Embed Size (px)
Citation preview
1
2
3
COMPANY
HIGHLIGHTS
4
Abilities India Pistons & Rings Limited -- a renowned name in Piston
manufacturing Established in the year 1968 by Mr. R.S. Arora.
Converted into a limited company in 1995.
• No. of employees is 300.
- Customer value driven approach
- Practice of Lean Manufacturing System
- Structured Problem Solving Approach such as Six Sigma
- Quality Circles In All Departments
- 5S, POKA YOKE & Kaizen Part of Daily Activities
- Focus on Employee Engagement & Involvement
Company details
5 ST
AR
TE
D
PR
OD
UC
TIO
N
OF
PIS
TO
N R
ING
S
AQ
UIR
ED
IS
O /
TS
16
94
9
CE
RT
IFIC
AT
ION
JO
INE
D A
CM
A A
CT
EN
GIN
EE
RIN
G
EX
CE
LL
EN
CE
CL
US
TE
R P
RO
GR
AM
RE
CE
IVE
D E
XP
OR
T H
OU
SE
CE
RT
IFIC
AT
ION
FR
OM
GO
VE
RM
NM
EN
T O
F I
ND
IA
JO
INE
D A
CM
A U
NID
O
CL
US
TE
R P
RO
GR
AM
CO
MM
EN
CE
D S
UP
PL
IES
TO
FIR
ST
OE
M C
US
TO
ME
R I
N C
HIN
A
JO
INE
D A
CM
A A
CT
AD
VA
NC
E
CL
US
TE
R P
RO
GR
AM
CO
MM
EN
CE
D S
UP
PL
IES
TO
FIR
ST
OE
M C
US
TO
ME
R I
N U
SA
1st E
XP
OR
T O
F O
EM
SU
PP
LIE
S T
O E
UR
OP
E
AQ
UIR
ED
IS
O 9
00
1
CE
RT
IFIC
AT
ION
Sta
rted
OE
M
sup
pli
es t
o T
VS
Mo
tor
& E
nfi
eld
Con
ver
ted
In
to a
Lim
ited
Com
pan
y
1982
2000
1998
1996
1995
2006 2007
2008 2009
2004
2005
2011
About the Acquirer/Applicant
6
CO
MM
EN
CE
D
SU
PP
LIE
S T
O M
AR
UT
I
SU
ZU
KI
FO
R 2
W E
NG
INE
S
Ma
jor
Ex
pa
nsi
on
, In
tro
du
ctio
n
of
New
Tec
hn
olo
gy
& M
ov
ing
To
wa
rds
Gre
en M
an
ufa
ctu
rin
g
Sy
stem
CE
RT
IFIC
AT
E O
F A
PP
RE
CIA
TIO
N F
RO
M
AC
MA
FO
R E
XC
EL
LE
NC
E I
N T
EC
HN
OL
OG
Y
CO
MM
EN
CE
D S
UP
PL
IES
TO
OE
M C
US
TO
ME
R I
N J
AP
AN
GO
LD
WIN
NE
R A
CM
A E
XC
EL
LE
NC
E
IN E
XP
OR
T
SIL
VE
R W
INN
ER
AC
T C
AS
E S
TU
DY
CO
MP
ET
ITIO
N -
IN
NO
VA
TIO
N
AC
HIE
VE
D S
TA
R E
XP
OE
T
HO
US
E C
ER
TIF
ICA
TIO
N
FR
OM
GO
VE
RN
ME
NT
OF
IN
DIA
AQ
UIR
ED
IS
O
1
40
01
& O
HS
AS
18
00
1
CE
RT
IFIC
AT
ION
2013
2015
2015
2015
2013
2014
2013
About the Acquirer/Applicant 2016-17
Certificate of
Appreciation
from Maruti
Suzuki on 2
wheeler
Engine
2017-18
Certificate of
Appreciation
from HONDA
7
2008- Received Export
Excellence silver trophy
from EEPC of India
2008- Won ACMA
Productivity & Quality award
Bronze trophy
2008- Received Export
Excellence Silver trophy
from ACMA
2009- Received Export
Excellence silver trophy
from EEPC of India
8
