EXISTING OPERATION SEQUENCE OF 170 SERIES CONNECTING ROD MACHINING

Opn. Operation Description Work Center Description Work In Mins UNIT

No Center Set Up Labour M/C UNIT TIME
Code Time Time Time TIME Hrs
9 TOP & BOTTOM ROUGH MILLING UNIVERSAL MILLING MACHINE WC1 120 30 30 32 0.53
10 TOP & BOTTOM GRINDING - ROUGH & S/F SURFACE GRINDING MACHINE WC2 120 18 18 20 0.33
20 SMALL END ROUGH BORING LATHE WC3 31 14 14 14 0.24
21 SMALL END SF-BORING & C'FERING BORING & SLITTING MACHINE WC4 76 9 9 10 0.17
30 SIDE & BOLT SEAT MILLING BORING & MILLING MACHINE WC5 122 29 29 30 0.50
40 BIG END SLITTING BORING & SLITTING MACHINE WC4 45 15 15 15 0.25
60 JOINT FACE GRINDING -ROD & CAP SURFACE GRINDING MACHINE WC2 60 12 12 13 0.21
70 BIG END BORING BORING & MILLING MACHINE WC5 51 13 13 14 0.23
80 BOLT HOLE DRILL,REAM & C'FER 4 SPINDLE SPM WC6 120 38 38 40 0.66
81 TAPPING OF BOLT HOLE RADIAL DRILLING MACHINE WC7 30 12 12 12 0.21
90 DOWEL DRILLING & REAMING ROD & CAP CNC DRILL & REAMING MACHINE WC8 60 9 9 10 0.16
100 NOTCH MILLING OF ROD & CAP NOTCH MILLING MACHINE WC9 62 12 12 13 0.21
110 GUN DRILLING OF OIL HOLE IN ROD SINGLE SPINDLE GUN DRILLING SPM WC10 60 17 17 18 0.30
120 LAPPING OF JOINT FACES IN ROD & CAP LAPPING MACHINE WC11 31 10 10 10 0.17
140 ASSEMBLY OF ROD & CAP MANUAL WORK
150 TOP & BOTTOM SURFACE GRINDING- FINISH SURFACE GRINDING MACHINE WC2 54 14 14 15 0.25
160 S/F BORE - BIGEND & SMALL END TWO SPINDLE FINE BORING SPM WC12 213 21 21 24 0.40
165 BIG END-CHAMFERING TWO SPINDLE FINE BORING SPM WC12 42 13 13 14 0.23
170 BUSH PRESSING IN SMALL END MANUAL WORK
180 SMALL END KEY STONE MILLING UNIVERSAL MILLING MACHINE WC1 52 17 17 18 0.30
190 FINISH BORING OF BIG & SMALL ENDS TWO SPINDLE FINE BORING SPM WC12 75 21 21 22 0.37
200 WEIGHING & BALANCING OF ROD & CAP MANUAL WORK 0.00
210 HONING OF BIG END BORE HONING MACHINE WC13 75 15 15 16 0.27
Total (Takt Time) 5.98
 WORK CENTER WISE LOAD & CAPACITY ON EXISTING PRODUCT LINE

In Mins
Work UNIT
Opn.
Operation Description Work Center Description Center Set Up Labour M/C UNIT TIME
No
Code Time Time Time TIME Hrs

