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India Private Limited

A Report on, DFA/DFM IDEA GENERATIONS IN 988H LWL,

CYCLE TIME IN 988H LWL, WORKSTATION 4,

RIW IDEA GENEREATION IN 988H LWL,

DATA COLLECTIONS IN WORK STAIONS 1, 2, 3 – KITTING,

PBA IN HYDRAULIC EXCAVATION,

SPAGHETTI MAPPING FOR 777D,

Submitted to, Mr. THEJASVI,

HUMAN SERVICES,

CATERPILLAR PVT LTD,

THIRUVALLUR, INDIA.

Submitted by, Mr. ADITYA VELAYUTHAM, B.S. III YEAR,MECHANICAL ENGINEERING & TECHNOLOGY,

PSG INSTITUTE OF ADVANCED STUDIES,

COIMBATORE, INDIA.

Under the guidance of, Mr. DHARMARAJ PARAMESHWARAN,

MANUFACTURING ENGINEERING ASSEMBLY PROCESS,

CATERPILLAR PVT LTD,

THIRUVALLUR, INDIA.

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TABLE OF CONTENTS

ACKNOWLEDGMENTS…………………………………………………….3

PREFACE…………………………………………………………………….4

ABOUT CATERPILLAR INC……………………………………………...…5

CATERPILLAR INDIA PVT LTD (CIPL) ……………………………..…..… 6

DFA/DFM IDEA GENERATIONS IN 988H LWL………………………..…8

CYCLE TIME IN 988H LWL, WORKSTATION 4……………………........11

RIW IDEA GENEREATION IN 988H LWL…………………………………13

DATA COLLECTIONS IN WORK STAION 1, 2, 3 – KITTING..................16

PBA IN HYDRAULIC EXCAVATOR…………………………………..….20

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SPAGHETTI MAPPING FOR 777D, WORKSTATION 11…………….....24

CONCLUSION………………………………………………………….….27

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ACKNOWLEDGMENTS Currently I am completing my 3rd year mechanical engineering and technology in PSG Institute of Advanced studies, Coimbatore, India. And I will be pursuing my final year in Farmingdale State College, New York, USA. The reason I chose to do my internship in Caterpillar is that they have got all kinds of machines, equipment’s and software’s to manufacture an engine, start from scratch, since they are the world's leading manufacturer for construction, mining equipment, diesel and natural gas engines, industrial gas turbines and diesel-electric locomotives. With more than US$89 billion in assets, so I wanted to get exposed and gain knowledge from the company. I am also very much interested in the field of automotive sector, as it offers great potential for career development and many research and development activities are taking place due to its significance of reducing the impact of environmental pollution and climate change. To simply put, I could have not done this work without the help and guidance I received cheerfully from the Engineers in whole process management team and the labours working in each workstations and substations in off high way truck, large wheel loader and hydraulic excavator. The work culture in Caterpillar is really really enthusiastic. Everybody is such a friendly and cheerful companion here that, work stress is never comes in way. I am also highly indebted to my supervisors Mr. Dharmaraj and Mr. Shiyam, who seemed to have guided me to all the problems which I have faced.

Thank You

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PREFACE

In this internship report I will describe my experiences during my internship period. The internship report contains an overview of the Caterpillar Inc. and the activities, tasks and projects that I have worked. I have tried my best to keep report simple yet technically correct. I hope I succeed in my attempt.

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ABOUT CATERPILLAR INC

Caterpillar Inc. is an American corporation which designs, manufactures, markets and sells machinery and engines and sells financial products and insurance to customers via a worldwide dealer network. Caterpillar is the world's leading manufacturer of construction and mining equipment, diesel and natural gas engines, industrial gas turbines and diesel-electric locomotives. With more than US$89 billion in assets, Caterpillar was ranked number one in its industry and number 44 overall in the 2009 Fortune 500. Caterpillar stock is a component of the Dow Jones Industrial Average. Caterpillar Inc. traces its origins to the 1925 merger of the Holt Manufacturing Company and the C. L. Best Tractor Company, creating a new entity, the California based Caterpillar Tractor Company. In 1986, the company re-organized itself as a Delaware corporation under the current name; Caterpillar Inc. Caterpillar's headquarters are located in Peoria, Illinois, United States. Caterpillar machinery is recognizable by its trademark "Caterpillar Yellow" livery and the "CAT" logo.

