project report tafe final

A Study on Effectiveness of Existing Layout at TAFE Ltd., 1

ST.JOSEPH’S COLLEGE OF BUSINESS ADMINISTARATION

18, Residency Road, Bangalore 560 025

A Study on Effectiveness of Existing Layout at TAFE Limited

Project Report

Submitted in partial fulfillment of the requirement s

for the award of

The Post Graduate Diploma in Management

(A TWO YEAR FULL TIME PROGRAM IN MANAGEMENT)

Submitted by

Polisetty Sai Chaitanya

Roll No. 14023

PGDM 2014-16


ST.JOSEPH’S COLLEGE OF BUSINESS ADMINISTARATION

18, Residency Road, Bangalore 560 025

CERTIFICATE

This is to certify that the project report entitled “A Study on

Effectiveness of Existing Layout at TAFE Ltd., ” is an authentic record

of the project carried out by Mr.Polisetty Sai Chaitanya (Reg.No.14023)

in partial fulfillment of the requirements for the award of The Post

Graduate Diploma in Management.

Prof. V.J.Lawrence

Associate Professor

Rev.Dr.S.Peter S.J. Prof.Edwin L Castelino

Director Dean


DECLARATION

I hereby declare that the project report entitled “A Study on effectiveness of Existing

Layout at TAFE Limited” has been prepared by me during the period from 15 April

2015 to 30 May 2015 under the guidance or Mr.Kumaresan Deputy Manager, TAFE

Limited and Prof. Lawrance, Faculty Member, St.Joseph’s College of Business

Administration, Bangalore.

I also declare that this project has not been submitted nor shall it be submitted in

future to any other University or Institution for the award of any other Degree or

diploma.

Signature …………………………………..

Polisetty Sai Chaitanya

Dated the 30th May, 2015


ACKNOWLEDGEMENT

Words are only representations of our regards and gratitude that we have

towards our actions and their inherent associations. As a matter of fact, without co-

operation, no thought could be coined into real action. Consistent motivation and

invaluable support throughout any project is an issue that cannot be quantitatively

measured. These acknowledgements are only a fraction of regards towards their

gestures.

“Vital to every operation is co-operation”. We really agree to this wonderful

quotation put forth by Mr. Frank Tyger. This project was successful due to the co-

operation extended by people who have truly contributed towards it. We gratefully

acknowledge Mr.Lawrence, St. Joseph’s College of Business Admin istration

Bangalore who’s deep sharing and synergy has moved us many levels beyond our

own thinking. We express our deep sense of gratitude to ma`am who has been a

source of inspiration throughout the course of this work with her inestimable advice

and moral encouragement.

We are thankful to following persons for their valuable inputs and their kind

co-operation and guidance which helped us in carrying out this project study.

• Mr. Prem Ramesh , Deputy General Manager, Production Engineering Department

TAFE Ltd.,

• Mr. Kumaresan , Deputy Manager, Production Engineering Department TAFE Ltd.,

• Mr. Nirmal Kumar , SeniorEngineer, Production Engineering Department TAFE

Ltd.,

We take this responsibility to express our profound and sincere gratitude to

St. Joseph’s College of Business Administration, Ba ngalore for providing us

with the opportunity to explore the corridors of the corporate world and gather

invaluable knowledge and practical experience via the Production and Operations

Management project. Finally, we would like to thanks those people who all are

attached to this Project directly or indirectly.


Table of content

S.No. Description

Page No.

1 Executive Summary …………………………………………………. 8

2 Company Profile …………………………………………………….

• AGCO ………………………………………………………….

• Warwick Manufacturing Group, UK …………….…………..

• Nature of Business …………………………………………..

• Nature of Products …………………………………………..

• Other Information about the Plant …………………………

9

11

11

11

12

13

3 Introduction to the project …………………………………………..

• Topic of Study ……………………………………………….

• Background of the research topic ………………………….

• Review of Literature in the area of study ………………….

• Existing practices of the organization in the area of study..

14

14

14

15

16

4 Design of Study ………………………………………………………

• Objectives of the Study ……………………………………...

• Scope of the Study …………………………………………..

• Tools and Techniques for collection of data ……………….

• Operational definition of concepts …………………………..

19

19

19

20

26

5 Analysis of Data ………………………………………………………

• Data Collection ………………………………………………..

• Man activity chart ……………………………………………..

• Cell Ergonomics ………………………………………………

29

29

33

33

6 Conclusion ……………………………………………………………. 57

7 Bibliography ………………………………………………………….. 58


List of Tables and Graphs

SNo. Description

Page No.

