Summer Internship Project Report

(24-May-2019 to 04-July-20191)

Titled
1. Overall understanding of fabrication processes
2. Drawing management of excavator part
3. Preparation of process sheets
4. Time study for SMM validation.

A report submitted to

TATA HITACHI CONSTRUCTION MACHINERY CO. PVT. LTD.

KHARAGPUR, WEST BENGAL

Project Guide Project Mentor Project Report by

R.N. MAHARANA SAYAK DE & SONA SINGH VIPUL MUDGAL

TΛTΛ HITACHI

Reliable solutions

Village - Rupnarayanpur, post office – Jakpur, Kharagpur- 721301

District- Paschim Midnipur, West Bengal

1
If request for extension of internship period accepted.

VIPUL MUDGAL 1
 CERTIFICATION

It is certifying that VIPUL MUDGAL a student of B.Tech. (Mechanical

engineering), Bundelkhand Institute of Engineering and Technology; Jhansi
has undergone the summer internship/training from 24 MAY 2019 to 04 JULY
2019 at Tata Hitachi Construction Machinery Co. Pvt. Ltd., Kharagpur plant.
He worked over a project titled

1. Overall understanding of fabrication processes.

2. Drawing management of excavator parts.
3. Preparation of process sheets.
4. Time study for SMM validation.

during his Internship/Training. He has submitted a project report to the

undersigned on 04 July 2019. His project report was found original and he did
great work during internship.

Project Guide PROJECT MENTOR

Mr. R.N. MAHARANA MR. SAYAK DE & MR. SONA SINGH

VIPUL MUDGAL 2
 DECLARATION

I, the undersigned solemnly declare that the project report titled

1. Overall understanding of fabrication processes.

2. Drawing management of excavator part.
3. Preparation of process sheets.
4. Time study for SMM validation.

is based on my own work carried out during my summer internship. The work contained
in the report is original and has been done by me under the supervision of my guide and
mentor. The work has not been submitted to any other company/Industry for any other
internship/training project or by any other candidate in this industry. I have followed the
guidelines provided by the industry and mentor in writing the report, also I am not sharing
any confidential report related to the industry in this report. Wherever I have used
materials (data, theoretical analysis, text and figures) from other sources, I have given due
credit to them in the text of the report and given their details in the References.

SIGNATURE
(VIPUL MUDGAL)

DATE: - 04-July-2019

VIPUL MUDGAL 3
 ACKNOWLEDGEMENT

The internship opportunity I had with TATA HITACHI CONSTRUCTION MACHINERY Co. Pvt.
Ltd. was a great chance for learning and professional development. Therefore, I consider
myself as a very lucky individual as I was provided with an opportunity to be a part of it. I
am also grateful for having a chance to meet so many wonderful people and professionals
who led me though this internship period.

Bearing in mind previous I am using this opportunity to express my deepest gratitude and
special thanks to the Mr. Abhijit kar [Divisional Manager] who did gave me the reference
for this esteemed organisation and to Mr. Somen lodh [Officer-HRD] who did allow me to
join this internship in spite of being extraordinarily busy with his duties, and allowing me
to carry out my project at their esteemed organization and extending during the training.

I express my deepest thanks to Mr. Rudra Narayan Maharana, [Sr. Divisional Manager]
for giving necessary advices and guidance and arranged all facilities to make internship
period full of learnings. I choose this moment to acknowledge his/her contribution
gratefully.

It is my radiant sentiment to place on record my best regards, deepest sense of gratitude

to Mr. Sayak De [Sr. Manager], Mr. Sona Singh, [Asst. Engineer], for their careful and
precious guidance which were extremely valuable for my study both theoretically and
practically.

I perceive as this opportunity as a big milestone in my career development. I will strive to

use gained skills and knowledge in the best possible way, and I will continue to work on
their improvement, to attain desired career objectives. Hope to continue cooperation
with all of you in the future.

Sincerely,
Place: Kharagpur

VIPUL MUDGAL
Date: 04-july-2019

VIPUL MUDGAL 4
 SUMMARY

This project report is summer internship project report by Vipul mudgal completed at TATA
HITACHI CONSTRUCTION MACHINERY Co. Pvt. Ltd., Kharagpur plant. The project assigned
to author was related to production engineering or more precisely, it was fabrication shop
under production engineering department. From introduction to the various shops
followed by the discussion of fabrication shop has been covered in the introduction
chapter. Also, various distinguished things adopted by the industry like 5S, KAIZEN are also
covered in the introduction chapter. Next chapter consists of the industry profile that
includes its vision and mission, its market shares and product range. Technical literature
part consists of the “why” and “what” part of the internship and the remaining part “how”
is discussed in Methodology chapter of the report.

