Models developed at AFX I-95 (2019-20)

Actual
Plan Dispatch Constraints during
S.No. Customer Model Name Dispatch Improvements Remarks
Date Development
Date
KQY-BCK 1.Cross-Curvature
1.Mold repaired for
NG
achieving C/C.
01. KIA MOTORS 05-May-19 30-Apr-19
2.Correction done in
2.Positioner cut out
Press ring.
in right side.
1.Cross-curvature
1.Mold repaired for
NG.
achieving C/C.
02 HYUNDAI HBC-BCK 25-Jun-19 15-Jun-19 2.Press ring
2.Alignment done as per
alignment & level
requirement.
with outer frame is
NG.
1.Cross-Curvature
NG 1.Mold to be repaired for
next trials.
03 M&M MW6-BCK 25-July-19 19-07-19
2.Mould heater 2.Heaters connection
connection in wrong corrected
side

1
Models Developed at AFX I-94 (2019-20)
Plan Actual
Model Constraints during
S. No Customer Dispatch Dispatch Improvements Remarks
Name Development
Date Date
KQY-RQ 1. Laser Eye logic and P1
1. Glass Position NG at
distance modified by
Bending Ring.
Electrical Maintenance
KIA 2. Movement of glass
01. 05-May-19 30-Apr-19
MOTORS was not stable on pre
2. Trial on R2 was taken and
forming Rollers due to
model developed
Small size.
successfully.

1. Catcher Bar changed

1. Glass not Stable on according to glass position.
Cather Bar. 2. Laser Eye logic and P1
02 HYUNDAI BI3-RQ 25-May-19 20-May-19
2. Glass Position NG on distance modified by
Bending Ring. Electrical Maintenance.

1. Quenching Pressure
1. High Curvature on
Optimized
03 M&M MS2-FD 20-Jun-19 21-Jun-19 Upper Edge.
2. Size corrected in Next
2. Size minus.
run.
2
 Tact Time Reduction I-94
Before After
Part No : FD/RD TEMPERED GLASS Date: 20 June 2019 Part No : FD/RD TEMPERED GLASS Date: 5 JULY 2019
Bottleneck- loading to Centering table drop Standardized work Combination Table Cycle Time: 4 sec Bottleneck- Standardized work Combination Table Cycle Time: 3.5 sec
M/C No.-I-94 Process Name :Loading M/C No.-I-94 Process Name :Loading
Time Operation Time (Unit in Sec.) Time Operation Time (Unit in Sec.)
SQ. Operation Sequence Manual Auto Walk 5 10 15 20 25 30 35 40 45 SQ. Operation Sequence Manual Auto Walk 5 10 15 20 25 30 35 40 45

From loading to centering table drop 8 sec From loading to centering table drop 7 sec
1 1

Centering to logo Marking Table 8 sec Centering to logo Marking Table 7 sec
2 2

Logo Marking to final pick up table 8 sec Logo Marking to final pick up table 7 sec
3 3

Final pick up table to loading conveyor 8 sec Final pick up table to loading conveyor 7 sec
4 4

First Operation was Bottleneck and it consists of two motions: a)Loading the glass b) Homing

Homing was taking extra time so we bypassed the Homing motion, so Loading time reduced from 8 sec to 7 sec. After this
every operation sequence was taking 7 sec each so our Tact time reduced from 4 sec to 3.5 sec.

3
 FACED CHALLENGES DURING THE DEVELOPMENT OF BI3-RQ MODEL
QUENCHING ZONE

Upper Upper

ZONE-5 ZONE-6

Lower Lower BENDING ZONE

1. ELECTRIC EYE CENSOR PROBLEM : Laser of 3. GLASS VIBRATION DURING 4. CATCHER BAR MODIFICATION:
2. GLASS POSITION WAS NOT PROPER ON MOLD: Due
electric eye could not detect the glass when it was BLOW OFF : Glass position Previously glass was falling from
to some design issues glass position was improper on
moving through the heating zone. was not stable during blow off the catcher because of small size of
mould. So, we changed the design of bending ring.
operation . glass during shuttle movement .

ELECTRIC EYE ELECTRIC EYE BEFORE AFTER

STUCK NO STUCK
4