Project

REDUCTION IN REJECTION OF LAY SHAFT

By
Team

GURGOPAL SINGH AKSHAY YADAV

(12109030) (12109003)

GUIDE - Mr. ARJAN SINGH

(Sr. Manager
Gear shop)

1
Introduction & Statement of Problem
Introduction: Sonalika group of companies that is the one of leading company
in India in tractors, MUV, and agricultural accessories. Lay shaft is the component
of our MUVs. The lay shaft is given transmission to the gears and meshed with
gear located with second shaft named main shaft. The PCD runout in this
component is very critical. More PCD create noise problem during running and
create problem in gear shifting. To tackle this problem a classification toolkit has
been designed using some statistical and soft computing based approaches to
cluster the data, to predict the possible class of incoming data, to generate some
rules in the term of confidence parameter. The data may be given in image form
or some tabular form having all numeric or categorized attributes.

1.2 Statement of problem: The %age of rejection in Lay Shaft 3.5% per annum.

2
 Process route of Lay Shaft
Forging is the process in which we make the shape of component with the
Forging
help of dies. It also increase the strength of steel and reformation of grains

Turning is the process in which remove unwanted material from forging and
Turning make components as per specification.

Hobbing Hobbing process is an actually tooth cutting process. Desired gear is

produced with the help of hob.

Shaping is also used to make splines on the shaft where hob does work due
Shaping to space constraints.

Shaving Shaving is the process that gives smooth finishing to the tooth of gear and
makes their dimensions precisely.

Heat Heat treatment is the process in which we carburised the component to gives
Treatment desired hardness to prevent it from wear and tear.

Shot Shot blasting process used to remove the carbon sooting developed on
component during heat treatment process
Blasting

Straightening It is the process used to straight the shafts that have distort after heat
treatment

Grinding is the process used to make the bearing dia on the shaft with very
Grinding close tolerances.

3
 Photograph of the component

Methodology Use
Our team has decided to use following methodology to identify the proper root
cause.

1. Stratification
2. Brainstorming
3. Cause and effect diagrams

4
 Stratification
Rejection of Lay Shaft Month wise

20 19
18
16
16
14
14
12
12
10
REJECTION
8
6
4
2
0
MARCH APRIL MAY JUNE

Month March April May June

Rej. Qty 19 14 16 12

5
 Stratification Cont.
Rejection of Lay Shaft section wise

15 13 4
3.1
22
REJECTION

3.8 11
2.49 3

%AGE
10 2.6
2
5 3
1 2 0 1
2 2 1 1 1 1 1 1
0 0
March April May June

Month
TURNING H.T. GRINDING TEETH CUTTING %AGE

Graph: 2
We have observed from above stratification is that the major rejection occurred in
hobbing section instead of other sections. So, now we have focused on the
hobbing section to find out the reason of rejection.

Rejection of Lay Shaft reason wise

12 11

10 9 9

8 8

4
2 2 2
2 1
0 0 1
0 0
March April May June

PCD R/O DENTS SIZE VARIATION

It is clear with above stratification that the major rejection is due to PCD runout.

6
 Brainstorming

The points that overcome from Brainstorming are as under:

Hardness at soft stage is low Surface hardness of blank is checked on Brinell

hardness tester and it should lies between 160-180BHN.

Improper normalizing Improper normalizing also related with the surface hardness
and microstructure after normalizing. As per specification, distribution of ferrite and
pearlite grains should distribute properly, no banding is required.

Bending of shaft during loading and unloading This statement is related with
the banding due to over staging and improper method of loading and unloading of
components from trucks.

Geometrical test of hobbing machine As per our norms, machine should have
geometrical test that shows the capability of machine. in geometrical teat, all parameters
related with bed, jig fixture, play and error in the machine.

Wear and tear in jigs and fixture used during hobbing, shaping - By using jig
and fixture for long time, it may be wear and tear and shows error.
Heavy cut during hobbing Cut during hobbing should be controlled, the RPM of
hobbing is in controlled. As the feed and RPM increased, it will create more stress on the
component.

Misalignment of centers on hobbing machine It is also related with geometrical

test of the machine
Tool quality is not good or not as per specification.
Improper coolant used in hobbing machine.
Components not are manufactured with one reference point.
Distortion after heat treatment After quenching in heat treatment from
temperature 820*c, the component get stressed and have some distortion like bending.

