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PROJECT SEMESTER REVIEW

Name: Zorawar Singh Nandwal

Roll No: 401257013

Organization: Munjal Showa, Manesar

Department: Rear Assy, I.E

Project Guide: Mr. Narinder Madan

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Munjal Showa in very few years of its existence has become a national leader in manufacturing of Suspensions for 2 & 4-Wheelers. Since its formation in 1987 with Showa group of Japan it has grown substantially and has achieved success in both national and international markets. Today Munjal Showa Limited is one of the largest suppliers of shock absorbers to major auto giants.

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PROJECT TITLES

1. Improvements in Rear Assembly

2. Air Pollution Control in machine shop

3. Value Stream Mapping

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ACTIVITY PLAN

S.NO ACTIVITY JAN FEB MAR APR MAY JUN

1 IMPROVEMENTS IN REAR ASSEMBLY

2 AIR POLLUTION CONTROL IN MACHINE SHOP

3 VALUE STREAM MAPPING

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Objectives

1. Productivity Improvement

2. Reduce man-material movement

3. Manpower Management

4. Observing Standard Operating Procedure (SOP)

5. Maintenance of newly installed features

6. Improving cleanliness in the new air tight enclosure

IMPROVEMENT IN REAR ASSEMBLY

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PRODCUTIVITY IMPROVEMENTS

Calculated cycle time of all 6 lines.

Compared cycle times of each line to set a standardized way of operating the same equipment on different lines.

Found out rod guide pressing of line-5 was taking longer time than others

Located a fault in ECU of the equipment.

Excess cycle time of piece bottom pressing in Line-3 i.e. 4.4 secs as compared to 1.5-1.75 in other lines.

Maintenance dept informed about the fault. ..\MunjalShowa\Assembly\RearAssy\Layout\Rear Assy\LayoutLine5.xlsx..\MunjalShowa

\Assembly\RearAssy\CycleTime\Rear Assy\Line5\KSPGCycleTimeline5.xlsx

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OBSERVING SOP

In rod guide pressing the worker had to keep on pressing the buttons till the time the process was not completed.

Whereas in other machines the operator just presses the button once and during the processing time he/she unloads the next piece from the bin.

Maintenance dept was informed and necessary action was taken.

Cycle Time

4.4

1.75

OLD NEW

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Reduce man-material movement

Often wrong raw material is brought to the work station due to which time is wasted.

Naming done on raw material.

Newly installed chute should have particular rack for the same type of raw material.

This will lead to worker’s proper understanding.

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In oil filling trolley movement was reduced by making the RM available at a shorter distance. Also by creating side racks the need for a trolley at all times was eliminated.

Initial Final0

102030405060

Series 154

14

STEPS

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MANPOWER MANAGEMENT

Between Rod guide pressing and rolling the manpower is 3. 1st workers operates the RGP m/c, 2nd worker places the end plate & checks the moment and the 3rd worker operates the rolling m/c.

The rod guide pressing operator can insert the end plate and can place in the loading bin of rolling worker.

Existing New0

0.51

1.52

2.53

3.5

MANPOWER

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Maintenance & Improvement of Newly installed features

The new chute installed which is used to slide down the final assembled part outside the air-tight enclosure had started bending after 2-3 days of use.

A support was provided in between the chute so that it doesn’t bend and the smooth flow continues.

The rack installed in the air tight system which allows the trolley operator to load the raw material without entering the air tight enclosure. Thus saving man and material movement.

Here there no particular rack for a particular raw material. Therefore a proper description was provided on each rack.

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Improving cleanliness level in the new air tight enclosure

In gas shock absorbers an air gun is used to clean the remains of oil on the part. This led to accumulation of oil droplets on the wall and the floor.

This also led to accumulation of oil on the conveyor which further would effect the work piece.

