Upload
prajkta-ranpise
View
105
Download
0
Embed Size (px)
Citation preview
Presented By - Rohit.R.Ranpise
Company Name - Kirloskar Oil Engines
Renovation of the existing assembly lines
To design an efficient Layout
To create conducive work Environment
To calculate the time required for various steps
which leads to the complete manufacturing of
the engine on the assembly line
The time calculated by using this process will be used to study and implement various methods to optimize and increase productivity and conversion costs respectively
Product Information
Engine Model HA R-1080 SL90
No. Of Cylender
2,3,4,6 2,3,4,6 6
WORK CONTENT EVALUATION & LINE BALANCING
WORK CONTENT EVALUATION & LINE BALANCING
WORK CONTENT EVALUATIONWORK CONTENT EVALUATION LINE BALANCINGLINE BALANCING
Enlist all the activities carried out on the Assembly Line
Identify the waste activity
Eliminate the waste activity
Reduction in work content
Enlist all the activities carried out on the Assembly Line
Identify the waste activity
Eliminate the waste activity
Reduction in work content
Everyone is doing the same amount of work
Variation is ‘smoothed’
No one overburdened
No one waiting
Everyone is doing the same amount of work
Variation is ‘smoothed’
No one overburdened
No one waiting
Number of activities are carried out
CLYLINDER HEAD FITMENT PIPE FITMENT
ALTERNATOR FITMENT
Introduction:Initially in the first week I was shown around the assembly lines, store, testing, packing areas.
Video shooting: Started with the Video Shooting of Assembly lines of SL-90, 4R-1080, 6R-1080, HA-6 and Later RA.
After Shooting the videos were loaded on the Desktop.
Stage wise break up of videosThe videos were stage wise broken up and labeled
accordingly. Video Analysis
The video analysis of the videos taken were done. Detail Break up of each Activity was done. The time required for each activity involved were listed according to the videos. The start and end time for each step of a particular activity, the manpower involved in itSTATION
NUMBERSERIAL NUMBER
ACTIVITYTIME
MANPOWER(PER STATION)
ORIENTATION
( SIDE UP )
OPERATION ON FACE
TOOL USED
START END
Identifying & Eliminating Non-Valuable Activity
Briefing of each activityThis Analysis was then briefed into the time taken for
each activity neglecting the non valuable activity.
Targeted dataData for the number of stations planned and number of
engines targeted was taken.
Existing Assembly Line Layout
Total Time = 144 min
Station Number
Operations Work Force Cycle Time(sec)
1 Crankcase plugging 1 0:07:13 2 Crankshaft fitment 2 0:15:44 3 Crankcase loading 1 0:04:31 4 Header, Lubrication Oil Pump assembly 2 0:06:39 5 Connecting Rod assembly 2 0:06:56 6 Bell housing & Flywheel assembly 2 0:09:54 7 Gear casing assembly 1 0:15:57 8 Lube. Oil Sump assembly 2 0:07:12 9 Fuel timing and alternator mounting 2 0:21:21 10 Engine unloading 1 0:06:14 11 Cylinder head fitment 2 0:09:52 12 Tappet and pipes fitment 2 0:15:04 13 Turbo accessories fitment 2 0:15:55 14 Leak testing - 0:01:31 15 Turbo completion - 0:07:13 16 Special engine completion 1 0:15:44
Total 23 144 min
Station No.16
Station No. 5
Number 5
Nu
Station No. 6
Station No. 7
Station No. 8
Station No . 9
Station No. 10
Station No.11
Station No.12
Station No.13
Station No.14
Station No.15
Station No.1
Station No.4
Station No.3
Station No.2
Everyone is doing the same amount of work
Doing the same amount of work to customer requirement
No one overburdened No one waiting Everyone working together in a
BALANCED fashion Variation is ‘smoothed’
Unbalanced Assembly Line
Unbalanced Assembly Line
Balanced Assembly Line
Balanced Assembly Line
The line balancing was done for each Assembly
lines
( 6R, SL-90, HA-6 ) according to the data given.
Change of Stations when orientation change,
clubbing of activities which can be carried on
the same side and which doesn’t depend on
other activities were done
For HA 6 Engine
Targeted Engines per shift = 10
Working hours per shift = 460 minutes
Efficiency = 90%
Effective Working Hours = 414 minutes
TAC time = 41 minutes 24 seconds
Time taken for the entire engine to be assembled = 2 hours 17
minutes 46 seconds.
After balancing of the line, the time required for one engine to
be completed is 1 hour 56 minutes 18 seconds.
For 6R 1080 Engine
Targeted Engines per shift = 20
Working hours per shift = 460 minutes
Efficiency = 90%
Effective Working Hours = 414 minutes
TAC time = 21 minutes 10 seconds
Time taken for the entire engine to be assembled = 2 hours
24 minutes 03 seconds.
After balancing of the line, the time required for one engine
to be completed is 1 hour 38 minutes 3 seconds.
For SL90 Engines
Targeted Engines per shift = 10
Working hours per shift = 460 minutes
Efficiency = 90%
Effective Working Hours = 414 minutes
TAC time = 41 minutes 24 seconds
Time taken for the entire engine to be assembled = 2
hours 44 minutes 10 seconds.
After balancing of the line, the time required for one engine
to be completed is 2 hour 09 minutes 29 seconds.
Proposed Assembly Line Layout
Total Time = 98 min
FLOW
Station Number
Operations Work Force Cycle Time(sec)
1 Core Plugging & Camshaft assembly 1 0:21:00 2 Loading, Deflector, LOP, Bell Hsg,
Flywheel ass. Con rod ,Header 2 0:20:32
3 Cam bush, Gear Casing, Tappet, Gear fitment, Cam shaft ,Crank pulley ,
2 0:18:53
4 Fuel Timing ,Alternator, Belt, Fuel Filter 2 0:11:04 5 Engine Unloading, Starter, Pipe fitment,
Push Rods, Rocker lever, Tappet Setting. 2 0:16:23
6 Rocker cover, Pulley and Belt fitment, Turbo pipes fitment, Turbo accessories fitment.
2 0:11:00
Total 11 98 min
Station No .1 Station No. 2 Station No. 3 Station No. 4 Station No. 5 Station No.6
Engine ModelRA
EnginesHA
EnginesSL90
Engines
Present Work Force
23 15 11
Proposed Work Force
11 12 7
Reduction In Work Force
12 3 4
Percentage Reduction In Work Force
52.2% 20.0% 36.4%
Total Work Force Reduction 19
Reduction in the Work Force
Initially some of the stations were overloaded
High WIP
Excess workforce were allocated than required
Lot of engines were accumulated after station 2
Sharing of equipment increased the assembly
time
Work content was reduced
Assembly time was reduced
Line Imbalance was reduced
Optimum work force was calculated
Productivity will increase
THANK YOU