Professional Documents
Culture Documents
PPT
PPT
Agenda
1 Presentation
2 Plant Visit
3 Project review on shop floor
4 Feedback
Member Present
Dr. Venkatash Balasubramanian IITM
Mr. Gaurav Munjal AMX
Mr. Sudhir Srivastva Plant Head - CYI
Mr. Jai Prakash Chauhan Manufacturing Head
Mr. Vipin Malik Process Engineering
Mr. Gulab Singh AMX B4
Mr. Manoj Kumar AMX B4
RM
Raw Material Storage Inspection
Blank load
in hopper
3.3 m 3.5 m 6m
Dipping in
Forging Forging Forging graphite
MF22048 MF22012 MF22024
Blank
13 m 11 m 15 m heating at
700 to 745
deg. Celsius
12 m
10 m Forging
Forging
MF22065
Observations
Forged ring fall down on the shop floor after processing.
Raw material blank fall down on the shop floor from the loading conveyor.
Colour coding on bins is not visible.
Safety curtain on machine number 48 is not covering the working zone.
Oil and graphite coming out from the joint of floor covering sheet
Three manpower are working on machine no MF22065 while on other
machines one man power is working
Graphite fall on shop floor while re filling the dipping tank of graphite.
Smoke collector not available on machine no MF22048.
Forging 3S Score is 8 out of 16.
Audit Observation –
Graphite spillages
3S Score – 8 @
Forging shop
Oil & graphite coming out from Part fall on shop floor due to
the joint of floor covering sheet over filling
No smoke collector
at machine no
MF22048 Graphite fall on shop
floor while re filling the
graphite tank
Easy
component
separation
from Die
Minimize
Minimize
energy
usage
NEED wear of
expensive
forging dies
Effects the
manufacturing
cost - scrap,
production
rate, die life
Curiosity
Water Water
Oil based
Description based based
Graphite
graphite synthetic
Carbonaceous smoke Yes Yes No
Better 3S No No Yes
Flammable Yes No No
Cost Rs. 980 / liter Rs. 160 / liter Rs. 140 / liter
Process re validation
Yes
1st No
trial
Yes
2nd No
trial
Yes
Stop 3rd
No
trial
Yes
4th No
Final Approval
trial
Yes
5th No
trial
Trials - Summary
Supplier
S.No. Lubricant Type Trial Date Result Remarks Trial Sheet
Name
Radius on key slot and teeth is
Refer trial sheet no. -
1 5 6/1/2016 Not Ok 1.2mm , Boss dia more
HF01
63.52mm
Refer trial sheet no. -
2 10 7/1/2016 Not Ok Radius on key slot and teeth
HF02
YUSHIRO HF 1080 Refer trial sheet no. -
3 25 7/1/2016 Not Ok Radius on key slot and teeth
HF03
4 100 - - - -
5 500 - - - -
13/01/201 Refer trial sheet no. -
6 5 OK -
6 KS01
13/01/201 Refer trial sheet no. -
7 10 OK -
6 KS02
8 KISAN SHINE LUBE 25 - - - -
3510 28/01/201 Radius on key slot and teeth , Refer trial sheet no. -
9 100 Not Ok
6 Boss dia more KS03
10 500 - - - -
Refer trial sheet no. -
11 5 - - -
SR01
28/01/201 Refer trial sheet no. -
12 10 OK -
6 SR02
30/01/201 Refer trial sheet no. -
13 SUNRISE METAFORGE – 25
6
OK -
SR03
S36 Refer trial sheet no. -
14 100 9/2/2016 OK -
SR04
Refer trial sheet no. -
15 500 10/2/2016 OK -
SR05
IIT PE’s Batch#4 Module ‘4’ GS - MK 15
Project 2 Charter
800
7000 720
700
6000 5760
600
5000
500
4000
400
3000 2744
300
2000
200
114
1000
100
0
0
Actual Target Actual Target
Curiosity
Working Height: 1 m.
Assembly Weight: 70 gm Double cavity forging
press
4 Walk towards the ring box to re fill the input bin & come 0.1
back towards the working station
5 Diverting the component from furnace to machine 3.4
6 Pressing the cycle start button till the process completion 3.08
2000
1770
1800
1600
1400
1200
1000 900 Total
800
down
time is
600
370 3515 of
400 270
150 one
200 week
0
FF PL R&D MT SS
FF Fire in Furnace
PL Machine stop in lunch & tea time
R&D Trial of outer part
Autoloader adjustment & rubber
MT
pipe change time
SS Changeover time
IIT PE’s Batch#4 Module ‘4’ GS - MK 23
Action Plan - Improvements
3 No lunrication on punch Auto lubrication on punch Mr.J.P. Chauhan 12th Feb'16 closed
4 Manual air die cleaning Auto air die cleaning Mr.J.P. Chauhan 12th Feb'16 closed
Highest production in
a shift is 5200 against
Target 5760
IIT PE’s Batch#4 Module ‘4’ GS - MK 26
IITM AMX BATCH # 4
IIT PE’s Batch#4 Module ‘4’ GS - MK 27