1 Table -1 Cycle time details for machines …………………………. 29

2 Graph - 1 Cycle time ………………………………………………… 30

3. Table - 2 Production volume details for machines ………………. 30

4. Graph - 2 Production Volume ……………………………………... 31

5. Graph - 3 Comparison of Cycle time and Production Volume …. 32

6. OIB Axle Housing Assembly ………………………………………... 34

7. OIB Wheel Axle Bolt Press …………………………………………. 38

8. Axle Housing Sleeve Press …………………………………………. 40

9. Turkey End Cover Assembly ……………………………………….. 42

10. End Cover Assembly ………………………………………………… 45

11. HLC Cylinder Sub Assembly ……………………………………….. 59

12. HLC Assembly ………………………………………………………... 52


Executive summary

Now-a-days there is a tremendous growth in the industrial sector, particularly

the manufacturing sector. The project is about how effectively the plant layout is

performing at the TAFE ltd., who is the 3rd largest manufacture of tractors.

In the current scenario, the fast growing needs the company have to deliver

the products on the due date or earlier to the due date to gain the customers and

increase the market share. In order to achieve the peak of the production the

company have to design the layout according to the some standards which would

help the company to meet the target.

In this project, it presents about how effectively the company is performing, to

find the performance of the company there are several parameters are to be

considered. They are operator movements, ergonomics of operator by using these

parameter we can find the efficiency of the plant layout. The organization and

education institution should keep on research on the plant layout design and find the

easier way for high production and new technology which should benefit for the

company and the customers.

Company Profile


COMPANY PROFILE

Tractors and Farm Equipment Limited (TAFE), is an Indian tractor major

incorporated in 1960 at Chennai, with an annual turnover of INR 96 billion

(2013-14). The third-largest tractor manufacturer in the world and the second

largest in India by volumes, TAFE wields 25% market share of the Indian tractor

industry with a sale of over 170,000 tractors (domestic and international)

annually.

TAFE's partnership with AGCO Corporation and the Massey Ferguson

brand for 53 years is a stellar example of its commitment to building long-term

relationships with its stakeholders, through fair and ethical business practices.

TAFE has earned the trust of customers through its range of products that

are widely acclaimed for its quality and low cost of operation. A strong

distribution network of over 1000 dealers effectively backs TAFE's three iconic

tractor brands of Massey Ferguson, TAFE and Eicher. TAFE exports tractors,

both in partnership with AGCO and independently, powering farms in over 75

countries which includes developed countries in Europe and the Americas.

From a humble beginning with just one tractor model in 1961, TAFE today

is recognized as a high quality mass-manufacturer with an extensive product

range to meet the expectations of every farmer and every farm mechanization

need. TAFE's R&D facilities are centers of excellence renowned for their

innovative design and engineering expertise and have been recognized by the

Department of Scientific and Industrial Research, Government of India.

Extensive research and testing ensures that TAFE's products meet its exacting

performance standards.

TAFE's plant at Turkey manufactures a range of tractors for distribution in

Turkey through AGCO's dealer network, while another new facility has been

setup at China to cater to TAFE's ever growing global sourcing needs and value

addition to its Indian and worldwide operations. TAFE acquired Eicher's tractors,

gears and transmission components and engines business in 2005 through a

wholly owned subsidiary, TAFE Motors and Tractors Limited (TMTL).

Company Profile


With six tractor plants, an engine’s plant, two gears and transmission

components plants, two engineering plastics units, two facilities for hydraulic

pumps and cylinders and one batteries plant besides other facilities, TAFE

employs over 2500 engineers apart from a number of specialists in other

disciplines.

TAFE believes in sound corporate governance and is reputed for being a

consistent profit-making company and ethical business practices. TAFE's

commitment to CSR involves contribution to the environment and society while

facilitating growth of all stakeholders with equal fervor, embodying the role of a

responsible corporate citizen. TAFE's social focus has been significant since

inception and it contributes towards education, healthcare, agriculture,

community development and supporting traditional art forms.

TAFE is committed to the Total Quality Movement (TQM). In the recent past

various plants of TAFE have garnered, three 'TPM Excellence Awards' from the

Japan Institute of Plant Management, the 'Frost & Sullivan - IMEA Award' for

significant progress towards reliable processes, the 'Regional Contributor Award' for

quality supplies from Toyota Motor Company, Japan, and the 'Manufacturing Supply

Chain Operational Excellence - Automobiles Award' at the second Asia

Manufacturing Supply Chain Summit for its supply chain transformation, as well as a

number of other regional awards for TPM excellence. Its tractor plants are certified

under ISO 9001 and under ISO 14001 for their environment friendly operations. In

2008, Business Standard awarded TAFE the 'Star Award for Unlisted Companies'

and in 2013the Public Relations Council of India conferred TAFE with the 'Corporate

Citizen of the Year'

TAFE is a part of the Amalgamations Group based at Chennai, one of India's

largest light engineering groups, comprising of 41 companies, involved in the design,

development and manufacture of diesel engines, automobile components, light

engineering goods, plantations and services.

