TRAINING REPORT

*OF *SIX MONTHS INDUSTRIAL TRAINING, UNDERTAKEN *AT

FEDERAL-MOGUL GOETZE (INDIA) LIMITED BAHADURGARH, PATIALA

*IN *DEPARTMENT *PISTON MACHINE SHOP

Submitted By: Name: HARMANJEET SINGH College Roll No.: 83015 Class: 5th semester. Branch: Mechanical Department: Piston foundary & machine shop

HISTORY OF FEDERAL MOGUL

Escort is a creation of Nanda Brothers with contraction vision committed and determined. The Escorts group under the dynamics leadership of Mr. Nanda (Chairman&M.D.) is a professionally managed multi product organization. The Escorts group was founded at Lahore Pakistan 17th October 1944 as an agency house-the Escorts (agents) Ltd. It came in to being with a vision that was nurtured by Mr. Hari Nanda, Yudi Nanda, & C.K. Hazari. In infancy he suffered a severe blow because of partition of India in 1947. How ever the founder members shifted their operations to New Delhi and in sort he steered the concern to a place of reorganization, which is crystal clear performance. After partition in 1947 Nanda brothers continued the agency for electrical products for westing house and in mean time in undertaking another agency for heavy machinery also manufactured by westing house, in 1949 following the devaluation of rupee the company found that their agency is not working up to mark they found that government was laying much emphasis on major irrigation and industrial projects after independence. Garbing the opportunity-Escort took an agency for heavy machinery from various countries like U.S.A., U.K, Germany, Japan, & Poland. During this time ESCORTS (agents) LTD was formed. Yudi Nanda looked after the second company, which imported & sold (M.F.) tractors in India with fraternity of 22,000 employees, 20 manufacturing plants & a turn over exceeding Rs.30 billions, the Escort group today ranks among the top industrial giants in the country a persistent annual growth rate 27% of the past decade. It is the 5th largest Engg. Company among both public & private companies. According to economic times the Escorts is ranked among 7th in sales & 5th in profit while amongst Engg. Companies, it is ranked 4th in sales and 2nd in profit. In 1954, the company got the incorporation certificates from the govt. of India. It decided to branch into manufacturing & collaborated with Goetze Werke of Germany to manufacture world-class pistons in India, which it felt the need of quality if pistons to complement the Goetze ring it joined hands with Mahle of Germany. For four decades Mahle pistons and Goetze rings remained undisputed leaders in OEM and after market segments the demands for tractors was increasing fast and the company decided to set up tractor manufacturing plant at Faridabad.

GOETZE (INDIA) LTD.

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 LTD. ventured into manufacturing of pistons in 1958 with the collaboration of M/S Mahle GmbH, Germany, which delivered the Indian automobile industry its piston in 1960. ESCORTS entered in collaboration with M/S SUKO GmbH, Germany, for piston pins in 1967 and manufacturing started in 1968.To meet the increasing demand of market, in 1977 a parallel unit to manufacture pistons & piston pins was set up in Bangalore. Technological leadership matched with innovated thinking has made Escorts and Goetze products to enjoy a high degree of customer confidence and are the first choice of discerning customer for application ranging from bi- wheeler to battle tanks. 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 mogul, a well-known group of U.S.A. In June 2000, both Escorts Mahle Limited and Goetze have become QS 9000 certified companies.

Following items are manufactured at Patiala plant of Escorts: a) Aluminium pistons b) Piston pins c) Piston rings d) Chrome plated rings e) Moly rings f) Cylinder liners g) Light metal cylinder heads for motorcycles

REGULAR CUSTOMERS OF ESCORTS MAHLE LIMITED 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Tata Trucks Escorts Tractors Eicher Tractors Sonalika Tractors Maruti Cars Hind Motors Bajaj Scooters LML Scooters Yamaha Motercycles Hero Honda Motercycles TVS Mopeds.