2009- Achieved Gold trophy
from ACMA for Excellence in
Quality & Productivity
2009- Achieved Gold trophy
from ACMA for Excellence in
Export
2010- Achieved 1st Prize in
IMTMA-Siemens Productivity
Champion Ship Award
2010- Achieved 1st Prize
for TEI in CII National
Cluster Summit
9
2011- Commendation
Certificate in Rajiv Gandhi
National Quality Award For
The Year 2010
2011 - Commendation
Certificate in DL- Shah
National Awards on Economics
of Quality For The Year 2010
2011- National Award Special
Recognition For Research &
development Efforts By
MSME For The Year 2010
2012 - Received Export
Excellence Star Performer
Trophy from EEPC of India
for the Year 2009-10 &
2010-11
10
Trophy Received
“Silver Winner ”
for the ACMA - ACT Case Study
Competition – Innovation on 16th & 17th
February, 2015 Pune
Received EEPC(Govt. of India)
“Star Performance National
Award”
for the year 2012-13 at Mumbai
on 22nd January, 2014
Gold Trophy for Excellence in Export
11
Certificate of
Appreciation
From
Maruti Suzuki
Appreciation Certificate
12
13
TECHNOLOGY
We have developed here at Abilities the technology/ expertise for
manufacturing Pistons for chain saws and 2 & 4 stroke engines, right from raw
material to finished product ensuring Higher Level of Quality and durability.
20,000 Sq Meters Factory Land.
Well Trained Staff & Skilled Associates
CAD / CAM Interface Through Uni-Graphics, Solid Works & PRO-E
Creo Parametric 4.0 M020
WINCAST software
Well Equipped in House Tool Room including VMC from Mazak Japan
CNC CAMLESS Machining Facility
4 Index Fine Boring & Circlip Grooving Facility
Company details
14
Key Products / Product Families
Cylinder
Pistons & Rings
Pistons With
Connecting Rod
Assembly
15
Business Share Export V/s Domestic
Export 55%
Domestic 45%
Business Contribution
16
Our Valued OEM Customers
17
New Piston Line Installed (Capacity increase
3 million pistons/ year)
1 CNC For Rough Turning
2 CNC IS/RG/HF
1 Circlip Grooving CNC
1 Casting M/c
2 SPM’s Made in House
1 Stamping M/c
Company details Additional investments for increased capacity year 2017-18
Piston Ring (Capacity increase
10 million Piston Rings / year)
1 DD grinder
1 Cam Turning
1 Vertical Boring
1 CNC Barrel Honing
1 Lapping M/c
Laser Marking M/c
18
Expansion Plan – 2018-19
-Complete Piston Machining
Line (2 Sets)
- Gravity Casting Machines
(3 Nos.)
