training project

TRAINING REPORT

TO REDUCE THE REJECTION RATE IN PISTONSSubmitted by:Karan guptaRoll No. : CO12124Under the Guidance ofFaculty coordinator Industry coordinator MR.Amoljit singh gill Er. Charanjeet SinghTraining coordinator,CCET

Asst.Manager,PMS

FMGIL

CHANDIGARH COLLEGE OF

ENGINEERING

&

TECHONOLOGY

DECLARATIONI hereby declare that the project work entitled To Reduce the Rejection Rate in Pistons is an authentic record of my own work carried out at Federal Mogul Goetze India Ltd as requirements of training for the award of degree of B.Tech (Mechanical Engineering), Chandigarh College of Engineering and technology under the guidance of Er. Charanjeet Singh (industry coordinator), MR.AMOLJIT SINGH GILL (faculty coordinator) from 09.06. 2014 to 05.07.2014.

(Signature of student)

Place: __________________ Name of Student: Karan guptaDate: __________________ Roll No.: 10903053 (4ME2)

Certified that the above statement made by the student is correct to the best of our knowledge and beliefFaculty coordinator Industry coordinator MR.Amoljit singh gill Er. Charanjeet Singh

Professor,CCET

Asst. Manager,PMS

FMGIL

ACKNOWLEDEMENTI Karn gupta would like to give my sincere thanks to all people (Piston Machine Shop) who have contributed in completing it. Theseare people who simply by being there influenced and insspired me to do different things. I acknowledge my gratitude and indebted toEr.Charanjeet Singh(Training coordinator) who is a source of continuous guidance and inspiration to me. Without their guidance and motivation this report could not completed.

I acknowledge my indebted and gratitude to both of these as they had taken keen interest in work and gave their valuable advice from time to time. I really thanks to them for guide me to complete my project.

Place: ______________Date: ______________ KARAN GUPTACONTENTS

Summary/abstract General introduction (organization)

General introduction (shop) Projects 1. Rejection reduction in pistons on defect operation missing.

CONTAINS: Introduction ( projects) Objective of project Methodology adopted Analysis procedure Testing Implementation Result/Salient outcomes of project Summary/AbstractThis report contains lot of content about study of the pistons, project on rejection reduction in the pistons. PROJECT STUDY ABOUT PISTONS: This topic contains the all the processes done on the pistons, different parameters of piston, constructional details. PROJECT-I (Rejection reduction in pistons on defect operation missing) this project contains a technique tom reduce the scrap in piston on defect of the operation missing. First of all, problem is analyzed by daily inspection then reasons are founded behind the problem. After this flow process diagrams and 5s techniques used for reducing the operation missing scrap. Prato chart analysis is used for obtaining the final result. PROJECT-II (Rejection reduction in pistons on defect skirt size diameter) this project contains a technique tom reduce the scrap in piston on defect of the skirt size dia. First of all, problem is analyzed by daily inspection & fishbone diagram then reasons are founded behind the problem. After this why why technique used for reducing the scrap skirt size dia. X and R chart is used for obtaining the final result. PROJECT-III (Rejection reduction in pistons on defect of PH & KH) this project contains a technique tom reduce the scrap in piston on defect of the KH & PH. First of all, problem is analyzed by daily inspection & fishbone diagram then reasons are founded behind the problem. After this why why technique used for reducing the scrap KH & PH. X and R chart is used for obtaining the final result. PROJECT-IV (Rejection reduction in pistons on defect of transport scrap) this project contains a technique tom reduce the scrap in piston on defect of the transport scrap. First of all, problem is analyzed by daily inspection & fishbone diagram then reasons are founded behind the problem. After this why why technique used for reducing the transport scrap. Direct analyzing technique is used for obtaining the final result.Introduction About Organization:Federal Mogul (Goetze) India ltd.FEDERAL MOGUL GOETZE (INDIA) LIMITED BAHADURGARHLOCATION: GOETZE LIMITED BAHADURGARH is situated at Patiala Rajpura road at about 10 kilometers from Patiala.INTRODUCTION: GOETZE (I) LIMITED, BAHADURGARH was set up in 1954 with the collaboration of M/S GOETZE WERKE, GERMANY, which started its production of piston rings for automobile industry in 1957. Considering the need of complete piston assembly ESCORTS LIMITED ventured into the manufacturing of pistons in 1958 with the collaboration of M/S MAHLE, GmbH GERMANY, which delivered the pistons in 1960.

ESCORTS entered in collaboration with M/S SUKO GmbH, GERMANY for pistons pin in 1967 and manufacturing started in 1968.

To meet the increasing demand of market in 1977 a parallel unit for manufacturing pistons ring was set up in BENGALURU.

1. Established in 1954.

2. 22000 employees.

3. 20 plants in all.

4. The headquarters are in Delhi.

5. Pride of establishing the first dealer networking in the country.

6. Collaboration with GOETZE of Germany.

7. Productions of 1st class pistons ring.

8. Collaboration with MAHLE of Germany.

ORGANIZATION OVERVIEWFederal-Mogul Corporationis a global supplier of automotive components, systems and modules serving the world's original equipment manufacturers and theglobal aftermarket. The companyutilizes its engineering and materials expertise, proprietary technology, manufacturing skill, distribution flexibility and marketing power to deliver products, brands and services ofvalue to its customers. Federal-Mogul is focused on global profitable growth to create valuefor and bring greater satisfaction to its customers, employees and stakeholders.

Federal-Mogul World Headquartersis located at 26555 Northwestern Highway, Southfield, MI 48033, U.S.A. It also have 111 manufacturing sitesworldwide.

Federal-Mogul has 45,000 employees in 35 countries. Worldwide annual sales for year-end 2007 were $6.9 billion. In 2005, OE accounted for 58% of our annual sales, while aftermarket sales are 42%.

Federal-Mogul design, engineer and manufacture a variety of automotive products for its aftermarket and OE customers. Its products include, but are not limited to, bearings, pistons, piston pins, rings and liners, valve seats and guides, dynamic seals, hot and cold static gaskets and seals, liquid elastomeric molded (LEM) seals, systems protection, friction products and aftermarket products (engine components, gaskets, antifriction bearings and seals, brakes, chassis, wipers, fuel pumps, ignition and lighting).

Federal-Mogul aftermarket products are sold under a variety of power brands, including, but not limited to, AE engine products, ANCO wipers, Champion spark plugs and wipers, Fel-Pro gaskets, Ferodo brake pads, Glyco bearings, Goetze piston rings, Moog chassis products, National Wheel End Components, Nral pistons, Payen gaskets, Sealed Power engine products and Wagner lighting and brake products.

GOETZE (I) LIMITED, BAHADURGARH was set up in 1954 with the collaboration of M/S GOETZE WERKE, GERMANY, which started its production of Piston Rings for automobile industry in 1957. Considering the need of complete PISTON assembly ESCORTS LIMITED ventured into manufacturing of Pistons. In 1958 with the collaboration of M/S MAHLE, GERMANY, this delivered the Indian automobile industry its Piston in 1960. ESCORTS entered in collaboration with M/S SUKO, GERMANY, for Piston Pins in 1967 and manufacturing started in 1968.To meet the increasing demand of market, in 1977 a parallel unit for manufacturing Pistons and Pistons Pins was set up in BANGLORE.

