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Undercarriage Components
Rajesh Shah
Pramod Kokane
August 2015
Table of Contents
Abstract:................................................................................................................................... 3
1.
Introduction ................................................................................................................. 3
2.
3.
3.1
3.2
3.3
3.4
4.
4.1
4.2
4.3
4.4
4.5
4.6
4.7
5.
6.
Conclusion .................................................................................................................... 8
7.
References ................................................................................................................... 9
Abstract:
In recent years, the undercarriage components market has grown competitive.
Suppliers are facing huge competition to manufacture parts at lower cost by using
advanced techniques to meet the prevailing market demand and specification.
Comparative analysis of undercarriage components provide a good insight into the
properties of your own product/components vis--vis competitor and helps the
undercarriage manufacturers to optimise their own product. This paper highlights
the process followed in comparative analysis and various tests conducted to
achieve the desired output with findings and conclusions for product cost
performance optimization.
Keywords - Comparative analysis, Benchmarking, Metrology, Value Engineering,
Undercarriage Assembly, Construction Equipment
1.
Introduction
This pressure of keeping prices low has also forced the industry to
consolidate, because bigger suppliers can realize economies of scale and offer
products at lower prices. The suppliers have responded by redesigning products to
be less expensive without losing functionality or quality, and by maximizing
manufacturing efficiencies. On the other hand, technological advances have
opened various avenues to market leaders to adopt state of the art technologies
resulting in significant growth in market share.
In this scenario, it is important to know the trends of competition with respect to
technology, cost, performance prediction and product range. Hence, comparative
analysis of companies product vis--vis competition product becomes a very
important activity to understand these trends and these can be best achieved by
detailed competitive benchmarking. Through the exercise of benchmarking,
undercarriage manufacturers understand how the competitors are better from a
design, manufacturing and performance standpoint, leveraging cost reduction
opportunities and exceeding customer expectations. In addition, the intention of
management is to look beyond engineering and market place and cater most
market needs.
2.
Methodology Adopted
3.
Tools Used
Below are the major tools used for comparative analysis under various processes.
3.1
i.
ii.
iii.
iv.
3.2
i.
ii.
3.3
i.
ii.
iii.
4
Dimensional Measurement
Micrometre
Coordinate Measuring Machine
Vernier Callipers
Radius & Thread Gauges
Material Characterization
Optical Emission Spectrometers
Optical Microscope
Hardness Characterization
Surface Roughness Tester
Surface Comparators
Hardness Tester
3.4
i.
ii.
Sample Preparation
Wire Cut
Water Jet Cutting
Based on the above tools and methodologies, the intention of this project is to
unfold the following information:
a)
Dimensional comparison of components
b)
c)
d)
e)
f)
g)
4.
Project Activities
ii.
Coordination with freight forwarder from the pick-up to the arrival in India
iii.
iv.
Sample preparation
v.
Metallurgical testing
vi.
Should-costing
vii.
Report preparation
i.
ii.
iii.
iv.
v.
vi.
ii.
4.3
i.
Dimensional Measurement
Measurement of major dimensions using conventional tools like vernier
caliper and micrometre
ii.
iii.
4.4
Sample Preparation
Under this process test pieces are prepared for its microstructure analysis and
heat transition zone. This can be done by:
i.
ii.
Parts with high hardness and large size use the following methods:
Wire Cutting
Water Jet Cutting
4.5
Metallurgical Testing
i.
ii.
Surface Roughness
iii.
iv.
v.
Microstructure Examination
vi.
Macrostructure Examination
vii.
Micro Hardness
viii.
ix.
Hardware Testing
x.
Bimetal Thickness
4.6
i.
ii.
iii.
iv.
v.
4.7
Should-Costing
i.
ii.
Detail cost for each manufacturing process performed considering the batch
size & setup cost of special machines
iii.
5.
During this project, the team has generated test reports for all the components.
Below is a glimpse of the activities performed:
i.
ii.
iii.
Layout design for efficient utilization of space and easy accessibility to parts
iv.
v.
vi.
Project plan with details at micro level for each activity with responsibility
matrix
vii.
viii.
ix.
x.
xi.
xii.
6.
Conclusion
The detailed process followed for benchmarking results in a good amount of data
for analysis of undercarriage components. The type of data gathered and its
interpretation is captured in the table below:
Data
Dimensional
Interpretation
Machining operations, Fits
Depicts
Design
Intent,
Cost
of
machining
Material
Heat Treatment
Type
of
heat
treatment
Process
Visual Observation
functionality
and
Good
Any special feature and its
reliability
comparison
competitors
parts
with
and
the
life
maintenance
including
cost
of
the
assembly
Such interpretation provides a platform for engineering and product design teams
to re-visit various in-house manufacturing processes and product designs to
consider cost reduction opportunities in order to exceed customer expectations.
7.
References
i.
ii.
iii.
iv.
v.
vi.
Cooper R., Slagmulder R., 1997. Target Costing and Value Engineering,
Productivity Press, Oregon.
vii.
Ugo I., Paulo C. K., 2006. Product development process with a focus on
value engineering and target costing: A case study in an automotive
company. International Journal of Production Economics 105(2007) 459474.
2015 L&T Technology Services. No part of this document may be modified, deleted or
expanded by any process or means without prior written permission from L&T Technology
Services.
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