spot design clinic - dcs to spot design clinic for msmes m/s soudamini instruments i products...

Compiled by | SHRIKANT CHANDANE

Spot Design Clinic

Date : 29th December, 2011

MSME CLUSTER

• TOY INDUSTRY CLUSTER

• FABRICATION CLUSTER

M/s SOUDAMINI INSTRUMENTS Pune ,

M/s PARAB CONVEYOR SYSTEMS ,Pune .

Introduction to Spot Design Clinic for MSMEs

M/s SOUDAMINI INSTRUMENTS

IProducts

Miniature products ManufacturingMiniature Train Toys And Instruments manufacturing of Toys

Process

From 2d drawingsMaster Die MakingTool Making Die making for plastic Injection mouldingABS moulding

IIProducts

Conveyor manufacturing, Industrial product fabricationSlat conveyorsMaterial Handling SystemsBucket EleavatorPick and place devicesVehicle Body buildingBIW fixturing

Process

Designing of conveyorsFinal designInterference Checking Inventory managementSheet metal fabricationAlluminiun extrusionBelt procurementMotors and drives asseblyBearings assembliesPlates machiningControl panel assebly Testing

Introduction | Observations | Design intervention

SMC DESIGN

M/s PARAB CONVEYOR SYSTEMS

M/s Soudamini Instruments

• Miniature Trains

• Miniature products

• Miniature vehicles

• Instruments

• Toys manufacturing

SMC DESIGN

Existing Product Development


• 2d drawings are provided by companies and get a miniature prototype manufactured at 1:100

• Color scheme provided

• HO international gauge is followed at 1:87

• According to dies distribution of whole body and

and paint

• Separate drawings of Autocad software ,Total no.of drawings created for dies.

• All 2 d drawing are required

• Master die making is made in Graphite on CNC

milling.in 2 and 1/2D scale

• Material used ABS

• From master cavity is made for die at 0.2 mm

accuracy.

• ABS injection moulding is made and components are assembled

SMC DESIGN

Exhisting Products

SMC DESIGN

Matrix Material

• For Die Steel

• Special ABS material for plasic

• Special processes

• Machinery requirement

Processes

• Manual

• semi automatic

• Investment

• Out sourcing

ResourcesSkill set requirements

• Local availability

• Training needs

• Attrition rate

•Infrastructure

• Electricity

• Transport availability

Procurement

• Inventory

• Sourcing

• Availability

• Lead time

• recovery


SMC DESIGN

Factor affecting the product mfg time

Product

Sub system breakup

Electronics

Mechanical

Hydraulic

Pneumatic

Mechanism

Patented process etc.

Market need

Design

Development

Feasibility

Testing

Validation

After sales support

End of life cycle

Recycle, reuse

Purchased items

Customized – out sourced

Standard items –fasteners,

consumables

In-house processing

Primary Processes

Machining

Finishing –

Functional

Secondary

Coloring , storage,

Packaging, dispatch

Fixtures , Jigs

Understanding the process

• Micro level analysis

• Identify Other stake holders

• Understand bottle necks

• Flow chart , time estimate

• Alternative process

• make – partner - buy decision

• Primary Tools - power assisted / manual

• Secondary tools – loading unloading, transport, material handling

• Cycle time calculation, reduction optimizing process

• Total product time requirement , total cycle time break up

• Critical path

• Areas of improvement

• Risks management

• External factors – social, cultural, human, infrastructure, labor related, policy related

• Improving quality


SMC DESIGN

Procurement -

• Procurement – As per the confirm order – against the advance to reflect the client seriousness. Also ensure the enough lead time.

• Transportation limitations and develop alternative vendors to supply special material to avoid last minute rush.

• Allocate minimum order quantity to stream line product process and improve efficiency.

• Storage – Proper incoming in process out going bins, rack system for storage

• Avoid dust accumulation on the product

• Project wise raw material sorting helps to know and order missing components

• Plant layout

• Understand the process and use small Asseby line a s per process flow to reduce material handling & there by damage.

Other items

Floor cleanliness

Floor should be clean every day and free of oil , sharp objects wastage of sheet p\metal pieces and burr.

This will avoid accidents.

Storage racks

Separate storage racks for incoming project wise components and parts

Due care of fragile electronic items and also PCBs and other electronics

SMC DESIGN


Process improvement

Storage racks for finished

stage is not available currently it

will create more work space of

employee.

Semi finished product needs

separate area.

Separate deburring area will

improve safety.

.

Using tool BOARD helps to find

tools easily.

Location need to be changed to

standing posture. Probable

solution is on the column in the

center.

Work desk is mainly steel and

height need to be checked for

employee eight so that it is

ergonomically suitable. Earthling

point is required so that welding

can be easily carried on the table.

