Project report

Isgec Heavy Engineering limited, Yamuna Nagar

IDLE TIME AND REWORK TIME REDUCTION

Submitted by
Manjeet Sheoran
Roll No. 100908056

Under the Guidance of

(Dr. VK Jain- Professor)

(Vinay chawla- Deputy Manager)

Faculty Coordinator

Industry Coordinator

Department of Mechanical Engineering

THAPAR UNIVERSITY, PATIALA
June 2012

DECLARATION

I hereby declare that the project work entitled Idle time and rework time reduction is an
authentic record of my own work carried out at Isgec Heavy Engineering Limited as
requirements of six months project semester for the award of degree of B.E. (Mechanical
Engineering), Thapar University, Patiala, under the guidance of Mr. Vinay Chawla and Dr.
VK Jain, during January to June, 2012.

(Manjeet Sheoran)
(100908056)

Date: ___________________

Certified that the above statement made by the student is correct to the best of our knowledge
and belief.

(Dr. VK Jain- Professor)

Faculty Coordinator

(Vinay chawla- Deputy Manager)

Industry Coordinator

CONTENTS OF THE REPORT

1.

Cover page

2.

Inner page

3.

Declaration

4.

Acknowledgement

5.

Contents

Summary / abstract (Maximum one page about the work content)

Introduction (About the organization)

Project/s

6.

Title of the project (problem identification)

Methodology
Implementation
Results (e.g. cost benefit analysis)

Conclusions and Future Scope of Work

References (if any)

Impediments/difficulties faced during project semester on project work;

Suggestions related to work/project semester.

PREFACE

Training in an industry is a dynamic tool to get feeling of practical aspect of whatever has been learnt
by us in books. It greatly enhances knowledge with the practical experience. Training in such great
and well-managed company is a great opportunity for the trainer as apart from the basic training.
Also we get a chance to be familiar with certain other aspects of industry.

Our objective of undergoing industrial training is to acquire practical knowledge. Training enables
us to get a clear-cut view of the subject that we have studied. Both theory and practical are essential.
Hence we can say, The theory is blind without practical and practical without theory. In fact, both
are complementary to each other.

I am proud of receiving Industrial Training at Isgec, which is one of the top heavy engineering
industries in India.

ACKNOWLEDGEMENT

To start with, I wish to express my sincere gratitude to Mr. Daljeet Singh and Mr. Kishore
Khanna for providing me an opportunity to undergo six months Industrial Training at Isgec,
Yamuna Nagar, Haryana.

I give my great sense of privilege in submitting this project work, for which I am grateful
and indebted to Mr. Rajinder Agnihotry (Training Officer) for allowing me to undergo my
training and to do this project at Isgec. I sincerely acknowledge his help, efforts and
cooperation as well as timely guidance, which helped me to complete my project.

I express my sincere gratitude to my industry guide Mr. Vinay Chawla, (Head- Industrial
Engineering), Mr. Rahul S Mor, Mr. Ankit Kalra fordable guidance, continuous support and
co-operation throughout my project, without which the present work would not have been
possible. I would also like to thank the entire team of Isgec, for the constant support and help
in the successful completion of my project.

I convey my heartiest thanks to all those officers and employees of Isgec who have given
me their full co-operation and devoted their valuable time, for rendering me their needy
services, guidelines during the course of imparting me practical training and with whose
sincere and precious helps, I have been able to complete my practical training successfully.

ABSTRACT
The objective of this research is to identify opportunities for improvement to current
production system by performing method study on the manual operators activities,
determining current operators utilization as well as establish standard time for manual
process & to find the ideal method or the method nearest to the ideal that can be practically
used in Industry. Method study in productivity improvement could be done in two
approaches; which are work study and time study. The standard process, utilization and
recommendation for man power planning could be established through method study. These
results could be used for improving the labour productivity in Industries.

The managing of personnel is an approach to obtain the highest productivity possible

without Sacrificing quality, service or responsiveness. The operations manager uses job
design techniques to structure the work so that it will meet both the physical and behavioural
needs of the human worker. Method measurement methods are used to determine the most
efficient means of performing a given task, as well as to set reasonable standards for
performing it. People are motivated by many things, only one of which is financial reward.
Operations managers can structure such rewards not only to motivate consistently high
performance but also to reinforce the most important aspects of the job.