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Caterpillar India Private Limited (CIPL)

Caterpillar Inc. has a significant presence in India through three key ventures:

• Caterpillar India Private Limited (CIPL) is a wholly-owned subsidiary of Caterpillar Inc., formed after the acquisition of the earthmoving equipment division of Hindustan Motors by Caterpillar in February 2001, for an estimated US$ 71 million. The company manufactures construction and mining equipment at its facility in Thiruvallur, about 45 kilometres from Chennai, Tamil Nadu.

• Caterpillar also has a majority-owned subsidiary called Hindustan Powerplus Limited (HPL) which manufactures diesel engines and generating sets in the 180 KVA to 2250 KVA range. HPL was incorporated in 1988 and has a manufacturing facility for internal combustion diesel engines and generator sets at Punapalli village near Hosur in Tamil Nadu. The company also sells spare parts for the engines.

• Caterpillar Commercial Private Limited is a 100 per cent subsidiary of Caterpillar Inc. Established in 1998, the company deals with various Caterpillar products such as machines and large and medium speed engines. The company is also involved in the operations and maintenance of mega power plants.

Over the past 3 years, Caterpillar has been consolidating its position in the Indian market. Two world-class dealers, GMMCO Ltd. and TIL Ltd., support Caterpillar in India. The company launched the first CAT brand earthmoving equipment to be manufactured in India (424 series I backhoe loader), in August 2003. Before the launch, of CAT brand machines, motor graders, hydraulic excavators and even wheel loaders were imported.

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Factors for success

Focus on quality and operational efficiency:

From the outset, CIPL has had a strong focus on quality. To this end, it focused on implementing Six Sigma and the pursuit of operational excellence using Class A disciplines.Superior product development capabilities:

Caterpillar’s unique New Product Introduction (NPI) process gives guidance, direction and accountability to all stakeholders while ensuring its overall success. The cornerstone of this product development process is the customer validation exercise where machines are placed in a non-clinical environment and evaluated for more than 3,500 hours. The company uses tools like the Prediction of Estimated Reliability Growth Plan (PERG) and statistical tools such as the Weibull Analysis for checking machine performance prior to launch. Such processes and tools enabled the company to successfully launch their products, and assure success in a competitive market. Engineering capabilities:

Caterpillar has its Engineering Services Division (ESD) in India. Located at Thiruvallur, the division caters to the engineering design needs of Caterpillar Inc.’s various facilities located across the world. It converts the 2D legacy drawings to 3D compatible to Pro E software, Caterpillar’s own software.Future plans:

• CIPL plans to launch more models after the backhoe loader, such as the 1025 Series I truck• Caterpillar plans to outsource auto components from Indian component suppliers.

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DFA/DFM IDEA GENERATIONS IN 988H LWL

Design for Assembly:

DFA is a tool used to assist the design teams in the design of products that will transition to productions at a minimum cost, focusing on the number of parts, handling and ease of assembly. Design for Manufacturing:

DFM is a tool used to select the most cost effective material and process to be used in the production in the early stages of product design. Principles:

Minimize part count Design parts with self-locating features Design parts with self-fastening features Minimize reorientation of parts during assembly Design parts for retrieval, handling, & insertion Emphasize ‘Top-Down’ assemblies Standardize parts…minimum use of fasteners. Encourage modular design Design for a base part to locate other components Design for component symmetry for insertion

Benefits:

• Lower Assembly Cost • Shorter Assembly Time • Increased Reliability • Shorter Total Time-To-Market

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CYCLE TIME STUDY IN 988H LWL, WORKSTATION 4

Cycle time :

Cycle time is the period it takes for a manufacturer to complete development and production of a new or modified product. The time it takes for this process is significant because it impacts the ability of a company to reach market windows or to react to changes in customer needs or desires. Reducing your cycle time can improve efficiency and optimize profit potential.Operator cycle time Total time required for a worker to complete one cycle of an operation.Machine cycle timeTotal time for a machine to finish one complete cycle, it includes loading and unloading.BENEFITS

• Improved Capacity • Lower Unit Costs • Shorter Cycle Times • Improved Man Power• Improved Customer Satisfaction • Greater Productivity • Quicker Time to Market • Increased Effectiveness • Improved Profitability

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RIW IDEA GENEREATION IN 988H LWL

Caterpillar production system 8 wastes :

The ultimate goal of CPS is the elimination of waste. Waste is any activity that consumes resources, but creates no value for the customer.