7
 Cause and affect diagram

Machine
Jig & fixture not
Loose foundation
calibrat0ed Negligence
Vibration
Over time
Misalignment of fixture Lack of training
Misalignment of centers
Fatigue skill
Heavy work

PCD
Centers of Component not
Improper
shaft not manufactured
normalizing Tool Quality
clean with one
reference not good

Runout in Low Improper coolant

blank Heavy cut during
surface used hobbing
hardness

Material Method

Formulation of Theories- I
We have observed with stratification that the major rejection is generated on
hobbing section that components having PCD run out more than 0.06mm. the
acceptance norms of PCD runout is up to 0.06mm. Our team decided to take trial
with 25 pcs. Of Lay shaft to identify the basic root cause. . All 25 pcs. Of lay shaft
were checked physically. The inspection parameters of blanks are as under

8
 Data of PCD runout at blank stage:

S.no Surface Hardness R/oDia 22 R/o dia 45 R/o Dia 39 R/o Dia
mm mm mm 35mm
1 162 0.02 0.02 0.01 0.02
2 159 0.01 0.02 0.02 0.02
3 172 0.02 0.02 0.02 0.02
4 172 0.02 0.02 0.02 0.02
5 169 0.02 0.03 0.02 0.02
6 141 0.03 0.02 0.02 0.02
7 162 0.02 .0.2 0.02 0.02
8 172 0.02 0.02 0.02 0.03
9 162 0.02 0.02 0.02 0.02
10 169 0.03 0.02 0.02 0.02
11 159 0.02 0.03 0.02 0.02
12 172 0.02 0.02 0.02 0.02
13 147 0.02 0.02 0.02 0.03
14 162 0.01 0.02 0.03 0.02
15 169 0.02 0.02 0.03 0.02
16 162 0.02 0.02 0.02 0.02
17 162 0.02 0.02 0.02 0.02
18 172 0.02 0.02 0.02 0.02
19 169 0.02 0.02 0.02 0.02
20 162 0.02 0.02 0.02 0.02
21 172 0.02 0.02 0.02 0.03
22 144 0.01 0.03 0.02 0.03
23 179 0.02 0.02 0.02 0.02
24 169 0.01 0.02 0.02 0.02
25 169 0.02 0.02 0.02 0.02

We have re-verified the parameters of hobbing machine and observed following

data
S. Condition of Conditio Hobbing Fixture Shaper
no shaper cutter n of hob fixture runout cutter
for Z-22 runout runout
1 OK OK 0.010 0.012 0.012
2 OK OK 0.014 0.013 0.014
3 OK OK 0.011 0.011 0.014
4 OK OK 0.009 0.010 0.016
5 OK OK 0.012 0.013 0.012
6 OK OK 0.012 0.015 0.014
7 OK OK 0.014 0.011 0.013
8 OK OK 0.015 0.014 0.016
9 OK OK 0.008 0.009 0.011 9
S. Condition of Conditio Hobbing Fixture Shaper
no shaper cutter n of hob fixture runout cutter
for Z-22 runout runout
10 OK OK 0.011 0.016 0.014

11 OK OK 0.013 0.015 0.010

12 OK OK 0.014 0.010 0.013

13 OK OK 0.012 0.013 0.011

14 OK OK 0.012 0.015 0.014

15 OK OK 0.016 0.010 0.012

16 OK OK 0.015 0.014 0.010

17 OK OK 0.010 0.012 0.016

18 OK OK 0.015 0.014 0.011

S. Condition of Conditio Hobbing Fixture Shaper

no shaper cutter n of hob fixture runout cutter
for Z-22 runout runout

19 OK OK 0.014 0.009 0.012

20 OK OK 0.013 0.011 0.013

21 OK OK 0.016 0.011 0.014

22 OK OK 0.015 0.012 0.013

23 OK OK 0.011 0.013 0.014

24 OK OK 0.012 0.014 0.011

25 OK OK 0.014 0.015 0.010

10
Observation: - The all parameter that are necessary to ensure are
within control limit. The acceptance limit for runout of above
parameters is less than 0.020mm. These parameters were checked
on every component (25 nos.) that we were manufactured.

Results after hobbing of trialed

components (25 nos.)
We were inspected all 25 components after hobbing and get following results.

S.No R/o dia R/o dia R/o dia R/o dia

22mm 45mm 39mm 35mm

1 0.03 0.04 0.03 0.02

2 0.02 0.02 0.02 0.03
3 0.02 0.02 0.03 0.03
4 0.03 0.03 0.03 0.03
5 0.03 0.03 0.03 0.03
6 0.07 0.03 0.04 0.05
7 0.03 0.02 0.02 0.02
8 0.02 0.03 0.02 0.03
9 0.02 0.02 0.03 0.03
10 0.02 0.02 0.02 0.02

11
S.no R/o dia R/o dia R/o dia R/o dia
22mm 45mm 39mm 35mm

11 0.03 0.04 0.03 0.02

12 0.02 0.03 0.03 0.03
13 0.08 0.05 0.05 0.06
14 0.03 0.03 0.03 0.03

15 0.03 0.03 0.03 0.03

16 0.03 0.03 0.03 0.03
17 0.03 0.02 0.02 0.02
18 0.03 0.03 0.03 0.03
19 0.02 0.03 0.03 0.02
20 0.02 0.02 0.02 0.02

S.No R/o dia R/o dia R/o dia R/o dia

22mm 45mm 39mm 35mm

21 0.03 0.04 0.03 0.02

22 0.07 0.05 0.06 0.06
23 0.03 0.02 0.02 0.02
24 0.03 0.03 0.03 0.03

25 0.03 0.03 0.04 0.03

12
observation: - We have observed those components that
have surface hardness less than 150 BHN having PCD
runout.