9 TOP & BOTTOM ROUGH MILLING UNIVERSAL MILLING MACHINE WC1 120 30 30 32 0.53
180 TOP & BOTTOM GRINDING - ROUGH & S/F SURFACE GRINDING MACHINE WC1 52 17 17 18 0.30
10 SMALL END ROUGH BORING LATHE WC2 120 18 18 20 0.33
60 SMALL END SF-BORING & C'FERING BORING & SLITTING MACHINE WC2 60 12 12 13 0.21
150 SIDE & BOLT SEAT MILLING BORING & MILLING MACHINE WC2 54 14 14 15 0.25
20 BIG END SLITTING BORING & SLITTING MACHINE WC3 31 14 14 14 0.24
21 JOINT FACE GRINDING -ROD & CAP SURFACE GRINDING MACHINE WC4 76 9 9 10 0.17
40 BIG END BORING BORING & MILLING MACHINE WC4 45 15 15 15 0.25
30 BOLT HOLE DRILL,REAM & C'FER 4 SPINDLE SPM WC5 122 29 29 30 0.50
70 TAPPING OF BOLT HOLE RADIAL DRILLING MACHINE WC5 51 13 13 14 0.23
80 DOWEL DRILLING & REAMING ROD & CAP CNC DRILL & REAMING MACHINE WC6 120 38 38 40 0.66
81 NOTCH MILLING OF ROD & CAP NOTCH MILLING MACHINE WC7 30 12 12 12 0.21
90 GUN DRILLING OF OIL HOLE IN ROD SINGLE SPINDLE GUN DRILLING SPM WC8 60 9 9 10 0.16
100 LAPPING OF JOINT FACES IN ROD & CAP LAPPING MACHINE WC9 62 12 12 13 0.21
110 ASSEMBLY OF ROD & CAP MANUAL WORK WC10 60 17 17 18 0.30
120 TOP & BOTTOM SURFACE GRINDING- FINISH SURFACE GRINDING MACHINE WC11 31 10 10 10 0.17
140 S/F BORE - BIGEND & SMALL END TWO SPINDLE FINE BORING SPM
160 BIG END-CHAMFERING TWO SPINDLE FINE BORING SPM WC12 213 21 21 24 0.40
165 BUSH PRESSING IN SMALL END MANUAL WORK WC12 42 13 13 14 0.23
170 SMALL END KEY STONE MILLING UNIVERSAL MILLING MACHINE
190 FINISH BORING OF BIG & SMALL ENDS TWO SPINDLE FINE BORING SPM WC12 75 21 21 22 0.37
200 WEIGHING & BALANCING OF ROD & CAP MANUAL WORK
210 HONING OF BIG END BORE HONING MACHINE WC13 75 15 15 16 0.27
Total 5.98
ISE LOAD & CAPACITY ON EXISTING PRODUCT LINE

Unit Available Annual Work

Load on Hrs per Centerwise
the WC Work Manf. Capacity
Center Nos.

0.82 3657 4443

0.79 3657 4654

0.24 3657 15528

0.43 3657 8578

0.74 3657 4975

0.66 3657 5532

0.21 3657 17671
0.16 3657 22314
0.21 3657 17061
0.30 3657 12304
0.17 3657 21036

3683
0.99 3657
( Bootle Neck
Machine )

0.27 3657 13678

5.98
 Note :
1) Available Productive Hours per machine / year= Shift Hours (7.17) x No. of shifts in a day (2) x No of working days in a year (300) x Efficiency factor (85 %)
= 3657 Hours
2) The line capacity based on the bottle neck machine = Approx. 3700 Connecting Rods per year

Observation in the existing line :

1 There are 13 work centers arranged in the sequence in product layout. There is backtracking of components.

2 The line consists of SPMs and Conventional machines accommodating one component at time. Multiple component machining not possible.

3 Set-up change and Component Loading/Uloading is on-line activity contributing to machine idle time.

4 The machines are old and motions are slow.

5 Tool loading is manual .

6 The machines are dedicated for one kind operation . Multiple operation not possible
x No. of shifts in a day (2) x No of working days in a year (300) x Efficiency factor (85 %)

ut. There is backtracking of components.

ing one component at time. Multiple component machining not possible.

