PROJECT REPORT

ON
POSSIBLE REASONS FOR TIME DELAY IN
BOOM DIPPER ASSEMBLY AND FINDING
SOLUTIONS FOR THE SAME

SUBMITTED BY: JATIN VIRMANI

SUBMITTED TO:MR PUNIT KUMAR
 STEPS INVOLVED

1) IDENTIFICATION OF THE PROBLEM

2) FINDING POSSIBLE CAUSES OF PROBLEM
3) FINDING THE ROOT CAUSE
4) WORK OUT SUITABLE SOLUTIONS
 STEP 1
IDENTIFICATION OF PROBLEM
 PROBLEM DEFINED

THE BOOM DIPPER SUB ASSEMBLY HAS TO ARRIVE AT

ZONE- 4 SO THAT IT CAN BE ASSEMBLED TO VEHICLE.
BUT, OFTEN IT IS UNABLE TO REACH THE ZONE-4 ON TIME.
HENCE THERE IS A DELAY IN PRODUCTION PROCESS.
 STEP 2
POSSIBLE REASONS FOR THE PROBLEM
 FISH BONE DIAGRAM
MACHINE METHOD Rams are attached are
station 3 and previous
During ram
stations remain idle
assembly in
Cannot be 4DX models ,
modified only one crane is method
used for all the used for
rams 4DX
EMS 4DX models mod els
MACHINE require large time
Runs at
cranes
constant

TIME DELAY
speed 3CX
whether line Previous operators models
is moving have to sit idle
fast or slow waiting for the crane
Ram assembly of two rams is
done at a time

regular
operator will
Shortage take less time
of tipping
links Labour
turnover
Other material Replaced operator will
shortage take more time
Operator Error

Time delay by
operator in combining
trolley with the truck

MATERIA MAN
L
 CAUSES
1) MAN

• The operator who is assigned the task of loading the boom dipper
subassembly for the 3DX variant to EMS also has to load the boom
and dipper of the 4DX variant to the industrial car which takes
about 25-30 seconds and during this time there are chances of halt
in the boom and dipper sub-assembly area.
• Labour Turnover : When a regular operator is not available then he
is replaced by another operator and there are chances that he is
not dexterous. This may directly affect the running of line.
2) MATERIAL
In case of shortage of tipping link or
any other part in the sub-assembly
area, the operator is not permitted to
assemble the incomplete part and he
therefore circumvents the operation
at the sub-assembly area and then
this operation is performed at Zone-4
which increases the idle time of
operator at sub-assembly and also
increases the cycle time of operation
at Zone-4.
 3) METHOD
• Ram assembly of two 3CX variant booms take
place at the same time. As a result , time is also
invested in part which is to be utilised later on and
remains unutilised in zone 4 until its turn comes.
Hence , boom dipper of 3DX are not able to reach
zone 4 on time. This also increases the load on the
operators in sub assembly area which is later on
compensated.
• For the 4DX variant all three the rams are
assembled at one station using the same crane to
load the rams , this increases the cycle time at the
station and results in halt at the previous stations.
 4) MACHINE
• EMS system used for transferring
boom dipper subassembly of 3DX
variant to zone-4 cannot be
modified and it runs at constant
speed. For example; if the line is
running at higher speed then also
EMS will operate at constant
speed and as a result there will
shortage at zone-4.
• For 4DX models , ram assembly takes place at station-
4 and the tackle and hoist system which is used for
ram picking is the same one which was used for 3DX
models. Hence all the previous stations remain idle
and the idle time is larger as the 4DX ram
subassembly takes larger time.
 STEP 3
FINDING THE ROOT CAUSE
 ROOT CAUSE

All the rams of 4DX variant are assembled at the same station and
the tackle and hoist system used is the same that is used for 3DX
variants. Also the operating time on 4DX variant is large as compared
to other variants. Therefore , previous stations remain idle for a
considerable time and there are chances of halt in sub assembly line.
 STEP 4
WORK OUT SUITABLE
SOLUTIONS
 SOLUTIONS
1) Rams for 4DX at station no 1

On an average , three 4DX variants are

assembled each day which requires 9
rams in total. Out of these, three rams
can be placed and assembled at station
no 1. This will decrease the load on
station no 3 and in turn will decrease
the idle time of the stations in between.
This will decrease the fluctuations in
availability of boom dipper sub
assembly at zone-4.
2) Extra unloading trolley at zone-4

At zone-4 , sometimes the boom dipper

sub assembly arriving from sub assembly
region via EMS has to wait above. As a
result, all back operations are affected
and operators remain idle sub assembly.
So we can provide extra unloading trolley
at zone-4 so that the boom dipper sub
assembly can be unloaded and stored
there. And now the production process
will not stop and hence there will be no
shortage when line is running at higher
speed.
3) Assigning duty of 4DX trolley

The task of connecting 4DX trolley and empty trolley to the industrial
cart has to be done by cart driver only otherwise if the person who is
responsible for loading to EMS will do that task , then there is
unnecessary wastage of time and can lead to delay in availability of
boom dipper sub assembly at zone-4.
4) Highlighting the EMS loading area

The operator who loads the trolley to the EMS system takes time to
align the trolley with respect to EMS. This time can be reduced by
highlighting the specified area. This can be done by highlighting the
area with a marking tape.
 CONCLUSION

At the completion of our training, we were able to acquire and

apply fundamental principles of engineering and management. We
could relate and reinforce things that we have learned in our
curriculum. Apart from this, we understood the importance of
sustainability and cost effectiveness.
We were able to identify the problems based on our observations
and come up with some possible feasible solutions as well. We
understood that identifying a problem and its solution can only be
achieved by proper research .
In the end, we understood that for maintaining/improving any
industry, the methods of engineering and management go hand-
in-hand and their coordination is what results in its proper
functioning higher productivity.