SMC DESIGN


Process flow and alternative materials

ABS is prone to many

Scratches.

Breakage during transportation by air for export and assembly has main impact of in warranty replacement cost.

CNC master making result s in improving process finishes and productivity.

• Manual process to reduce production cost has resulted in rework and spend lot of time in getting the slots using EDM .

SMC DESIGN


Manual Assembly of Miniature Trains and toys

• Manual asembly

• Of dies for plastic moulding

• small Components developments

• Rail assemblies

• fitting with adhesives

• Electronically operated doors

• Pentograph

• springs

• Indicators

• Head lamp assembly

SMC DESIGN


DIE making from graphite masterTool box wall panel will be

prepared in next phase.

Clamping units with

fixtures will be decided as

per project need basis.

Depending upon the volume of

production.

Separate area of procuring

the material, using

consumable items and also for

tools.

Plant layout for incoming product to dispatch of finished goods.

Painting area to separate from the rest and / or out sourced to near by vendor.


ABS injection moulding


Assembly area for miniature train

• Suggestions• Instead of Creating models on Autocad 3d Worksstation

should be used for the model making

• 3d modeling workstations with CAD CAM software for developments of products right from concept to making dies and prototype.

• For the critical die making the CNC path to be generated on CAM software.

• The work of graphite master making can be improved

• Die making on EDM for small parts and detailing required and for more accuracy the process can be replace d with imported machines.

• For injection moulding of small components SPMs required .

• Cabin dies should be separate it should not be one.

• For competitiveness of design all new processes should be implemented.

Design Interventions


Design Interventions:

• Aesthetic design can improve regular look of the train.

• New innovative designs of various types of toys can be added.

• New products like miniature of cars as per the company specificaiton

( e.g. model of TOYOTA fortuner is the need of the product in the market for children )

The hobby groups of people can adopt a basic of the systems and keep on adding the

Other accessories.

Finishied Miniature products for export


SMC DESIGN

New Diversification Suggestedmake a working toys and product suggested

under MSME DESIGN CLINIC schemeLOCAL TRAIN TOY

SMC DESIGN

DR. RAVI JOSHI HAS GIVEN FEEDBACK ON OUT SPOT DESIGN CLINIC SCHEME

THE DESIGN CLINIC SCHEME IS GOOD FOR THE INNOVATION IN MSMES AND THE FINANCIAL SUPPORT PROVIDED BY NID IS APPRECIATING. AT THE SAME TIME THE DESIGN CLINIC SCHEME SHOULD HAVE A TEAM OF INDUSTRIAL

EXPERIENCED TEAM,WHO CAN SEE THE PRODUCTS FROM THE POINT OF VIEW OF DEVELOPMENTS IRRESPETIVE OF THE CLUSTERS AND CORE AREAS OF DESIGNTHE NEED OF MSME SHOULD BE CATERED FOR PRODUCT DEVELOPMENTS.

THE PRODUCTS WHICH ARE INNOVATIVE AND CAN CATER MARKETS OF WORLD .THE FACILITIES SHOULD BE SUGGESTED TO THE MSMES FOR COMPETITIVENESS WHICH IS NOW DONE BY THIS SCHEME.

THE QUALITY IMPROVEMENT IN PRODUCT MANUFACTURING IS STILL NOT COMPETIVE BECAUSE OF THE LACK OF FACILIITIES LIKE OTHER COUNTRIES.

THE INCUBATORS SHOULD BE DEVELOPED EVERY INDUSTRIAL CITIES.WHERE DEISGNERS AND MSMES CAN DO EXPERIMENTS AND DEVELOP E PRODUCTS WITH INTERNATIONAL FACILIITIES.

THE FACILITIES IN PRECISION WOKING LIKE PAINTING, PACKAGING ,PLASTIC MOULDINGS AND DIEMAKING ARE NOT UP TO THE MARK TO COMPETE IN WORLD MARKETS.

LIKE CHINA AND EUROPE THE QUALITY PRODUCTS SHOULD BE DEVELOPED ,GOVT SHOULD TAKE LEAD AND NID SHOULD GIVE FEED BACK TO GOVT. THAT THE GOVT .SHOULD PROVIDE FACILIITIES LIKE KOREA AND CHINA TO DEVELOP PRODUCTIVITY.

DR.RAVI JOSHI IS THAKFUL TO SMC DESIGN TO PUT THE VIEWS OF DR.RAVI JOSHI AND TAKING M/S SOUDAMINIINSTRUMETNS FOR SPOT DESIGN CLINIC EVEN AFTER REJECTION OF PROJECT SUBMITTED BY SOUDAMINIINSTRUMENTS

THE REASON FOR THE REJECTION OF THE PROJECT SUBMITTED FOR THE MINIATURE TRAIN MANUFACTURING WAS NOT CONVINCING. THE TRY OF SMC DESIGN TO PUT FOCUS ON THE INDUSTRY STUDY REALLY APPRECATING.

