Meeting Agenda

Objective - Project review at chang yun India

Date - 17/02/2016
Time - 02:30 pm
Location - Conference Room at chang yun India

Agenda
1 Presentation
2 Plant Visit
3 Project review on shop floor
4 Feedback
Member Present
Dr. Venkatash Balasubramanian IITM
Mr. Gaurav Munjal AMX
Mr. Sudhir Srivastva Plant Head - CYI
Mr. Jai Prakash Chauhan Manufacturing Head
Mr. Vipin Malik Process Engineering
Mr. Gulab Singh AMX B4
Mr. Manoj Kumar AMX B4

IIT PE’s Batch#4 Module ‘4’ GS - MK 1

 PROJECT REVIEW
Project 1 Cost reduction of forging lubricant
Project 2 Improve productivity of MF 22065 (Forging Press)

PROJECT CHAMPION Mr. Jai Prakash Chauhan

SUPPORTING TEAM Mrs.Mamta , Mr.Bir Singh , Mr.Pandey , Mr.Vipin

IIT B4 TEAM Gulab Singh , Manoj Kumar

DATE 16th Dec’15 to 30th April’16

PLACE OF DOING Gurgaon

PLACE OF COLLECTION Chang Yun India

IIT PE’s Batch#4 Module ‘4’ GS - MK 2

 Project 1 Charter

Business Case: Opportunity Statement:

• High graphite cost
• 3S Improvement in forging shop
• Elimination of large amounts of oil fumes and
the associated health hazards
Goal Statement :
• To reduce the graphite cost from 2.0 million to
0.4 million per annum till Feb’16.
• 3S Score to be increased from 08 to 16.
Project Plan:
• The potential saving will be 1.6 million per
annum by reducing the graphite cost.
• Black graphite free shop floor in forging process
which will improve forge shop 3S score.
Project Scope :
• The project cover only part number 1014113
(Model C) on machine no MF22048 .
• Tools used – Observations, curiosity &
hypothesis cycle .
Project Team:
Team Leader : Mr. Jai Prakash Chauhan
Supporting Team : Mrs. Mamta , Mr. Bir singh ,
Mr. Vipin Malik, Mr. Faizal, Mr. Sunil Pandey
AMX B4 Team : Gulab Singh , Manoj Kumar

IIT PE’s Batch#4 Module ‘4’ GS - MK 3

Milestone Project Chart

IIT PE’s Batch#4 Module ‘4’ GS - MK 4

 P Map - Forging Shop

RM
Raw Material Storage Inspection

Blank load
in hopper
3.3 m 3.5 m 6m
Dipping in
Forging Forging Forging graphite
MF22048 MF22012 MF22024
Blank
13 m 11 m 15 m heating at
700 to 745
deg. Celsius
12 m
10 m Forging
Forging
MF22065

Forging Storage Material movement from

RM store to machines Machining
Material movement from
machines to forging storage
IIT PE’s Batch#4 Module ‘4’ GS - MK 5
 Observations

Observations
 Forged ring fall down on the shop floor after processing.
 Raw material blank fall down on the shop floor from the loading conveyor.
 Colour coding on bins is not visible.
 Safety curtain on machine number 48 is not covering the working zone.
 Oil and graphite coming out from the joint of floor covering sheet
 Three manpower are working on machine no MF22065 while on other
machines one man power is working
 Graphite fall on shop floor while re filling the dipping tank of graphite.
 Smoke collector not available on machine no MF22048.
 Forging 3S Score is 8 out of 16.

IIT PE’s Batch#4 Module ‘4’ GS - MK 6

5S Audit Observation

Audit Observation –
Graphite spillages

3S Score – 8 @
Forging shop

IIT PE’s Batch#4 Module ‘4’ GS - MK 7

 Observations

Oil & graphite coming out from Part fall on shop floor due to
the joint of floor covering sheet over filling

No smoke collector
at machine no
MF22048 Graphite fall on shop
floor while re filling the
graphite tank

IIT PE’s Batch#4 Module ‘4’ GS - MK 8

 Initial Curiosity

1. Which lubricant using in forging?

2. Need of forging lubricant?
3. How lubrication is useful for component?
4. Lubricant is environment friendly or not?
5. Consumption of lubricant?
6. Cost of lubricant?
7. Number of supplier of forging lubricant?

IIT PE’s Batch#4 Module ‘4’ GS - MK 9

 Need of a Forging Lubricant

Easy
component
separation
from Die

Minimize
Minimize
energy
usage
NEED wear of
expensive
forging dies

Effects the
manufacturing
cost - scrap,
production
rate, die life

IIT PE’s Batch#4 Module ‘4’ GS - MK 10

 Curiosity cycle

Why graphite as a forging lubricant?

Curiosity

 Good material flow  Good lubricity properties

Experience Hypothesis
 Heat resistance  Cost effective
 80 % forging companies  Easy availability
are using graphite

IIT PE’s Batch#4 Module ‘4’ GS - MK 11

 Types of Forging Lubricant

Types of Forging Lubricant

 Oil based graphite .
 Water based graphite.
 Water based synthetics.