Technological leadership matched with innovated thinking has made ESCORTS and GOETZE products to enjoy a high degree of customer confidence and are the first choices of discerning for application ranging from BI-WHEELER to BATTLE TANKS. The plant manufacture over 3.4 million & 2.9 million Piston-Pins & Crank Pins annually .Around 50% of its production is being fitted by original equipment manufacturers of Automobile, Bi-wheelers, Tractors, Stationary Engines, Generator etc. Among its biggest customers are the MUL for which it manufactures pistons for Maruti-800, Esteem, Zen etc. Other customers include Peugeot, Escorts Division-Faridabad, Bajaj, Hindustan Motors, TVS, Rajdoot and many others. The company also directly supplies its products to all the authorized dealers of the spare part for the above companies throughout INDIA.

From 1st October, 1996, ESCORTS LIMITED entered into joint venture with M/S MAHLE GmbH, GERMANY with the formation of new company, ESCORTS MAHLE LIMITED. In 1998, GOETZE also became the part of FEDERAL MOUGAL, a well known group of U.S.A.

9. In June 2000, both ESCORTS MAHLE LIMITED and GOETZE have become QS 9000 certified companies. Wide range of pistons and pins are also exported to U.K., Iran, Bangladesh, Sri-Lanka, Egypt, Singapore and Malaysia.

10. In October 2006 name changed Goetze (India) Limited to FEDERAL-MOGUL GOETZE (INDIA) LIMITED because majority stake holding acquisition by Federal-Mogul Corporation. Federal-Mogul Goetze (India) Limitedis the largest manufacturerof pistons and piston rings in India Pistons are varying from 30mm to 300mm diameter. The most modern production facilities at Federal-Mogul Goetze (India) Limited Patiala is certified TS 16949, ISO14001 and OHSAS 18001.GOETZE AND ITS PRODUCTSGOETZE LIMITED is one of the biggest private concerns in India, which manufactures a variety of products like pistons, gudgeon pins, rings, sleeves and cylinder head. Its present chairman is Mr. ANIL NANDA

PRODUCTS OF PATIALA PLANT PISTONS PISTON RINGS

PISTON PINSEXPORT DESTINATION ANGOLA

BANGLADESH

BHUTAN

EGYPT

MOZAMBIQUE

NEPAL

SRI LANKA CUSTOMERS MARUTI UDYOG LTD.

HINDUSTAN MOTORS

BAJAJ AUTOS

TVS SUZUKI LTD.

MAJESTIC AUTO LTD.

KINETIC ENGINEERING LTD.

HERO MOTORS

EICHER MOTORS

ESCORTS LTD. (FARMTRAC DIVISION)PMS (NEW) CUSTOMERS:

Maruti & Suzuki Ltd. Renault Ltd. Skoda India

Mahindra & Mahindra ltd.

Tata motorsMAJOR CUSTOMERS

I. COMMERCIAL VEHICLES: Telco

Ashok Leyland

Swaraj Mazda Ltd.

Bajaj Tempo Ltd.

Eicher Motors Ltd.

State Transport Undertakings

II. BI-WHEELERS:

Yamaha Motor India Private Ltd.

Bajaj Auto Ltd.

Kinetic Engineering Ltd.

TVS Motor Company

Majestic Auto Ltd.

Ideal Jawa (I) Ltd.

Monto Motors Ltd.

Enfield

Hero Motors Ltd.

III. TRACTORS:

Eicher Tractors Ltd.

Mahindra & Mahindra Ltd.

Escorts Ltd. (Td)

Escorts Ltd. (Farmtrac Division)

Mahindra Gujrat Tractor Ltd.

Hmt Ltd. (Td)

Swaraj Engines Ltd.

New Holland Tractors Ltd.

International Tractors Ltd.

L & T John Deer

IV. PASSENGER CARS & JEEPS:

Maruti Suzuki

Hindustan Motors Ltd.

Mahindra & Mahindra Ltd.

Telco.

V. DEFENCE & RAILWAYS:

Vehicles Factory, Jabalpur.

Alco

VI. COMPRESSORS /AIR CONDITIONERS:

Telco.

Elgi Equipments Ltd.

Voltas Ltd.

Sundram Clayton Ltd.

L & T - Komatsu Ltd.

State Transport Undertakings

VII. STATIONARY ENGINES:

Kirloskar Oil Engines Ltd.

Ruston & Hornsby Ltd.

Birla Yamaha Ltd.

Greaves Lombardini Ltd.

VIII. INTERNATIONAL CUSTOMER

Chevrolet

BMW

Mitsubishi

Ferrari

MANUFACTURING PLANT IN INDIACurrently company has the following manufacturing facilities:

S No.PlantProducts manufacturedRemarks

1.PATIALA

Piston Rings, Pistons,

PinsOriginal FMGIL facility balance acquired through

Escorts Pistons Ltd.

2.BhiwadiValve Train Components & Structural Components

Acquired through merger of Federal-Mogul Sintered Products Limited with our Company.

3Bangalore

Piston Rings, Pistons, Pins

Partly original FMGIL

facility and the balance

acquired through merger

of Escorts Pistons Ltd.

4.Bangalore

Steel Piston Rings

Facility of our subsidiary

FMG PATIALA PLANT

Product:

Pins, Piston & Piston Rings

Processes:

Melting.

Casting.

Cutting & machining.

Inspection

Packaging

Current Employees: over 2500 Site Square Meters: 243333.56 Sq.mPistons

Pins

Rings

FEDERAL MOGUL BRANDS

Federal-Mogul's Abex brand provides commercial-grade brake products, including High-endurance brake pads, brake linings and brake shoes.

AE is recognized throughout the world as a leading brand of quality engine replacement parts. The AE product line includes pistons, piston rings, bearings, valves, timing belts and kits, cam train and other ancillary engine products.

ANCO is the leader in replacement wiper blades, refills, washer pumps and wiper arms. ANCO products ensure the cleanest windshield for every driving condition, making ANCO the Clearest Choice in Wiper Blades.

The Atlas brand is Federal-Mogul's market-leading brand of gaskets in Mexico for diesel engines and heavy-duty equipment. Atlas is part of Federal-Mogul's Sealing Solutions group.

Federal-Mogul's Beral brand provides brake linings and disc brake pads to millions of commercial vehicles, including trucks, trailers, semi-trailers and buses all over the world.

The Carter fuel pump brand provides proven replacement parts with OE fit and form. This approach makes Carter the first choice in aftermarket fuel pumps.

For more than 100 years, Champion has been one of the world's most respected brands, providing a wide array of service replacement parts. These trusted products include spark plugs, wiper blades and filters.

DURON is a specialist in heavy-duty friction and brings exceptional braking power and durability to commercial vehicles and original equipment customers in Europe.

Fel-Pro is the industry's leading brand of aftermarket sealing products for passenger cars, light trucks, medium-duty truck and heavy-duty applications.

For more than a century, Ferodo has led the development of friction materials in their modern form. Ferodo offers brake pads and shoes, brake discs, brake fluids, racing products and motorcycle products.

FP Diesel heavy-duty engine parts and gaskets include a comprehensive range of precision-engineered components for the construction, marine, agricultural, mining, gas compression, trucking and industrial sectors.

Each year, Glyco OE bearings are installed on more than 10 million automotive, maritime and stationary engines, as well as on agricultural and construction equipment.

Federal-Mogul's Goetze brand is a leading name in the automotive world, offering quality piston rings and cylinder liners as well as a range of sealing solutions.