DIAGRAM OF A PISTON:

PROCESS FLOW CHART

CASTING FIXTURE SEAT DIA OUTER DIA TURNING GROOVING ROUGH BOTTOM BOSS OIL HOLE ROUGH BORING CIRCLIP GROOVING FINISH PIN HOLE DEBURRING FINISH GROOVING FINISH CROWN FINISH OUTER DIA VALVE SEAT MACHINING ROLLING PACKING

1. FINISH SEAT DIA.

MACHINE NAME: KD2 CNC MACHINE MACHINE DEVICE AND TOOL FOR MANUFACTURE: 1. STEEL JAWS 2. CNC PROGRAM 01431 3. PCD TOOL FOR FACING, BORING AND CHAMFERING TOOL LIFE: 75000 4. CENTRE DRILL (2.0 MM) TOOL LIFE: 3200

PARAMETERS:
1. FIXTURE SEAT DIA.: (0.060.01) 2. INTERNAL DEPTH: 0.50 3. LUG HEUGHT: 0.20 4. CENTRE CONCENTRICITY: 0.05 MAX. 5. CENTRE HOLE HEIGHT W.R.T. FINISH CROWN CENTRE:(56) 0.25

2. PRE. OUTER DIA TURNING AND GROOVING, CROWN FACING MACHINE NAME: LC 16 XL MACHINE DEVICE AND TOOL FOR MANUFACTURE:
1. CNC PROGRAM: 01431 2. TURNING FIXTURE: F-2/4185 3. CARBIDE INSERT (2 SIDE) FOR OVER TURNING TOOL LIFE: 1000/SIDE FROM 1 SIDE (0.8R) 4. CARBIDE INSERT (2 SIDE) FOR FACING TOOL LIFE: 1000/SIDE FROM 1 SIDE (0.8R) 5. PCD INSERT (0.8R) FOR PRE OVER TURNING TOOL LIFE: 20000 6. PCD TOOL FOR PRE GROOVING (WIDTH 1) TOOL LIFE: 75000

PARAMETERS:

1. PRE OUTER DIA.: (53.28 + 0.10) (53.75+0.10) 2. PRE GROOVE DIA.: (49+0.20) 3. PRE GROOVE WIDTH: (1+0.002) 4. PRE GROOVE HEIGHT W.R.T. SEAT FACE: (24.550.05) 5. ROUGH TOTAL HEIGHT : (45.80.1) 6. WALL THICKNESS DIFFERENCE: 0.40 MAX.

3. BOSS OIL HOLE DRILLING: MACHINE NAME: DRILLING MACHINE MACHINE DEVICE AND TOOL FOR MANUFACTURING:
1. HSS DRILLS 2, 2MM DIA DRILLS TOOL LIFE: 100 3. BOSS OIL FIXTURE: F 3/4086

PARAMETERS:
1. OIL HOLE DIA.: (20.2) 2. NO. OF OIL HOLES IN PIN BOSS: 2 3. OIL HOLES LOACTION: OIL HOLE ON CENTRE 4. DRILL BREAKAGE IN OIL HOLES: NO DRILL BREAKAGE

4. OIL HOLES DRILLIMG IN THIRD GROOVE MACHINE NAME: CNC OIL HOLE DRILLING MACHINE MACHINE DEVICE AND TOOL USED FOR MANUFACTURING: 1. CNC PROGRAM 1431
2. HSS DRILLS (1- 1.2 MM DIA) TOOL LIFE: 100 3. FINISHED TURNING FIX (F 4/3140) 4. DRIVING PIECE (F 4/141)

PARAMETERS: 1. OIL HOLE DIA: (10.2)

2. NO. OF OIL HOLES: 8 3. OIL HOLE LOCATION W.R.T. MAJOR AXIS: 12.5 APART FROM MAJOR AXIS. 4. OIL HOLE LOCATION W.R.T. SKIRT END: IN 3RD GROOVE 5. DRILL BREAKAGE IN OIL HOLE: NO DRILL BREAKAGE