VIPUL MUDGAL 5
 TABLE OF CONTENTS

ACKNOWLEDGEMENT ................................................................................................................................. 4
SUMMARY ..................................................................................................................................................5
LIST OF FIGURES .......................................................................................................................................... 7
LIST OF TABLES ...........................................................................................................................................8

1 INTRODUCTION .................................................................................................................................. 9
1.1 FABRICATION AND OTHER SHOPS ........................................................................................................ 9
1.2 DUTIES OF FABRICATION ................................................................................................................. 10
1.3 FABRICATION PROCESSES ................................................................................................................ 11
1.4 PURPOSE OF FABRICATION SHOP ...................................................................................................... 14
1.4.1 Safety ......................................................................................................................................... 14
1.4.2 Quality ....................................................................................................................................... 15
1.4.3 Delivery ...................................................................................................................................... 15
1.4.4 Cost ............................................................................................................................................ 15
1.5 5 S ............................................................................................................................................. 15
1.5.1 Seiri/Sort .................................................................................................................................... 16
1.5.2 Seiton/Set in order ..................................................................................................................... 16
1.5.3 Seiso/Shine................................................................................................................................. 17
1.5.4 Seiketsu/Standardize ................................................................................................................. 17
1.5.5 Shitsuke/Sustain ........................................................................................................................ 18
1.6 KAIZEN...................................................................................................................................... 18
1.7 DURING INTERNSHIP ...................................................................................................................... 19
2 A BRIEF ABOUT TATA HITACHI .......................................................................................................... 20
2.1 STRUCTURE AND ITS MARKET SHARE.................................................................................................. 20
2.2 VISION AND MISSION .................................................................................................................... 20
2.3 PRODUCT RANGE OF TATA HITACHI .................................................................................................. 21
3 TECHNICAL LITERATURE.................................................................................................................... 25
3.1 ABOUT PRODUCTION ENGINEERING .................................................................................................. 25
3.2 PRODUCTION ENGINEERING AT TATA HITACHI..................................................................................... 25
3.3 FABRICATION SHOP DUTY ................................................................................................................ 26
3.4 STUDY OF DRAWING ...................................................................................................................... 27
3.5 MARKING OF THE DRAWING ............................................................................................................ 29
3.6 PREPARATION OF PROCESS PLANNING CHARTS .................................................................................... 32
3.7 TIME STUDY ................................................................................................................................. 32
3.8 SQDC IN DETAILS ......................................................................................................................... 34
3.8.1 Safety ......................................................................................................................................... 34
3.8.2 Cost ............................................................................................................................................ 36
3.8.3 Quality ....................................................................................................................................... 37
4 METHODOLOGY ............................................................................................................................... 39
4.1 DRAWING MARKING. ..................................................................................................................... 39
4.2 PROCESS PLANNING SHEET. ............................................................................................................. 40
4.3 TIME STUDY. ................................................................................................................................ 41

REFERENCES .............................................................................................................................................. 43

VIPUL MUDGAL 6
 LIST OF FIGURES

Figure 1 flow of material ..................................................................................................................................9

Figure 2 Excavator Arm [1] .............................................................................................................................10
Figure 3 Excavator Boom [3] ..........................................................................................................................10
Figure 4 Excavator Frame [2] ..........................................................................................................................11
Figure 5 Gas metal arc welding. [4] ................................................................................................................12
Figure 6 Fillet welding. [5] ..............................................................................................................................13
Figure 7 Welding gun [6] ................................................................................................................................13
Figure 8 Market shares ...................................................................................................................................20
Figure 9 ZAXIS20U5A [9].................................................................................................................................21
Figure 10 TMX 20 [9] ......................................................................................................................................21
Figure 11 EX 70 [11]........................................................................................................................................21
Figure 12 ZAXIS80 [11] ...................................................................................................................................22
Figure 13 EX130 [11].......................................................................................................................................22
Figure 14 ZAXIS470H [12] ...............................................................................................................................22
Figure 15 ZAXIS650H [12] ...............................................................................................................................22
Figure 16 ZAXIS870-5G [12] ............................................................................................................................23
Figure 17 SHINRAI [13] ...................................................................................................................................23
Figure 18 TH86 [13] ........................................................................................................................................23
Figure 19 TL 340H [14]....................................................................................................................................23
Figure 20 EH 600 [10] .....................................................................................................................................24
Figure 21 Components of excavator. .............................................................................................................25
Figure 22 Fabrication shop’s duty ..................................................................................................................26
Figure 23 Sample drawing [15] .......................................................................................................................28
Figure 24 Time study observation sheet ........................................................................................................33
Figure 25 Drawing marking sample ................................................................................................................40
Figure 26 Process planning sheet sample ......................................................................................................41

VIPUL MUDGAL 7
 LIST OF TABLES

Table 1 English meaning of 5S ......................................................................................................................... 16

Table 2 Common weld symbol in use .............................................................................................................. 29
Table 3 Colour code in the drawing................................................................................................................. 30
Table 4 Tackle for material handling ............................................................................................................... 36

VIPUL MUDGAL 8
 1 Introduction

Introduction consists of description of internship site, workshops layout and work done
during the internship.

1.1 Fabrication and other shops

At Tata Hitachi Kharagpur plant the first shop with which the material interact with
processes is “Fabrication shop”, where the plates and other material from various vendors
collected and planning is done over how to do the various processes as mentioned in the
drawing and keeping the main purpose in the mind, i.e. SQDC. where

S for safety, Q for quality, D for delivery, C for cost.

