Industrial Training Presentation- 2

on
PROTEC
Rajkot, Gujarat

Prepared By: In t e rn a l G u i d e :
Mehul mer P ro f . M i h i r Ve l a n i
15SOEEE11018
A si st . P ro f . , E E

E x t e rn a l G u i d e :
M r. D e e p a k S o m a i y a
Department of Mechanical Engineering,
School of Diploma Studies, RK
S e n i o r S u p e r v i so r
University
Content
 5S Implementation
 Machine Maintenance
 Rejection Material
 Incoming Material Inspection Report
 Standard Room Instruments
 References
 Conclusion
5S Implementation Process
 To implement any system it is necessary to decide the
best system to implement for making Lean
Manufacturing process. These are several steps given
below .
 Management Decision
 Sorting of various Department
 Sorting of Manpower according to division.
 Idea’s from all of the employees.
 List of best ideas to be implemented and the things

required for implementation.

 5S
1. Sort.
2. Set in order.
3. Shine.
4. Standardise.
5. Sustain.
 Sorting of Department
 The departments are divided into various zones.
 Each zone is having zonal Heads and other employee.
 Firstly idea’s from all workers is gathered and the best

one idea is chosen for implementation.

Sorting of Zones
Examples Implemented Ideas
5S Tape Marking
5S Tape Marking
Maintenance of Machine
 Maintenance of Machine is done on the given Basis.
 Daily Maintenance
 Weekly Maintenance
 Monthly Maintenance
 Yearly Maintenance
 Preventive Maintenance
 Breakdown Maintenance &
 CLIT Sheet (Cleaning, Lubrication, Inspection, & Tightening )
 Daily Maintenance Points
1. Cleaning of Machine & Checking of near about area.
2. Cleaning of all Electric Motor & checking of it’s
heating.
3. Cleaning of Electric Panel Board from Outside.
4. Oiling in Dresser & Machine Slide.
5. Checking of vibration of Dresser.
6. Cleaning of Comparator Stand & Dial Indicator.
7. Covering of Grinding Area with Plastic.
8. Checking of Dial of Machine Slide.
 Weekly Maintenance Points
1. Checking of all Electric Motor for heating.
2. Checking of extra noise in Hydraulic Motor.
3. Checking of extra noise in Machine.
4. Checking of Gear oil Level with color
5. Checking of extra noise & heating of feeder motor.
6. Checking of Point of Diamond of Dresser.
7. Cleaning of Dresser.
8. Checking of feeder rolls by using of different series.
9. Checking of Poka-Yoke system status and Proxy
Sensor.
Type of Rejection Piece:-

Accident on Outer Diameter & Face

Corrosion + Uneven Cutting Edge
Length Minus + Improper Face Forging Defected
Proxy Sensors
Parameters to be checked at all
machines
1. Rough Center less Grinder 1. End Face Grinder
o OD Size o Length
o Taper o Face Run out
o 3 Point Ovality o Face Radius
o Visual o OD 3 Point Ovality
o Face RA
o Visual
2. Semi-Finish Center less 2. Finish Center less Grinder
Grinder o OD Size
o o Taper
OD Size
o o OD Profile
Taper
o OD Profile o OD Roundness
o o OD RA Value
OD RA
o o OD 3 Point Ovality
OD 3 Point Ovality
o Visual o Visual
Parameters to be checked :-
Sr. No. Parameter Instrument
1 Roller OD Diameter Dial Comparator Stand ( 2-point )
2 Taper Variation Dial Comparator Stand ( 2-point )
3 2pt. Ovality Dial Comparator Stand ( 2-point )
4 3pt. Ovality Dial Comparator Stand ( 3-point )
5 Length Length Dial Comparator Stand
6 Face Run out Dial with V-Block
7 Radius Runout Dial with V-Block
8 Dimple Runout Dial with V-Block
9 Indent (Dimple) Diameter Vernier Caliper
10 Indent (Dimple)Depth Vernier Caliper
11 Indent (Dimple) Visual Visual
12 Small End Visual Visual
13 Hardness Rockwell Hardness Tester
Standard Room Instruments
 There are mainly 2 instruments in the standard room.
1. Mahr MMQ 100 &
2. Mahr XC 20

 Mahr MMQ 100 is used to measure Roundness, Radial &

Axial Run out, Concentricity, Flatness & Profile of Work
Piece.
 Mahr XC 20 is use for measuring Straightness & Profile of
Work Piece.
Mahr MMQ 100
Mahr XC 20
References
Web links:-
 https://www.referenceforbusiness.com/management/Or-Pr/Poka-Yoke.html
 http://scholar.google.co.in/scholar?q=poka+yoke+prevention+based+and+detec
tion+based&hl=en&as_sdt=0&as_vis=1&oi=scholart
 https://thepexstringofariadne.wordpress.com/2013/04/27/poka-yoke-prevention
-detection-or-both/
 https://www.ijser.org/researchpaper/Implementation-of-5S-Methodology-in-a-
Manufacturing-Industry.pdf
 https://www.isixsigma.com/tools-templates/5s/practical-approach-successful-pr
actice-5s/
 https://www.creativesafetysupply.com/articles/howimplement-5s/
Books:-
 “Poka-Yoke : Improving Product Quality by Preventing Defects”
by Nikkan Kogyo Shimbun
 “Zero Quality Control : Source Inspection and the Poka-Yoke System”
by Shigeo Shingo
Conclusion
 As experience is getting more and more there are lots
of knowledge that we got rather that before CIE-1.
 After implementation of 5S Manufacturing System
working environment is became clean and systematic.
 Contribution of all of the other departments concept of

Model Machine is became successful.

 In current time we are controlling and maintaining the

major machines of the process with the help and

support of Supervisors and Operators.