Slide 1
INDUSTRIAL TRAINING REPORT
SUBMITTEd BY:-Sandeep kumarHarmeet singhArun kumarHarjot
singhPROJECTS UNDERTAKENPROJECT-1:STUDY OF EXCESSIVE NON VALUE
ADDINGWORK DONE BY WORKERS IN AXLE ASSEMBLYSTATION.
PROJECT-2:STUDY OF ENGINE TESTING FACILITYManual Assembly
lines:
A production line that consists of a sequence of workstations
where assembly tasks are performed by human workers.Products are
assembled as they move along the line.At each station a portion of
the total work content is performed on each unit.
Work Transport Systems-Manual Methods:
Manual methods:Work units are moved between stations by the
workers (by hand) without powered conveyor.
Problems:Starving of stations:The assembly operator has
completed the assigned task on the current work unit, but the next
unit has not yet arrived at the stationBlocking of stationsThe
operator has completed the assigned task on the current work unit
but cannot pass the unit to the downstream station because that
worker is not yet ready to receive it.
ASSEMBLY LINE
REAR AXLE
FRONT AXLETypes of wastes:Following are some of the
non-value-adding processes during assembly:
1)Transportation2)Inventory3)Motion4)Waiting5)Over-processing6)Over-production7)Defects
*WASTES= Activities that dont add any value to the final
productAxle assembly station:The present axle assembly stations
layout brought many inefficiencies in the production process like
:
LESS FLEXIBILITY NON VALUE ADDING WORKHIGH PRODUCTION TIMENOT
PROPER CAPACITY UTILISATION
Our study was aimed at reducing these inefficiencies by making
suitable improvements in the present layout of workstation. PRESENT
LAYOUT
Rear AxleSUGGESTED LAYOUT
BENEFITS OF NEW LAYOUTFLEXIBILITY .REDUCTION IN NON VALUE ADDING
WORK.REDUTION IN TIME.CAPACITY UTILISATION.ENGINE TESTING SETUP
ENGINE TESTING PARAMETERSWATER INLET AND OUTLET TEMPRATURE.AIR
INLET AND EXHAUST.INTERCOOLER INLET AND OUTLET TEMPRATURE AND
PRESSURE.LUBRICATING OIL TEMPRATURE AND PRESSURE.RPM
S NOParameters of engine
testingOutput1Output2Output31RPM1218200027922Water outlet
temp29C30C30C3Exhaust temp50C55C62C4Engine air inlet
temp45C46C46C5Air temp(before intercooler)62C89C136C6Air temp(after
intercooler)40C40C40C7Intake water temp40C42C45C8Lubricant oil
temp113C124C138C9Lubricant oil pressure1 bar1bar1bar10Boost
pressure(before intercooler)0.0840.3050.66611Boost pressure(after
intercooler)0.0670.2610.56112Engine air intake pressure-29kg/cm-50
kg/cm-75 kg/cm13Intercooler temp46.2C46.9C49.6C14Idle oil
pessure1.7 kg/cm4.5 kg/cm4.9 kg/cmRESULTS
CAUSES OF ENGINE REJECTION
1)Noise from the turbocharger2) Engine fails to start3) Noise
from the bearings of engine4) Leakage from oil filter5) Engine head
noise6) Water leakage from engine7) Less power output than
required8) Leakage from cylinder head
Analysis: FITMENTProblemWhy?Why?Turbocharger making noise during
the testing stageWrong bolts used during engine testing for fitment
of turbocharger duct to the inlet of turbocharger.Mix-up of bolts
at engine testing for fitment of turbocharger duct to turbocharger.
ROOT CAUSE IDENTIFIED:
Wrong fitment of bolts during assembly of duct to
turbocharger.
Wrong bolts were used because two different kinds of bolts used
for testing setup didnt have any identification marks.
The different bolts were not segregated in different boxes.
SUGGESTED SOLUTIONS:
Use same standardized bolts
Use standardized tool
Use color code for bolts
Put the different bolts in different boxes
Inspection of all testing arrangementsIMPACT OF SOLUTIONS:
Time impact: Less wastage on the rework of defected engines.
Customer satisfaction impact: Higher production rates and
in-time delivery of the finished product.
Cost impact: Cost of poor quality would be reduced as less
amount of rework would be needed.THANK YOU