 TIME STUDY MACHINING CENTRE

con. proces no. of clamp discription of machining 170 tool no. material of internal coolant supply
no. s no. mach. pos. cutter
x 170 Drg no. -51Z3100022
x
x
PW x
Gauge to reference at Fixture x
POS, TS 0, POS x
Tool change during pallet change x
1 103 2 op10 Rough Milling Top face big end x T1 HM yes
1 103 2 op10 Rough Milling Top face small endx T1 HM yes
1 OP20 Positioning x
1 103 2 OP20 Rough Milling Bottom face big end x T1 HM yes
1 103 2 OP20 Rough Milling bottom face small end
x T1 HM yes
POS, TS 90, POS x
1 103 2 op10 Rough Milling RH side face big x T72 HM yes
POS,
end TS 180, POS x
1 103 2 op10 Face mill
Rough with 75
Milling cutting
LH side angle
face big x T72 HM yes
WZW,
end TS 0 x
1 103 1 op10 Rough
Face mill
boring
with small
75 cutting
end bore-
angleInput
x 60 T73 HM yes
WZW x
1 103 1 op10 Semi-finish boring small end borex T74 HM yes
WZW x
1 103 1 op10 Chamfering 45 of bore top side byx interpolation
T34 HM
with chf cutter
yes
NTRE costume BEML

tool diameter cutting speed spindle speed n

d1 d2 vc1 vc2 <min-1>
<mm> <mm> <m/min> <m/min>

50 160 1019
50 160 1019

50 160 1019
50 160 1019

50 160 1019

50 160 1019

72 140 619

74.1 160 687

32 160 1592
 component: Con-Rod
Mysore drg no.:
India material: ES1133
speed n no.of cutters feed / cutter feed f feed rate vf tool stroke l
> z fz <mm/U> <mm/min> <mm>
<mm/z>

5 0.2 1 1019 488

5 0.2 1 1019 104

5 0.2 1 1019 488

5 0.2 1 1019 104

5 0.20 1.00 1019 190

5 0.20 1.00 1019 190

3 0.12 0.36 223 70

2 0.15 0.3 206 70

3 0.17 0.51 812 172

tool stroke l cutting time th idle time tn total time tges
<mm> <s> <s> <s>

13 13
20 20

488 57.5 1.3 58.9

104 12.3 1.6 13.8
2.3 2.3
488 57.5 0.8 58.3
104 12.3 2.2 14.5
2 2
190 22.4 9.3 31.7
2.7 2.7
190 22.4 2.8 25.2
6.5 6.5
70 18.8 1.6 20.4
6.5 6.5
70 20.4 1.6 21.9
6.5 6.5
172 12.7 1.9 14.7
 WZW, TS 90 x
2 100 2 op20 Milling bolt seat face - with R8 corner
x T75 HM yes
WZW, TS 90 x
1 103 2 op10 Finish Milling Top face big end x T87 HM yes
1 103 2 op10 Finish Milling Top face small endx T87 HM yes
1 OP20 Positioning x
1 103 2 OP20 Finish Milling Bottom face big endx T87 HM yes
1 103 2 OP20 Finish Milling bottom face small end
x T87 HM yes
WZW, x
2 100 1 op20 Big end slitting - Slitting cutter x T6 HM yes
Deburring of sharp corner x Customer scope
Numbering / Etching on rod and Cap x Customer scope
WZW, TS 90 x
1 103 2 30A Milling Joint face Cap face x T51 HM yes
1 103 2 30B Milling Joint face Rod face x T51 HM yes
WZW, x
TIME STUDY MACHINING CENTRE

con. proces no. of clamp discription of machining 170 tool no. material of internal coolant supply
no. s no. mach. pos. cutter
1 103 2 30B Pre - Drilling of bolt holes - Rod x T76 VHM yes
WZW, x
1 103 2 30A Drilling & chamfering of bolt holesx - CapT77 HM yes
1 1 30B Position x
1 103 2 30B Counter drilliing of bolt holes - Rod
x T77 VHM yes
WZW, x
 40 160 1273

80 160 637
80 160 637

80 160 637
80 160 637

250 120 153

80 160 637
80 160 637

CENTRE costume BEML

coolant supply tool diameter cutting speed spindle speed n

d1 d2 vc1 vc2 <min-1>
18.5 <mm> <mm> <m/min>
80 <m/min> 1376

21 24 90 103 1364

21 90 1364
 4 0.15 0.6 764 420

8 0.12 0.96 611 488

8 0.12 0.96 611 104

8 0.12 0.96 611 488

8 0.12 0.96 611 104

12 0.17 2.04 312 268

8 0.2 1.6 1019 266

8 0.2 1.6 1019 266

component: Con-Rod
Mysore drg no.:
India material: ES1133
spindle speed n no.of cutters feed / cutter feed f feed rate vf
<min-1> z fz <mm/U> <mm/min>
1376 2 0.12 <mm/z> 0.24 330