Feed back of the owner Dr.Ravi Joshi

M/s Soudamini Instruments Contact

Registered Name of Company m/s SOUDAMINI INSTRUMEMTS

Contact person Name and Designation Dr.RAVI JOSHI

Partner

Contact Details:

Address: Address: 12,Kothrud Industrial Estate,Pune,411038

Tel No. : 020 25435378

No. 9822048398

Email : [email protected]

URL : www.soudamini.com

Unit falls under Small

Registration status with DCS Yes

•MSME Unit Details:

SMC DESIGN

mailto:[email protected]

http://www.soudamini.com/

PARAB CONVEYOR SYSTEMS


• Belt Conveyor

• Slat Conveyor

• Pick and place device

• Automation in conveying systems

• Screw Conveyors

• Vehicle Body building

• BIW fixtures

• Bucket Conveyors

SMC DESIGN

Matrix Material

• CRC, MS, Aluminum

• Special material



Processes

• Manual

• semi automatic

• Investment

• Out sourcing

Resources• Skill set requirements


• Training needs

• Attrition rate

•Infrastructure

• Electricity


Procurement

• Inventory

• Sourcing

• Availability

• Lead time

• recovery


SMC DESIGN

Existing Product Development


• 2d drawings are provided by companies and custom made design for conveyors

• Color scheme provided by customers

• Final Design of systems

• Checking of design and finalization

• Procurement of material like Belt for conveyor ,sheet metal for fabrication, Aluminium Extrusion cutting as per requirements,motors,drives ,bearings,Plates machined ,control panel for system ,Housing Rollers.

• Conveyor stand manufacturing

• Housing Rollers machined.

• Tensioning arrangements

• And painting.

• Packaging

SMC DESIGN

Matrix

• Skill set requirements


• Training needs

• Attrition rate

•Infrastructure

• Electricity


• Inventory

• Sourcing

• Availability

• Lead time

• recovery

• Manual

• semi automatic

• Investment

• Out sourcing

• CRC, MS, Aluminum

• Special material



Material Processes

ResourcesProcurement


SMC DESIGN

Factor affecting the product mfg time

Product

Sub system breakup

Electronics

Mechanical

Hydraulic

Pneumatic

Mechanism

Patented process etc.

Market need

Design

Development

Feasibility

Testing

Validation

After sales support

End of life cycle

Recycle, reuse

Purchased items

Customized – out sourced

Standard items –fasteners,

consumables

In-house processing

Primary Processes

Machining

Finishing –

Functional

Secondary

Coloring , storage,

Packaging, dispatch

Fixtures , Jigs

Understanding the process

• Micro level analysis

• Identify Other stake holders

• Understand bottle necks

• Flow chart , time estimate

• Alternative process

• make – partner - buy decision

• Primary Tools - power assisted / manual

• Secondary tools – loading unloading, transport, material handling

• Cycle time calculation, reduction optimizing process

• Total product time requirement , total cycle time break up

• Critical path

• Areas of improvement

• Risks management

• External factors – social, cultural, human, infrastructure, labor related, policy related

• Improving quality


SMC DESIGN


Back ground -This products are conveyors and automation related

demand need to look for alternative product which can help to

make more independent products.

The strong desire to improve process and train resources

to use new tools and techniques needed.

ObservationsInitial product is in aluminium , alternative process – sheet metal

Process improvement – CO2 welding– CNC laser cut and bending

Process time - 15 days to 4 days, reduction in wastage

Batch size : 4 units

Previous method of assembly - Aluminium extrusion cutting,assemblies,Stand fabrication,painiting – Packaging, transportation

Process time - 2 weeks for 1 units 21 days for 2 units

New process

Laser cutting of fabrication, welding , grinding, powder coating or painting .

Process time - 1 week for 1 unit

Rejection – no rejection

SMC DESIGN

Observations


• Procurement – Per per the confirm order – against the advance to reflect the client seriousness. Also ensure the enough lead time.

• Transportation limitations and develop alternative vendors to supply special material to avoid last minute rush.

• Allocate minimum order quantity to stream line product process and improve efficiency.

• Storage – Proper incoming in process out going bins, rack system for storage

• Avoid dust accumulation on the product

• Project wise raw material sorting helps to know and order missing components

• Plant layout

• Understand the process and use small Assemly line a s per process flow to reduce material handling & there by damage.

Other items

Floor cleanliness

Floor should be clean every day and free of oil .


Storage racks


Due care of fragile electronic items .

SMC DESIGN

Suggestions


Storage racks for finished

stage is not available currently it

will create more work space of

employee.

Semi finished product needs

separate area.

Grinding sparks are harmful and

cause distraction from work this

area can be separate.

