Brakes India Limited, Padi

UNIT
UNIT–22
–22
WHEEL
WHEELCYLINDER
CYLINDERMACHINING
MACHINING

CASE
CASESTUDY
STUDYON
ONSETTING
SETTINGTIME
TIMEREDUCTION
REDUCTION
IN
INREAMING
REAMING--22
 Brakes India Limited, Padi

CELL I - Set Up Time Reduction - ( Loss Number 2 )

Theme : Set Up Time Reduction

Machines : REAMING 2
Back Ground : -
•12 Product Varieties are Handled in Reaming Machine -2.
•Customers require weekly delivery schedule than monthly delivery.
•Capacity constraint is there to accommodate all the varieties by – weekly
•From pareto, we found setting time increased due to high frequency

Operation : Fine Reaming & Rolling PARETO CHART ON LOSS HOURS IN REAMIING 2

100
10
100
Product : Wheel Cylinder Machining 8.2
95.79 98.08 90

80
8
78.54 70
Approach:

PERCENTAGE
TIME IN HRS

60
•Cross functional team formed 6
50

• VTR Study conducted 4

5 40

•Activities Classified as Removal, Fixing 30

1.8
& adjustments 2 20

10
• Counter Measures & Kaizens Identified 0
0.24 0.2
0
• Target set - 2 Months SETTING TOOL CHANGE ADJUSTMENT BREAK DOWN
LOSS
 Brakes India Limited, Padi
SET UP TIME REDUCTION • Identify Machine
METHODOLOGY • Set Theme

• Conduct Time Study, Video Study

• Categorize Activities – Removal,Fixing & Adjustments.

Identify Identify
KAIZENS KAIZENS

Implement Kaizens for Tool Presetting Implement Kaizens for Conversion from Implement Kaizens for
Fixture Presetting etc., Internal to External activities Internal & Adj. Activities

Observe Performance

Sustain

• Standardise
• Horizontal Deployment
• Savings Evaluation
 Brakes India Limited, Padi
Activities Split Up
Machine : Reaming 2
Counter Time Taken (Secs)
Sl.No Activities Where Why Action Plan ( How )
Measure Existing Target
Removing Activities
1 Removal of Acrylic Guard Spindle To Aviod Oil Spillage Required - 5 5
3 Nos Alen screw loosening from Top
2 Fixture For holding Top locator Required - 30 30
locator
3 Nos Alen screw removal from Top Elongated radial Slot to be Provideded in
3 Fixture To change the Part No Eliminate 65 0
locator Top locator
4 Grub screw loosining from spindle Spindle For holding the spindle Required - 15 15
5 Reamer & Locator removal Fixture & Spindle To change the Part No Reduce PLC to be modified 35 15
6 Bottom locator removal Fixture To change the Part No Required - 10 10
7 Washing exsisting Locators Kerosine Tank To remove the burr Required - 10 10
8 Removing Rolling tool Rolling m/c To change the Part No Required 60 60
Fixing Activity
9 Washing new Locators Kerosine Tank To remove Forign materieal Required - 10 10
10 Fixing Bottom Locator Fixture For holding the Part Required - 25 25
11 Fixing Top Locator Fixture For holding the Part Reduce PLC to be modified 30 10
12 Fixing Reamer Spindle For cutting the bore Reduce PLC to be modified 35 10
13 Tightning Grub screw to spindle Spindle For holding the spindle Required - 12 12
Elongated radial Slot to be Provideded in
14 3 Nos Alen screw fixing to Top locator Fixture For holding Top locator Eliminate 65 0
Top locator
15 Tightning 3 nos alen screw to top locator Fixture For holding Top locator Required - 25 25
16 Fixing Acrylic Guard Spindle To Aviod Oil Spillage Required - 5 5
To meet the Specification of
17 Fixing Rolling tool Rolling m/c Required - 25 25
the Product
Adjustment Activity
18 Bottom Dog Loosining Limit Switch To change the Part No Required - 5 5
19 Bottom Dog Adjustment Limit Switch To change the Part No setting Reduce Setting Block to be introduced 15 5
20 Bottom Dog Tightning Limit Switch For holding the Dog Required - 5 5
21 Slide Postioning slide ways For travel of reamer Eliminate Setting Block to be introduced 60 0
22 Approch Dog Loosining Limit Switch To change the Part No Required - 5 5
23 Approch Dog Adjustment Limit Switch To change the Part No setting Reduce Setting Block to be introduced 15 5
24 Approch Dog Tightning Limit Switch For holding the Dog Required - 5 5
25 Slide Postioning slide ways For travel of reamer Reduce Setting Block to be introduced 25 10
To meet the Specification of
26 Adjustment Rolling tool Rolling m/c Eliminate Pre setting to be Introduced 240 0
the Product
Internal Activity
Control Plan,Drawing,Locators,& Before Setting all tools lying in near the
27 Tool Store To change the Part No Eliminate 300 0
Reamer taken from Store Machine
Before Setting all tools lying in near the
28 Mercer Plug taken from store Tool Store To change the Part No Eliminate 150 0
Machine
29 Adjustment of Mercer Plug Setting Gauge Stand To meet Master Value Reduce Pre Setting to be Introduced 80 20
Bore Concentricity checking at Surface
30 Inspection Table To Meet Product Specification Reduce Kept in Near the Machine 90 30
Table
Bore Surface Finish checking at
31 Inspection Table To Meet Product Specification Reduce Kept in Near the Machine 120 60
Stds.Room
32 First off Report Preparation Inspection Table To preparation of Product History Reduce Kept in Near the Machine 180 120
Total in Seconds 1757.00 537
Total in Minutes 29.28 8.95
 Brakes India Limited, Padi