After fabrication of the material and completing the machining processes the finished job
dispatched to the next shop i.e. paint shop. Where all the parts get paint as per the
instructions.
Assembly shop receives the jobs to assemble after the paint shop. Fully assembled
machine then left for final checking and testing.
A general layout of the all the functional workshops in sequence is given below

Fabrication shop Paint shop Assembly shop

Dumper paint Dumper assembly

shop

Fabrication shop Sheet metal

Inventory/store
paint shop

Frame paint Excavator

shop assembly shop
Figure 1 flow of material

VIPUL MUDGAL 9
 1.2 Duties of fabrication

There are mainly three parts those are fabricated in the fabrication shop, these are the
main parts of the excavator these parts are shown in below figures from “Figure 2
Excavator Arm to Figure 4 Excavator Frame”. How the fabrication is done is discussed in later
sections

What does production engineer do at Tata Hitachi?

Fabrication shop deals with fabrication of three major parts of excavator those parts are: -

 Arm

Figure 2 Excavator Arm [1]

 Boom

Figure 3 Excavator Boom [3]

VIPUL MUDGAL 10
  Frame

Figure 4 Excavator Frame [2]

At fabrication shop every activity is performed to achieve the one or more of the five
purposes. The importance of those purposes is discussed below briefly and the steps we
take to fulfil those purposes are also discussed. Broad explanation is given in upcoming
sections/chapters.

1.3 Fabrication processes

Fabrication processes consist of preparation of weld joints, joining the parts by proper
welding methods followed by performing any other process as per drawing instructions.

Welding process: -

At various industries and at Tata Hitachi too, Highley adopted welding method is GMAW
(Gas metal arc welding). Gas metal arc welding (GMAW) is a high-speed, economical
process that is sometimes referred to as metal inert gas (MIG) welding. In this process, an
arc is struck between the base metal and a continuously supplied consumable electrode,
which provides filler metal for the weld . The electrode is bare, containing no coating or
core. The shielding, to protect the molten metal from reacting with constituents of the
atmosphere, is supplied by an external gas, usually containing one of a mixture of the
following: helium, argon, or carbon dioxide. A significant amount of fume can be generated
when welding with this process. Most of the fume generated during GMAW is derived from
the consumption of the electrode and not from the base metal.

VIPUL MUDGAL 11
 Figure 5 Gas metal arc welding. [4]

Weld Joint Preparation: -

Proper preparation of the weld joint is considered a very important part of welding. A
variety of mechanical and thermal cutting methods are available for initial weld joint
preparation. The plasma arc cutting process is commonly used to cut alloy plate into
desired shapes and prepare weld angles. Edge preparation can be performed using
machining and grinding techniques.

Cleanliness is considered an extremely important aspect during base weld joint

preparation. Prior to any welding operation, the welding surface and adjacent regions
should be thoroughly cleaned with an appropriate solvent

Weld joint design: -

Typical butt joint designs that are used with the, gas metal arc welding (GMAW) are:
(i) Square-Groove, (ii) Single-V-Groove, and (iii) Double-V-Groove, as shown in Gas
tungsten arc welding is often the preferred method for depositing the root pass for square-
groove or single-V-groove joints, where there is access to only one side of the joint. The
remainder of the joint can then be filled using other welding processes as appropriate. For
groove welds on heavy section plates greater than 3/4 inch (19 mm) thick, a J-groove is
permissible. Such a joint reduces the amount of filler metal and time required to complete
the weld. Other weld joint designs for specific situations are shown

VIPUL MUDGAL 12
 Figure 6 Fillet welding. [5]

Equipment of welding processes: -

 Welding gun.
The typical GMAW welding gun has several key parts—a control switch, a contact
tip, a power cable, a gas nozzle, an electrode conduit and liner, and a gas hose. The
control switch, or trigger, when pressed by the operator, initiates the wire feed,
electric power, and the shielding gas flow, causing an electric arc to be struck. The
contact tip, normally made of copper and sometimes chemically treated to reduce
spatter, is connected to the welding power source through the power cable and
transmits the electrical energy to the electrode while directing it to the weld area.
It must be firmly secured and properly sized, since it must allow the electrode to
pass while maintaining electrical contact. On the way to the contact tip, the wire is
protected and guided by the electrode conduit and liner, which help prevent
buckling and maintain an uninterrupted wire feed. The gas nozzle directs the
shielding gas evenly into the welding zone.

Figure 7 Welding gun [6]

VIPUL MUDGAL 13
  Shielding gases.
Shielding gases are necessary for gas metal arc welding to protect the welding area
from atmospheric gases such as nitrogen and oxygen, which can cause fusion
defects, porosity, and weld metal embrittlement if they come in contact with the
electrode, the arc, or the welding metal. This problem is common to all arc welding
processes. Gases generally used for shielding purposes are carbon dioxide, argon
and other inert gases sometimes the mixtures of the any gases is used.
 Electrodes
The electrode is a metallic alloy wire, called a MIG wire, whose selection, alloy and
size, is based primarily on the composition of the metal being welded, the process
variation being used, joint design, and the material surface conditions. Electrode
selection greatly influences the mechanical properties of the weld and is a key
factor of weld quality.
 Power supply
Current supply for GMAW remains 240±10% volts and voltage supply remain ~32
volts.