In the present work the method-study analysis has been applied in an Industry where the
components are Fabricated, Machined & Assembled. An attempt has been made to implement
standard process at Isgec Heavy Engineering private limited, manufacturer of mechanical
presses, hydraulic press, machineries for steel, cement, sugar industries and contract
manufacturing. The findings show that the surveyed firm view the method study as a way to
increase productivity, to eliminate waste & to reduce inventories.

INRODUCTION

Pressure
Vessels
& Heat
Exchangers

Isgec is the engineering. Unit of SISL (Saraswati Industrial Syndicate Limited) established in
1946. Over the years Isgec diversified into the manufacturer of heavy engg, Equipment.
Collaboration with John Thompson in UK established a joint company by the name of Isgec
John Thompson which was subsequently merged with SIS (Saraswati Industrial Syndicate) in
1960 as a unit. The unit located at Delhi supplies the boilers & auxiliary equipments on
turnkey basis. Isgec process division also located at Delhi provides engg, procurement and
construction services for sugar plants.
Isgec at present offers a wide range of products for diverse applications including pressure
vessels, heat exchangers, Reactors, columns, hydraulic 7 mechanical presses, CNC, Press
brakes, Ton containers for liquefiable gases, steel plant, machinery iron & steel castings as
well as turnkey sugar plants.

It is a US$ 300 million turnover public company established 75 years back in India.
The group technical capabilities are supported by a highly trained cadre of 460 qualified
engineers, covering a wide gamut of specifications thermal, metallurgical, mechanical,
electrical, instrumentation, civil & project management

APPROVALS

Isgec Heavy Engineering Ltd. has been approved by

Lloyds Register Asia (LRA) of quality assurance as an
ISO-9001: 2000 company.

The American Society of Mechanical Engineers (ASME)

approves Isgec for the use of ASME U, U2, R & S
code stamps.

Lloyds Register Asia as class-I Manufacturing of Fusion

welded pressure vessels approves ISGEC up to 200 mm
thickness.

Engineers

India

Ltd.

(EIL)

approves

Isgec

for

Manufacture of vessels and columns in carbon and alloy

steels up to 155mm thickness and in clad steel up to
130mm thickness.

Engineers India Ltd. approves Isgec for Manufacture of

Heat Exchangers up to maximum tube sheet thickness of
300mm.

China Safety Quality License

INFRASTUCTURE

1.

Isgec has a sprawling works covering an area of about 25 hectares including covered
production area of around 35,000 square meters.

2.

It has the capacity to handle jobs weighing upto 100 tonnes (single piece).

3.

Extensive facilities for hot & cold rolling, machining, welding, heat treatment and
stringent quality controls to ensure strict compliance to international standards.

4.

More than 125 sophisticated machines and machine tools are installed in various
production bays. Apart from these, more than 100 welding machines (for various
processes including SMAW, SAW, MIG, TIG and flash butt welding and under
operation).

5.

Isgec has own captive power generation of 3650 KV through DG sets.

CORPORATE PROFILE

The Saraswati Industrial Syndicate Limited grew from the sugar mill and the
general Engineering group. The engineering group was launched in 1946 with the
establishment of the Indian Sugar And General Engineering Corporation now it is famous
as Isgec. Today, Isgec is ISO 9001:2000. Company concentrates its production activities at
Yamuna nagar, Haryana about 200 km. North of Delhi, manufactures a variety of heavy
Engineering equipments such as Chlorine Containers, Boilers, Sugar Machineries, Cement
Machinery, Pressure Vessels, Mechanical and Hydraulic Presses, Plate Bending Rolls and Iron
Castings.
This flagship unit of group also maintains the process division at New Delhi;
responsible for the design, sales, contracting, and erection and commissioning of turn key
plants besides equipment for sugar and cement industries.
In 1960 ISGEC collaborated with John Thompson, UK (now known as NEI
International Combustion Limited, UK). Located at New Delhi, ISGEC John Thompson
(IJT) designs, sales, erect a range of boilers and associated equipments.

UP Steels was acquired in 1981 and later merged with the parent company.
Established as a foundry in 1966 with the technical know how from Japans Kobe steels, UP
Steels, an ISO 9002 company at Muzaffar Nagar, UP about 100 km. North of Delhi,
manufactures sophisticated alloy steels and steel casting, both hand and machine moulded
as well as alloy iron castings steel ingots.
Saraswati Sugar Mill (SSM) located at Yamuna Nagar, Haryana is having crushing
capacity of 9600 tonnes per day and has recorded best overall recovering in India.

