STAPLER MANUFACTURING/ASSEMBLY

ANALYSIS

By Saurabh Dewan (78) Diana (105) Prakhar Rastogi (107) Siddhi Agrawal (110) Manjushree (112)

Overview of the component assembly procedure

EXPLODING THE BOM (AS RECOMMENDED BY

THE GROUP PRESENTATION IN THE CLASS)

Base Spring - 2 Central Rod - 1

Pin Pusher - 1

Central Spring - 1

Arrester pin - 1
3

Carrier - 1

Hammer with Holder - 1

Base - 1

Carrier Locker - 1
4

SUB ASSEMBLY 1

Assy 1 - Hammer with Hammer holder + Base Spring

Assy 2 - Base + Base Spring

Assy 3 - Central Rod + Central Spring + Pin pusher

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SUB ASSEMBLY 2

Assy 4 - Carrier + Assy No. 3

FINAL ASSEMBLY

Fully assembled Stapler

TIME STUDY
Assy No
1 2 3 4

Assembly process
Push the spring into the grooves provided on the Holder. It will sit there. Same as above Put the central rod through pusher and then put the central spring Put one side of Assy No. 3 in the hole provided on right side of carrier and adjust the other side and fix it Align Assy No. 1 and 2 and use arrestor pin to hold them in position Now, align Assy No. 4 and hold it in position by pushing arrestor pin in the hole Take the Carrier Locker and align with the Assy No. 4 and lock it in position Finaly, push the Arrestor Pin through holes of all the assembled components Packaging into a small box Repackaging into a bigger box Total(including delays)

Time taken(sec)
5 8 12 15

45

6 7

5 120/20=6 96

FINAL SOLUTION

Required output 500 staplers in a shift Tc = (8 * 60 *60* 90%)/500 = 52 sec

So 96 sec single piece flow to be reduced to atleast 52 sec Solution Final assembly to be concurrently done with the sub assemblies using jigs for proper alignment. We can also employ two operators in place of one

Subassembly 1 Assemble hammer with hammer head and base Move to final Assembly

Subassembly 2

Assembly Flow Chart

Assemble Base and base spring Move to Final Assembly

Subassembly 3 Assemble Central Rod , Central Spring and Pin pusher Assemble carrier with above assembly Move to Final Assembly

Final Assembly Pick Subassembly 1 and subassembly 2

Align Assy No. 1 and 2 and use arrestor pin to hold them in position

Pick Subassembly 3
Now, align Assy No. 3 and hold it in position by pushing arrestor pin in the hole Take the Carrier Locker and align with the Assy No. 3 and lock it in position Finaly, push the Arrestor Pin through holes of all the assembled components Put stapler into small packet Put Stapler into larger box

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THANK YOU

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