GOOD EVENING

COMPANY PROFILE
IP Rings was born out of the technical collaboration between India Pistons Limited and Nippon Piston Ring Company Ltd., Japan - a world class leader in Ring Technology.

IP Rings is the only Company in India, which has under got one roof, facilities for : Chromium Plating Moly flame spray Plasma spray Gas Nitriding Nifflex Cell

Entire spectrum of the automobile industry from two-wheelers to Heavy Commercial Vehicles and Tractors are catered by us.

CLIENTS

OBJECTIVE PRODUCTIVITY IMPROVEMENT IN GAS NITRIDING CELL THROUGH: Improvement in throughput time Improvement in operator efficiency Improvement in operator utilization

THE PROBLEM
There was no particular sequence being followed by the operator, except at the start of the operations. At the start of the operations first the degreasing process is started. Once the first rod is degreased and the operations progress the rest of the operations are carried out as convenient. NO PROPER SEQUENCE OF OPERATION.

RESEARCH METHODOLOGY
Research Design: Descriptive research Data Collection: Primary data through observation Sampling Method: Judgemental non-Random Sampling

FORMULAS TO BE USED 1. Normal time = Av. Cycle time X Performance rating 2. Standard time = Normal time X Allowance factor

Where, Allowance Factor = 1/(1- Allowance Fraction)

DEGREASING
1. Loading first rod 2. Degreasing 3. Loading rod II 4. Degreasing 5. Unloading and loading

OBSERAVTI ON 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Average cycle time

Time for loading first rod 7.82 7.66 8.1 7.59 7.9

7.814

Cycle time for degreasing 200.07 199.07 197.06 198.27 198.55 199.11 198.76 198.21 196 199.31 198.28 198.21 197.33 198.28 196.96 198.03 199.76 198.25 197.88 198.18 197.2785

OBSERVATION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Average time

Loading rodII 13.11 12.42 13.22 13.83 13.8

Unloading & loading 22.5 17.3 18.41 18.33 21.21 16.53 20.28 22.76 19.66 18.61 17.89 23.41 18.22 17.39 19.91 20.29 21.12 21.89 16.39 18.86 19.548

13.276

S no. 1 2 3 4 5

Operations Loading rod Degreasing Loading rod II Degreasing Unloading and loading Standard time for degreasing

Average cycle time 7.8 197.7 13.2 197.7 19.5

Standard time 8.7 197.7 14.8 197.7 21.8 440.7

DRY HONING
1. Mandrel loading 51.5 seconds 2. Loading to DH machine 11.4 seconds 3. Dry honing 197.2 seconds Mandrel loading 51.5 seconds Unloading from mandrel 45 seconds Loading to GN basket 17 seconds 4. Unloading and loading 18.3 seconds

Observation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Average cycle time

Mandrel loading 58.8 33.21 50 47.77 39.28 41.11 53.21 48.96 47.94 38.81 43.23 50.01 57.44 48.25 45.48 45.71 41.28 36.71 40.49 56.26 46.1975

Loading to dry honing machine 10.84 10.51 9.76 10.11 10.25 11.03 10.45 8.61 10.18 10.77 9.39 10.49 11.23 9.88 10.31 8.49 11.99 10.18 10.83 9.97 10.2635

Observation 1 2 3 4 5 6 7 8 9 10 Average time

Unloading from mandrel 41.39 38.43 37.89 37.36 38.43 39.88 52.51 39.94 40.40 38.70 40.4

Loading to GN basket 16.18 14.21 14.33 17.23 15.03 14.83 15.56 14.88 16.01 15.49 15.3

Observation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Average cycle time

Dry honing 196.27 197.26 196.18 196.33 200.02 197.21 196.77 198.10 196.88 197.13 196.81 196.21 197 198.18 196.96 199.21 196.69 196.8 198.31 197.57 197.2945

Unloading loading 16.12 24.4 15.81 14.13 17.22 13.21 16.81 15.25 16.13 16.8 17.03 14.99 17.22 15.03 16.13 15.09 16.18 14.29 21.4 16.02 16.463

S no. 1 2 3 4 5 6 7

Operation Mandrel loading Loading to dry honing machine Dry honing Mandrel loading II Unloading and loading Unloading from mandrel Loading to GN basket Standard time for dry honing

Average cycle time 46.1 10.2 197.2 46.1 16.4 40.4 15.3

Standard time 51.5 11.4 197.2 51.5 18.3 45 17 278.4

SEQUENCE SUGGESTED
1. DEGREASING 2. DRY HONING

Time optimally required through suggested sequence

10098.7 + 9760.4 =19859.1 seconds = 330mins and 59.1seconds = 5hours 30mins and 59seconds

Therefore, the time saved 7.5hrs 5hrs 30mins and 59.1secs

= 1hr 59mins and 1secs

DEGREASING CHART

REFINED SEQUENCE
DEGREASING 1. Loading rod 8.7 seconds 2. Degreasing 197.7 seconds 3. Loading rod II 14.8 seconds 4. Degreasing 197.7 seconds 5. Unloading and loading rod 21.8 seconds DRY HONING 6. Mandrel loading 51.5 seconds 7. Loading to DH machine 11.4 seconds 8. Dry honing 197.2 seconds Mandrel loading 51.5 seconds Unloading from mandrel 45 seconds Loading to GN basket 17 seconds 9. Unloading and loading 18.3 seconds

1 2 3 4 5 4 6 7 8 5 4 9 8 5 4 9 8 5 - 4 . so on

Total time projected in accordance to the sequence

=2hours 52mins and17seconds

Time that will be saved upon successful implementation of sequence =7.5hrs 2hrs 52mins and 17secs

=4hours 37mins and 43seconds

BENEFITS OF THE PROPOSED SEQUENCE

1. Increase in productivity 2. Higher operator efficiency 3. Higher operator utilization and Lower cost 4. Saves time and energy

THANK YOU

QUESTIONS??