5. ROUGH BORING, CIRCLIP GROOVING, FINISH PIN HOLE BORING MACHINE NAME: 6 INDEX MACHINE CNC PROGRAMMED MACHINE DEVICE AND TOOL USED FOR MANUFACTURE:
1. TURNING FIXTURE ( 6 NO.) (F 3/4052) 2. SOLID CARBIDE DRILLS (12.75 MM) TOOL LIFE: 10000 3. CIRCLIP GROOVING TOOLS: CT 3/ 923 TOOL LIFE: 10000 4. PCD SEMI FINISH BORING TOOL TOOL LIFE: 75000 5. PCD FINISH BORING TOOL TOOL LIFE: 75000

PARAMETERS:
1. ROUGH BORE SIZE: (12.750.10) 2. PIN HOLE OFFSET: (0.60.15) 3. C.G. DIA. : (14.20.10) 4. C.G. WIDTH: (1.1+0.1) 5. PIN HOLE DIA.: (13000+0.003) (13000+0.008) 6. PIN HOLE SQUARENESS: 30 MM MAX. (AFTER FINISH O.D. TURNING) 7. BORE ALIGNMENT: GUDGEON PIN SHOULD PASS THROUGH FREELY 8. OVALITY IN PIN HOLE: 3 MAX. 9. PIN HOLE FINISH: Ra0.90 MAX.(BEFORE ROLLING), Ra0.63 MAX.(AFTER ROLLING) 10. FINISH HEIGHT AT 48 DIA.: (19.840.10) 11. TAPER IN PIN HOLE: 3 MAX 12. PIN HOLE CO. AXIALITY: 5 MAX 13. BURR OUTSIDE PIN HOLE: NO BURR OUTSIDE PIN HOLE

6. DEBURRING: MACHINE NAME: DEBURRING MACHINE

MACHINE DEVICE AND TOOLS USED FOR MANUFACTURE:

1. DEBURRING CUTTER

PARAMETERS:
1. BURR: NO BURR

7. FINISH GROOVING: MACHINE NAME: CNC M/C LT2XL MACHINE DEVICE AND TOOLS USED FOR MANUFACTURE: 1. CNC PROGRAM 01431
2. PCD GROOVING TOOL TOOL LIFE: 75000 3. PCD CHAMFERING TOOL TOOL LIFE: 75000

PARAMETERS:
1. GROOVE DIA. FOR GR. 1 & 2: (47.5 0.1) 2. GROOVE DIA. FOR GR. 3: (48 0.1) 3. GROOVE INCLINATION FOR 1ST ND 2ND GROOVE: (1.5 MM 4.4 MM) 4. GROOVE INCLINATION FOR GR. 3:(5 15) UPWARDS 5. GROOVE WIDTH FOR GR. 1: (0.8+0.020) (+0.040) 6. GROOVE WIDTH FOR GR. 2: (0.8+0.010) (0.030) 7. GROOVE WIDTH FOR GR. 3: (1.5+0.0010) (0.02) 8. STEP UPTO FLANK GR. 2: (36.850.1) 9. STEP UPTO FLANK GR. 1: (40.30.1) 10. GROOVE CHAMFER FOR ALL GROOVES: (0.2*45) MAX. 11. GROOVE ECCENTRICITY:0.15 MM 12. GROOVE FLANK SURFACE FINISH: Ra=0.63 13. SKIRT LENGTH: (33.30.10) 14. GROOVE WAVINESS: 15 MICRON MAX. 8. FINISH CROWN AND CAVITY

MACHINE USED: LC16XL CNC M/C

MACHINE DEVICE AND TOOLS USED FOR MANUFACTURE:

1. CARBIDE SEMI FINISH TOOL LIFE: 10000 2. PCD FINISH CROWN TOOL LIFE: 40000

PARAMETERS:
1. TOTAL HEIGHT: (45.50.20) 2. RADIUS TOTAL HEIGHT AT 48 DIA.: (44.640.10) 3. CAVITY PROFILE: (R270) SPHERICAL