ISGEC COLLABORATIONS
Working continuously towards further excellence in technology, ISGEC entered into
technical collaborations with international well known companies.

To mention a few:1955

A.F. Cariag & Co. U.K.

Sugar Machinery

1960

John Thompson, U.K.

Industrial Boilers

1963

Kawasaki, Japan

Cement Machinery

1964

Farrels, U.S.A.

Sugar Mills

1966

John Shaw & Sons

Hydraulic Presses

1968

Bronx, U.K.

Plate Bending & Leveling machine.

1979

NEI International

Pulverized Fuel

Combustion, U.K.

Boilers.

1980

Rovetta, Italy

Mechanical Press.

Product range

FIELD SERVICES

Site construction and commissioning

Operation and Maintenance
Retrofitting and revamping

PRESSURE VESSEL AND HEAT EXCHANGERS

PRESSES

Straight Side Presses - Mechanical

Straight Side Presses- Hydraulic

'H' Frame Presses - Mechanical

BOILERS

Dump Grate Boilers

Travelling Grate Boilers

Atmospheric Fluidised Bed Combustion Boilers (AFBC)

Circulating Fluidised Bed Combustion Boilers (CFBC)

Oil / Gas Fired Boilers

Waste Heat Recovery Boilers

Deaerators

Spares

STEEL CASTINGS

Hydro Turbine Castings

Gas Turbine Castings

Steam Turbine Castings

Valve Castings

Mn Steel Castings

Ni - Hard Casting

Pump Castings

General Castings

Sugar Mill Castings

Cement Mill Castings

S.G. Iron Castings

SUGAR PLANTS AND MACHINERY

Complete Cane Sugar Plants

High Performance Cane Mills

Process House Equipment

Bagasse Fired Boilers

Spares

IRON CASTINGS

Castings for Pump and Compressor Industry

Castings for Chemical & Dye Stuff Industry

Castings for Soda Ash Industry

Castings for Tool & Dies Industry

Castings for Machine Tools Industry

Castings for Steel Plant Industry

Castings for Sugar Industry

LIQUIFIED GAS CONTAINER

Model 'A'
Model 'B'
Model 'C'
Model 'D' (approved by DOT, USA)

CONTRACT MANUFACTURING
Custom Job Work
(Heavy Engineering Equipment as per Client's Designs and Drawings)

COMPETITORS
ISGEC has diverse competitors for its varied range. In container group. ISGEC has
monopoly till 1997 as its market! Here nearly 95% different products of ISGEC have
different market shares. But the major competitors can be categorized as:
GODREJ
HMT
L&T
BHEL

CLIENTS

1. A.O. Smith Corporation

2. ABB Ltd.
3. Ador Welding Ltd.
4. Abhyuday Manufacturing & Automotive Ltd.
5. Aerospace International Inc.
6. Alf Engineering Pvt. Ltd.
7. Amada (India) Pvt. Ltd.
8. Amalgamations Valeo Clutch Pvt. Ltd.
9. Amtek Auto Ltd.
10. Anusaya Auto Press Parts Pvt. Ltd.
11. APJ-SLG
12. Ashika Commercial Pvt. Ltd.
13. Ashok Leyland Ltd.
14. Ashok Leyland Nissan Vehicles Pvt. Ltd.
15. Asia Motor Works Ltd.
16. Associated Manufacturing Co.
17. Austin Engineering Co. Ltd.
18. Auto Profiles Ltd
19. Autoline Industries Ltd.
20. Automotive Composite Systems (International) Ltd.
21. Automotive Stampings & Assemblies Ltd.
22. Bajaj Auto Ltd.
23. Bellsonica Auto Component (I) Pvt. Ltd.
24. Tata Motors Ltd.
25. BEML Ltd.
26. Tata Ryerson Ltd.
27. TC Springs Ltd.
28. Technical Stampings Automotive Ltd.
29. Thai Summit Neel Auto Pvt. Ltd.
30. Thai Summit Neel Auto Pvt. Ltd.
31. ThyssenKrupp Electrical Steel India Pvt. Ltd.
32. ThyssenKrupp JBM Pvt. Ltd.
33. Toyota Kirloskar Motor Pvt. Ltd.
34. Unisys Global Services India
35. Vardhman Industries Ltd.
36. UOR Services
37. Veegee Industrial Enterprises

Certification from Various Agencies

Standardization of various systems and procedures to meet the quality requirements is one
of the important step toward TQM. This need is being met by adopting ISO-9000. Lloyds
Register of Quality Assurance has awarded ISO-9001 to ISGEC. ISGEC have also been

accredited with ASME U & S Stamps, signifying quality of products to international

standards.