The Federal-Mogul Moog line is the preferred brand of replacement chassis parts by professional technicians. Our Moog products solve steering and suspension problems and make installation easier.

Federal-Mogul's National brand has built a reputation as one of the most respected names in wheel end products. Our design team keeps pace with the industry and provides advanced solutions to meet the needs of today's vehicles.

Necto, the main friction brand in Spain, is characterized in offering an exceptional power of braking and durability. The wide Necto product range includes the most advanced friction materials on the market.

Nral is at the forefront of piston technology. Nral has years of experience in rapid product development, ultra-modern production technology and flexible service.

The Federal-Mogul Payen brand of gaskets, oil seals and cylinder head bolts represents innovative design technology and strict manufacturing standards - qualities that support our reputation as a trusted manufacturer to the automotive aftermarket.

PowerMAX spark plug wire delivers maximum protection and maximum power.

The quality of Federal-Mogul Precision Universal Joints can be seen in all aspects of our parts, from our forged and case-hardened alloy steel crosses to our high-quality, heat-treated needle bearings.

Raimsa is a trusted brand in Mexico that provides an extensive line of kingpins, clutch-release bearings and hanger bearings.

Federal-Mogul's Sealed Power product line represents a complete system of application-engineered internal components, including pistons, piston rings, engine bearings, camshafts, oil pumps, timing components and valve train products.

Speed-Pro has built a reputation for performance engine components. Meeting specific needs - from increased durability to reduced weight, higher temperature demands or excellence in oil control - is the Speed-Pro advantage.

Wagner - the world's leader in brake pads - offers product lines that feature quick, convenient, precise installation for passenger vehicles and medium-duty commercial applications.

Wagner Lighting Products, the Automotive Lighting Experts, has been a visionary in automotive lighting since the development of the sealed-beam headlamp.

MILESTONES1954: Incorporated as a JV with Goethe Werke

1957: Ring & Liner Production, Patiala

1958: Piston Production as Escorts (Automotive Division)(Collaboration: Mahle), Patiala

1960: Cast Iron / Forged Piston Production, Patiala

1968: Pins / Ring Carrier Production. Patiala

1977: Piston / Ring Production, Bangalore

1982: Steel Rings / Large Bore Locomotive Piston, Bangalore

1985: Light Alloy Products, Patiala

1989: Auto Thermic Pistons Production, Bangalore

1990: Molly coated / IKA / Chrome Oil Rings, Patiala

1992: Large Bore Rings / Pistons for Battle Tanks Bangalore

1994: Composite Pistons / New Ring Foundry, Bangalore

1996: Escorts (Automotive Division) hived off into joint venture with M/s Mahle, Germany

1997: Goetze TP (India) Ltd. setup for manufacture of Steel Rings

2000: Merger of Federal-Mogul Sintered Products Ltd. with Goetze (India) Ltd.

2003: Merger of Pistons activities with Goetze (India) Ltd.

2004:Introduction of CHROME-CERAMIC RINGS

2004: Technical Collaboration for Pistons with Federal-Mogul Corporation

2006: Majority stake holding acquisition by Federal-Mogul Corporation

2006: Name changed Goetze (India) Limited to FEDERAL-MOGUL GOETZE (INDIA) LIMITED

RECEIVED BY COMPANY SINCE 1998

1998-1999 Received the best performing supplier award from Tata Cummins Ltd.

1999Our plant at Bhiwadi received the OHSAS 18001:1999 certificate from TUV Certification Body for Environmental Management Systems of RWTUV

Systems GmbH.

2000-2001Escorts Mahle Ltd. received an award of excellence for performance in quality from Maruti Udyog Ltd.

2001-2002Escorts Mahle Ltd. received a certificate of appreciation from Kinetic Engineering Limited for supply of quality materials and meeting schedules.

2002Received the best performance vendor award for casting from Yamaha Motors

India Pvt. Ltd.

2004Our plant at Bhiwadi received ISO 14001:2004 certificate from TUV Certification Body for Environmental Management Systems of RWTUV

Systems GmbH

2004-2005Received the award for QCDDM in Machining Category from Honda

Motorcycle & Scooter India (Pvt.) Limited.

2005 2006Received a certificate of appreciation from Standard Group of Companies for

Supply of components, maintaining quality and adhering to schedules.

2005 2006Received the best supplier performance award from Mahindra & Mahindra

Ltd in the category Proprietary and Electrical.

Introduction:

Piston machine shop (New)

LVD PISTON MACHINE SHOPThe pistons from piston foundry shop are sent to blank stores. From there they are then transported to Piston Machine Shop for machining purpose. Most of the machines are imported from Germany and Japan having very high accuracies up to few microns. In this shop, the cast or the forged pistons are machined to the required size and finish; this is done in a series of operations performed on a piston on different machines. After the pistons have been properly machined, finished and finally inspected; they are send for packing in finished

Article.

The pistons are produced in machine shop in groups or batches. Each batch contains a particular type of piston and is machined for particular time according to demanded customer order. After one batch has been produced, another batch can be brought for production on the machine line. The machines are readjusted according to the specifications of the new type. Identical machine lines have been set up in GASOLINE. Each machine line is used for particular range of sizes of pistons. Different operations on pistons are performed on the different machines, which are placed in sequences so that the pistons can be taken from one place to the other without wastage of time.This shop equipped with the most modern and sophisticated machines have very high accuracies. Each machine does different operations and the piston goes from one machine to another in a sequential way.SHOP ALLOTED: PISTON MACHINE SHOPMajor CustomersLVD1MARURI SUZUKI, FIAT, TATA

LVD2RENAULT, TOYOTA

LVD3TATA, MAHINDRA & MAHINDRA

LVD4MAHINDRA & MAHINDRA

MACHINING SECTIONMACHINE SHOP IS DIVIDED INTO FOLLOWING SECTIONS: -

1. Machine section.

2. Surface treatment section.

3. Lock pin assembly.

4. Groove cutter section.

5. Tool store.

6. Maintenance (Electrical & Mechanical) section.

7. Intermediate & Final InspectionPROJECT STUDY ABOUT PISTONSFUNCTION OF A PISTON:The functions which a piston is called upon to perform in an I.C. engine are:

1. To transmit the force of explosion to the crankshaft.

2. To form a seal so that the high pressure gases in the combustion chamber do not escape into the crank case.

3. To serve as guide & bearing for small end of the connecting rod.

DESIRABLE CHARACTERSTICS OF PISTON 1. It should be silent in operation both during warming up & on normal running.

2. The design should be such that the seizure does not occur.

3. It should offer sufficient resistance to corrosion due to some product of combustion.

(Exp. Sulphur dioxide)

4. It should have the shortest possible length so as to decrease over all engine size.

5. It should be lighter in weight so as inertia forces created by its reciprocating motion are minimum.

6. It must have long life.OPERATING CONDITIONS

The pressure in Combustion Chamber

GASOLINE: Up to 75 bar in NA (Naturally Aspirated)

DIESEL 80 to 110 bars in Naturally Aspirated Engines 130 to 180 bars in Supercharged Engines

Piston Speed Gasoline17m/Sec

Diesel22m /Sec

During each working cycle, the pressure and inertial forces generates complicated load system, depending upon power and speed. The mechanical loads are superimposed by Thermal stresses, which are generated by temperature gradient.