1.4 Purpose of fabrication shop

Along with the fabrication of excavator parts fabrication shop also look for SQDC.
What is SQDC?
We know the full form of the SQDC, so now we will discuss each briefly here and in details
in upcoming chapter.

1.4.1 Safety

Safety plays the very vital role while performing any task. We use PPs for safety for personal
protection that contains the Gloves, Safety shoes, Helmet and Gloves, because no product
is valuable then one’s life. Also, while lifting the material or transferring any material from
one place to another we use various equipment that means we don’t lift/transfer the
material directly by chains. Any components heavier than 20 kg should not directly lift by
hands. Details of safety and its equipment will be discussed in further chapters.

Equipment use for lifting the material depends upon the shape, size and weight of the
material.

VIPUL MUDGAL 14
 1.4.2 Quality

Quality is mainly concerned with the quality of the final product getting ready in the
fabrication shop that contains type of welding used, final finishing of the welding and
dimensions.

To give the better quality of the product fabrication workshop try to follow all the
instructions given in drawing. All the methods adopted for the final quality will be discussed
in the details.

1.4.3 Delivery

Here delivery means with the finishing of jobs of fabrication so that job parts may
procced to the next shop.

1.4.4 Cost

With cost, we simply mean cost of the final product from the fabrication shop. A simple
raw material (in form of plates and other required part) with some cost come to the
fabrication shop then some process in the fabrication shop add cost to the material those
processes may be welding, grinding, labour cost, inventory etc.

Our main aim remains to lower the cost along with maintaining quality and safety.

To lower the cost, we perform time study analysis (to reduce the labour cost), but time
study analysis is not only limited to lower the cost. It has other important roles too which
we will discuss in detail.

1.5 5S
5S is acronyms which stands for five Japanese words those words are Seiri, Seiton, Seiso, Seiketsu,
Shitsuke.

5S is a system for organizing space so work can be performed efficiently, effectively and
safely. This system focuses on putting everything from where it belongs and keeping the
workplace clean, which makes it easier for people to do their job without wasting time or
risking injury.

VIPUL MUDGAL 15
 Japanese words English meaning

Seiri Sort

Seiton Set in order

Seiso Shiny clean

Seiketsu Standardize

Shitsuke Sustain

Table 1 English meaning of 5S

1.5.1 Seiri/Sort
Seiri is sorting through all items in a location and removing all unnecessary items from the
location.

Goals: -

 Reduce time loss looking for an item by reducing the number of items.
 Reduce the chance of distraction by unnecessary items.
 Simplify inspection.
 Increase the amount of available, useful space.
 Increase safety by eliminating obstacles.

Implementation: -

 Check all items in a location and evaluate whether them presence at the location is
useful or necessary.
 Remove unnecessary items as soon as possible. Place those that cannot be
removed immediately in a 'red tag area' so that they are easy to remove later.
 Keep the working floor clear of materials except for those that are in use to
production.

1.5.2 Seiton/Set in order

Seiton is putting all necessary items in the optimal place for fulfilling their function in the
workplace.

Goal:

VIPUL MUDGAL 16
  Make the workflow smooth and easy.

Implementation:

 Arrange workstations in such a way that all tooling / equipment is in proximity, in

an easy to reach spot and in a logical order adapted to the work performed. Place
components according to their uses, with the frequently used components being
nearest to the workplace.
 Arrange all necessary items so that they can be easily selected for use. Make it easy
to find and pick up necessary items.
 Assign fixed locations for items. Use clear labels, marks or hints so that items are
easy to return to the correct location and so that it is easy to spot missing items.

1.5.3 Seiso/Shine
Seiso is sweeping or cleaning and inspecting the workplace, tools and machinery on a
regular basis.
Goals:
 Improves the production process efficiency and safety, reduces waste, prevents
errors and defects.
 Keep the workplace safe and easy to work in.
 Keep the workplace clean and pleasing to work in.
 When in place, anyone not familiar to the environment must be able to detect any
problems within 50 feet in 5 sec.
Implementation:
 Clean the workplace and equipment daily, or at another
 appropriate (high frequency) cleaning interval.
 Inspect the workplace and equipment while cleaning.

1.5.4 Seiketsu/Standardize
Seiketsu is to standardize the processes used to sort, order and clean the workplace.
Goal:
 Establish procedures and schedules to ensure the repetition of the first three ‘S’
practices.
Implementation:

VIPUL MUDGAL 17
  Develop a work structure that will support the new practices and make it part of
the daily routine.
 Ensure everyone knows their responsibilities of performing the sorting, organizing
and cleaning.
 Use photos and visual controls to help keep everything as it should be.
 Review the status of 5S implementation regularly using audit checklists.

1.5.5 Shitsuke/Sustain
Shitsuke or sustain the developed processes by self-discipline of the workers. Also
translates as "do without being told".
Goal:
 Ensure that the 5S approach is followed.
Implementation:
 Organize training sessions.
 Perform regular audits to ensure that all defined standards are being implemented
and followed.
 Implement improvements whenever possible. Worker inputs can be very valuable
for identifying improvements.
 When issues arise, identify their cause and implement the changes necessary to
avoid recurrence.