Scope of stamps:

U Stamp

For manufacturing of unfired Pressure

Vessels under ASME Sec. VIII Div. 1

U2 Stamp

For manufacturing of unfired Pressure

Vessel under ASME SEC. VIII Div. 2

S-Stamp

For manufacturing and assembly of power

Boilers.

DIVISION OF ISGEC

ISGEC has been divided into three divisions as follows:-

1.

PRESSURE VESSEL DIVISION (PVD)

Pressure vessel division is the oldest of ISGEC and it manufactures pressure vessels such
as boilers, heat exchangers etc. It is sub-divided into following shops:a)

PVD-I

b)

PVD-II

c)

PVD-III

d)

PVD-IV

2. MACHINE BUILDING DIVISION (MBD)

Machine building division is very important division of ISGEC and it manufactures sugar
mill machinery. Press components and other Steel plant machinery. It is sub-divided into
following shops:-

a)

FABRICATION SHOP-I,II

b)

MACHINE SHOP-I,II

c)

ASSEMBLY SHOP

d)

QUALITY SHOP

3. FOUNDRY GROUP (FG)

Foundry group is the third important group of ISGEC and it is responsible for casting of
large castings for the big industries.

4. TUBE SHOP
Tube shop deals with tube manipulation and fabrication of tubing system used in
economizers and super-heaters.

6.

CONTAINER SHOP

Container shop manufactures chlorine, ammonia and other gases containers.

MAJOR INDUSTRIES SERVED

Metallurgical
Hydro Power
Power Generation
Sugar
Cement
Particle Board & Plywood

Manufacturing & Testing Facilities

Infrastructure

Forming

Drilling

Welding

Testing

Heat Treatment

Codes & Standards

Infrastructure
Forming

Rolling: Thickness - 200 mm (8 inches)

Head / Dished End: Thickness - 125 mm (5 inches)

Drilling

Thickness - 300 mm (12 inches)

Welding

Strip Cladding
Automatic Internal Bore Cladding
Tandem Wire Submerged Arc Welding
Submerged Arc Welding
Metal Inert Gas Welding
Tungsten Inert Gas Welding
Shielded Metal Arc Welding

Testing

Radiography up to 200 mm (8 inches) thickness

Tensile Testing including Elevated Temperature Testing upto 800 deg. C

(1470 deg. F)
Impact Testing up to (-) 196 deg. C (-320 deg. F)
In situ Alloy Analyzer
Metallurgical Microscope X-2000 with Photography facility
Ferrite Measurement

Helium Leak Testing

Ultrasonic Testing
Magnetic Particle Testing
Liquid Penetrate Testing

Heat Treatment

Four Gas Fired Furnaces

Size up to: 4500 mm x 4000 mm x 14500 mm

(15 ft. x 13 ft. x 48 ft.)

Stress Relieving, Annealing, Quenching and Tempering as well as Solution Annealing

of Stainless Steels
Local Stress Relieving by Electrical Resistance Method
Stress Relieving by Internal Firing Method
Stress Relieving of large jobs in Temporary Furnaces

I did my industrial training in INDUSTRIAL ENGINEERING DEPARTMENT of MBD

division. The main tasks of this department are-

Preparation of Expansion with estimation of machines, Equipment, tools, manpower & space
Requirement for capacity enhancement.
Execution of expansion plan for timely procurement of equipment & machines.

Allocation of time to machining request / rework from assembly & contractors.

Preparation of Incentive Time Sheet from Drawing & Processes for Shop / DVD
and Sub-contracting, and feeding of standard time in SAP

Daily monitoring of time booking on machines/work centre w.r.t. time allocated.

Checking/clearance of incentive job cards for workers, incentive & own time.

Method/productivity improvements in shops for cycle time reduction.

Various MIS reporting for manpower/ utilization/rework/incentive for management.

Time/method study for developing time standard of activities.

Developing Piece meal basis rate for piece mill & contract work.
layout preparation for the division.