1364 2 0.13 0.26 355

1364 2 0.16 0.32 437

 6.5 6.5
420 66 2.5 68.5
6.5 6.5
488 95.9 1.3 97.2
104 20.4 1.6 22
2.3 2.3
488 95.9 0.8 96.7
104 20.4 2.2 22.6
6.5 6.5
268 51.6 3 54.6

6.5 6.5
266 31.3 2 33.3
266 31.3 2 33.3
6.5 6.5
proposal no

tool stroke l cutting time th idle time tn total time tges

<mm> <s> <s> <s>
73 26.4 2.6 29
6.5 6.5
77 26.2 2.1 28.3
1.6 1.6
33 9 1.9 11
6.5 6.5
43 103 2 30B Taping,in_M20x1.5 - Feed IN thru. x T78 HSSE yes
Reversieren x
44 103 2 30B Taping, out_M20x1.5 x T78 HSSE yes
WZW, x
1 103 2 30A Chamfering of bolt holes - Cap fromx jointT15
face side
VHM yes
WZW, TS 90 x
1 103 1 30A Rough boring -half side on Cap. x T79 HM yes
1 1 30B Position x
1 103 1 30B Rough boring -half side on Rod. x T79 HM yes
WZW x
1 103 1 30A Notch milling -half side on Cap. x T80 HM yes
1 1 30B Position x
1 103 1 30B Notch milling -half side on Rod. x T80 HM yes
WZW x
1 103 4 30A Pre - drilling of dowel holes_cap -x 11.5mm
T55deep HM yes
1 1 30B Position x
1 103 4 30B Pre - drilling of dowel holes_rod x T55 HM yes
- 11.5mm
WZW x
1 103 4 30B deep
Reaming of dowel holes_rod - 7.5mm
x deep
T43 HM yes
WZW x
1 103 4 30A Reaming - dowel holes_cap - 7.5mm x deep
T68 HM yes
WZW, TS 90 x
1 103 1 30C Spot facing of long oil hole x T18 HM yes
WZW x
1 103 1 30C Pilot drilling of long oil hole x T19 HM yes
TIME STUDY MACHINING CENTRE
 20 18 286

20 22 350

20 120 1910

113.5 140 393

113.5 140 393

45 120 849

45 120 849

6 70 3714

6 70 3714

6.35 50 2506

6.31 50 2522

7 60 2728

6.45 60 2961
costume BEML
286 1 1.5 1.5 430

350 1 1.5 1.5 525

1910 4 0.08 0.32 611

393 4 0.2 0.8 314

393 4 0.2 0.8 314

849 4 0.1 0.4 340

849 4 0.1 0.4 340

3714 2 0.07 0.14 520

3714 2 0.07 0.14 520

2506 3 0.05 0.15 376

2522 3 0.05 0.15 378

2728 2 0.05 0.1 273

2961 2 0.06 0.12 355

component: Con-Rod
Mysore drg no.:
47.5 13.3 3.3 16.5
1 1
47.5 10.9 10.9
6.5 6.5
7 1.4 3.5 4.8
6.5 6.5
77 14.7 1 15.7
1.6 1.6
77 14.7 1 15.7
6.5 6.5
38 6.7 1.5 8.2
1.6 1.6
38 6.7 1.5 8.2
6.5 6.5
16 7.5 1.9 9.5
1.6 1.6
16 7.5 1.9 9.5
6.5 6.5
12 7.9 1.9 9.9
6.5 6.5
12 7.9 2 9.8
6.5 6.5
18 4 3 7
6.5 6.5
28 4.7 2.3 7
proposal no
 TIME STUDY MACHINING CENTRE