Agenda of caterpillar production system:

Make it Visual/Align the Targets–Communicate goals and post results so that employees can see progress.Go, See, Act –Empower employees to make suggestions and report activities that don’t comply with procedures (Continuous Improvement cards).Drive Standard Work -Standard Work created to shutdown boilers and other high energy use equipment during extended shutdown periods.Develop People –Establish training program for all employees on waste minimization and recycling program.Validate our Processes–Investigation of water usage created 6Sigma project to reduce water consumption through flow restriction and recycling of water.Lifting magnet:

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Observation:

Lifting magnets are permanent magnets used for lifting some metal objects which cannot be carried easily by workers. These magnets used are in rectangular shape are not convenient to place it on the parts of the body properly, so the workers are keeping it in different positions to choose the right place, so that the centre of gravity lies. If this goes on it will take some time.Solution:

In order to reduce time, we can use circular lifting magnets which has surface area lesser than other shapes used.

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Rectangular lifting magnets

have higher surface area

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GENEIE SCISSORS LIFTS:

OBSERVATION:

Genie scissor lifts are generally used for temporary, flexible access purposes such as maintenance and manufacturing works. They are designed to lift limited weights — usually less than a ton, although some have a higher safe working load. They are usually capable of being set up and operated by a single person. While using this lift, workers are unable to carry the tools and equipment’s with them to work since they are breadth is small for them to rate around, so what they do is that they place all the required tools and equipment’s needed for the working in the platform of the lift itself. Due to this the workers are bending down each time to take the required tools. So this results in wasting of time and man power.Solution:

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Tools are been kept on the platform

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By mounting a removable tool palette on the sides of the scissors lift will help them to reduce their energy and time.

DATA COLLECTIONS IN WORK STAION 1, 2, 3 – KITTING

Kitting:

Kitting is the gathering of components and parts needed for the manufacture of a particular assembly or product. Individual components are gathered together, as a kit, and issued to the point of use.

Benefits:

Save facility space by reducing stock. Make operations more efficient by keeping parts at hand

at each station in the line and allowing storage of components and assemblies at a centralized location.

Ease production changes by keeping bulk parts at a kitting area offline.

Improve productivity by eliminating the need for assembly employees to search for parts.

Decrease employee training time. Improve quality control by pushing parts inspection and

verification to an earlier point in the production process

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Flow chart:

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MACHINE

ASSEMBLY

PARTS WILL BE

FROM KIT

LEFT OUT PARTS IN THE

BOX

ADD TO LIST

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PBA IN HYDRAULIC EXCAVATOR

Paint before assembly :

To enhance assembly process for Paint before assembly in HEX assemblyCASUSES:

Damage during movement Foot marks on Machine Paint parts stacked one over above Birds droppings Cylinder rested on wood Tub placed over component Pendant left over and sides on paint finished machine

REMEDIES:

These are mats which has magnets in the end of it are been used to place it on each of its respective parts in order to prevent it from the damages.

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Mat Introduction

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One point lesson:

OBSERVATIONS:

Workers while working in 320D hydraulic excavator, they are standing on the upper frame performing operations without wearing shoe protective cover.IMPLEMENTATION:

Workers were provided with shoe protective cover while performing operation over the upper frame. From now the upper frame coming from ware house is prevented from damages and dirt.

Characteristics matrix:

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UF00 UF01 UF02 UF03 UF04 UF05 UF06 UF07 UF08 UF09 BF01 BF02 BF03 BMO1 BM02 BM03 BM04 BM05 VMC FF01 FF02Additional Quantity