Gantt Chart
Activities Time In MINS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
REMOVING
Elongated Slot
2 Introduced
1 Remove Locators
1
1
2 Remove Reamer PLC panel
1
3 Remove Rolling Tool
1
FIXING
2
5 Fixing Locators
1
1
6 Fixing Reamer
0.3
1
7 Fixing Rolling tool
1 Setting
ADJUSTMENT Block
Introduced 2
9 Bottom Dog Adjustment
1
2
11 Approch Dog Adjustment
Pre Setting
Introduced 3
13 Adjustment Rolling tool

Internal
Control
Before Setting all tools 5
14 Plan,Drawing,Locators,&
Reamer taken from Store lying in near the Machine
Mercer Plug taken from 2
15
store
Adjustment of Mercer 1
16
Plug Setting 0.2
Bore Concentricity
2
17 checking at Surface
Table 0.3
Bore Surface Finish 2
18
checking at Stds.Room 1 Kept in Near the Machine 3
First off Report
19
Preparation 2

AFTER - 8.95 Mints BEFORE – 29.28

 Major Improvements
Before After

PLC Control has been changed in Electrical Panel

Elongated Slot has been changed in Top locator

 Major Improvements
Before After

 Setting Block has been Introduced

 Brakes India Limited, Padi
Machine : Reaming - 2
Grouping Details For Setting Block

Part No Over all Length Reamer No Reamer length

2966 3388 / 89 58.2 / 57.8 22RS2099 170
2966 6449 58.2 / 57.8 22RS2098 170
2966 6136 / 37 58.2 / 57.8 22RS2101 170
2966 5877 59.0 / 58.5 22RS2052 160
Group A
2966 5073 59.0 / 58.5 22RS2065 170
2966 5084 59.8 / 60.3 22RS2052 160
2966 5089 59.8 / 60.3 22RS2065 170
2966 4765 63.7 / 63.2 22RS2033 170
2966 2540 52.0 / 51.6 22RS2100 150
Group B 2966 5632 55.3 / 54.8 22RS2081 150
2966 5744 55.3 / 54.8 22RS2099 170
Group C 2966 2800 90.9 / 90.4 22RS2058 190
6467 5317 79.1 / 79.7 22RS2033 170
Group D
2966 5518 79.1 / 79.7 22RS2057 190

GROUP – A GROUP – B GROUP – C GROUP - D

 Brakes India Limited, Padi
Results
Results
ACTIVITIES IN SETTING - REAMING 2 EXTERNAL ACTIVITIES
40 36 8

N U M B ER O F A C T IVIT IES
GOOD GOOD
NUMBER OF ACTIVITIES

6
30 6

20 18 4

2
10
0
0
0 INTERANAL
BEFORE EXTERNAL
AFTER
BEFORE
Before AFTER
After
N U M B E R O F A C T IV IT IE S

ACTIVITIES SPILT UP IN SETTING - REAMING 2

10 GOOD
7.5

3.83 3.86
2.4
2
0.7

0
REMOVING FIXING ADJUSTMENT
 Brakes India Limited, Padi

Results
Results
FREQUENCY INCREASED

38 GOOD
40

30
Nos

19
20

10
INVENTORY REDUCED
0 8000
7000
BEFORE
BEFORE AFTER
AFTER GOOD
6000

QTY.
4000

2300
2000

0
BEFORE
BEFORE AFTER
AFTER
 Brakes India Limited, Padi

Results
Results

SETTING TIME TREND

35
30
T IM E IN M IN T S.

30
25
After
20
15
Before
10 9
5
0
May '05 June '05 July '05 Aug '05 Sep '05 Oct '05

Benefits :
• Set Up Time Per Set Up Reduced from 30 to 9 Mins.
 Brakes India Limited, Padi

OEE TREND AVAILABILTIY TREND

80 88
86

AVAILABILITY %
75
84
OEE %

70 82
65 80
78
60
76
55 74
2002 2003 2004 Apr- May- Jun- Jul-05 Aug- Sep- 2002 2003 2004 Apr- May- Jun- Jul- Aug- Sep-
OEE 65.49 70.3 72.61 74.3 74.6 72.21 74.56 76 78 AVAIL. 80.63 84.81 78.25 82.02 82.3 82.85 83.1 85 85.9

PERFORMANCE TREND CHART

QUALITY RATE TREND

100
100
99.95 80

PERFORMANCE
QUALITY RATE

99.9 60
99.85 40
99.8
20
99.75
0
99.7 200 200 200 Apr- Ma Jun- Jul- Au Se
2002 2003 2004 Apr- May- Jun- Jul- Aug- Sep-
PERFORMANCE 81.2 96.6 92.9 92.8 90.3 87.3 89.8 88.9 91
QUALITY 99.8 99.95 99.91 99.96 99.92 99.91 99.92 99.98 99.98