1.6 KAIZEN
Kaizen is combination of two Japanese words - “Kai” and “Zen”. “Kai” means “to change or
modify” and “Zen” means “to improve or make better” and together they translate as
“improvement”. It is the process of continuous improvements in small increments that
make the process more efficient, effective, & adaptable. Kaizen is small improvements
carried out on a continual basis and involves all people in the organization.
Kobetsu Kaizen begins with an up-front planning activity that focuses its application where
it will have the greatest effect within a business and defines a project that analyses
machine operations information, uncovers waste, uses a form of root cause analysis (e.g.,
the 5 Why approach) to discover the causes of waste, applies tools to remove waste, and
measures results.

VIPUL MUDGAL 18
 Tools used in Kaizen

 PM analysis
 Why - Why analysis
 Summary of losses
 Kaizen register
 Kaizen summary sheet
1.7 During internship
During internship, I learnt to: -

1. Overall understanding of fabrication processes.

2. Drawing management of excavator parts.
3. Preparation of process sheets.
4. Time study for SMM validation.

The methodology and theory review for above is discussed in upcoming chapters.

VIPUL MUDGAL 19
 2 A brief about Tata Hitachi

Here the type of industry, its structure, market shares and product range are discussed,
including its vision and mission.

2.1 Structure and its market share

TATA HITACHI CONSTRUCTION MACHINERY Co. Pvt. Ltd. Company Private Limited, the
leader in construction equipment in India, enhances the operational performance of its
customers, leading to improved profitability and competitiveness by offering constructive
solutions. Tata Hitachi is a subsidiary company of Hitachi Construction Machinery Co. Ltd.,
which holds 60% share and Tata Motors Ltd. holding 40%, shown in figure below “Figure 8
Market shares”

TATA
40%
HITACHI
60%

TATA HITACHI

Figure 8 Market shares

Tata Hitachi is focused on capitalizing the opportunity in the domestic arena for which the
key market segments are excavators, wheeled products, cranes and others. Tata Hitachi’s
consistent growth and success has been built on the foundation of the company’s ability
to understand customers’ needs and provide equipment alongside support solutions that
increase profitability and competitiveness. [7]

2.2 Vision and Mission

Tata Hitachi is continuing its path with its very clear vision and mission, which is

Vision: - Reliable solutions for building a greater tomorrow

VIPUL MUDGAL 20
 Mission: - Be the preferred partner for providing reliable solutions for mining and
infrastructure sectors. while dominating the domestic market, we will become a global and
development hub. Our hallmark shall be our motivated people, customer centric culture,
superior technologies and strong partnership, all working safely in unison with
environment and society. [8]

2.3 Product range of Tata Hitachi

Tata Hitachi has varying product range that include excavator, wheeled product, cranes
and others, some of the products are shown in the below figures ( from “Figure 9
ZAXIS20U5A” to “Figure 20 EH 600” )

 Mini excavators [9]

Figure 9 ZAXIS20U5A [9]

Figure 10 TMX 20 [9]

 Construction excavators [11]

Figure 11 EX 70 [11]

VIPUL MUDGAL 21
 Figure 12 ZAXIS80 [11]

Figure 13 EX130 [11]

 Mining excavators [12]

Figure 14 ZAXIS470H [12]

Figure 15 ZAXIS650H [12]

VIPUL MUDGAL 22
 Figure 16 ZAXIS870-5G [12]

 Backhoe loaders [13]

Figure 17 SHINRAI [13]

Figure 18 TH86 [13]

 Wheel loaders [14]

Figure 19 TL 340H [14]

VIPUL MUDGAL 23
  Dump trucks [10]

Figure 20 EH 600 [10]

VIPUL MUDGAL 24
 3 Technical literature

This section contains the theoretical part which is necessary to be known before
performing any work in the shop/office. Here the tasks assigned to the production engineer
in general are discussed also the work a production engineer used to do at Tata Hitachi is
also discussed.

3.1 About production engineering

Production is set process or procedure developed to transform the set of input like man,
machine, material, power and capital into the final good/product. The essence of
production is creating the good either by converting the raw material or by assembling the
small parts and fabricating them.

3.2 Production engineering at Tata Hitachi.

At Tata Hitachi production engineer deals with the Drawing from the PPC (production
planning and control) then marking of the drawing those are to be stick at production site.
Training of the employee time study for removal of unproductive body movement.
Preparation of process planning sheet and checking of the dimensions and quality of the
work.

As in previous chapter ‘Introduction’ to all the workshops has been discussed, among all
the workshops fabrication plays a very important role, that we will get to know sooner in
this section.

Main components of excavators those are fabricated in the fabrication shop at Tata Hitachi
are shown in below fig.

BOOM ARM

FRAME BUCKET

Figure 21 Components of excavator.

VIPUL MUDGAL 25
 For fabrication of denoted parts of the excavator (in above figure) Fabrications shop deals
with following: -

 Study of drawing.
 Marking using different colour codes.
 Preparation of process planning charts.
 Inspection of sensitive dimensions given in the drawing.
 Time study exercises.