Vendor search, evaluation, razing PR, coordination for procurement, commission & of
Machines / equipments for expansion and modernization.
Preparation of operation and service PR for all functions in manufacturing.
Preparaing Service orders & bills for Piece Meal & Contract Activities.
Confirmation of service order activities.sssss

Material flow in shops of MBD division

Preparation shop

Fabrication shop

Machine shop

Assembly shop

Preparation shop- To provide raw material (plates) to various divisions, after

flame cutting to shape and size, as required in drawings, for various jobs.

Fabrication shop- Material to be fabricated is sent to fabrication shop. All of

the fabrication is done in this shop.

Machine shop- Job after fabrication is sent to machine shop. This shop is fully
equipped with new technology machines.

Assembly shop- The component from machine shop and fabrication shop are
sent in assembly shop for assembly.

I spent around 1st four months of my training in fabrication shop of MBD division.
Activities done in Fabrication shop are mainly1.
2.
3.
4.
5.

Fitting.
Welding.
Grinding.
Stress relieving.
Grit blasting

1. Fitting- This is first activity of the shop to start the job. It is very important activity
as the fitter gives 2D drawing to 3D actual job with locating different plates in
different direction & in different location & inclination. Every plate which comes
from preparation shop has a specific mark no. Supervisor gets process layout of how
to proceed in fitting and drawings of different parts and in different views. He
instructs to Fitter to fit up the plates as per drawing as per drawing & process he
obtains from planning thru industrial Engineering Department.

2. Welding- The second main activity performed in fabrication shop is welding.

Different types of welding performed in shop are

SMAW
GMAW
MIG
TIG
FCAW
SAW

The quality of welding is tested by following process

Visual Testing (done for all job in 100 %)

Liquid Penetrate Testing (done for 100% root run & 20-40% for final welding)
Magnetic Particle Testing (as per requirement )
Ultrasonic Testing (as per requirement)
Radio Graphy Testing (as per requirement)
In case there is requirement of full penetration joint then another process is done
named as BACK GOUGING. In case if we finds any defect in any of the above

Non Distructive testing then the faults either removed by grinding (for surface
defects) & GOUGING ( for more than 10mm depth) is used as the process making
cavity for reweld.
Back gauging-In this process a carbon electrode is used with compressed air to remove off
welding as the fastest process for removing weldment.

3. Grinding- Grinding is done on the welded surface to remove spatters, merge start &
end points and improve the aesthetic look of job.

4. Stress relieving- This is the most common heat treatment used for remove the
concentration of stresses developed during welding & helped in uniformly
distribution of thermal stresses aroused in job due to welding.
5. Grit blasting- It is the process of removing scale from surface of job to make it rough
and clean so that primer can easily adhere on it. A nozzle from where an abrasive at
very high velocity comes out and strikes the surface of the shell.

Next two months were spent in assembly shop. All of the components are assembled in
fabrication shop. There are three assembly shops of MBD divisionSub assembly station
Old assembly
New assembly shop
Assembly drawings are provided to shop workers. They assembles the job as per drawing

PROJECT UNDERTAKEN IN FABRICATION SHOP

1.
2.

Idle time reduction of welders during gas problem.

Designing of jig for air tank mounting.

PROJECT UNDERTAKEN IN ASSEMBLY SHOP

1. Reduce rework during fitting of platform.
INTRODUCTION OF PROJECT
TECHNIQUE USEDMethod study was used as technique to eliminate the occurring problems. Method study can
reduce and control costs, improve working conditions and environment and motivate people.
Manufacturing management and engineers are prepared to design work stations, develop
efficient and effective work methods.
Method study investigates the work done in an organization and aims at finding the best and
the most efficient way of utilizing the available resources (man, material, money and
machinery) to achieve best possible quality work in minimum possible time with best
method.

Why we use it?

Productivity
Improving equipment utilization
Conserving materials and energy
Reducing human effort
Advancing the goals of the organization on many fronts

Method study is considered to be the backbone of industrial engineering, industrial

technology, and industrial management programs because the information that method
studies generate affects so many other areas, including the following:
1. Cost estimating
2. Production and inventory control
3. Plant layout

4. Materials and processes

5. Quality
6. Safety

Method study comes first before the setting of time standards. Method study is a

detailed analysis of the work method in an effort to improve it.

Method studies are used to

1. Develop the best work method.

2. Develop method consciousness on the part of all employees.
3. Develop economical and efficient tools, fixtures, & production aids.
4. Assist in the selection of new machines and equipment.
5. Train new employees in the preferred method.
6. Reduce effort and cost.