-Heat Treatment Automatic
Quenching Furnace (T6)
-Ultrasonic Cleaning For
Packing - New Line
(Piston Capacity 4 million / year)
June 2018
19
Company details
PISTON FOUNDRY SHOP PISTON MACHINE SHOP
20
CNC MACHINES
Company details
TAKISAWA CNC CAMLESS
OVAL TURNING
FOUR INDEX FINE BORING
& CIRCLIP GROOVING
YOU JI OVAL TURNING
CNC OIL HOLE DRILLING VMC MAZAK
21
Pressure Die Casting 250 Ton with Vacuum attachment
SAM Casting Machine Casting Machining Line
Company details
22
Piston Ring Finish ID Boring Machine Piston Ring CAM Turning Machine
CNC Barrel Turning Piston Ring Machine Piston Ring Finish Gap Sizing Machine
Company details
23
Company details
Machine Movie
Automatic Piston
Ring Mounting
Machine (on Pistons)
24
ROUNDNESS TESTER
SPECTROMETER IMAGE ANALYZER
MICRO HARDNESS
TESTER
CONTOUROGRAPH
CMM
FORM MEASURING STATION
Company details
25
Digital Read Out Gauge For
Connecting Rod Checking
Company details
Fully Automated Piston Inspection System
26
Distinctive TEI Initiatives
All activities started during ACMA Advance Cluster
Program
1. Employee Family Visit - Every Week
2. Annual Family Day Function
3. Birth Day Celebration
4. Summer Computer Class
5. Kitchen Garden
6. Potable Drinking Water
7. Canteen
8. In House Dispensary
9. Common Uniform
10. Safety Awareness activities
11. Talent Development Program
12. Conducting Training Session
13. Quality Circle Activities
14. Reward & Recognition
15. CEO Monthly Address
16. Tea with MD
17. Best Employee of the Month
18. Tobacco & Pollution Free Company
19. Care for the Environment
20. Suggestion Scheme
27
Training Session
Safety Audits and NC
7
28
24
9
25
39
11
41
21
7
18
10
7
28
23
9
25
38
11
41
20
6
18
10
0
5
10
15
20
25
30
35
40
45
1 2 3+4 5 6 7 8 9 10 11 7-A 11-A
Num
ber
Cum.NC Identified
Cum.NC removed
Information Centre
Family Day Photo Safety Audit
Kitchen Garden
Total Employee Involvement
Kaizen Reward
28
Annual Family Day Function
Musical Chair Competition Families enjoying their Lunch Race Competition
Painting Competition Employee Children's are playing
29
Distinctive TEI Initiatives
Birth Day Gift to the Employee Tea with MD
30
Corporate Social Responsibility
- Company and Its employees regularly contribute for
Prime Minister Relief Fund in case of natural calamities
such as UTTARAKHAND & NEPAL
- Scholarships granted to employee children to encourage
them in studies, sports activities etc.
31
Common Canteen
In House Dispensary for all the employees
Distinctive TEI Initiatives
32
TS16949
Certificate
Star Export
House
2015
OHSAS -18001
Certificate
Proud Achievements
ISO -14001
Certificate
33
ACMA Advance Cluster Road Map
We are part of ACMA ADVANCE CLUSTER program to
upgrade our facilities to BEST IN CLASS standards.
Time in Months 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
1. Kaizen
2. QCC
3. 7 QC Tools
4. QC Story
5. 7 Management tools
6. Talent Development
30th
May
'09
Month
1st J
un'0
7
Jul'0
7
Aug
'07
Sep
'07
Oct
'07
Nov
'07
Dec
'07
Jan'
08
Feb'
08
Mar
'08
Apr
'08
May
'08
Jun'
08
Jul'0
8
Jan'
09
Feb'
09
Mar
'09
Apr
'09
Sep
'08
Oct
'08
Nov
'08
Dec
'08
Aug
'08
Deliverables
VAPCO
VAR
Road map for Advance Cluster
Lead time
ITR
Process Stability
- Quantity
- Quality
Customer Quality - PPM
OEE / OLE / OPE
Cost Losses
Cellular
Manufacturing (Productivity Culture )
Integrated Flow
Manufacturing (Business Result Culture )
1. Concept of Cell design & Implementation
1.1 SMED (Integrate to SPF )
1.2 LCA ( Integrate to operator fatigue / Stresses
1.3 Integrated Quality Control ( Poka-yoke , Vision Control )
2 .Equipment Maintenance
2.1 Implement step 1, 2 ,3 & Practice
2.2 Preventive maintenance - Implement and Practice
2.3 Organisation / Management
2.4 Cost loss analysis
3. FIFO
3.1 First IN First Produced ( Integrate to quality traceability )
3.2 Production planning & control
1. Value adding management , concepts design and Implementation
1.1 Implementation of 14 steps
1.2 Production balancing and leveling
2. Integrated cellular manufacturing - Implementation and Practice
Audit Score
PQC Improvement
Total Employee Involvement
Satisfaction Score
Participation Kaizen / QCC
TEI (Continuous
Improvement
culture through
TEI )
Advance 5 S (Sustenance culture through Discipline)
1. Institutionalize all 5 S Basics
2. 6 M concept design &
implementation
3. Holding gains and Corrective
actions
34
ACMA-ACT Engineering Excellence Cluster
Road Map
We are part of ACMA ACT ENGINEERING CLUSTER program to
upgrade our facilities to BEST IN CLASS standards.