Available Quality

WK-559009411 COVER BF-LH REXINE WITH MAG 1 1 1 1 1 1 1 1 1 1 1 11 5WK-559009412 COVER BF-RH REXINE WITH MAG 1 1 1 1 1 1 1 1 1 1 1 11 5WK-559009413 COVER OC -REAR REXINE WITH MAG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 14 5WK-559009418 COVER OC -LEFT REXINE WITH MAG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 14 5WK-559009419 COVER OC LEFTSIDE DOOR1 REXINE WITH MAG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 14 5WK-559009420 COVER OC LEFTSIDE DOOR 2 REXINE WITH MAG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 14 5WK-559009421 COVER TOOL BOX REXINE WITH MAG 1 1 1 1 1 1 1 1 1 1 1 1 12 5WK-559009422 COVER UF FRONT FLOORING MAT REX.WITH MAG 0 5WK-559009423 COVER -UF FRONT LEFTGUARD PANEL REX./MAG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 18 5WK-559009424 COVER -UF RIGHT LEFTGUARD PANEL REX./MAG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 18 5WK-559009425 COVER -UF LEFT BACK CHANNEL REX./MAG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 15 5WK-559009426 COVER -LEFT FRONT FLOORG MAT UF REX./MAG 1 1 1 3 5WK-559009427 COVER -UF LEFT HORIZTL CHANN1 REX./MAG 1 1 1 1 4 5WK-559009428 COVER-UF LEFT FLOORING REAR MAT REX./MAG 1 1 1 3 5WK-559009429 COVER-UF LEFT INNER CHANNEL REX./MAG 1 1 1 1 4 5WK-559009430 COVER-UF LEFT LONG VERTICHANNL1 REX./MAG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 18 5WK-559009431 COVER-UF LEFT LONG VERTICHANNL2 REX./MAG 0 5WK-559009432 COVER-UF RIGHT BACKSIDE CHANNEL REX./MAG 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 15 5WK-559009433 COVER-UF RIGHT INCLINE PLATE1 REX./MAG 0 5WK-559009434 COVER-REAR FLOORING MAT UF REX./MAG 1 1 1 1 4 5WK-559009435 COVER-UF RIGHT INCLINE PLATE 2 REX./MAG 1 1 1 1 4 5WK-559009436 COVER-UF REAR LEFT GUARD PANEL REX./MAG 1 1 1 1 4 5WK-559009437 COVER-UF REAR RIGHT CHANNEL REX./MAG 1 1 1 1 4 5WK-559009438 COVER-UF REAR RIGHT GUARD PANEL REX./MAG 1 1 1 1 4 5WK-559009439 COVER-UF RIGHT INCLINEDCHANNEL2 REX./MAG 1 1 1 1 4 5WK-559009441 LH Door Cover Eng side LH 1 1 1 1 1 1 1 1 1 1 10WK-559009442 LH Door cover Rear side 1 1 1 1 1 1 1 1 1 1 10WK-559009443 RH Door cover rear side 1 1 1 1 1 1 1 1 1 1 10WK-559009444 RH door cover Front side 1 1 1 1 1 1 1 1 1 1 10WK-559009440 COVER-UF RIGHT INCLINEDCHANNEL3 REX./MAG 1 1 1 1 4 5

ATTACHING COVER REMOVING COVERSFLOW

CAB SA/ UF04

Door SA/ UF08

Trolley trial has been taken & observed few points for modification

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IMPACT ON CYCLE TIME:

Cycle time was noted for before and after using mats and flow chart were done.

Add and Remove cover list station wise:

Cover list were put up for each workstation for workers to understand which all covers will be used for each operations.

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SPAGHETTI MAPPING FOR 777D, WORKSTATION 11

Spaghetti is a method of viewing data to visualize possible flows through systems. Flows depicted in this manner appear like noodles, hence the coining of this term. This method of statistics was first used to track routing through factories. Visualizing flow in this manner can reduce inefficiency within the flow of a system.PURPOSE

The purpose of spaghetti mapping is to identify whether there is waste of movement in a process.BENEFITS

Saves resources such as money, time, and energy Visualizes improvement ideas prior to implementation Provides a graphic display of overlapping movement paths

that could cause delay

OBSERVATIONS:

No of workers in work station 11 = 4Area of the work station = 10m x 6mCycle start time =10:05amCycle end time =11:45amTotal cycle time taken =1hour 50 minutesTotal movements taken by workers=50

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Distance travelled by operators:

Lift operator taking away the fixtures to the tools rack – Movement- 4Removing fixtures for rear right suspension – Movement – 2Removing fixtures for rear left suspension – Movement – 2Removing adapter from front side – Movement – 3Removing adapter in from middle – Movement – 2Lift operator taking away the front adapter – movement -3Lift operator taking away the middle adapter – movement -3Nitrogen and oil charging – movement - 5Body mounting – movement – 3Mounting left body pin – movement - 3Mounting right body pin- movement – 3Mounting steps in front (2) - movement – 4Mounting left hoist pin – movement – 2Mounting right hoist pin – movement – 2Mounting left Shock pad – movement- 3Mounting right shock pad – movement- 3Removing suspension C- Clamp – movement - 3

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CONCLUSION

The whole experience of working at Caterpillar Inc. was great. I got insight into professional practice. I learned the different facets of working within the company. This organization has an amazing work culture, great minds and very high quality of work. I learned a lot of about Design for assembly and design for manufacturing, cycle time study, Rapid improvement workshop Kitting, Paint before assembly, and about Spaghetti Mapping. The work I could complete here was very satisfactory. I hope my work on Caterpillar Inc. meet its goals. The internship was also good to find out what my strengths and weaknesses are. This helped me to define what skills and knowledge I have to improve in the upcoming time.

On the whole, this internship was a useful experience. I have gained new knowledge, skills and met many new people.

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