Analysis: - Less hardness of component after normalizing is

the main cause of rejection. During hobbing and shaping,
cutting load bend the component that create the PCD
Runout.

Formulation of Theories II
1. We have taken another trial with components (10
nos.) having surface hardness less than 150BHN
to proven our hypothesis.

2. Check surface hardness of to identify the

variation.

Data detail of trial taken on 10 components has

surface hardness less than 150 BHN

13
Comp. Surface R/o dia R/o dia R/o dia R/o dia
No. hardness 22mm 45mm 39mm 35mm

7968 145 0.03 0.02 0.01 0.02

8044 147 0.10 0.02 0.02 0.02

8121 145 0.02 0.02 0.02 0.02

8244 147 0.02 0.02 0.02 0.02

8178 141 0.02 0.03 0.02 0.02

7933 141 0.02 0.02 0.02 0.02

8289 145 0.02 0.02 0.02 0.02

8190 147 0.02 0.02 0.02 0.03

8061 141 0.02 0.02 0.02 0.02

7970 147 0.03 0.02 0.02 0.02

We have re-verified the parameters of hobbing machine and observed following

data

S.no Condition of Condition Hobbing Fixture Shaper

shaper cutter of hob for fixture runout cutter
Z-22 runout runout
1 OK OK 0.014 0.011 0.012

2 OK OK 0.011 0.012 0.011

3 OK OK 0.013 0.011 0.012
4 OK OK 0.010 0.010 0.015
5 OK OK 0.012 0.014 0.012
6 OK OK 0.012 0.013 0.014
7 OK OK 0.011 0.011 0.012
8 OK OK 0.013 0.013 0.015
9 OK OK 0.007 0.010 0.011
14
10 OK OK 0.010 0.012 0.014
 Observation: - The all parameter that are necessary to
ensure are within control limit. The acceptance limit for
runout of above parameters is less than 0.020mm. These
parameters were checked on every component (10 nos.)
that we were manufactured.

Results after hobbing of trialed

components
(Surface hardness less than 150 BHN)

S.No R/o dia R/o dia R/o dia R/o dia

22mm 45mm 39mm 35mm

1 0.08 0.07 0.06 0.05

2 0.07 0.04 0.05 0.06
3 0.06 0.04 0.08 0.05
4 0.08 0.07 0.04 0.07
5 0.06 0.07 0.04 0.06
6 0.07 0.03 0.04 0.05
7 0.06 0.08 0.07 0.06
8 0.07 0.08 0.05 0.05
9 0.07 0.07 0.08 0.07
10 0.05 0.08 0.04 0.07

Analysis: - It is clear with above trial is that the

components that have surface hardness less than
150 BHN have PCD runout more than 0.06mm.

15
 Remedial Journey
First of all, we need to find out the reason of low surface hardness on
components, for this we were decided to collect data at vendor end
and their supplies in last two years

Tray: 1
Sample no. 1 2 3 4 5 6 7 8 9
Surface 162 164 162 168 164 162 164 164 162
hardness

Tray: 2
Sample no. 1 2 3 4 5 6 7 8 9
Surface 164 164 164 162 164 162 162 164 162
hardness

Tray: 3

Sample no. 1 2 3 4 5 6 7 8 9
Surface 165 167 162 164 167 164 165 167 164
hardness

Holding gains/ Preventive action

1. Monthly preventive maintenance system to be implement.
2. Do process validation on monthly basis.
3. Do furnace validation on monthly basis.
3. In case of major breakdown during the process, components
that are being processed should be kept separate for rework.
4. Increase sample inspection quantity (10 out of 100).
5. Check sheet prepared for audit & routine audit is done.
6. Regular Awareness Training Programmes to be done.

16
 Improvement after modification

14 13 4
3.8 12
12 3.5
11
3.2
3
10 9
2.6 2.5
8 2.4

%age
Nos.

2
6
1.5
0.8
4 3 1
2 2 2 2
2 1 1 1 1 1 1 1 1 1 0.5
0 0
0 0
March April May June July
Month
TURNING GRINDING TEETH CUTTING H.T %AGE

17
18