35
ACMA-CII ZED Cluster Road Map
36
Best Practices
Low Cost Automation
No of Trials / Parts 1 2 3 4 5 6 7 8 9 10
1 1.45 1.49 1.46 1.41 1.47 1.39 1.37 1.38 1.48 1.43 Repeatability ( Equipment Variation)
2 1.46 1.48 1.46 1.42 1.47 1.39 1.38 1.38 1.47 1.43 EV = R double bar * K1
3 1.46 1.49 1.46 1.42 1.48 1.39 1.38 1.38 1.47 1.43 Reproducability ( Appraiser Variation)
Avg. Xa 1.457 1.487 1.460 1.417 1.473 1.390 1.377 1.380 1.473 1.430 AV(X diff * K2)²-(EV²/nr)}
Range Ra 0.010 0.010 0.000 0.010 0.010 0.000 0.010 0.000 0.010 0.000 Repeatability & Reproducability (R&R)
No of Trials / Parts 1 2 3 4 5 6 7 8 9 10 R & R (EV² + AV²)
1 1.45 1.49 1.46 1.41 1.47 1.39 1.38 1.38 1.48 1.44 Part Variation ( PV )
2 1.46 1.50 1.46 1.41 1.46 1.38 1.38 1.39 1.48 1.44 Pv = Rp X K3
3 1.45 1.50 1.46 1.41 1.47 1.38 1.38 1.39 1.48 1.44 Total Varaiation ( TV )
Average Xb 1.453 1.497 1.460 1.410 1.467 1.383 1.380 1.387 1.480 1.440 TV (R&R² + PV²)
Range Rb 0.010 0.010 0.000 0.000 0.010 0.010 0.000 0.010 0.000 0.000 % Equipment Variation ( EV )
No of Trials / Parts 1 2 3 4 5 6 7 8 9 10 % EV = ( EV / TV ) *100
1 1.46 1.49 1.45 1.41 1.47 1.39 1.38 1.38 1.48 1.43 % Appraiser Variation ( AV )
2 1.46 1.48 1.46 1.41 1.47 1.39 1.37 1.39 1.48 1.43 % AV = ( AV / TV ) *100
3 1.46 1.49 1.45 1.41 1.47 1.39 1.38 1.38 1.48 1.44 % Repeatability & Reproducability (R&R)
Average Xc 1.460 1.487 1.453 1.410 1.470 1.390 1.377 1.383 1.480 1.433 % R & R = ( R & R / TV ) *100
Range Rc 0.000 0.010 0.010 0.000 0.000 0.000 0.010 0.010 0.000 0.010 % Part Variation ( PV )
% PV = ( PV / TV ) * 100
X D.Bar= 1.4348 No. of Distinct Data Categories
Rp = 0.1122 ndc = 1.41 (PV / GRR)
Repeatability & Reproducability (R&R)
w.r.t Total Tolerance
A2 D3 D4 K1 K2 K3
1.023 0 2.58 0.5908 0.5231 0.3146
Analysis of Results :
Condition 1 : % GRR < 10 Acceptable Results Accepted
10 < % GRR < 30 Conditionally acceptable (if % GRR w.r.t Total tolerance is less)
% GRR > 30 Not acceptable
Condition 2 : The number of out of control points in Average chart should be more than 50 % to ensure part-to-part variation Results Accepted
Condition 3 : No out of control points in the Range Chart Results Accepted
Condition 4 : The number of distinct data categories (ndc) should be greater than or equal to 5 Results Accepted
Conclusion & Remarks :
Prepared By Approved By
F/QA/16
GAUGE REPEATABILITY & REPRODUCABILITY STUDY
A
P
P
R
A
I
S
E
R
RAJ
NA
RAYA
N 1.4340
1.4340
1.4350
1.4343
0.0050
RESULTS / EVALUATION
Trials / Appraisers r = n =
3 Trials 3 Appraisers Number of Parts Number of Trials
+0.10
Average
Part Average
1.4360
1.4357
0.0050
1.490 1.458 1.412 1.470
DEV
END
ER
Performed By
Date
Record Number
Part Name
Gauge / Equipment Name
Gauge / Equip. Least Count
PISTON
BALL MICROMETER
RADIAL THICKNESS
-0.00
0.10
DATA COLLECTION
0.01mm
Upper Control Limit
Lower Control Limit
Tolerance
0.0013
1.478
Part Number
Gauge/Equip. No.