9. FINISH OUTER DIA. TURNING

MACHINE USED: TAKISAWA TPS- - 31005

TOOL USED:
1. PCD DIAMOND TOOL (OTR) TOOL LIFE: 3000

PARAMETERS:
1. FINISH OUTER DIA. AT 6.8 MM HEIGHT: (52.9820.006) 2. OVALITY AT 12.8 MM HT. (0.2600.010) 3. SKIRT ROUGHNESS PITCH: (Ra O.7 1.8MM) 4. LINEAR FORM :( 1K1143111REF.) 5. POLAR FORM: 1K11431/1REF. 6. TOP CHAMFER: (O.2 0.5*45) 7. SKIRT END CHAMFER: EDGES TO BE SHARP AND FREE FROM BURR. 8. OBLIQUITY: 0.020 MM

10. VALVE SEAT MACHINING: MACHINE USED: BROTHER TC 52 A MACHINE DEVICE AND TOOL USED:
1. CNC TAPPING CENTRE CUTTER HOLDER ADOPTER

2. VALVE SEAT MILLING FIXTURE (CAGE TYPE) 3. CARBIDE INDEXABLE INSERT TOOL LIFE: 40000

PARAMETERS:
1. VALVE SEAT DEPTH ROM PIN HOLE CENTRE: FOR SMAAL VALUE (25.4 0.25), FOR BIG VALUE: (23.8 0.25) 2. VALVE SEAT POSITION: AS PER DRAWING

11. P.H. ROLLING

MACHINE USED: ROLLING MACHINE PARAMETERS: HOLE: NO BURR IN PIN HOLE

PROCESS FLOW CHART LINE 4.

CASTING PLUNGE CUTTING FINISH SEAT MACHINING ROUGH CAVITY PRE OUTER DIA. TURNING PRE CROWN FACING PRE BORING

FINISH GROOVING FINISH OUTER DIA. TURNING FINISH PIN HOLE BORING FINISH C.I. GROOVING FINISH CROWN FACING CAVITY MACHINING CIRCLIP GROOVING ROLLING CLEANING FINAL INSPECTION PACKING 1. PLUNGE CUTTING
MACHINE NAME: LOCKESH MACHINE. MACHINE DEVICE AND JIG TOOL FOR MANUFACTURE: 1. GUIDE SLEEVE: F-2/1624 2. DRIVING PIECE: F-3/1625 3. HOLLOW CENTRE:C-2/1040 4. CARBIDE INEXABLE: INSERT FOR PLUNJING 5. CARBIDE INDEXABLE: INSERT FOR ROUGH BOTTOM THICKNESS TURN. TOOL LIFE: 300 6. CARBIDE INDEXABLE: INSERT FOR OUTER DIA. TURNING. TOOL LIFE: 1000

PARAMETERS:

1. ROUGH OUTER DIA AT SKIRT.: 99+0.50, 99+0.80 2. ROUGH OUTER DIA. AT C.I. RING ZONE: 96.80.60 3. BOTTOM THICKNESS: 30.500.10 4. WALL THICKNESS: 0.60 MM MAX.

2. FINISH SEAT MACHINIG MACHINE NAME: KD2F CNC MACHINE. MACHINE DEVICE AND JIG TOOL FOR MANUFACTURE
1. KD2F CNC M/C: ALUMINIUM JAWS 2. CARBIDE INSERT FOR ROUGH CUT TOOL LIFE: 300. 3. PCD INSERT FOR SEAT BORING AND FACING TOOL LIFE: 30000 4. CENTRE DRILL TOOL LIFE: 1500

PARAMETERS:
1. FIXTURE SEAT DIA.: 91.3+0.06, 91.3+0.01 2.FIXTURE SEAT DEPTH: 40.1 3. INTERNAL DEPTH: 71.70.30 4. CENTRE CONCENTRICITY: 0.050 MM MAX.