With no violation of SQDC.

Study of drawing, marking using different colours, preparation of process planning charts
and time study exercises for validation of SMM are discussed in detail in upcoming
chapters.

3.3 Fabrication shop duty

There are many activities those are to be performed in the background of the actual
process seems to be happening

Tacking of the plates over the

fixtures folllowed by the tack
welding.
loading

Loading of the part over the robo

for robo welding.
unloading

Unloading from the the robo

followed by the manual welding.

Figure 22 Fabrication shop’s duty

VIPUL MUDGAL 26
 Instructions for performing the above processes used to mention in the drawing, so for
performing the above processes drawing study is required and that is important too.

3.4 Study of drawing

Study of drawing requires knowledge to understand the information given/shown in the

drawing with the help of symbols, title box, types of line used, and instructions given in the
drawing for specific processes. Signs may be of welding, machining, finishing and
instructions may also be there for same.

A perfect drawing consists of: -

 Title box generally present at bottom right centre of drawing containing

information like scale, date, projection (3rd angle or 1st angle) drawing name,
company name etc.
 Grid line is present at the periphery of the drawing, grid helps to locate the parts in
the drawing easily. Naming for the vertical grid is done by English alphabets and for
horizontal grid we have digits.
 Instructions are given generally just above the title box, but it is not the thumb rule.
 Process symbols with all information like tools to be used.
 Sections view and Details view are used to represent the sectional view of the
components and details or magnifying view of the small components.
 Symbols are used to specify the instructions in sign language rather than writing
those, also symbols use less space in the drawing.

A representation of drawing with above discussed sections in shown in figure below

“Figure 23 Sample drawing

VIPUL MUDGAL 27
 Instructions Section
Grid
view

VIPUL MUDGAL
Figure 23 Sample drawing
[15]
view
box
Title

Details

28
 There are many types of the symbols adopted by the industry to represent the various
processes in the drawing,

Why symbols are used?

Use of the symbols is convenient way because writing the instructions in the words may
take time to read and understand also writing instructions will cover more space in the
drawing.

Following is list of symbols frequently used in the drawing for welding purpose: -

Designation Symbols

Single V butt welding

Fillet welding

Square butt weld

Single U butt weld

Single bevel butt weld

Single J butt weld

Table 2 Common weld symbol in use

3.5 Marking of the drawing

After understanding the instructions, symbols, and other important information
mentioned in the drawing, we use to mark the concerned information (related to

VIPUL MUDGAL 29
 fabrication only) using the different colour code, because drawing consist of instructions
for all process that is to be carried out to convert that drawing into the final product, but
there are few those are of our concerned. Drawing may consist instructions for machining
and other processes too so to highlight the instructions for welding only marking of
drawing is necessary.

Marking is important to highlight the important instructions.

Marking colour code and illustration

Areas to be marked Colour code

Title box

Uncommon welding

Revision

Tolerated dimensions

Table 3 Colour code in the drawing

Title box: - We use to cover the information in the title box by RED sketch pen.

Revision: - Revision is used to highlight by NEON colour. It is important because it contains

the recent or latest changes made in the drawing.

Tolerated dimensions: - There are some dimensions those are not allowed for general
dimensions as given the list, so they are needed to highlight. It is highlighted by the RED
colour sketch pen.

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 Uncommon welding: -

Edge lap in butt welding: - Some time it is called to keep some distance between root of
butt welding, so that is necessary to mark. It is marked by ORANGE highlighter.

Finishing of the weld: - At some parts of the structure finishing is required, finishing may
be done by grinding or any other process that is mentioned. It is coloured by the RED
sketch pen.

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 3.6 Preparation of process planning charts

It consists of series of process to be carried out with details of tools to be used and the
pattern in which the processes to be performed maintaining the minimum time. Methods
for preparation for process planning charts is discussed in Process planning sheet. Section of
chapter Methodology.

3.7 Time study

What is time study?

Time study is a technique to estimate the time to be allowed to a qualified and well-trained
worker working at a normal pace to complete a specified task by using specified method.

This technique is based on measuring the work content of the task when performed by the
prescribed method, with the allowance for fatigue and for personal and unavoidable
delays.

Objectives of time study.

1. Reducing the unproductive time.

2. Validation of SMM (Standard Man Minutes).
3. Increase in labour efficiency.
4. To determine the cycle time for completion of a job.
5. To provide a basis for setting piece rate or incentive wages.
6. To determine equipment and labour requirements.

Equipment of time study.

 Timing device
 Time study observation sheet
 Time study observation board
 Other equipment.

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 Figure 24 Time study observation sheet

Allowances of time study.

Allowances in time study can be defined as the extra time figures which are to be added to
the basic time of an operation to account for personnel desires, delays, fatigue of

operators, any special situation and the policies of the firm or organization. Standard time
of a job is obtained by adding various allowances to the basic or normal time of the job.

These allowances are considered or provided to compensate the worker/operator for the
production interruptions that may occur due to his personnel legitimate needs or the
factors beyond his controls. For example, the delay may occur due to operators’ personnel
needs such as drinking water, taking tea, going to toilet etc., unavoidable delays like waiting

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 for tools, materials or equipment, maintenance of machine and periodic inspection of
parts/materials.