Characteristics
OM-2930; Ø34MM
9M2
DHIRMENDRA
December-05
4
0.0138
1.4330
1.4340
1.4360
1.4343
0.0060
1.4350
R D.bar= {(Ra+Rb+Rc)} /3
X Diff ={ Max X - Min X } 1.429
UCLx = {X D.bar + (A2 * R)}
LCLx = {X D.bar - (A2 * R)}
1.440
0
UCLr = R D.bar X D4
LCLr = R D.bar X D3
0.0053
LAX
MA
N 1.4360
1.457 1.388 1.378 1.383 1.434
Preventive Maintenance Gauge R & R , Calibration
Nov'
08
Dec'
08
Jan '
09
Nov'
08
Dec'
08
Jan '
09
Nov'
08
Dec'
08
Jan '
09
Nov'
08
Dec'
08
Jan '
09
Nov'
08
Dec'
08
Jan '
09
Nov'
08
Dec'
08
Jan '
09
1Casting
machine
24 27 19 41 40 19
2PISTON M/C
SHOP Line no.
1 to 5
32 37 35 37 40 28
3Face grinders(
rings)
32 26 24 26 21
4 Cam turning 31 28 32 32 32 15
5 Boring 29 27 30 32 34 15
6Notch
grinding/milling 30 32 34 32 28 15
7 Honing 4 3 2 5 4 4
MachineSr
.N
o.
Total DiesLess than 5
Minutes
>=5 Minutes <
10 Minutes
>=10 Minutes <
30 Minutes
>=30 Minutes
< 1 Hour
No of dies
>=1 hour
Minutes < 2
Hours
SMED Matrix
Example of Cp & Cpk Calculation POKA – YOKE Station Laser
37
Improving competitiveness….
Aligning with customer varying demand using the tools like:
Takt Time
Value Stream Mapping
Production Leveling & Balancing
To Identify & Eliminate The Waste We Use
Process Mapping
Low Cost Automation
Operating Ratio
Cycle Time Study By Video Graphy
Standard Work Combination
Standard Operating Procedures
CLITA Standard
38
Quality Tools Used
VAR :- Before = 0.76 After = 11.95
Standardised Work Combination table REV 03
Product : PO414 Machine : LINE # 2 Required output/ day : 2000 Manual
Process : MACHINING DATE: 15 th JAN08 Department: MACHINE SHOP Takt Time : 37 Auto
1 2 3 4 5 6 7 8 9
1
0
1
1
1
2
1
3
1
4
1
5
1
6
1
7
1
8
1
9
2
0
2
1
2
2
2
3
2
4
2
5
2
6
2
7
2
8
2
9
3
0
3
1
3
2
3
3
3
4
3
5
3
6
3
7
3
8
3
9
4
0
4
1
4
2
4
3
4
4
4
5
1 Rough turning 7 15 22
2 Center bore drilling 4 4
3 Locating seat 5 14 19
4 Size turning and ring grooving & HF 6 15 21
5 0
6 Lock pin drilling, fitting & pressing 30 30
7
8 Rough boring 10 21 31
9 Fine boring 11 23 34
10
11 Circlip grooving 23 23
12 Bore chamfer 5 5 10
13
14 Bore burnishing 10 10
15 Boss facing 6 29 35
16 IBC 8 8
17 0
18 Oval turning 15 21 36
19 PORT FILE 7 7
20
21
22 0
31
Step
Manual
Time in Seconds
Auto
Tota
l
CLICK HERE FOR DETAILS
Value Stream Mapping Standard Work Combination
Process Mapping
VALUE STREM MAPPING PRODUCT FAMILY PO-414 (Feb,16)
VAR :- Before = 0.76 After = 21.95
39
• Virtual Designing & Validation
• Design capability acquired from consultants retired from FM plant. Have recently engaged a retired Chief Engineer from HGA -Honda Two Wheelers, Japan for augmenting our design & innovation capabilities