Using tool BOARD helps to find

tools easily.

Location need to be changed to

standing posture. Probable

solution is on the column in the

center.

Work desk is mainly steel and

height need to be checked for

employee height so that it is

ergonomically suitable.

Earthling point is required so that welding

can be easily carried on the table.

A removable work top of laminate

will help to covert the existing

bench to a demonstration table

and for testing purpose when not

in use.

SMC DESIGN

Safety and security


Gringding safety required it may cause the accidents

Safety Glows and goggles should be used dugingoperations. .

Necessary training before work should be provided.

Breakage during transportation and assembly has main impact of in warranty replacement cost.

CNC bending result s in improving process finishes and productivity.

Laser cut process has resulted in the clean product and is looking professional.

SMC DESIGN

Work area observations


• Manual bending using hammer and anvil

• Tack welding for the fixing the shape to the grill

• Manual bending results in error and need lot of time to get the final shape

• Welding does not ensure 90 degree and perpendicular alignment

• this results in the cutting and unweldingof angles and sq rods

SMC DESIGN

Assembly areas


SMC DESIGN

Other items

Floor cleanliness

Floor should be clean every day and free of oil .


Storage racks


Due care of fragile electronic items .

Storage for machines and tools


SMC DESIGN

• Manual process to reduce production cost has resulted in rework and spend lot of time in getting the slots using Jjg saws and scissors. Manual filing has also resulted in uneven bending and dents.

• Flip top mechanism has reduced the earlier slider mechanism reducing the assy.

Work area


SMC DESIGN

Tool box wall panel will be prepared in next phase.

Clamping units with

fixtures will be decided as

per project need basis.

Depending upon the volume of

production.

Separate area of procuring

the material, using

consumable items and also for

tools.

Plant layout for incoming product to dispatch of finished goods.

Painting area to separate from the rest and / or out sourced to near by vendor.

Product Diversification suggestedMobile Conveyor under Design

Clinic Scheme

SMC DESIGN


Design Intervention

Design Interventions:

Aesthetic design can change the regular look of

the conveyors

Nicely treated edges for safety.

Painting quality can be increased by using

Powder coating.

Graphics can add new meaning for mobile conveyor.


Suggestions

• Suggestions• It was observed during the study that the MSME is only following the drawings according to the

companies provide.

• The need of the hour is the MSME should be independent enough to create and use design facilities in premises.

• Premises is not planned properly for manufacturring

• The placements of the procured material should be stored in proper racks and to get it easily marking or numbering should be done.

• The workers are facing problems to get the tools also because of the improper storage of tools

• Plant layout should be improved.

• Painting are should be converted with compartments.

Feed back of Mr.Nitin Parab Proprietor of M/s Parab Conveyor Systems

• MSME design clinic scheme is a useful and important scheme for improvement of products .

• Design interventions and suggestion really will help MSMEs for improvements.

• Diversification generally MSME doesn’t think of suggestions are really good.

• Design interventions and suggestions helped us in thinking in the various aspects from the point of view of designs.

• After this spot design clinic we are able to analyse various new processes and method where areas of improvements were suggested.

• Small things are there but never thought of implementing such things which can save time ,money,

and It can also safety aspects to the workers .

We thank NID and m/s SMC DESIGN for conducting such spot design clinic at our wokshop.

Parab Conveyor Systems contact

Registered Name of Company m/s Parab Conveyor Systems

Contact person Name and Designation Mr. Nitin Parab

Proprietor

Contact Details:

Address: Address: 25/7 Dedge Indl Estate Nanded Phata,Pune-411041

Tel No. : 020

No. 09922909281

Email : [email protected]

URL: www.parabconveyors.com

Unit falls under Small

Registration status with DCS Yes

•MSME Unit Details:

SMC DESIGN

mailto:[email protected]

http://www.parabconveyors.com/

• The purpose of the survey conducted in the two industries of different clusters to observe the industries

and study the working methods and process to seek implementation of MSMEs DESIGN CLINIC project to increase the competiveness of MSMEs in long run.

• It was observed during the study that the MSME is only follow the designs and drawings according to the companies provide.It can be a new design and development possible which can create new innovative products which can help industry to diversify and cater new markets,from the point of view of export of the prducts.

• The MSMEs should be independent enough to create and use design facilities in premises.They should plan properly and implement modern design facilities ,workstations like 3d modeling software and new machineries which can improve quality of all aspects.

• They should place the procured material and to be stored in proper racks and to get it easily marking or numberings .The workers who facing problems to get the tools also because of the proper storage of tools

• Improved plant layout .

• This survey was conducted to give these two industries new point of view,suggetions ,design interventions and product diversifications.

Synopsis

spot design clinic - dcs to spot design clinic for msmes m/s soudamini instruments i products...

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