour tank 0:04:50 0:05:08 0:00:185 Hydraullic oil filling 0:00:40 0:06:02 0:05:226 Bolting the front axle 0:06:40 0:07:50 0:01:107 Bolting the hydrallic tank 0:08:01 0:08:18 0:00:178 Instal floor plate L.H. with insulator 0:09:26 0:11:52 0:02:26

0:11:520:01:00

Total cycle time ( filled simultaneously)Total motion time

MCFA Time & Motion StudyPRODUCT DESCRIPTION: KIBO EMERGING MARKET PERFORMED BY : RAJAT

OPERATION DESCRIPTION: OIL FILLING STUDY BY:

START TIME :

Assignment 7 Time Study for the Kibo Truck

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Approach Recorded the video for each station. Calculated the start time and end time for

each process. Calculated the material Handling time for

motion study.

Challenges faced Part Shortage Mismatch in scheduling plan vs action plan Waiting for the frame or other parts

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Table

Process Total Cycle Time Total Motion Time Total TimeSub-Assembly 4:12:34 1:24:50 5:37:24Power Station 1&2 0:47:56 0:09:34 0:57:30Power Station 3 & 4 1:00:11 0:35:22 1:35:33Main line Station 1 & 2 1:09:17 0:53:09 2:02:26Main line Station 3 & 4 1:23:09 0:48:52 2:12:01Main line Station 5 0:46:23 0:07:24 0:53:47Main line Station 6 0:11:52 0:01:00 0:12:52Total 9:31:22 4:00:11 13:31:33

Graph

Results

Sub-A

ssembly

Power Sta

tion 1&2

Power Sta

tion 3 & 4

Main lin

e Stati

on 1 & 2

Main lin

e Stati

on 3 & 4

Main lin

e Stati

on 5

Main lin

e Stati

on 60:00:00

1:12:00

2:24:00

3:36:00

4:48:00

6:00:00

Total Cycle TimeTotal Motion TimeTotal Time

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Suggestion 5 - For Scheduling

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Total Cost

Make BuyOrdering Cost 3,250.00$ 101,000.00$ Total cut Cost 91,617.03$ Holding Cost 6,673.03$ 2,200.61$ Total Uncut Cost 58,672.54$ Labour Cost 6,100.38$ Total Cost 74,695.95$ 194,817.64$

Graphical Representation

Assignment 8 Make Vs Buy for the Hose Cut

Ordering Cost

Total cut Cost

Holding Cost

Total Uncut Cost

Labour Cost

Total Cost

$-

$50,000.00

$100,000.00

$150,000.00

$200,000.00

$250,000.00

Chart Title

Buy Make

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Suggestions

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Suggestion 6- for sensitive machines

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Questions?