• Have successfully designed Two Piston assemblies for an OEM European company & received order for production of one assembly & for tooling of the second assembly
Technology Focus Areas
40
•Have offered successful solutions to OEM customers for
eliminating seizing problems in customer’s own designed
pistons
•Modified existing piston ring design of OEM customer with new
material & changed OD profile achieving 20% better engine life
& 3% reduction in emissions.
• Introduced NPD Systems
• Product & Process Optimization & Validation
• Engine Testing
• FEA techniques initiated to prepare the company to be
“Design Enabled”
Technology Focus Areas
41
Technology Focus Areas - Rapid Prototyping
SAMPLE KICK OFF
Casting
Die Manufacturing
Proofing
Heat Treatment
Machining
Inspection
Solid Bar Casting
Rough Counter
Milling
5 Axis Milling M/c
Conventional Prototyping
Inspection
Machining
Heat Treatment Heat Treatment
Rapid Prototyping
6 Weeks
1 Weeks
1 Weeks
1 Day
3 Day
1 Day
Readily
Available
2 Days
3 Days
1 Day
2 Day
1 Day
42
Technology Focus Areas - Rapid Prototyping
• Pistons are made out of standard solid bars through gravity Die Casting.
• Casting Quality is similar to Conventional Casting technique.
• Piston is completely machined from all around.
• Solid are in steps of 5mm each depending on size / diameter of the piston.
43
Technology Focus Areas - Rapid Prototyping
Solid bar is milled
down to achieve
desired internal cast
contour through high
Speed Axis milling
operation
ROUGHING INTERNAL CONTOUR MILLING By VMC
44
D10 Moly coating
for Pistons (Dow
Corning)
Technology Focus Areas
Graphite coating
Phosphating
45
Technology Focus Areas
Tin Coating Nickel Plating
46
Technology Focus Areas
Dynamometer Engine Test Control Cell
47
Planting New Trees
UPDATED INFORMATION
48
Global data mapping for similar application for
Power, torque etc.
Optimizing from perspectives of
Optimized design - weight, chamfers, tolerances
Reduction in weight of Pistons by VA/VE
HOUSE OF QUALITY
49
Technology oriented solution
- Lean manufacturing (Single Piece Flow, Adoption of LCA,
Adoption of latest technology machines)
- Lean Machines with Lean Hydraulics, Pneumatics,
Electricals & no chips / coolant on floor
HOUSE OF QUALITY
50
Thank you for your attention
Abillities India Piston & Rings Ltd.
Plot No. 3, F-301, IIIrd Floor
Ashish Complex, Local Shopping Centre,
New Rajdhani Enclave Vikash Marg,
Delhi-110 092 (INDIA)
Phones: 0091-11-22059744
Telefax: 0091-11-22059755
E-mail : [email protected]
www. aippistons.com
ご清聴ありがとうございました
धन्यवाद Gracias por su atención
感谢您的关注
Grazie per l'attenzione
İlginiz için teşekkür ederiz