3. ROUGH CAVITY MACHINING MACHINE NAME: PMT MACHINE HOLDING JAW. MACHINE DEVICE AND JIG TOOL FOR MANUFACTURE:
1. PMT M/C HOLDING JAW 2. F-3/5025 3. DRIVING PIECE: F-2/502 4. BRAZED CARBIDE TOOL TOOL LIFE: 400

PARAMETERS:
1. ROUGH CROWN HEIGHT: 0.20.20

4. PRE OUTER DIA. TURNING AND PRE CROWN FACING MACHINE NAME: M8R MACHINE. MACHINE DEVICE AND JIG TOOL FOR MANUFACTURE:
1. FINISH TURNING FIX F-4/3957 2. REVOLVING CENTRE 3. CARBIDE BIT FOR OVER TURNING TOOL LIFE: 500 4. BRAZED CARBIDE FACING TOOL & GROOVING TOOL TOOL LIFE: 1000

PARAMETERS:
1. PRE OUTER DIA.: (97.88+0.50)-(97.88+0.70) 2. ROUGH OUTER DIA.: 96.80.10 3. ROUGH TOTAL HEIGHT: 100.60.10 4. WALL THICKNESS: 0.5 MM MAX.

5. PRE BORING MACHINE NAME: WB1 MACHINE MACHINE DEVICE AND JIG TOOL FOR MANUFACTURE:
1. BORING FIXTURE: F-4/3960 2. DRIVING PIECE: F-4/3961 3. CARBIDE DRILL SIZE: 4. BORE ALLIGNMENT 5. BOSS SQUARENESS 6. ROUGH BORE POSITION

PARAMETERS:
1. BORE SIZE: 34.350.20 2. ROUGH BORE HEIGHT: 17.820.20 3. PIN HOLE OFFSET: 0.60.20 4. BOSS SQUARENESS: 0.30 MM MAX.

6. PRE OUTER DIA TURNING & FINISH GROOVING MACHINE NAME: M8F MACHINE MACHINE DEVICE AND JIG TOOL FOR MANUFACTURE:
1. M8F M/C FINISH TURNING FIXTURE F: 4/3957 2. F TYPE DRRIVING PIECE: F-3/4462 3. TAIL STOCK CENTRE SOLID CARBIDE GROWING TOOLS TOOL LIFE: 1500 4. BRAZED CARBIDE CHAMFERING TOOL TOOL LIFE: 5000 5. CARBIDE LIPPED OVERTURNING INSERT TOOL LIFE: 400

PARAMETERS:
1. PRE OUTER DIA. TURNING: 97.18+0.20 2. GROOVE DIA. FOR 2ND AND 3RD GROOVE:87.3-0.20 3. GROOVE WIDTH: 1ST GROOVE: 2 2ND GROOVE: (2.5+0.040) (2.5+0.060) 3RD GROOVE: (4+0.020) (4+0.040) 4. SKIRT LENGTH UPTO GR. 3: 64.20.20 5. GROOVE SQUARNESS: 3MW FOR 1MMM 6. GROOVE ECCENTRICITY: 0.20 MM MAX. 7. RING LAND:50.1 8. WAVINESS OF RING GR. FLANKS: 15 MM MAX. 9. TOP CHAMFER SKIRT END CHAMFER: 0.50.20*45, 0.80.3*30. 10. ROUGH TOTAL HT. : 100.5.10 11. GROOVE CHAMFER FOR 2ND AND 3RD GROOVE: (0.1-0.4)*45. 12. STEG DIA N3: 96-0.20 13. RECESSING BELOW GROOVE 3: 20.2*30.

