HITEC University

Taxila Cantonment
Department of Electrical Engineering

Heavy Industries Taxila

HULL MACHINING OF M113

ARMOURED PERSONEL CARRIER

Supervised By:
Col. Syed Irshad Ali
GM APC Factory

Completed By:
Nisar Ahmed Rana
Sheikh Muhammad Arshad
Introduction and Background
This case study was performed in ORGANIZATION-IV in the year 2008. The organization-IV
has 75 employees and an annual turn over of around 90 million. The organization is
providing APCs since 2001. It has launched a large no of variants of this product. The
manufacturing is characterized by many highly automated processes and lots of manual
transportations and manual assembly operations.

Objective and Methods

The case study was initiated in order to further develop and validate the performance
measurement method. Overall equipment effectiveness is used as a performance
measurement method. The reason behind its use is that we are dealing with internal
business process only. We have no external customers in this Organization.

During the case study, the OEE method is applied in the organization. The data collection
about the company and OEE was done by conducting site visits. Several interviews of two
employees were conducted. Some internal documents were also studied.

Internal Business Process Hull Machining

7 hours
Manufacturing Process:
The process of hull machining starts from Fixing of Hull in Jigs
computer programming. Since this process 45 minutes
almost based on computer control machine
(Horizontal Boring Machine) that’s why it needs
less manpower. A miner mistake while giving the Aligning of machine and
instruction to machine can do a big loss. Only a Loading required program
highly expert worker operates this machine.

After the complete welding in the fabrication Facing of Surface

shop, the hull is sent to this horizontal machine
center for machining. This hull is lifted through
crane and hull is fitted on jig with proper Boring of Holes
orientation. It takes 45 minutes to fix hull in jigs.

First of all worker start the machine and machine

aligned itself. When aligning process complete Chambering
then worker goes to MDI section in which axes of
machine and tool changer are aligned.
Drilling
After this worker insert the command G99 to
omit the previously existing data. Then G92
command is given to the machine to start a new
program. The first tool which we manually adjust Threading
used for facing. After this boring and chambering
is carried out.

10 bore are performed on one side of hull which includes 5 small and 5 large holes. After
this the drilling process starts. This process takes time because total 134 holes are drilled on
the hull.

These holes categorized in following way

a) 16 holes for two Idlers
b) 34 holes for two sprockets
c) 18 holes for six shock absorbers
d) 6 holes for adjusters
e) 60 holes for arms

After complete drilling, last process of threading is carried out. This process is performed in
all the drilled holes. After threading the process of hull machining completes.
Overall Equipment Effectiveness
Item Data
Shift Length 8 hours = 480 min.
Short Breaks 0 @ 0 min. = 0 min.
Meal Break 1 @ 30 min. = 30 min.
Down Time * 20 minutes
Ideal Run Rate ** 0.00238 pieces per minute
One piece should be produced in 7 hour. 0.00238% piece should be
produced in one shift.
One suspension system is fitted in 5 hours.
Total Pieces 1 piece
Reject Pieces 0.005 piece

* Delay due to any mal function.

** %age of Vehicles produced per minutes

Planed Production Time

= [Shift Length – Breaks]
= [480 minutes – 30 minutes]
= 450 minutes

Operating Time
= [Planed Production Time – Down Time]
= [450 minutes – 20 minutes]
= 430 minutes

Good Pieces
= [Total Pieces – Rejected Pieces]
= [1 – 0.005]
= 0.995 pieces

Availability = Total Time / Operating Time

= Operating Time / Planed Production Time
= 430 minutes / 450 minutes
= 0.9556 (95.56 %)

Performance = (Total Pieces / Operating Time) / Ideal Run Rate

= (1.227 / 405) / 0.0037
= 0.9771 (97.71%)

Quality = Good Pieces / Total Pieces

= 0.995/1
= 0.9950 (99.90%)
OEE = Availability x Performance x Quality
= 0.9556 x 0.9771 x 0.9950
= 0.9290(92.90%)

A comparison between world class OEE and its other factors are given below in the table.
We can monitor our performance and quality by relating it to world class OEE.

OEE Factors World Class OEE OEE of PRODUCT-II

Availability 90.00% 95.56%
Performance 95.00% 97.71%
Quality 99.90% 99.50%
OEE 85.00% 92.90%
Results
The above data and OEE factors indicate availability, performance and quality. As the whole
process is automated there is little manpower required. All factors are according to world
class OEE so we have not any need to improve any factors. But performance can be further
increased. The horizontal boring machine is a computer numerical controlled machine. It is
totally automated machine. At the time of study it was not working properly. Some of its
functions are to be set manually. Tool changer function of the machine is out of work so it is
changed manually by operators. There is declined performance due to this. Also there is a
danger of wrong tool that if due to negligence of operator he changes a wrong tool then it
will cause a huge quality loss. If the tool changer of machine is corrected then performance
as well as quality will increase.