TIME STUDY MACHINING CENTRE

con. proces no. of clamp discription of machining 170 tool NBH internal
material 6 coolant tool diameter
no. s no. mach. pos. no. of supply d1
WZW x cutter <mm>
1 103 1 30C Long drilling of long oil hole x- positioning T20 HM yes 6.4
1 103 1 30C Long drilling of long oil hole x T20 HM yes 6.4
Assembly of Rod and Cap x Customer scope
Top and Bottom Face finish Grindingx Customer scope
WZW, TS 90 x
1 103 1 OP40 Semi finish boring - big x T81 HM yes 114.3
end.
WZW x
1 103 1 OP40 Chamfering of small end bore x 1x30 chf. T4 HM yes 75
1 103 1 OP40 Semi finish boring. Guide pad x tool. Small end.
T82 Cermet yes 74.7
1 103 1 OP40 Finish boring. Parent bore. Guidex pad tool.T82
Small end.
Cermet yes 75
WZW x
1 103 2 OP40 Chamfering of Big end bore x3.05x45 chf. Interpolation
T86 HM - top yes
and bottom face 32
Bush Pressing in small end x Customer scope
Crack detection test x Customer scope
WZW, TS 90 x
1 103 3 OP50B Small end taper milling - 1st xside T51 HM yes 80
1 1 OP50C Position x
1 103 3 OP50C Small end taper milling - 2ndx side T51 HM yes 80
WZW, TS 90 x
1 103 1 OP50 Finish boring 68 (+0.050/0.069).x Guide pad
T83tool. PCD
Small end.
yes 68
C
WZW x
tool diameter cutting speed spindle speed n
d1 d2 vc1 vc2 <min-1>
<mm> <mm> <m/min> <m/min>
6.4 2 99
6.4 60 2984

114.3 160 446

75 80 340
74.7 200 852
75 201 852

32 160 1592

80 160 637

80 160 637

68 350 1638
 India material: ES1133
no.of cutters feed / cutter feed f feed rate vf tool stroke l
z fz <mm/U> <mm/min> <mm>
<mm/z>
2 5 10 995 23
2 0.06 0.12 358 175

2 0.15 0.30 134 78

1 0.10 0.10 34 4
3 0.08 0.24 205 92
1 0.075 0.08 64 72

3 0.15 0.45 716 257

8 0.2 1.6 1019 160

8 0.2 1.6 1019 160

1 0.05 0.05 82 72
oke l cutting time th idle time tn total time tges
<s> <s> <s>
6.5 6.5
23 1.4 1 2.4
175 29.3 1.2 30.6

6.5 6.5
35.0 1.6 36.6
6.5 6.5
7.1 2.0 9.0
27.0 0.5 27.5
67.6 1.1 68.7
6.5 6.5
43.1 3.0 46.1

6.5 6.5
160 28.3 1.4 29.7
1.6 1.6
160 28.3 1.4 29.7
6.5 6.5
52.7 2.0 54.8

6.5 6.5
1 103 1 OP50 Step Semifinish & Finish x T84 Cermet yes 114.7
C boring tool with
1 103 1 OP50 Step
GuideSemifinish
pad. Semi&finish
Finish boring
x tool with Guide
T84 pad.
Cermet
Finish boring
yes 114.94 +0.02.
114.94
Big end.
C boring. Big end.
x
x
x
x
114.7 200 555

114.94 200 555

Total machining time (sec) for Con Rod model 170

Total machining time (min) for Con Rod model 170
 4 0.08 0.32 178 100

1 0.075 0.08 42 80

od model 170
od model 170
33.8 0.5 34.3

115.3 1.2 116.5

1588.29
26.47
HMC Capacity

Set up change Off line

Set up change time Zero
Component loading Off line
Component loading/unloading time Zero

Per componenet tac time 27 min

Allowance @15 % 4 min
Total Time ( Mins) 31 min
0.52 Hrs
AVL Time per year ( Two shifts basis) 3657 Hrs
Volume /Annum 7171 Nos
Say ~ 7200

Increase in Production (Productivity Improvement)

With new HMC per Year 7200
Existing production capacity 3700
Increase in Production (Productivity Improvement) 3500
% increase 94.59
Other benefits
No of machines reduced 11
Floor space saving 200 Sq met
Manpower saving 5 person
Quality improvement
Reduction in rejections
Improved operator morale/motivation
High end technology
Reduced inspection, supervision