PISTON DESIGN & MATERIAL RECUIREMENT

-Low Density to lower inertial forces

-High Thermal Conductivity so the temperature remains low

-Good strength properties at elevated temperatures, so that thereis high resistance to deformation and fatigue fracture.

-Good wear characteristics even at high temperatures.

-Low co-efficient of thermal expansion; as close as possible to that of Cast Iron in order to limit running clearance in the cylinders.

The above properties are satisfied by AlSiCu alloyPISTON MATERIALSIntroduced in 1926 as standard piston alloy with 12% Silicon varying between 11% ~13% Si and approx. 1% Cu. CSA 12Increasing the Si contents with approximately 18% varying between 17~19% gives hyper-eutectic alloy. -CSA 18Increasing the Si contents with approximately 24%, high Silicon alloy CSA 24 The later 2 alloy allowed reduction in heat expansion and wear. However strength is scarified.

Aluminum Copper Alloy with 3~4% Cu is used for increased Hot strength, limited used in high Load applications-CSCU / S2NConstructional Features

OPERATIONS PISTON CASTING

OD turning/crown facing

Spigot turning

Oil hole Drilling

Rough pin hole Boring/ Circlip grooving/Counter boring/Outer Chamfer

Ultrasonic Testing

Combustion Bowl Formation

Eddy current testing

Valve pocket milling

Aluminum & Cast iron grooving

Finish Surface Turning

Finish pin hole Boring

Washing Surface heat TreatmentPROFILE OF THE PARAMETERS

In the manufacture of pistons there are various problems that are being faced by the firms. Some of these are:-

1. STEP ON GROOVE GROUND

With the step on groove ground, the ring does not fit properly and the piston assembly could not be installed.

2. GROOVE WIDTH

Groove Width is one of the very important parameters of a piston because if the width of the groove is more than the ring then the ring will be loose in the assembly and the gases may escape from the ring surface to the bottom of the piston.

Whereas, if the groove width is less than the ring will not fit and the assembly could not be installed.

3. GROOVE DIAMETER

If the groove diameter is less than the ring will start fluttering and the gases may escape from the piston top to the bottom of the cylinder.

Whereas, if the diameter is more, than the ring will not fit and problem will be faced during the assembly installation.

4. WEIGHT

In case of multi-cylinder engines the pistons are assembled according to weight as it has a lot of impact inside a running engine.

The weight of the pistons are kept in the range of 2 grams because if there is too much variation in the weights of the pistons inside a running engine than the pistons may exert an unbalancing force on the crankshaft which may bend the crankshaft.

5. SKIRT SIZE

Skirt size is also one of the main parameters of the pistons.

If the skirt size is more than the given tolerance than it will seize the engine and if it is less than the lubricating oil will start leaking and the lubrication will not be done properly.

6. STEP ON SKIRT

A step on the skirt will increase the diameter of the skirt more than the tolerance which may either damage the cylinder lining or seize the engine or both.

7. PIN HOLE DIAMETER

The PH. Diameter is also an important parameter which is being checked.

If the diameter of the pin hole is more than the pin will be loose, which will allow fluttering of the pin causing damage to the boss.

Whereas, if the pin hole is tight than the pin will not pass through the hole

8. PIN HOLE SQUARENESS

The pin hole squareness means that whether the crown is perpendicular to the axis of the pin or not.

If the squareness is not ok than the piston will move in a tilted state and will damage the cylinder lining.

9. PIN HOLE OFFSET(acc. to drawing)

In pin hole offset the pin is tilted horizontally. Offset is decided according to the design of the connecting rod. If the offset is more than the required value, the connecting rod may touch the skirt of the piston and damage it.10. UNCLEAR PIN HOLE

If the pin hole is unclear than it will not result in smooth functioning of the pin, as the pin will not rotate smoothly.11. DAMAGE IN PIN HOLE

Due to damage in pin hole the pin will not operate properly.

12. STEP IN PIN HOLE

If there is step in pin hole, it will reduce the pin hole diameter and the pin will not be inserted in the pin hole.

13. COMPRESSION HEIGHT14. COMPRESSION HEIGHT

Compression height is another parameter which has an important role in the working of the piston.

If the comp. height is more than the tolerances than it will surpass the T.D.C and will touch the cylinder head and damage it.

Whereas, if the comp. height is less than the tolerances than more fuel will start entering the assembly which will result in lesser mileage and efficiency.

15. CAVITY

Cavity is another parameter of piston as according to drawing. The main function of the cavity is to properly burn the mixture of air and fuel because if the fuel drops at the centre of the cavity then the force is exerted mainly on the piston.

Whereas, if the fuel is distributed equally inside the chamber than the force is exerted equally in all the directions and only a part of the force is exerted on the piston which produces lesser power.

16. CIRCLIP GROOVE(Snap ring)

Circlip groove is a groove in the pin hole which is provided for the locking of the pin. If the groove is not correctly made than the pin will not stay at its place and connecting rod may move out of the assembly and seize the engine.

17. CRACKS

These refer to the cracks which are present on the piston surface.

18. TOTAL HEIGHT

Total height refers to the length of the piston from top to bottom.

Whereas, if the height is increased from the top, it will touch the top of the cylinder .

19. ROUGHNESS AVERAGE(Ra)

The roughness which is provided on the piston surface helps in retaining the oil film

20. GROOVE ANGLE

Groove angle should always be positive so that when the pressure is exerted from the top the ring is sealed.

Whereas, if the groove angle is already negative, the pressure exerted will further increase the angle and result in more space and leakage of gases will be there accompanying further consequences.

21. GROOVE WAVINESS

Waviness of the groove flank is checked. If there is waviness the ring will rest on lesser surface area and will press the flank resulting in more space, which will result in leaking of gases.

22. CONCENTRICITY

If the chamfer of the skirt is not concentric, the piston will move in a tilted position in the engine which may result in eroding of the cylinder lining.

23. OPEN BORE

To regulate the weight of the piston, open boring is done on some of the casting pistons. A cut as per the requirement is made on the boss.Based upon Performance and Fitment

-Alloy / Material

-Hardness

-Profile / Outside Diameter

-Compression Height

-Groove Axial / Groove Geometry

-Pin Hole Geometry

-Surface Roughness

-Circlip Groove Geometry

-Eye Distance

-WeightCasting Simulation:

Compression -Compression Height

-Roundness / Flatness-RoughnessIn the Engine Piston compression Height is designed to produce optimum Compression Ratio. Any variation in the same may cause drop in Engine power or hitting of piston with Cylinder Head or Valves in case of Diesel Engine or Gasoline Engines have Valve Recesses.

Flatness in any case should be with 0.025 and in any case should not be CONVEX other wise

hitting chances will improve.GROOVE GEOMETRYBLOW-BY: Blow-by is the amount of combusted and non combusted fuel air mixture flowing per unit time between piston and cylinder wall into the crankcase. OIL CONSUMPTION: An engine has a lot of moving and sliding parts. Certain amount of lubrication oil is continuously consumed to reduce friction. The owner comes to know when the engine starts consuming higher quantity of oil . Reduction of oil consumption is one of the main problem in construction of an engine.

SURFECE ROUGHNESS

Where the Cup shape and V-Shape helps in containing the lubricating oil, Saw tooth type profile helps in quick drainage. Piston roughness helps in achieving good bedding in pattern during engine operation and should be controlled with a pitch 0.15+/-0.05, if not defined in drawing.