Therefore a bin was created. Now the operator will use the air gun while pointing towards the bin

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Improving cleanliness level in the new air tight enclosure

Date 26/12 29/12 2/1 6/1 10/1 17/1 23/1 23/2 23/3 23/4 23/5

DFT Dirty Dirty Clean Clean Clean Clean Clean Clean Clean Clean Clean

Oil

Filling

Dirty Dirty Clean Clean Dirty Dirty Clean Clean Clean Clean Clean

Air Gun Very

Dirty

Very

Dirty

Very

Dirty

Dirty Dirty Clean Clean Dirty Clean Clean Clean

In oil filling machine where the chances of contamination are the highest it was ensured that the workplace will be cleaned at regular intervals by the operator.

Also in the Dampening Force Testing Machine due to the presence of heat exchanger the water used to get collected on the equipment. Though it happened very rarely but when it did it was ignored

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Reducing Rust in DAMPER CASE pipe

Rust inside the D/C pipe is a major problem which leads to contamination of oil and thus effects the performance of the shocker.

To reduce this damper case washing is done on a in-house manufactured machine. This process is the first step of any line in Rear Assembly.

A brush is used to clean the inside of the pipe.

The brush used to clean is only suitable for 30,000 cycles.Therefore it has to be changed every 3 days.

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Air Pollution Control in machine shop

Objectives

1. To update data regarding number of exhaust fans working.

2. To control pollution in Welding Shop & Buffing shop.

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ELECTRICAL EXHAUST FANS

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NATURAL EXHAUST FANS

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Air Pollution Control in machine shop

Data regarding Electric exhaust and natural exhaust fans was updated and reported to the industrial coordinator.

Ducts were introduced at every work station.

As the raw material consisted of oil and grease

It caused excess release of fumes during welding.

Therefore it was made mandatory for all operators to

First dip the RM in thinner(SOKLIN)

Also ducts were introduced above WIP

collecting trolleys

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The D/C parts that are sent by the vendors are full of oil and grease particles. When the operator starts to weld these parts the pollution caused is high because the electrode now has to penetrate through the oil layer as well.

Therefore the workers were instructed to dip the RM first inside thinner for 10-15 seconds and then take the lot to the work station.

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Air Pollution Control in machine shop

In buffing shop where bottom case is buffed, lot of dust is produced.

The ducts installed are not effective.

Some repairs were made to reduce dust inside

the shop.

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Value Stream Mapping(AAHA)

Objective To eliminate the avoidable NVA and to minimize unavoidable NVA

To understand Process Flow.

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CAUSE & EFFECT

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PROCESS FLOWDamper Case Welding Line

Loading/Unloading

Loading/Unloading

Store

Piston Rod Line

Piston Rod Cutting Piston Rod

Plating

U/S Washing

Assembly Begins

Assembly Ends

Despatch Area

Towards Buffing From

Buffing

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ELIMINIATING AVOIDABLE NVA & MINIMIZING UNAVOIDABLE NVA

1.The standard stoppage time is 50 mins for 1 shift. Though the average break time comes out to be more than 76 mins. There is a difference of 26 mins.

Keeping this in mind targets were given to each line each hour. If the line in consideration fails to achieve the target on regular basis, the HOD provides them with training.

2. Paint shop is located at the farther end of the plant. Due to this any major/minor breakdown takes time to be checked and corrected.

Many times the hose air pipe gets damaged and it takes more than 15 minutes to inform the maintenance dept and bring a new pipe for replacement. For this the supervisors and the operators were trained by the TPM dept. to take quick action if any such situation arises and the replacement pipes were present at the paint shop.. This would prevent line stoppage.

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ELIMINIATING AVOIDABLE NVA & MINIMIZING UNAVOIDABLE NVA

3. Due to the unavailability of trolley at the unloading station of the excise store the worker first had to place the goods on the floor and then wait for the trolley to be free. Then he loaded the goods on to the trolley.

Therefore two trolleys were made available to the workers. This would reduce the fatigue and increase productivity.

4.To reduce man material movement a new path was allocated for taking the piston rods to the plating line.

This lead to a decrease of 61% in man material movement.

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REDUCING MAN MOVEMENT & FATIGUE

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PREVIOUS PATH FOLLOWED (PISTON ROD LINE-->>PISTON ROD PLATING)

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NEW PATH FOLLOWED (PISTON ROD LINE-->>PISTON ROD PLATING)

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REDUCTION IN MAN MATERIAL MOVEMENT

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Thank You!