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AKSHAY MANCHANDA
Mechanical Engg., DELHI COLLEGE OF ENGINEERING
Engine Department
ENGINE DEPARTMENT
Engine
Assembly
line(35 stations)
Cam and Crank
assembly
Valves and piston
assembly
FIP and Oil cooler
assembly
..and many
more.
Engine
Testing
Not
Ok
Endurance
testing
Dyno
testing
Rework
Engine
Machine
Shop
O
k
Lacquer
Shop
Completed
Engine
Project Learning
Project name- Cycle time reduction of Engine Assembly Line
Reason- There are some Non-Value-Added activities in the assembly line which need to be
identified and removed.
Outcome- Cycle time of Engine assembly line is decreased thereby increasing engine
production rate from present rate.
Time taken by every station in the assembly line was noted down for 5 engines.
Carefully observed the activities at each station.
2
Readings
1. Station OP10A: Engine block loading. There are 15 activities in this operation
Activity
1st Trail
2nd Trail
3rd Trail
4th Trail
5th Trail
3.55
5.44
6.14
5.53
7.49
16.16
20.55
19.63
14.57
15.29
4.48
7.91
5.02
4.44
5.57
10
3.2
4.95
3.6
3.89
3.37
11
16.29
17.37
16.39
18.09
17.45
13
2.39
5.07
2.69
3.69
2.97
14
2.89
3.02
2.58
2.47
2.28
15
12.51
12.04
9.84
10.02
11.49
12
Readings
2. Station OP20: Tappet presence check.
There are 13 activities in this operation.
Activity
1
2
3
4
5
6
7
8
9
10
11
12
13
1st Trail
3.86
2nd Trail
7.08
3rd Trail
4.16
4th Trail
4.87
5th Trail
5.25
30.97
5.27
3.14
24.46
36.39
5.76
4.99
20.03
31.38
6.02
4.25
21.18
35.46
5.47
3.59
25.21
32.21
5.21
4.07
21.09
13.49
9.12
10.44
13.59
10.26
17.22
4.24
20.12
3.19
16.95
4.23
17.59
3.45
19.46
4.45
Readings
3. Station OP30: Sealant Dispensing.
This is done by fully automated machine.
Activity
Sealant
Dispensi
ng
12.75
13.07
3rd Trail
4th Trail
5th Trail
12.31
12.87
12.51
Readings
4. Station OP40A: Bedplate Assembly.
There are 10 activities in this operation.
Activity
2
3
4
5
6
7
8
9
10
1st
Trail
2nd
Trail
3rd
Trail
4th
Trail
5th
Trail
3.84
6.09
4.23
6.17
5.59
6.11
44.04
7.61
53.33
6.57
50.59
8.13
47.43
7.12
45.36
53.38
72.11
76.93
70.29
64.87
6.05
8.79
7.23
6.94
8.12
Readings
5. Station OP210: Auto Valve Lash.
This operation is done by a fully automated machine.
This step sets clearance between elephant foot and Valve Bridge which provide
Valve safety when engine get heated up.
Activity
1st Trail
2nd Trail
3rd Trail
4th Trail
5th Trail
Auto
Valve
Lash
208.71
237.95
209.26
240.13
230.36
Recommendations
A special trolley can be designed so OP10A such that it can accommodate enough
amount of bedplate carrier.
Tappet assembly in the engine block can be done at OP10B instead of OP20. It will
problem of accumulation of engine between OP10B and OP20.
Panel of OP150 can be shifted close to OP160.
In OP210 make the 2 probes, which set the valve lash, work independently.
Behavioral Learning
Self-awarness
Personal Effectiveness
Planning & Organizing
Problem Solving and Decision Making
THANKS