Circlip Groove GeometryThe function of Circlips is to lock the piston pin and restrict the end play. Any deviation in Circlip Groove parameters like distance, diameter and width may hinder the fitment or may increase the end play due to which circlip may come out and fail the engine.

Unique Design and Quality FeaturesThin Grooves

70% of friction is caused due to rings only. Thin low tension grooves reduce friction and improve fuel economy.

Matching of Boss Oil Hole with Groove Oil Hole Matching of Boss oil hole with groove oil holes ensure better lubrication of gudgeon pin.Accumulator Groove Pressure spikes that get trapped between the first and second compression ring tend to unseat the top ring. This action encourages Ring Flutter and loss of ring seal thereby increasing the reverse blow, which carries oil into the combustion chamber therefore increasing oil consumption. Accumulator groove creates an extra volume of space that tends to average the normal pressure present, keeping the pressure low enough to prevent lifting of top ring.

J -GrooveThis groove is machined on the second ring land of the piston to create a reservoir of oil that is scrapped off the second ring and also to control inter ring pressure. This groove helps in more effective oil drainage.Wedge shape groove and Keystone Groove

Keystone / Wedge type geometry of ring and groove leads to greater ring mobility relative to groove This results in continual local change in the gap width between ring and ring groove side by which any residue that are formed are worked off and ring sticking is prevented. Wedge shape groove are usually in Bi-Wheeler two stroke application and Keystone are in Diesel engine applicationFirst Groove -Lower Flank Sharp EdgeThe edge of first groove lower flank i.e the line where the surface of the piston skirt intersects with the groove side should be located as far to the outside as possible with limiting the clearance between piston and cylinder at this point. This results in a phenomenal decrease in the gases escaping downward i.e. blow by.SURFACE TREATMENT Phosphate Coating: Dark grayish color with thickness around 1 micron. It is used to produce a crystalline corrosion resisting layer. This coating helps to have a good anti frictional properties. Phosphating is done all over the piston.Graphite Coating: Grayish black in color with thickness around 15 -25 microns. It is done on the piston skirt and serves the purpose of emergency lubrication in newly assembled engine till such time normal lubrication is attained. Graphite acts as a dry lubricant and thereby prevents scoring / seizure of the piston till normal oil film is established.

Tin Coating: Ceramic white coating with layer thickness 1-3 microns. It is used to ensure smoother running in of the engine, better lubricated cylinder walls and freedom from cold start scuffing. Tin coating may be done all over the piston or with the exception of gudgeon pin hole.

Anodizing: Grayish layer of Aluminum oxide done on piston crown with thickness around five microns. Anodizing is done due to the fact that during combustion process, piston crown is exposed to very high temperatures. In order to avoid development of cracks in the piston crown due to thermal stresses, the upper layer is hardened by specialized anodizing process. This also prevents corrosion of piston crown.

MolyCoating: Black in cooler with layer thickness 5 -15 microns. Coating acts as anti friction layer which prevents pistons from scuffing during cold start. In some applications, this coating is also provided to reduce clearance, thereby reducing noise phenomenon. Unlike graphite coating this coating should be intact throughout the life of the piston.

PROJECT-IRejection reduction in pistons on defect of operation missingINTRODUCTION (PROJECT)

In LVD machine line; there are lots of surface removal processes done for converting the raw material to the finished work part (piston). During the lot of processes a no of times the piston is input & output to the different machines. But the no of work parts to be produced are more due to this reason, sometimes work parts remained operation free & declared scrap at the Final Inspection. Work part is called the OPERATION MISSING SCRAP. The process in which the piston remains operation free and without operation it reaches to the next machine called the Operation missing.

Common operation missing processes

Eddy current Oil hole Drilling

Stamping

Washing/Surface treatmentCODING TO THESE OPERATION MISSING SCRAPS

Surface treatment A1

Oil holes A2

Stamping A17

Eddy current-A29OBJECTIVE OF PROJECT

To reduce the scrap rejection rate at the end of final inspection: At the end of Final inspection lot of pistons founded operation free & these are declared as scrap. Main operations misses are stamping, eddy current testing, oil hole drilling, surface treatment/washing. These scraps are rejected at the end. To reduce this rejection rate controlling on operation missing to be done under this project. To improve the economy of the plant: If the rejection rate will be more means more scrap founded at the end. More the scrap means, wastage of the material, wastage of time, wastage of labor cost. Hence these wastages directly affect the economy of the plant. To impure the economy, there is necessary to minimize the operation missing. To reduce the wastages during the manufacturing: Sometimes the operator misses the operation and piston goes to next machine without machining and after that it founded un-machined during the manufacturing. It declared as scrap or waste. To reduce this wastage during the manufacturing controlling the operation is necessary.REASONS BEHIND THE OPERATION MISSING

1) Due to the lake of concentration of the machine operator.

2) Occupied space all around.

3) Wrong method of placing the piston.

4) Using same bin for Input & output wok parts.

.

5) Both input & output bins at same side.

6) During the checking sometimes operator misses the part.

7) During the time when the operator remains 2 or less pistons behind in box before any interruption (e.g. Washroom, tea break, tool install).

8) When the operator does not follow the standard operating procedure and flow process chart.

9) Input and output bins are not arranged systematically.

PROBLEM ANALYSIS

For the whole 1st month after the joining, the team was gathering information that despite so many measures taken, why the rejection rate is still so high. The reports are as follows.

So many pistons are founded scrap due to operation missing.

Eddy current operation missing scrap rate was so high.DISCUSSION ABOUT SOLUTION TO THE PROBLEM

After finding out the various reasons to the problem of scrap rate, discussions were carried out to find out the possible solutions. The solutions that were considered are as follows:- Training to be given to the operators.

Process follow diagram.

Standard operating procedure.

Control plain. Visually check around 10 pistons in every cell.

THE SHIFT INCHARGE WAS TO BE GIVEN THE REPORT OF EVERY CELL AFTER EVERY ROUND IN THE SHOP.

METHODOLOGY ADOPTED

FOLLOW THE PROCESS FLOW DIAGRAM: Process flow diagram can be defined as movements of the operator & flow of the wok piece from one machine to other in a machining line, while it converted from raw material to the end product.A) FLOW PROCESS DIAGRAM FOR CONTROLLING THE OIL HOLE DRILLING MISSING

MOVEMENT OF OPERATOR: left hand for un-loading Right hand for loading.

B) FLOW PROCESS DIAGRAM FOR CONTROLLING THE EDDY

CURRENT & STAMPING MISSING: MOVEMENT OF OPERATOR: left hand for un-loading Right hand for loading.

C) FLOW PROCESS DIAGRAM FOR CONTROLLING THE

ULTRASONIC & STAMPING MISSING: MOVEMENT OF OPERATOR: left hand for un-loading Right hand for loading.

5S TECHNIQUE 5S is the Japanese technique uses for systematic, good and clean working environment in an organization. Meaning of 5s Seiri- sorting

Seiton- straightening or setting in order / stability

Seiso- systematic cleaning / sweeping and shining

Seiketsu- standardizing

Shitsuke- sustaining the decipline HOW 5S USED FOR THE OPERATION MISSING:

1) If machines and bins are sorted in systematically order, the input and output parts will not mix up.

2) If the workers will maintain discipline in the line, lesser chance of operation missing.

STANDARD OPERATING PROCEDURES FOR TRAINING PURPOSE:

Standard operating procedures are those in which training is given to the operators About The setup the machines before starting them

Which parts should be machined

How to place the wokparts to the Machine

How to run the machine Which bins used for which purpose so that they cannot mix up.