Method study

Method Study is the systematic recording and critical examination of existing and
proposed ways of doing work, as a means of developing and applying easier and more

effective methods and reducing costs.

Method study is one of principal techniques by which work content in the product

manufacture or process could be decreased.

It is a systematic method of investigating and critically examining the existing
methods, to develop the improved ones.

Method study is, then, a technique to reduce the work content mainly by eliminating

unnecessary movements by workers and/or materials and/or equipments.

However, even after that, there could be substantial unnecessary time taken for the
process because of lack of management control and/or inaction of worker.

Area of application:
The application of methods engineering may be required in a variety of circumstances. It
ranges from the design of a new plant, to the design of a new product, to the design of
a new process, to the improvement of an existing process, to the improvement of an
existing workplace. Wherever work is being done, methods engineering is a desirable
function to ensure that the work is being done in the easiest, safest, and most productive
way.
IMPLEMENTATION ASPECTS Following factors have been suggested for successful
process improvement implementation:

Top Management Support.

Employee's Participation and Bottom up Management.
Education and Training.
Team Work.
Quality.
Commitment
METHOD STUDY PROCEDURE

METHODOLOGY
OF
IDLE TIME REDUCTION OF WELDERS

BRIEF INTRODUCTION OF PROCESS

In fabrication shop the welding process used mostly is GMAW.

GMAW- It is also called at ISGEC as MIG/MAG. The shielding gases used in this type of
welding are carbon-di-oxide and Argon. Wire electrode is fed automatically in the welding
torch. Argon and carbon-di-oxide gas is allowed to pass through the torch pipes. The
composition of gases used is 80/20(argon/ carbon-di-oxide). This is optimised composition
and produces minimum spatters (due to argon) and maximum penetration (due to carbon-dioxide).
Gas is supplied from Gas reservoir. Built at a distance of around 150 meter. from shop. There
are two large tanks of carbon-di-oxide and Argon. Gas is supplied from pipeline to every
welding machine. It also contains small gas cylinders.
Whenever large tanks gets empty. Welders brings cylinder from reservoir. Issues regulator
from store and use individual cylinder at their machines. During this period they remain idle.
Productivity of shop decreases due to increase in idle time

Need of the Project

Workers were remaining idle at an average of 1.3 hrs. /day.

Due to attitude of workers, more time wastage even if the cylinder is available.
The average idle time per month due to this problem was about 40 hrs.

SHOP IDLE TIME

Idle time due to gas problem

Month

(hrs.)

% of the Total

December

56.5

41

January

51

16

February

26

10

REASONS WHICH CAUSES THE PROBLEM

1. Frequent unavailability of gas.
2. No control over inventory.
3. Gas is transported regularly from outside. Transportation delay due to weather or any
other reason is uncontrolled.
Methodology:
The process was analysed for three weeks & was changed as below:
1.
2.
3.
4.
5.
6.

To study the complete process.

Analyzing steps in detail.
Find out the reasons due to which need of rework arises.
Study the various reasons and find out best solution.
Brainstorming with the concerned authority.
Recommend the solution to management.

Root cause analysis

Cause
Unavailability of gas
Production loss
Uncontrolled flow of material

Analysis
Inventory problem
Delay in arranging another gas cylinder
Wrong method of gas supply from store

Objective of project- To introduce proper system which can solve out problem of gas and
reduce or completely eliminates the idle time of workers .

SOLUTION GENERATED
The only thing we could control was to reduce the time of bringing the cylinder when
problem arises.

Target

Optimize production processes.

Reduce walking distances.
Cut physical strain.
Smooth & continuous production flow.

New ideas were generated.

The collected ideas are evaluated and after brainstorming with management and workers we
tried to find best solution

ACTION PLAN
We made a manifold connected to main gas supply pipe. Ten cylinders are connected to it
through check valve. These cylinders are brought by helpers.

When the tank gets empty with the help of valve the main supply gets disconnected and
manifold valve is opened. Now the gas from cylinders attached to manifolds is supplied to
welders.
OLD METHOD

NEW METHOD
MANIFOLD

CYLINDER

Now there is no need of wasting time. As tank gets empty the gas is supplied to welders from
this store.

MATERIAL USED IN MANIFOLD-

Later the copper coated tubes were replaced from pure copper tubes. Because the flexibility
of pure copper tubes is high. Also pure copper can withstand at very low temperature. Check
valve were used to prevent flow of gas back into cylinder When they are not in use.