Water Water
Oil based
Description based based
Graphite
graphite synthetic
Carbonaceous smoke Yes Yes No

Better 3S No No Yes

Flammable Yes No No

Personal safety and protection of environment No No Yes

IIT PE’s Batch#4 Module ‘4’ GS - MK 12

 Physical & Chemical Properties

Properties Oildag EU SHINE LUBE 3510 METAFORGE - S 36

Physical form Black fluid Pale yellow Pale white

Odour Oil Blend Blend
pH Not applicable 8 - 10 8 - 10
Viscosity 0.1 poise @23°C 1.8 poise @40°C 0.6 poise @23°C

Freezing point - 0°C 0°C

Flash point >200°C Not applicable Not applicable
Specific gravity 0.83 1.1 1.06

Density 0.96 g/cm³ 1.1 g/cm³ 1.2 g/cm³

Solubility in water Insoluble Soluble Soluble

Cost Rs. 980 / liter Rs. 160 / liter Rs. 140 / liter

IIT PE’s Batch#4 Module ‘4’ GS - MK 13

 Trials – Standard of Procedure
Start

Trial request approval

Plan – Machine &

material availability

Process re validation
Yes
1st No
trial
Yes
2nd No
trial
Yes
Stop 3rd
No
trial
Yes
4th No
Final Approval
trial
Yes
5th No
trial

IIT PE’s Batch#4 Module ‘4’ GS - MK 14

 Trial Summary

Trials - Summary
Supplier
S.No. Lubricant Type Trial Date Result Remarks Trial Sheet
Name
Radius on key slot and teeth is
Refer trial sheet no. -
1 5 6/1/2016 Not Ok 1.2mm , Boss dia more
HF01
63.52mm
Refer trial sheet no. -
2 10 7/1/2016 Not Ok Radius on key slot and teeth
HF02
YUSHIRO HF 1080 Refer trial sheet no. -
3 25 7/1/2016 Not Ok Radius on key slot and teeth
HF03
4 100 - - - -
5 500 - - - -
13/01/201 Refer trial sheet no. -
6 5 OK -
6 KS01
13/01/201 Refer trial sheet no. -
7 10 OK -
6 KS02
8 KISAN SHINE LUBE 25 - - - -
3510 28/01/201 Radius on key slot and teeth , Refer trial sheet no. -
9 100 Not Ok
6 Boss dia more KS03
10 500 - - - -
Refer trial sheet no. -
11 5 - - -
SR01
28/01/201 Refer trial sheet no. -
12 10 OK -
6 SR02
30/01/201 Refer trial sheet no. -
13 SUNRISE METAFORGE – 25
6
OK -
SR03
S36 Refer trial sheet no. -
14 100 9/2/2016 OK -
SR04
Refer trial sheet no. -
15 500 10/2/2016 OK -
SR05
IIT PE’s Batch#4 Module ‘4’ GS - MK 15
 Project 2 Charter
Business Case:
• Productivity is very low on MF 22065.
•Three man power are working on the machine
which leads to extra cost.
•Only single part(1019122) is forgeable.
Goal Statement :
• Productivity will improve from 114 to 720
units/man/hr on machine no. MF22065
(Forging Press) till March’16.
Project Plan:
IIT PE’s Batch#4 Module ‘4’ GS - MK
Opportunity Statement:
• The potential saving will be 0.72 million per
annum by eliminating the man power on
machine no MF22065 in forging shop.
• Machine will become flexible for other part
category & also increase plant capacity.
Project Scope :
•The project cover only brass ring of
1019122,1019132,1018132,2550131 on
machine no MF22065.
• Tools used – Observations, curiosity &
hypothesis cycle , SWCT.
Project Team:
Team Leader : Mr. Jai Prakash Chauhan
Supporting Team : Mrs. Mamta , Mr. Bir singh ,
Mr. Vipin Malik, Mr. Faizal, Mr. Harender
AMX B4 Team : Pushpender Dubey , Manoj
Kumar
16
Milestone Project Chart

IIT PE’s Batch#4 Module ‘4’ GS - MK 17

 Average Production Per Shift (Brass Ring)

800
7000 720
700
6000 5760
600
5000
500
4000
400
3000 2744
300
2000
200
114
1000
100
0
0
Actual Target Actual Target

Average Production per shift Productivity units/man/hr

IIT PE’s Batch#4 Module ‘4’ GS - MK 18

 Curiosity cycle

Why productivity is low on machine no. MF22065?

Curiosity

1. Low production 1. Inefficient process

2. High Break down Experience 2. Man power efficiency less
Hypothesis
3. Low human productivity 3. Non value added activity
4. Machine running in manual mode 4. Non standardized work
5. Manual furnace loading.
6. Single induction is feeding for
Double cavity.

