INTRODUCTION

AKSHAY MANCHANDA
Mechanical Engg., DELHI COLLEGE OF ENGINEERING
Engine Department

ENGINE DEPARTMENT
Engine
Assembly
line(35 stations)
Cam and Crank
assembly
Valves and piston
assembly
FIP and Oil cooler
assembly
..and many
more.

Engine
Testing

Not
Ok

Endurance
testing
Dyno
testing

Rework
Engine
Machine
Shop

O
k

Lacquer
Shop

Completed
Engine

Project Learning
Project name- Cycle time reduction of Engine Assembly Line
Reason- There are some Non-Value-Added activities in the assembly line which need to be
identified and removed.
Outcome- Cycle time of Engine assembly line is decreased thereby increasing engine
production rate from present rate.

Method used to execute the project is observational type.

Time taken by every station in the assembly line was noted down for 5 engines.
Carefully observed the activities at each station.
2

Readings
1. Station OP10A: Engine block loading. There are 15 activities in this operation
Activity

1st Trail

2nd Trail

3rd Trail

4th Trail

5th Trail

3.55

5.44

6.14

5.53

7.49

16.16

20.55

19.63

14.57

15.29

4.48

7.91

5.02

4.44

5.57

10

3.2

4.95

3.6

3.89

3.37

11

16.29

17.37

16.39

18.09

17.45

13

2.39

5.07

2.69

3.69

2.97

14

2.89

3.02

2.58

2.47

2.28

15

12.51

12.04

9.84

10.02

11.49

12

Readings
2. Station OP20: Tappet presence check.
There are 13 activities in this operation.
Activity
1
2
3
4
5
6
7
8
9
10
11
12
13

1st Trail
3.86

2nd Trail
7.08

3rd Trail
4.16

4th Trail
4.87

5th Trail
5.25

30.97
5.27
3.14
24.46

36.39
5.76
4.99
20.03

31.38
6.02
4.25
21.18

35.46
5.47
3.59
25.21

32.21
5.21
4.07
21.09

13.49

9.12

10.44

13.59

10.26

17.22
4.24

20.12
3.19

16.95
4.23

17.59
3.45

19.46
4.45

Readings
3. Station OP30: Sealant Dispensing.
This is done by fully automated machine.

Activity
Sealant
Dispensi
ng

1st Trail 2nd Trail

12.75

13.07

3rd Trail

4th Trail

5th Trail

12.31

12.87

12.51

Readings
4. Station OP40A: Bedplate Assembly.
There are 10 activities in this operation.

Activity
2
3
4
5
6
7
8
9
10

1st
Trail

2nd
Trail

3rd
Trail

4th
Trail

5th
Trail

3.84

6.09

4.23

6.17

5.59

6.11
44.04

7.61
53.33

6.57
50.59

8.13
47.43

7.12
45.36

53.38

72.11

76.93

70.29

64.87

6.05

8.79

7.23

6.94

8.12

Readings
5. Station OP210: Auto Valve Lash.
This operation is done by a fully automated machine.
This step sets clearance between elephant foot and Valve Bridge which provide
Valve safety when engine get heated up.

Activity

1st Trail

2nd Trail

3rd Trail

4th Trail

5th Trail

Auto
Valve
Lash

208.71

237.95

209.26

240.13

230.36

NON-VALUE ADDED Activities

At the station OP10, sometimes operator has to leave the station to carry bedplate
carrier to his station from OP40A.
At station OP20, operator takes time to assemble the shaft as he have to unpack the
crank shaft as the same time.
Operator at OP160 has to leave his station for 5-6 seconds to panel standing before
OP150 as its an automated machine so he has to pass the engine from that station.
An automated machine at OP210 (Auto valve lash) set the clearance between the
elephant foot and valve bridge starting from front part of engine(1 st Exhaust) to rear
part of engine(4th Intake) one by one. For that crank shaft have to move many times
to set it in firing order.

Recommendations
A special trolley can be designed so OP10A such that it can accommodate enough
amount of bedplate carrier.
Tappet assembly in the engine block can be done at OP10B instead of OP20. It will
problem of accumulation of engine between OP10B and OP20.
Panel of OP150 can be shifted close to OP160.
In OP210 make the 2 probes, which set the valve lash, work independently.

Cycle Time Analysis

Cycle time of an assembly line is solely dependent on station of max. working time.
In case of Engine assembly line, it is the OP210 (Auto valve Lash) which take on an average
of 3.75 mins.
Also by other way, Engine Assembly line give 135 engines in a shift of 8.5 hrs. which also gives
cycle time = 510/135 mins. = 3.77 mins.
From the suggestion of changing the design of Machine in OP210, we can considerably reduce
the its operation time to nearly half of its present working time.
New cycle time can be taken to average of 3.45 mins.
New production rate can be nearly 145 engine in a shift.

Behavioral Learning
Self-awarness
Personal Effectiveness
Planning & Organizing
Problem Solving and Decision Making

Changes Observed After Completion Of Internship

Time Management
Planning
Improved communication
Change in my behavior while dealing with others
Goal Oriented Approach

THANKS