IMPLEMENTATION STATUS-

STATUS
TIME TAKEN IN IMPLETATION
AREA
RESULTS

IMPLEMENTED
ONE DAY/2 MEN
CYLINDER STORE OF FAB. SHOP
IMPRESSIVE

RESULT AND OBSERVATIONSAfter implementing this system the study of some occasions was done to check its
significance.
Record of occasions when problem occured
Date of problem occuring
Time when gas was supplied from manifold
3-03-2012
9:28-13:00
7-03-2012
1:00- 5:00
9-03-2012
12:00-15:30
15-03-2012
9:00-11:30

The idle time in the month of march due to gas problem was 0.5 hrs.

RESULTS- After observing for 15 days we found that every time when problem arose it took
only few minutes to restart supply.
1. Idle time of welder due to gas problem was reduced.
2. Productivity of shop increased.
3. In the month of March the idle time due to gas problem noted was 1 hr. almost
negligible.

IN TEARMS OF SAVINGSaving of hours per month= 40

Annual saving of hours= 480
Hourly rate of fabrication shop= 400
Money saving= 192000

METHODOLOGY
OF
PROJECT
REDUCE REWORK IN FITTING OF AIR TANK ON CROWN OF MECHANICAL
PRESS

BRIEF INTRODUCTION TO CROWN AND AIR-TANK

PRESS- A press is a machine used to supply power to a die that is used to blank, form, or
shape metal or non metallic material. Thus, press is a component of a manufacturing system
that combines the press, a die, material and feeding method to produce a part

ANATOMY OF PRESSES-

AIR TANK

CROWN- It is the upper most part of press. It contains gears and these gears are driven by
flywheel which gets power from main motor. This power is then transferred to slide which
moves between uprights and exerts force on die.
AIR TANK- It is a cylindrical body having hemispherical dish end
attached at both ends. It is mounted on crown. It is basically an air reservoir which supplies
air to pneumatic system of press. It is prepared in fabrication shop.

AIR TANK

PAD BY WHICH IT
IS MOUNTED ON
CROWN

OBJECTIVE OF PROJECTTo find the reasons of rework during fitting of air tank and to adopt a method or way that
can eliminate rework.

MATERIAL FLOW AND WORKING PROCEDUR IN FITTING OF TANK ON

CROWN

NEED OF PROJECT

During assembly the hole of both air-tank and crown pad does not match in almost
every press. And a lot of rework needed to assemble air tank on crown.

For rectification workers of fabrication shop are sent to assembly shop to rectify the
problem.

Some rework is also done by assembly shop workers. As they have to dismantle the
air tank when problem arises.

REWORK HOURSRework hours of assembly fitter =2hrs

Rework hours of fabrication gas cutter man =2 hrs
Rework hrs of fabrication grinder man =2 hrs
The project was needed to eliminate time and resource wastage during rectification.

REWORK PROCESS-

As both crown and air tank are fabricated by fabrication shop, it becomes the fault of

shop & give rise in rework index at assembly shop.

For correcting this workers of fabrication shop and concerned supervisor go to assembly

shop with tools and machine like- gas cutting machine and cylinders Grinder.
Centre outing of holes is checked and size of holes is increased by gas cutting for
matching holes.

Research Methodology

To study the steps involve in fitting of pads on crown, air tank and steps of fitting airtank on crown.
Analyzing steps in detail.
Find out the reasons due to which need of rework arises.
Study the various reasons and find out best solution.
Designing of template using CAD.
Recommend the solution to management.

PROBLEM IDENTIFICATION

1. The work of hole matching is a work of precision. The whole work is not done by
single person.

2. The main problem was the alignment in the pads of crown. They were not aligned
properly to one another.
3. And to do work of little tolerance is difficult in fabrication shop.

4. Marking and drilling on pads of both air-tank and crown is done

In different shops by different workers. It is also a reason that matching becomes a
problem.

REASONS WHICH CAUSES REWORK

After studying every element involved in fitting of air-tank fitting on crown major reasons for
rework found were

The main problem was the difficulty of doing work in little tolerance. And the

involvement of a lot of workers.

And both of problems could not be eliminated. As if start work in little tolerance

productivity of shop was decreasing.

It is heavy work and work goes in shifts, so involvement of no. of workers could not be
eliminated

SOLUTION GENERATED
Two templates were fabricated as per drawing; holes were drilled in it for different air tankone for marking of air tank having two pad and another for tank having three pads.

