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Improvement of Machining process of Computer Numerical Control Machine

to Reduce Cycle Time of Water Inlet Housing

1*, 1 , 1 2 1 -

2 ,

E-mail: nuttapol@tni.ac.th*

Nuttapol Limjeerajarus1,*, Kotchakarn Nantasaksiri1, Patcharawat Charoen-amornkitt1

and Vitayakorn Khanviboon2 1 Research Center for Advanced Energy Technology, Faculty of Engineering,

Thai�Nichi Institute of Technology Bangkok 2 Engineering machining department, Asahi Tec Aluminium (Thailand) Co., Ltd. Samutprakarn

E-mail: nuttapol@tni.ac.th*

( )

(Cycle time)

(Kaizen) (line balancing)

27 (37.8 ) 38

870,000

Abstract

Since the growth rate of Thailand Automotive Industry has grown rapidly, to serve the increasing

customer�s demand, automotive manufacturers and their suppliers have to increase their production

capacity. From the study of the manufacturing process of water inlet housing at Asahi Tec Aluminium (Thailand) Co., Ltd., the machining process has the longest cycle time in which the bottle neck occurs.

This paper aims to improve the program of Computer Numerical Control (CNC) machining process by

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reducing wasted time. The Japanese philosophy called �Kaizen� and line balancing method which can be done immediately with low initial investment were applied. From the improvement, the cycle time was

reduced by 27 percent, which was equivalent to 37.8 seconds/piece, which contributed to the reduction in

annual operating cost of about 870,000 baht per year. As a result, the production capacity could be increased for 38 percent so that the customer�s demand could be satisfied. Keywords: Kaizen, Cycle time, CNC, Water Intel housing, Automotive parts manufacturing

1.

1 39.2

(GDP) [1] 3 12

[2] . . 2555

1 70.3 [3]

[4] ( )

60 . . 2557 [5] ( 1)

(Cycle time)

(Kaizen)

(Line balancing)

1

2.

(waste) 7 [7]

2.1

(Work in process, WIP)

2.2

2.3

2.4

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2.5

2.6

2.7

7

(continuous improvement)

[6]

3.

7 1

2 3

4 5

6

7

( 2)

2

10 1

3

9

4

3

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1

( )

( )

( )

4

( ), ( ) ( )

4.

1 Ø100.0

2

[8]

(Air cutting)

5 6

2 Ø9 Ø13 3

3 Ø9

2 4

4 Ø15.0

Ø16.8 3

( )

0. 0.20

1. Ø 100.0 0.47

2. Ø9 Ø13 0.19

3. Ø9 0.09

4. Ø15.0

Ø16.8

0.37

5. Ø5 Ø6.4 0.17

6. M6×1 0.17

7. Ø60 0.11

8. Ø20

Ø 30

0.16

9. Ø20 0.41

2

5 6

8 9

7

3 4

1

1

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( )

( )

5 ( ) ( )

( )

( ) 6 ( )

( )

18 . 5 Ø5 Ø6.4

2

1 . 6 M6×1

2

2

7 Ø60

8 7

8 Ø20 Ø 30 7

7 7 8

9 Ø20

8

Ø30

Ø60

Ø20

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2

27

38 12,441 17,119 8

8 [9]

870,000

2

( )

( )

( )

(%)

0. 0.20 0.20 0 0.0%

1. 0.47 0.35 -0.12 25.5%

2. 0.19 0.18 -0.01 5.3%

3. 0.09 - -0.09 100.0%

4. 0.37 0.23 -0.14 37.8%

5. 0.17 0.16 -0.01 5.9%

6. 0.17 0.17 0 0.0%

7. 0.11 - -0.11 100.0%

8. 0.16 0.15 -0.01 6.3%

9. 0.41 0.27 -0.14 34.1%

2.34 1.71 -0.63 26.9%

5.

8

27

( 2) 870,000

38

(

)

[1] Bank of Thailand. 2012. Structure of Economic in

Year 2012. [2] Ghazali, N.A., E., Latiff, M.K.M., Limjaroenrat, P.

and Whitesides, E. 2011. Thailand automotive cluster, Institute for strategy and competitiveness.

[3] International Organization of Motor Vehicle Manufacturers (OICA). 2013. World Motor

Vehicle Production by country 2011-2012.

[4] (TDRI). 2556. /

300 . [5] Department of Engineering, Asahi Tec Aluminium

(Thailand) CO., Ltd. 2013. Order Report.

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[6] Karkoszka, T. and Honorowicz, J. 2009. Kizen philosophy a manner of continuous improvement

of processes and products, Journal of

Achievements in Materials and Manufacturing Engineering, Aug, 2009 : 197-203.

[7] Ohno, T. 1998. Toyota Production System: Beyond Large-Scale Production, Productivity Inc.

[8] Kyocera. 2007. Kyocera cutting tools, Kyocera Asia Pacific (Thailand) Co., Ltd.

[9] Department of Engineering, Asahi Tec Aluminium (Thailand) CO., Ltd. 2013. Annual Report 2013.