Reasons for allowances: -

 Individual factor.
 Environment factor.
 Nature of work.

Time study to reduce the cost.

Advantages of time study.

3.8 SQDC in details

As we have discussed the SQDC in the brief in earlier section. Now it is discussed here in
the detail. All details like what is SQDC, what is its importance, what are the measure
adopted to follow the SQDC.

SQDC is an acronym which stands for Safety, Quality, Delivery and Cost.

3.8.1 Safety

Safety is important during performing any task, there are many safety equipment those
are used in the industry among them some are for personal protection and some are used
for material handling processes.

Measure to adopt full safety: -

 Follow the 5S (to be discussed later).

 Use of PP (personal protection).
 Lifting equipment for material weighing more than 20 kg.
 Training of the employees.

Personal protection consists of

 Safety shoes
 Gloves
 Mask and
 Safety glasses

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 Following is the list given containing the type of lifting equipment and description of
material for which it is used.

Name of equipment Image illustration of equipment

EOT CRANES

CRAENE HOOKS

MAGNETIC LIFTER

CRANE PLATE
CLAMP

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 MANIPULATOR
ARMS

Table 4 Tackle for material handling

 EOT cranes (electric overhead travelling cranes): - These cranes are some of the
most commonly used type of cranes in industries that have heavy duty operational
requirement. These cranes are used to lift or lower loads as well as to move heavy
materials during the operations

 Crane Hooks are used to lift the material by chains or ropes crane hooks are
provided to prevent the disengagement of the lifting wire rope sling, chain or
rope.
 Magnetic lifter is mainly used to lift steel plates, blocks, press modules etc.

 Crane plate clamp are used for lifting the plates.

 Manipulator arms are arm with all degree of freedom these are used for various
purposes, like welding, bolt tightening machines.

3.8.2 Cost

When the material comes to the fabrication shop from the various vendors and stores in
the inventory, where the material waits for the final process, there are various types of
process those add cost to material/job. There are some fixed cost and some variable cost.

What is variable cost?

variable cost consists of cost of those things/processes which can be varied by selecting
some alternatives to reduce the final cost of the job from fabrication shop.

Variable cost consists of: -

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  Weld wire cost
 Electricity power cost
 Grinding cost
 Labour cost
 shielding gas cost
 Abrasive cost

What is fixed cost?

Fixed cost is added by those process which are unavoidable. E.g. inventory cost, Load time.

How to reduce the variable cost?

 Weld wire cost can be reduced by selecting any good alternative with required
quality.
 Electricity power cost can be reduced by using appliances with high efficiency or
less electricity
 Grinding cost can be reduced by grind only those things those are necessary and
specify in the drawing.
 Labour cost labour/worker is getting paid for every hour or minute so by reducing
the time waste in unproductive movement the labour cost can be minimise. To
reduce the labour cost Time study exercises are performed those have been
discussed in the previous sections.
 Consumable cost: - It consists product like, anti-weld spatter, shielding gas etc.

3.8.3 Quality

Quality is concerned with the overall quality of the final product2 that is necessary for
customer satisfaction. It may consist of weld quality, surface finish quality, grind quality
etc.

Measure to adopt satisfactory quality: -

 Follow the instructions given in the drawing.

 Training of the employee.

2
Final product means the final product from the fabrication shop, after fabrication shop material goes to
paint shop and after that assembly shop.

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  Good quality of weld wire to be used for welding.
 Follow the 5 S.

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 4 Methodology

In this section, the methodology used for various activities is discussed. Those activities
consist of: -

1. Drawing marking.
2. Preparation of process planning sheets.
3. Time study.

These activities are necessary to run the production/fabrication easily. This section consists
of the importance of activities, steps taken to complete the activities and work sample of
the.

4.1 Drawing marking.

PE (production engineering) receives drawing from PPC (production planning and control)
with latest changes (revision) and instructions, drawings received from design department
contains work instruction for both welding and machining so it’s confusing; so we do work
instruction marking of only Fabrication in the drawing separately so that there is no
confusion convert that drawing into the final product.

Importance of Drawing marking: -

The purpose of checking is not only to mark the precaution points for preventing any work
miss; but also, for stabilizing the quality and to reduce the man hour.
Steps for marking the drawing: -
steps for marking the drawing consist of: -

1. selection of proper colour code so that the viewer or operator can easily see the
concerned parts of the drawing for operation.
2. Marking of the concerned area over the drawing like welding sign, tolerated
dimensions, instructions, latest ECN revision if any, uncommon welding, drawing
number and important instructions. Every area should be marked with different
colour and that colour should be use uniformly for all drawings.
3. Folding of the drawing should be in such manner so that the title block remains at
the top.
4. Stamping for authorising.

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 5. Placing or sticking of the drawing at the site.

Work sample (drawing marking): -

Figure 25 Drawing marking sample

4.2 Process planning sheet.

Process planning sheet is the layout or flowchart that consists of sequence wise processes
to be taken out at working station to complete any job.