Controlling the movements of the hand.

Both the input and output bins should not places at same side.

To ensure the checked part.

OK parts should be stamped.

OBSERVATION: By this procedure the operators are tested to their technique & founded comfortable to reduce scrap.

ANALYSIS PROCEDUREPARETO ANALYSIS CHART: What is a Pareto Chart? The Pareto Chart is named after Vilfredo Pareto, a 19th century economist who postulated that a large share of wealth is owned by a small percentage of the population. This basic principle translates well into quality problems. A Pareto Chart is a series of bars whose heights reflect the frequency or impact of problems. The bars are arranged in descending order of height from left to right. This means the categories represented by the tall bars on the left are relatively more significant then those on the right. This bar chart is used to separate the vital few from the trivial many. These charts are based on the Pareto Principle which states that 80 percent of the problems come from 20 percent of the causes. Pareto charts are extremely useful because they can be used to identify those factors that have the greatest cumulative effect on the system, and thus screen out the less significant factors in an analysis. Ideally, this allows the user to focus attention on a few important factors in a process.

Why should a Pareto Chart be used? You can think of the benefits of using a Pareto Charts in economic terms. A Pareto Chart breaks a big problem down into smaller pieces, identifies the most significant factors, shows where to focus efforts, and allows better use of limited resources. You can separate the few major problems from the many possible problems so you can focus your improvement efforts, arrange data according to priority or importance, and determine which problems are most important using data, not perception.

A Pareto Chart can answer the following questions:

o What are the largest issues facing our team or business?

o What 20% of sources are causing 80% of the problems?

o Where should we focus our efforts to achieve the greatest improvements?

When should a Pareto Chart be used? A Pareto Chart is a good tool to use when the process you are investigating produces data that are broken down into categories and you can count the number of times each category occurs. A Pareto diagram puts data in a hierarchical order, which allows the most significant problems to be corrected first. The Pareto analysis technique is used primarily to identify and evaluate nonconformities, although it can summarize all types of data. It is the perhaps the diagram most often used in management presentations. Making problem solving decisions isnt the only use of the Pareto Principle. Since Pareto Charts convey information in a way that enables you to see clearly the choices that should be made, they can be used to set priorities for many practical applications. Some examples are:

o Process improvement efforts for increased unit readiness

o Skills you want your division to have

o Customer needs

o Suppliers

o Investment opportunities PARETO ANALYSIS CHART FOR SCRAP

Frequency

46.45 88.5 97.56

FEB MAR 2012

TESTINGTeam members worked on the project regularly and the following results were obtained. Are the workers working according to the flow process diagram & following the standard operating procedure.

How much worker working to his concentration.

Are the work parts visually analyzed continuously? Are the workers maintaining 5s properly? All the piston of any bin are finished before any break.IMPLEMENTATION

The results that were obtained were as desired by the team. So the same routine was firmly accepted and put to practice for the rest of the time period also.RESULTS/ SALIENT OUTCOMES

SCRAP REJECTION RATE: By using this project, scrap rejection rate decreased. In 2011 (before this project)

operation codeScraps

Eddy current/ Oil holeA29/A61.52%

In 2012 (till 31/07/2012)operation codeScraps

Eddy current/Oil holeA29/A60.50%

Reduce in the scrap rejection rate will definite increase the economy of plant. Lesser scrap at the end of final inspection. Good working culture and flexibility in working. Fluency in the work.

COMPERISON OF SCRAP DATA 2011-2012

In 2011 (operation missing scrap): 1.52%In 2012 (operation missing scrap): 0.50% (till 31/07/2012)

Annual savings after accomplishing the project: 3.65lacs PROJECT-IIRejection reduction in pistons on defect of skirt sizeINTRODUCTION (PROJECT)

Skirt Size (d1 or d2): Skirt size is also one of the main parameters of the pistons. If the skirt size is more than the given tolerance than it will seize the engine and if it is less than the lubricating oil will start leaking and the lubrication will not be done properly.Diameter below the oil sweeping ring and combustion head (3rd ring) at 90 degree from pinhole symmetry axis.

Skirt Size dia. Scraps:The scrap which does not fulfilling the dimensional accuracy on size of skirt dia. known as skirt size dia. scraps. Coding to skirt size dia. scrap: A7Problem:

skirt diameter is not in proper dimensions. Over the tolerance limit Given tolerance: -5u to +5u Not accomplishing the end specifications.

OBJECTIVE OF PROJECT

To reduce the scrap rejection rate: Skirt size dia. is the maximum dia. of the piston. so it should be within the tolerance limit. If it is not within limits means these pistons will be founded scrap at the end of final inspection. To reduce this rejection rate is this projects main objective. To improve the economy of the plant: If the rejection rate will be more means more scrap founded at the end. More the scrap means, wastage of the material, wastage of time, wastage of labor cost. Hence these wastages directly affects the economy of the plant. To impure the economy, there is necessary to control the skirt size dia.PROBLEM ANALYSISMachine name: Weisser OVAL TURNING machineDetails of problem

TO REDUCE SKIRT SIZE DEFECT FROM 0.064% TO 0.2 %

SKIRT SIZE REJECTION TREND MONTHWISEPROBLEM ANALYSIS TECHNIQUE

Technique used: FISHBONE AnalysisKEYWORDS:Cause-and-Effect Diagram, Ishikawa diagram, Fishbone diagram, Root Cause Analysis.What Is a Cause-and-Effect Diagram?

A graphic tool that helps identify, sort, and display possible causes of a problem or quality characteristic.OBJECTIVES:The main goal of the Fishbone diagram is to illustrate in a graphical way the relationship between a given outcome and all the factors that influence this outcome. The main objectives of this tool are: Determining the root causes (G) of a problem.

Focusing on a specific issue without resorting to complaints and irrelevant discussion.

Identifying areas where there is a lack of data. Benefits of Using a Cause-and-Effect Diagram

Helps determine root causes Encourages group participation Uses an orderly, easy-to-read format Indicates possible causes of variation Increases process knowledge Identifies areas for collecting data

FIELD OF APPLICATION: The Fishbone diagram could be applied when it is wanted to: Focus attention on one specific issue or problem. Focus the team on the causes (G), not the symptoms. Organize and display graphically the various theories about what the root causes (G) of a problem may be. Show the relationship of various factors influencing a problem. Reveal important relationships among various variables and possible causes (G). Provide additional insight into process behaviors.

RELATED TOOLS Pareto chart, Scatter diagram, Flowcharts Check sheetsDESCRIPTION Dr. Kaoru Ishikawa, a Japanese quality control statistician, invented the fishbone diagram. It is often also referred to as the Ishikawa diagram. The fishbone diagram is an analysis tool that provides a systematic way of looking at effects and the causes that create or contribute to those effects. Because of the function of the fishbone diagram, it may be referred to as a cause-and-effect diagram. The design of the diagram looks much like the skeleton of a fish. Therefore, it is often referred to as the fishbone diagram. A cause-and-effect diagram can help identify the reasons why a process goes out of control. Often the fishbone diagram can be used to summarize the results of a brainstorming session, identifying the causes of a specified undesirable outcome. It helps to identify root causes (G) and ensures a common understanding of the causes. The steps for constructing and analyzing a Cause-and-Effect Diagram are outlined below:

Step 1 - Identify and clearly define the outcome or effect to be analyzed2.