7. FINISH OUTER DIA TURNING MACHINE NAME: TAKISAWA MACHINE DEVICE AND JIG TOOL FOR MANUFACTURE:
1. TPS- 31005 2. TPS- 4000

3. FINISH ASSEMBLY FOR TAKISAWA 31005: F-4/4463 4. DIAMOND TOOL, PCD TOOL LIFE: 8000 5. CARBIDE TOOL FOR C.I. RING ZONE TOOL LIFE: 500

PARAMETERS:
1. FINISH OUTER DIA. AT 11 MM: STD 96.8750.010 2. SKIRT ROUGHNESS RING ZONE ROUGHNESS: (163 ), (13-19) 3. LINEAR FORM: AS PER DRAWING 4. POLAR FORM: AS PER DRAWING 5. GROOVE PLANE INCLINATION: 92 MAX. 6. OVALITY AT D3 AT 84.7 MM HT.: (20020

8. FINISH OUTER DIA. TURNING MACHINE NAME: TAKISAWA TPS- 31005

TAKISAWA TPS- 4000

MACHINE DEVICE AND JIG TOOL FOR MANUFACTURE:

1. ASSEMBLY FOR TAKISAWA 31005: F-2/4420 2. DIAMOND TOOL, PCD TOOL LIFE: 8000 3. CARBIDE TOOL FOR C.I. RING ZONE TOOL LIFE: 500

PARAMETERS:
1. FINISH OUTER DIA. D1: STD 91.8750.015, 92.3750.015, 92.6250.015, 92.8750.015, 93.3750.015. 2. SKIRT ROUGHNESS: 2.5 3.8 3. LINEAR FORM: AS PER DIAGRAM, 3NKF 701ESB 4. GROOVE PLANE INCLINATION: 105 MAX. 5. OVALITY AT D1 AT 8.0 MM HEIGHT: (-28020 )

9. FINISH PIN HOLE BORING. MACHINE NAME: ZAY CNC MACHINE MACHINE DEVICE AND JIG TOOL FOR MANUFACTURE:
1. BORING MANDREL: F-4/2123

2. V- BLOCK: ZAY- 1/128 3. PCD TOOL FOR ROUGH CUTTING TOOL LIFE: 10000 4. DIAMOND TOOL TOOL LIFE: 5000

PARAMETERS:
1. PIN HOLE DIA: 32+0.007, 32+0.002 2. PIN HOLE OFFSET: 0.6+0.20 3. PIN HOLE SQUARENESS FOR 1MM LENGTH: 100 MAX. 4. ROUGH COMP. HEIGHT: 65.30.010 5. TAPER IN PIN HOLE: 3 MAX. 6. QUALITY IN PIN HOLE: 3 MAX. 7. PIN HOLE FINISH: RA 0.80 .

10. FINISH C.I. GROOVING MACHINE NAME: M8C1 GROOVING MACHINE. MACHINE DEVICE JIG TOOL FOR MANUFACTURE: 1. FINISH TURNING FIXTURE: F-4/2116
2. DRIVING PIECE: F-3/475 3. SOLID CARBIDE TOOL TOOL LIFE: 2000 4. ROLLER TYPE CHAMFERING WITH CHAMFERING TOOL. TOOL LIFE: 3000

PARAMETERS:
1. GROOVE DIA.: 82.3-0.20, 82.8-0.20, 83.05- 0.020, 83.3- 0.20, 83.8- 0.20 2. GROOVE WIDTH: 2.5+0.075+0.055 3. RING LAND: 6.70.20 4. GROOVE ECCENTRICITY: 0.2 5. GROOVE CHAMFER: 0.1*45 DEGREE MAX. 6. WAVINESS OF RING GROOVE FLANKS; 15 MAX.