IIT PE’s Batch#4 Module ‘4’ GS - MK 19

 M map – MF 22065

Cycle Time – 4 Sec

Tool Change – 15 min
Set up Frequency – 0
Model Running – 1
Tool life – 45000 nos

Light level – 102 lux Single

Noise level- 78db Single
induction
Temp- 20 degree part is
furnace
Safety sensor- 1 running
feeding to
Accident – 0 on
double
PPE’s – Gloves, ear Mf22065
cavity
plug & Safety shoes,
Helmet
RULA – 3
REBA - 2

Working Height: 1 m.
Assembly Weight: 70 gm Double cavity forging
press

IIT PE’s Batch#4 Module ‘4’ GS - MK 20

 Observations from M - map

Manual diversion of component Manual dipping and loading of

towards both forging dies component

Continuous pressing of cycle start button

Manual spray on punch for Manual air cleaning of dies

lubrication
IIT PE’s Batch#4 Module ‘4’ GS - MK 21
 Manual Activities on MF22065

Value Non value

S.No Activities added added
activities activities
1 Pick the 4 rings from the input bin 3.08
2 Dipping the rings inside the graphite 0.94
3 Placing and adjusting the ring on the machine conveyor 3.45

4 Walk towards the ring box to re fill the input bin & come 0.1
back towards the working station
5 Diverting the component from furnace to machine 3.4

6 Pressing the cycle start button till the process completion 3.08

7 Removing the component from the chute 1.36

8 Die cleaning with air & spray on punch after every 10 2
pieces
9 First forging 1
Total (sec) VA 1 & NVA 8 1.0 17.41
IIT PE’s Batch#4 Module ‘4’ GS - MK 22
 Down time of MF22065 (minutes)

2000
1770
1800
1600
1400
1200
1000 900 Total
800
down
time is
600
370 3515 of
400 270
150 one
200 week
0
FF PL R&D MT SS

FF Fire in Furnace
PL Machine stop in lunch & tea time
R&D Trial of outer part
Autoloader adjustment & rubber
MT
pipe change time
SS Changeover time
IIT PE’s Batch#4 Module ‘4’ GS - MK 23
 Action Plan - Improvements

TIME PLAN - IMPROVEMENTS @ MF 22065

S.No Descriptions Actions RESP Target Remarks
Auto loading (hopper) to be
1 Manual loading at furnace input Mr.J.P. Chauhan 29th Feb'16 In process
installed at furnace input

Manual diversion to transfer the blank Auto diversion mechanism to

2 Mr.J.P. Chauhan 3rd March'16 In process
on dies be incorporated

3 No lunrication on punch Auto lubrication on punch Mr.J.P. Chauhan 12th Feb'16 closed

4 Manual air die cleaning Auto air die cleaning Mr.J.P. Chauhan 12th Feb'16 closed

Continuously cycle start button pressing

5 Auto cycle start operation Mr.J.P. Chauhan 10th Feb'16 closed
to operate the machine
No temperature measuring system of
6 Pyrometer to be installed Mr.J.P. Chauhan 10th Feb'16 closed
blank
Temperature controller is 2 meter away Temperature controller to be
7 Mr.J.P. Chauhan 3rd March'16 In process
from OE shifted in front of OE

Dent mark on forged ring at output due Output station height to be

8 Mr.J.P. Chauhan 26th Feb'16 In process
to fallen from more height increased
Part stuck in between the coil and
9 Coil design to be changed Mr.J.P. Chauhan 29th Feb'16 In process
furnace bottom
Forged ring ejection not done due to Air ejector to be fitted with
10 Mr.J.P. Chauhan 26th Feb'16 In process
misalignment clips
No by pass system of furnace in case of By pass mechanism to be
11 Mr.J.P. Chauhan 27th Feb'16 In process
machine stop installed for blanks

Trials to be done of outer cone

12 Machine flexibility for outer cone family Mr. Gulab singh 8th Feb'16 closed
family component
Furnace catches fire due to oil based
13 Water base forging lubricant Mr. Gulab Singh 3rd March'16 In process
graphite

IIT PE’s Batch#4 Module ‘4’ GS - MK 24

 Actions - Done

Pyrometer installed to measure the Outer cone family developed on

blank temperature MF22065

Auto cycle start instead of manual Auto spray on punch instead of

cycle start manual spray

IIT PE’s Batch#4 Module ‘4’ GS - MK 25

 Production Trend shift wise

S. No. Date Shift Part No. Production

1 8/2/2016 A 1019122 2686
2 8/2/2016 B 1018132 2324
3 9/2/2016 A 1018132 460
4 9/2/2016 A 2550131 450
5 9/2/2016 B 1019122 3600
6 10/2/2016 A 1019122 2664
7 10/2/2016 B 1019122 1900
8 10/2/2016 C 1019122 2100
9 11/2/2016 A 1019122 2100
10 11/2/2016 B 1018132 2000
11 12/2/2016 A 1019122 3000
12 12/2/2016 B 1018132 1900
13 13/2/2016 A 1019122 2600
14 13/2/2016 B 1019122 3500
15 13/2/2016 C 1018132 1800
16 14/2/2016 A 1019122 2100
17 14/2/2016 B 1019122 3800
18 15/2/2016 A 1019122 3400
19 15/2/2016 B 1019122 4600
20 15/2/2016 C 1019122 5200

Highest production in
a shift is 5200 against
Target 5760
IIT PE’s Batch#4 Module ‘4’ GS - MK 26
IITM AMX BATCH # 4
IIT PE’s Batch#4 Module ‘4’ GS - MK 27