Formulate the problem and write it in a box on the right side of the diagram. Everyone must clearly understand the nature of the problem and the process/product being discussed. If everyone is not clear on the purpose of the session, the session will not resolve the problem. In this step the following rules have to be applied:

Decide on the effect to be examined. Effects are stated as particular quality characteristics, problems resulting from work, planning objectives, and the like.

Use Operational Definitions. Develop an Operational Definition of the effect to ensure that it is clearly understood.

Remember, an effect may be positive (an objective) or negative (a problem), depending upon the issue thats being discussed.

Using a positive effect which focuses on a desired outcome tends to foster pride and ownership over productive areas. This may lead to an upbeat atmosphere that encourages the participation of the group. When possible, it is preferable to phrase the effect in positive terms.

Focusing on a negative effect can sidetrack the team into justifying why the problem occurred and placing blame. However, it is sometimes easier for a team to focus on what causes a problem than what causes an excellent outcome. While you should be cautious about the fallout that can result from focusing on a negative effect, getting a team to concentrate on things that can go wrong may foster a more relaxed atmosphere and sometimes enhances group participation.

You must decide which approach will work best with your group. Step 2 - Use a chart pack positioned so that everyone can see it, draw the spine and create the effect box.

Draw a horizontal arrow pointing to the right. This is the spine.

To the right of the arrow, write a brief description of the effect or outcome which results from the process.

Draw a box around the description of the effect. Step 3 - Identify the main causes (G) contributing to the effect being studied. These are the labels for the major branches of your diagram and become categories under which to list the many causes related to those categories.

Establish the major causes, or categories, under which other possible causes will be listed. You should use category labels that make sense for the diagram you are creating.

Write the main categories your team has selected to the left of the effect box, some above the spine and some below it.

Draw a box around each category label and use a diagonal line to form a branch connecting the box to the spine.

Step 4 - For each major branch, identify other specific factors which may be the causes of the effect

Identify as many causes or factors as possible and attach them as sub branches of the major branches.

Fill in detail for each cause. If a minor cause applies to more than one major cause, list it under both.

Step 5 - Identify increasingly more detailed levels of causes and continue organizing them under related causes or categories. You can do this by asking a series of why questions. You may need to break your diagram into smaller diagrams if one branch has too many sub branches. Any main cause (3Ms and P, 4Ps, or a category you have named) can be reworded into an effect.Step 6 - Analyze the diagram. Analysis helps you identify causes that warrant further investigation. Since Cause-and-Effect Diagrams identify only Possible Causes, you may want to use a Pareto Chart to help your team determine the cause to focus on first.

Look at the balance of your diagram, checking for comparable levels of detail for most of the categories.

A thick cluster of items in one area may indicate a need for further study.

A main category having only a few specific causes may indicate a need for further identification of causes.

If several major branches have only a few sub branches, you may need to combine them under a single category.

Look for causes that appear repeatedly. These may represent root causes.

Look for what you can measure in each cause so you can quantify the effects of any changes you make.

BENEFITS Helps determine root causes

Encourages group participation Uses an orderly, easy-to-read format to diagram cause and effect relationships Indicates possible causes of variation Increases knowledge of the process by helping everyone to learn more about the factors at work and how they relate Identifies areas for collecting data

PREREQUISITES A problem is composed of a limited number of causes, which are in turn composed of sub causes.

Distinguish these causes and a sub cause is a useful step to deal with the problem. How CAUSE-&-EFFECT Diagram used in this problem analyzing

Facts behind the problem

Method:Wrong input methodimproper loading.Material:Material consumptionMachine:Incorrect cutting parametersChilling unit temperatureUneven clamping pressureHot axis alignment

Measurement:

Instrument not calibratedInstrument damageMan:Low skill level

Lack of trainingDISCUSSION ABOUT SOLUTION TO THE PROBLEM


Loading method should be proper.


Control plain. Visually check around 10 pistons in every cell. Operator should check the instrument by comparing with masters.

Operator should check the machine parameters.THE SHIFT INCHARGE WAS TO BE GIVEN THE REPORT OF EVERY CELL AFTER EVERY ROUND IN THE SHOP.Methodology AdoptedMethodology adapted to reducing the skirt size dia. scraps (A7): WHY WHY ANALYSIS.WHY WHY ANALYSISThere are so many reasons behind every problem. So the every action for problem is taken first all the reasons investigated behind the problem and then a flow diagram is made which tells all the reasons behind the problem. Then from flow diagram first of all last (bottom) problem is solved then one by one problems solved from lower problem to upper problem. This process is called the why why analysis. How this applied to controlling skirt size diameterWhy?

Why did we take above action?

Why?

Due to high scrap percentage of Skirt Size Defect

Why?

Due to temp variation

Why?

Due to the difference in temperature of Final inspection and linePROCESS

Coolant flow inside match to control the temperature variation

Control the temp. Variation b/w line & final inspection

Scrap of skirt size diameter will reduce

One point lessonMaster pistons put in the continue coolant flow inside match to control the temperature variation.RESULT/ SALIENT OUTCOMES

DATA ANALYSISHow: Directly by observationsInstrument used: Skirt dia. checking instrument.

Range of instrument: +30u to +30uLeast count of instrument: 0.01mm

Given Tolerance: -10u to +10uDATA BEFORE 7/01/2012:Present level of the scrap: 0.64%

DATA TILL 31/07/2012:Target level of the scrap: 0.20%

CHART OF SCRAP DATA COMPERRISON B/W 2011 & 2012

Saved amount: 4.27 lacs/yearPROJECT-IIIRejection reduction in piston on defect of PH & KH

Faculty members:

Gurpreet Singh (senior engineer)

& co-workersINTRODUCTION (PROJECT)

PH (Pinhole): The bore of the piston in which the pin is inserted to connect the connecting rod and piston known as the PIN HOLE.

PH offset tolerance: -10u to +10uPH squreness: -25u to +25u

COMPRESSION HEIGHT (KH):

Compression height is another parameter which has an important role in the working of the piston.

If the comp. height is more than the tolerances than it will surpass the T.D.C and will touch the cylinder head and damage it.

Whereas, if the comp. height is less than the tolerances than more fuel will start entering the assembly which will result in lesser mileage and efficiency

Compression height tolerance: -25u to +25uCoding: A (14)OBJECTIVE OF PROJECT

To reduce the scrap rejection rate: master piston is not compared to the instrument & pistons are not visually analyzed, these pistons will be founded scrap at the end of final inspection. To reduce this rejection rate is this projects main objective. To improve the economy of the plant: If the rejection rate will be more means more scrap founded at the end. More the scrap means, wastage of the material, wastage of time, wastage of labor cost. Hence these wastages directly affect the economy of the plant. To impure the economy, there is necessary to reduce the scrap of the pinhole & comp. height.

PROBLEM ANALYSIS

Machine name: Weisser Finish PH machineDetails problem (PH)1. PIN HOLE DIAMETER

The PH. Diameter is also an important parameter which is being checked.

If the diameter of the pin hole is more than the pin will be loose, which will allow fluttering of the pin causing damage to the boss.

Whereas, if the pin hole is tight than the pin will not pass through the holePinhole dia. scraps: A10

2. PIN HOLE SQUARENESS

The pin hole squareness means that whether the crown is perpendicular to the axis of the pin or not.