11. FINISH CROWN FACING & CAVITY MACHINING MACHINE NAME: MKV-8/FEMCO MACHINE.

MACHINE DEVICE AND JIG TOOL FOR MANUFACTURE:

1. CAGE FOR CAVITY: F-2B/855 2. CAVITY MACHINING FIXTURE: F- 3/275 3. BRAZED CARBIDE TOOL TOOL LIFE: 250 4. PCD TOOL TOOL LIFE: 15000

PARAMETERS:
1. CROWN HEIGHT: 650.05 2. TOP LAND: 17.60.20 3. CAVITY DEPTH: 16.90.10 4. CAVITY VOLUME: 38.650.5 5. CROWN ROUNDNESS CROWN TAPER: 0.08, 20 . 6. CAVITY LOCATION: AS PER DRAWING. 7. CAVITY DIA.: 600.25

PROJECT:IMPROVEMENTS IN LINE-7 TO INCREASE PRODUCTIVITY

INTODUCTION OF DRAWBACK 1: LINE 7 COMPRISES OF A 6 INDEX

MACHINE ON WHICH 6 PROCESSES CAN BE DONE SIMULTANEOUSLY.THIS IS A REALLY EFFICIENT MACHINE WHICH CAN INCREASE THE PRODUCTIVITY TO A LARGE EXTENT.FOLLOWING PROCESSES CAN BE DONE ON THIS MACHINE SIMULTANEOUSLY: 1. ROUGH BORING 2. FINISHED BORING 3. CIRCLIP GROOVING 4. ROLLOING 5. FINISH CIRCLIP GROOVING 6. CLEANING OF CHIPS BUT IN LINE 7 ONLY 3 PROCESSES ARE DONE ON THIS MACHINE.ONLY ROUGH BORING, FINISHED BORING AND CIRCLIP GROOVING IS DONE ON THIS MACHINE.THIS IS A BIG DRAWBACK BECAUSE PRODUCTIVITY SUFFERS DUE TO IT. CAUSE AND EFFECT IS DISCUSSED BELOW:

CAUSE: 3 PROCESSES ARE TAKING PLACE ON THIS MACHINE. WHEREAS 6

PROCESSES SIMULTANEOUSLY CAN BE DONE ON IT. EFFECTS: 1. TIME WASTE: EACH PISTON WHICH IS PLACED ON THIS MACHINE HAS TO GO WAIT ON THIS MACHIINE FOR A MUCH MORE TIME THEN IT SHOULD BE THERE.ONLY 3 PROCESSES ARE DONE ON THE PISTON BUT STILL IT HAS TO WAIT FOR APPROX. 2 MINUTES ON THE MACHINE.IT HAS TO WAIT FOR APPROX. 1 MINUTE EXTRA ON THE MACHINE FOR ITS TURN TO BE REMOVED FROM THE MACHINE.THIS REDUCES THE PRODUCTIVITY. 2. LENGTH OF THE LINE HAS INCREASED BECAUSE CIRCLIP GROOVING, ROLLING AND FINISHING HAS TO BE DONE ON OTHER MACHINES. 3. INCREASED LABOUR FORCE REQUIRED FOR CARRYING OUT ABOVE MENTIONED THREE PROCESSES SEPERATELY. 4. PRODUCTIVITY REDUCES. 5. COST INCREASES BECAUSE NEW MACHINES ARE TO BE USED FOR CARRYING OUT ROLLING, CIRCLIP GROOVING AND FINISHING. HOW TO IMPROVE: 1. ALL THE ABOVE MENTIONED 6 PROCESSES SHOULD BE DONE ON THIS MACHINE. THE MACHINE SHOULD BE REPAIRED AND WHERE EVER IMPROVEMENT IS REQUIRED SHOULD BE DONE. ADVANTAGES ON IMPROVING: 1. INREASE IN PRODUCTIVITY. 2. COST REDUCTION 3. TIME SAVED 4. LENGTH OF LINE REDUCES