CAD MODELING

2-D DRAWINGS

ACTION PLAN

Two templates were made for different presses as per drawing holes are drilled on it at
different pitch. One template for tanks having tree pads and one for tanks having 2
pads.
For pitch of 615

this side is taken as zero or refrence

for pitch of 720

Now the pads of air-tank are marked according to this template. Pitch of holes is marked on
template. The different size tanks can be marked easily as per pitch. The side assumed as
reference side is placed on one pad, and other pad is marked as per pitch.

During marking of pad on air tank, the template is put over pads and marking is done
as according to template.

PAD
TEMPLATE

CROWN

During the fitting of pads on crown, same template is put over the pads.
Pads are fitted according to template, holes are also marked as per template

PAD

PAD OF CROWN
TEMPLATE

Air tank
mounted on
crown

Now the both pads are fitted as per same template, so no mismatch occurs during assembly.

IMPLEMENTATION DETAIL-

Implemented/Not implemented
Time required in implementation
Job no.
Result achieved

Implemented
Nil
HM-2454 (crown) fabrication shop
Impressive

RESULTS AND OBSERVATIONS1. Marking and fitting time of pad on crown reduced.

2. No case of mismatch was accounted after using template.

3. Rework gets eliminated at assembly stage.

SAVING ON THE BASIS OF TIME AND MONEY-

Rework hours during assembly= 6hrs.

After using template= nil

There was no increment in marking and fitting time of pad on crown
Time saving per crown= 6 hrs.
Hourly rate of fabrication shop= 400 rs.
Average nos. of crown per year = 25
Cost saved/crown= 400*6=2400
Cost saved annually= 25*2400= 60000

METHODOLOGY
OF
PROJECT
TO REDUCE REWORK DURING FITTING OF PLATFORM

Objective of project- To find the reasons of rework in platform fitting and to adopt a method
or way which can eliminate rework.

PLATFORM- It is space provided around periphery on top side of press. It is provided to

check upper part of press in case of any problem.
PLATFORM

MATERIAL FLOW AND WORKING PROCEDUR IN FITTING OF TANK ON

CROWN

F A B R IC A T IO N S H O P

Need of project
1. The hole of mounting plate never matches with frame drill.
2. Minimum 24 hrs. Rework needed to fit the platform.
REWORK PROCESS

If centre is disturbed slightly. Buffering is done in holes of mounting plate and press.
For higher distortion holes in plate were filled by welding deposition and then
machined.
The project was needed to find a way or method to control rework and save wastage

of time and resources.

Research Methodology

To study the various steps in fitting of platform.

Analyzing steps in detail.
Find out the reasons due to which need of rework arises.
Study the various reasons and find out best solution.
Recommend the solution to management.

REASON CAUSING NEED OF REWORK

After studying the every element involved in platform fitting carefully, reason found was

1st holes are drilled in mounting plate.

Then plate is welded with platform.
Due to welding, distortion occurs in plate and holes falls out of centre.
Marking on both plate and press is according to drawing, due to distortion the holes of
plate doesnt match with holes of press.

Mounting
plate

Platform

Mounting plate
welded with platform

RECOMMENDATION-

Drilling of holes on mounting plate should be done after welding of mounting plate

on platform. So that welding distortion can be avoided.

To implement changed process route of job was changed.

Old route of platform assembly-

New route recommended-

FASSEMM A ACHBRI CI NBLATIE Y SHO N O SHP O P

IMPLEMENTATION STATUS-

IMPLEMENTED/NOT

IMPLEMENTED

IMPLEMENTED
TIME REQUIRED FOR

NIL

IMPLETATION
MM-D-L0007 AND FURTHER AI ALL HJOB NO.
RESULT ACHIVED

FRAME PRESSES
EXCELLENT

RESULT AND OBSERVATIONNew method of job making has eliminated the distortion effect of welding. During fitting no
mismatch occurs and the assembly completes in given time without rework.
ANALYSIS ON THE BASIS OF TIME AND MONEYTime taken in fitting when problem was occurring= 60 hrs.
Time allotted for fitting= 36 hrs.
Rework time= 60-36=24 hrs.
As the rework eliminated fitting time= standard time allotted= 36 hrs.
Saving of time/press= 24 hrs.
Average nos. of H-frame presses annually= 20
Total assembly hrs. Saved annually= 20*24=480
Hourly rate of assembly shop= RS. 400
Total money saving annually= 400*480= RS. 192000