If the squareness is not ok than the piston will move in a tilted state and will damage the cylinder lining.

Pinhole squreness scraps: A113. PIN HOLE OFFSET(acc. to drawing)

In pin hole offset the pin is tilted horizontally. Offset is decided according to the design of the connecting rod. If the offset is more than the required value, the connecting rod may touch the skirt of the piston and damage it.Pinhole offset scraps: A124. UNCLEAR PIN HOLE

If the pin hole is unclear than it will not result in smooth functioning of the pin, as the pin will not rotate smoothly.

Pinhole unclear scraps: A13 (a)5. DAMAGE IN PIN HOLE Due to damage in pin hole the pin will not operate properly.Pinhole damage scraps: A13 (d)6. STEP IN PIN HOLE

If there is step in pin hole, it will reduce the pin hole diameter and the pin will not be inserted in the pin hole.Step in Pinhole scraps: A13 (d)Details problem (KH)

Compression height was over the tolerance limit-25u to +25u

TO REDUCE KH & PH SCRAP FROM 2.33%+0.60% TO 1.00%

COMP. HEIGHT REJECTION TREND MONTHWISE

PROBLEM ANALYSIS TECHNIQUE

Technique used: FISHBONE AnalysisKEYWORDS:Cause-and-Effect Diagram, Ishikawa diagram, Fishbone diagram, Root Cause Analysis.How CAUSE-&-EFFECT Diagram used in this problem analyzing


Method:Wrong input methodImproper loading.Material:Material consumptionMachine:Incorrect cutting parametersAlignment of cooling pipesUneven clamping pressure

Measurement:

Instrument not calibratedInstrument damageMan:Low skill level

Lack of training

DISCUSSION ABOUT SOLUTION TO THE PROBLEM




Control plain. Visually check around 10 pistons in every cell. Operator should check the instrument by comparing with masters.

Operator should check the machine parameters.THE SHIFT INCHARGE WAS TO BE GIVEN THE REPORT OF EVERY CELL AFTER EVERY ROUND IN THE SHOP.Methodology Adopted

Methodology adapted to reducing these scraps (A7): WHY WHY ANALYSIS.

WHY WHY ANALYSIS

There are so many reasons behind every problem. So the every action for problem is taken first all the reasons investigated behind the problem and then a flow diagram is made which tells all the reasons behind the problem. Then from flow diagram first of all last (bottom) problem is solved then one by one problems solved from lower problem to upper problem. This process is called the why why analysis.

How this applied to KH & PH scrapsWhy?

Why did we take above action.

Why?

Due to high scrap percentage of Comp. height.

Why?

Due to Chip pressing on fixture seat.

Why?

Due to improper coolant flow on fixture.

Why?

Due to coolant pipe not proper position.PROCESS

Pipe placed to proper position

Proper flow of mixture automated

Removal of chip

Compression height & pinhole within range

One point lesson (corrective actions)Combustion bowl machine total height parameter +10u with finish PH compression height.Maintain PH master gauge temperature & use SP (setting piston) at shift start to control temperature variation.RESULT/ SALIENT OUTCOMES

BY DATA ANALYSISHow: Directly by observations

Instrument used: a) compression height checking instrument (KH).

Range of instrument: -30u to +30uLeast count of instrument: 0.001mmGiven Tolerance: -25u to +25ub) Pneumatic instrument (PH)Range of instrument: -30u to +30uLeast count of instrument: 0.0001mmGiven Tolerance: +1u to +5uDATA BEFORE 7/01/2012:Present level of the scrap: 2.33% + 0.60% (KH & PH)DATA TILL 31/07/2012:Target level of the scrap: 1.00%


Saved amount: 9.2 lacs/year

PROJECT-IVRejection reduction in pistons on defect of Transport

ScrapINTRODUCTION (PROJECT)

The scrap of piston due to transportation from one place to other for the different processes and shipping & it happens during the conveyor system problem mishandling.Coding to transport scrap: A21PROBLEMS: Cracks.

Change in shape.

Edge breaking. Total damage. Etc.

OBJECTIVE OF PROJECT

To reduce the scrap rejection rate: master piston is not compared to the instrument & pistons are not visually analyzed, these pistons will be founded scrap at the end of final inspection. To reduce this rejection rate is this projects main objective. To improve the economy of the plant: If the rejection rate will be more means more scrap founded at the end. More the scrap means, wastage of the material, wastage of time, wastage of labor cost. Hence these wastages directly affect the economy of the plant. To impure the economy, there is necessary to reduce the scrap of transport.

PROBLEM ANALYSIS

Machine name: WASHING MACHINEDetails problemTO REDUCE TRANSPORT DEFECT FROM 1.5% TO 0.5 %

TRANSPORT REJECTION TREND MONTHWISE

PROBLEM ANALYSIS TECHNIQUE

Technique used: FISHBONE AnalysisKEYWORDS:Cause-and-Effect Diagram, Ishikawa diagram, Fishbone diagram, Root Cause Analysis.How CAUSE-&-EFFECT Diagram used in this problem analyzing


Method:Wrong input methodImproper transportation

Improper loading.Machine:Conveyor problem

Man:Low skill level

Lack of training

Mishandling.

DISCUSSION ABOUT SOLUTION TO THE PROBLEM



Handling the material.

THE SHIFT INCHARGE WAS TO BE GIVEN THE REPORT OF EVERY CELL AFTER EVERY ROUND IN THE SHOP.Methodology Adopted

Methodology adapted to reducing these scraps (A7): WHY WHY ANALYSIS.

WHY WHY ANALYSIS

There are so many reasons behind every problem. So the every action for problem is taken first all the reasons investigated behind the problem and then a flow diagram is made which tells all the reasons behind the problem. Then from flow diagram first of all last (bottom) problem is solved then one by one problems solved from lower problem to upper problem. This process is called the why why analysis.

How this applied to transport scraps Why?

Why did we take above action.

Why?Due to high scrap percentage of Transport scrap.

Why?

Due to Improper material handling

Why?

Due to operation of washing was performed in another plant which was at some distance from the final operation, because od which transportation was more.PROCESS

A washing machine installed nearbyProper material handlingReduction in transport scrapOne point lesson (corrective actions)Single piston flow implement inline & single point lesson for process flow display for all awareness as per PFD.RESULT/ SALIENT OUTCOMES

DATA ANALYSISHow: Directly by observations

DATA BEFORE 7/01/2012:Present level of the scrap: 1.52% DATA TILL 31/07/2012:Target level of the scrap: 0.50%


Saved amount: 8.11lacs/year

EMBED Excel.Sheet.8

_1397735773.

_1397816683.

_1397819199.

_1397803100.

_1397801503.xlsChart2

5.78

4.27

4.44

5.18

2.38

3.27

2.07

1.71

%SCRAP

Sheet1

MONTH%SCRAP

AUG.5.78

SEPT.4.27

OCT.4.44

NOV.5.18

DEC.2.38

JAN.3.27

FEB.2.07

MARCH.1.71

Sheet1

%SCRAP

Sheet2

Sheet3

_1394382921.xlsChart1

7.32Eddy CurrentEddy Current

surface treatment2.71surface treatment

Oil HolesOil Holes0.59

7.32%

2.71%

0.59%

Sheet1

7.32%2.71%0.59%

Eddy Current7.32

surface treatment2.71

Oil Holes0.59

To resize chart data range, drag lower right corner of range.

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