INTRODUCTION OF DRAWBACK 2: LINE-7 IS A RELATIVELY

SMOOTH LINE WITH VERY LESS SCRAP.MOST OF THE SCRAP WHICH TAKES PLACE IN IT IS DUE TO ONE SINGLE FACTOR.IT IS DUE TO THE WRONG SEAT MAKING AND CENTRING.SEAT MAKING AND CENTRING IS DONE ON THE KD MACHINE.IF SOME STEPS ARE TAKEN TO IMPROVE THE CENTRING AND SEAT MAKING THEN IT IS OBVIOUS THAT SCRAP WILL REDUCE BY A LARGE EXTENT.IF CENTRING AND SEAT MAKING IS NOT PROPER THEN REST OF THE

PROCESSES ARE ALSO NOT PROPERLY DONE.RESOURCES ARE WASTED ON SCRAP PISTONS BECAUSE INSPECTION IS DONE IN THE END.

CAUSE: 1. WRONG PROGRAMMING OF THE MACHINE.

2. IMPROPER CASTING DONE IN THE FOUNDARY SHOP. 2. TOOL GETS BLUNT AFTER SOME TIME.

EFFECT:
1. AMOUNT OF SCRAP INCREASES. 2. TIME IS WASTED ON DOING THE NEXT PROCESSES ON THE PISTON. 3. MATERIAL IS WASTED. 4. RESOURCES LIKE TOOLS AND HUMAN ATTENTION ARE WASTED ON THE SCRAP PISTONS.

HOW TO IMPROVE: 1. INSPECTION SHOULD BE DONE IMMEDIATELY AFTER THE PROCESS OF

CENTRING AND SEAT MAKING IS OVER SO THAT THE SCRAP IS SEPERATED FROM OTHER PISTONS, IN THIS WAY RESOURCES WILL BE SAVED. 2. CHANGING THE TOOLS REGULARLY. 3. INSPECTION SHOULD BE CARRIED AFTER THE CASTING IS DONE SO THAT SCRAP IS SEPERATED THERE AND THEN. 4. PROPER PROGRAMMING OF THE MACHINE SHOULD BE DONE.

ADVANTAGES ON IMPROVING:
1. SCRAP REDUCTION. 2. TIME WASTAGE STOPPED 3. MATERIAL WASTAGE REDUCED. 4. RESOURCES SAVED.

IMPROVEMENT IN LINE-4:
INTODUCTION OF DRAWBACK 1: IN LINE 4 A MAJOR REASON FOR THE
SCRAP IS THE MISSING CAST IRON RING. THE PISTON MADE IN THIS LINE

HAS AN ADDITIONAL CAST IRON RING ADDED TO IT TO IMPROVE ITS PHYSICAL PROPERTIES LIKE HARDNESS AND LONG LIFE.SOMETIMES THIS CAST IRON RING IS ABSENT IN THE PISTON WHICH RESULTS IN THE SCRAP.DUE TO WHICH MATERIAL IS WASTED.THE MISSING CAST IRON RING IS DETECTED ONLY AFTER A COUPLE OF PROCESSES ARE ALREADY DONE ON THE PISTON.THEREFORE IT ALSO RESULTS IN WASTAGE OF TIME AND RESOURCES.

CAUSE:
1. HUMAN ERROR IN FOUNDARY SHOP: SOMETIMES THE OPERATOR FORGEATS TO PUT THE CAST IRON RONG INTO THE MOULD DURING CASTING. 2. SHIFTING MISTAKE IN FOUNDARY SHOP.

EFFECT:
1. TIME WASTAGE. 2. MATERIAL WASTAGE DUE TO SCRAP 3. DECREASE IN PRODUCTIVITY 4. RESOURCES WASTED.

HOW TO IMPROVE: 1. INSPECTION SHOULD BE DONE BEFORE THE FIRST PROCESS OF TURNING
IS CARRIED OUT. 2. HUMAN ERRORS IN THE FOUNDARY SHOP SHOULD BE REDUCED.

ADVANTAGES ON IMPROVING:
1. SCRAP REDUCTION 2. INCREASE IN PRODUCTIVITY 3. MATERIAL WASTAGE REDUCES 4. RESOURCES ARE SAVED. 5. TOOL LIFE MORE.