Importance of process planning sheet: -

Process planning sheet is important in view of quality, safety and time study. It used for
standardisation of the manner of completing any process.

Steps for preparation of process planning sheet: -

1. Visit the site for which the process planning sheet to be prepared.
2. Ask the operator/worker to work in simple manner as he/she do.
3. Click the images of all the process while operator is working. (make sure movement
of the operator should not disturb by your presence).
4. Images should be clear and of high quality.
5. Arrange the images in the sequential order and then in the Process planning sheet.
6. Process planning sheet should consist of the
 Activity name
 Model name
 Workstation

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  Date of creation
 Images in the sequence with description and references and process no.

Work sample (process planning sheet): -

Figure 26 Process planning sheet sample

4.3 Time study.

We have discussed the objectives, equipment and allowances of time study. But the
methods adopted for the time study are remained to discussed so they are to be discussed
here.

Steps for time study: -

For conducting time study, average workers and average machines are selected. This study
is conducted by the Time Study expert, who should be familiar with all information’s
related to the job and the conditions in which it is being done. The location of the expert
should be such that he can watch all the operations and the movement of the workers
without disturbing them from suitable distance.

VIPUL MUDGAL 41
 1. Select the work to be studied.
2. Obtain and record all the information available about the job, the operator and the
working conditions likely to affect the time study work.
3. Breakdown the operation into elements. An element is a instinct part of a specified
activity composed of one or more fundamental motions selected for convenience
of observation and timing.
4. Measure the time by means of a stopwatch taken by the operator to perform each
element of the operation. Either continuous method or snap back method of timing
could be used.
5. At the same time, assess the operators effective speed of work relative to the
observer’s concept of ‘normal’ speed. This is called performance rating.
6. Adjust the observed time by rating factor to obtain normal time for each element

7. Add the suitable allowances to compensate for fatigue, personal needs,

contingencies. etc. to give standard time for each element.
8. Compute allowed time for the entire job by adding elemental standard times
considering frequency of occurrence of each element.
9. Make a detailed job description describing the method for which the standard time
is established.

VIPUL MUDGAL 42
 5 References

[1] ecplaza, [Online]. Available: https://www.ecplaza.net/offers/arm-for-letourneau-excavator_8832854.

[Accessed 26 June 2019].

[2] [Online]. Available: http://www.osmco.co.kr/data/file/product/thumb-

1935305403_dp5kqyQC_Excavator-Lower-Frame_s04_228x146.png. [Accessed 26 June 2019].

[3] [Online]. Available: https://www.lxexcavatorparts.com/static/upload/product/201808/Hitachi-ZX870-

Excavator-Standard-Boom_big_1533197120.png. [Accessed 26 June 2019].

[4] ScienceDirect, “Gas Metal Arc Welding,” [Online]. Available:

https://www.sciencedirect.com/topics/materials-science/gas-metal-arc-welding. [Accessed 3 july
2019].

[5] “Weld Joint Design,” [Online]. Available: http://www.haynesintl.com/alloys/fabrication-

brochure/welding-and-joining/weld-joint-design. [Accessed 3 July 2019].

[6] Wkipedia, “Gas metal arc welding,” [Online]. Available:

https://en.wikipedia.org/wiki/Gas_metal_arc_welding. [Accessed 3 July 2019].

[7] TATA HITACHI, “PROFILE,” 2019. [Online]. Available: https://www.tatahitachi.co.in/profile/. [Accessed

16 JUNE 2019].

[8] TATA HITACHI, “VISION AND MISSION,” 2019. [Online]. Available:

https://www.tatahitachi.co.in/vision/. [Accessed 16 JUNE 2019].

[9] TATA HITACHI, “MINI EXCAVATORS,” 2019. [Online]. Available: https://www.tatahitachi.co.in/mini-

excavators/. [Accessed 16 JUNE 2019].

[10] TATA HITCAHI, “DUMP TRUCKS,” 2019. [Online]. Available: https://www.tatahitachi.co.in/dump-

trucks/. [Accessed 16 JUNE 2019].

[11] TATA HITACHI, “CONSTRUCTION EXCAVATORS,” 2019. [Online]. Available:

https://www.tatahitachi.co.in/construction-excavators/. [Accessed 16 JUNE 2019].

[12] TATA HITACHI, “MINING EXCAVATORS,” 2019. [Online]. Available:

https://www.tatahitachi.co.in/mining-excavators/. [Accessed 16 JUNE 2019].

[13] TATA HITACHI, “BACGKHOE LOADERS,” 2019. [Online]. Available:

https://www.tatahitachi.co.in/backhoe-loaders/. [Accessed 16 JUNE 2019].

[14] TATA HITACHI, “WHEEL LOADERS,” 2019. [Online]. Available: https://www.tatahitachi.co.in/wheel-

loaders/. [Accessed 16 JUNE 2019].

[15] ZALACO engineering and visualization, “Mechanical drafting drawing sample,” Friday June 2019.
[Online]. Available: http://zalaco.com/wp-content/uploads/2013/10/TEST-FIXTURE-OPTICAL-
MOUNT.pdf. [Accessed 7 JUNE 2019].

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