TAFE has a number of associations with industry and technology leaders

such as AVL of Austria, Warwick Manufacturing Group of the UK, Carraro and

Ricardo from Europe and from Massey Ferguson in its pursuance of product quality

and overall excellence. TAFE Motors and Tractors Limited has technology transfer

Company Profile


agreements with Ricardo of UK for engines and with SISU of Finland for higher HP

tractors.

AGCO

TAFE has an ongoing collaboration with AGCO Corporation, Duluth,

Georgia. AGCO is one of the world's largest manufacturer and distributor of

Agricultural Equipment, selling its products in over 140 countries. The

collaboration has lasted for 50 years and is built on mutual trust and respect for

each other's competencies. These competencies are individually and collectively

leveraged for mutual benefit across geographies through innovative

arrangements for specific markets.

Warwick Manufacturing Group, UK

At TAFE we have been working with the Warwick manufacturing Group

now known as WMG since the late nineties in managing change at TAFE

through company wide initiatives. With their wide exposure to manufacturing

technologies, materials and sustainability and operations and business

management, they have facilitated TAFE to manage the changing environment

in our industry through collaboratively devised approaches to our business that

have helped ensure sustainable success despite its cyclic nature.

Nature of Business

1. TAFE Motors and Tractors Limited (TMTL)

2. Application Business

3. Engineering Plastics

4. Power Sources

5. TAFE Access

6. TAFE Reach

7. Southern Tree Farms

Company Profile


Nature of Products

1. Tractors

2. Harvesters

3. Engines &Gensets

4. Gears & Transmission System

5. Batteries

6. Hydraulic Pumps

Players in the Industry along with the Market Share

The study conducted in the Tractor Division, where assembly of tractor and

painting is done. Here two brand name tractors are assembled. They are

1. TAFE

2. Massey Ferguson

M&M

46%

TAFE

23%

Escorts

13%

John Deere

11%

Sonalika

2%

HMT

3%

Others

2%

Market Shares

Company Profile


Other Information about the Plant

Current operation = 200 Tractors per day

Capacity operation = 230 Tractors per day

Time Taken to assemble a tractor is 4 minutes

Product Range = 25 HP to 100 HP

Models

National = 70 Models and 45 variants

Export = 55 Models and 275 variants

No.of Components = 9932

No.of Employees = 1200 persons

Introduction to the project


Introduction to the Project

Topic of Study

Facility layout means planning for the location of all machines, utilities,

employee workstations, customer service areas, material storage areas, offices and

computer rooms and for the flow pattern of materials and people around into and

within the buildings. Through facilities layouts, the physical arrangement of these

process within and around the buildings, the space necessary for the operation of

these process and provided the space required for support functions. As process

planning and facility layout planning information continuous interchange between the

two planning activities, because each affects the other objective of the facility layout

study is to minimize the total cost, the cost comprises of construction cost,

installation cost, material handling cost, ease of future expansion, production cost,

machine down time cost, in-process storage cost, safety cost, ease of supervision.

Operation layout design criteria

1. Efficient loading and unloading

2. Ease of inventory counts

3. Effective stocking

4. Effective use of layout

5. Increase the productivity

Background of the research topic

Facilities should be designed so that they can be easily expended or adjusted

to meet changing production needs. Flexible manufacturing system most often are

highly automated facilities having intermediate-volume production of a variety of

products. Their goals to minimize changeover and setup times for producing the

different products while still achieving close to assembly line production rates.

Objectives of a good layout

1. Movement of people and material

2. Production capacity

3. Labour efficiency in terms of ergonomics



4. Space utilization

5. Ease of supervision and maintenance

Principles for Ideal Layout

1. Minimum travel

2. Sequence

3. Usage and flexibility

4. Safety and satisfaction

5. Compactness and minimum investments

Provide optimum space to organize equipment and facilitate of goods and to

create safe and comfortable work environment. To promote order in production

towards a single objective and optimum use of work force and equipment.

Review of Literature in the area of study

Efficiency of a plant layout can be increased by redesigning the plant layout

using string diagram and layout planning. It provide basic details about the flow of

material through shop floor and the interrelation of various activities.

One such research explain about the planning methods and procedures for

various types of production facilities. The type of layout design to be adopted and

implemented during layout design and has also provided the key elements for the

layout design. The type of flow of material and requirement of basic process is also

explained. Many industries use Activity Relationship Charts (ARC) and diagrams for

layout redesign and layout planning. The use of activity relationship charts in

designing the layout as provided a basic steps for layout planning.

A research conducted to identify and improve the plant layout of pulley’s

factory to eliminate obstructions in material flow and thus obtain maximum

productivity.

Another research focuses on the problems occurred during designing flexible

plant layout for manufacturing facilities were product demands are subjected to

variability. A flexible layout is one that maintains low material handling cost despite

fluctuations in the product demand levels.



A research conducted in the industry explains about the warehouse redesign

of a manufacturing plant layout and also problems faced during the redesign of

layouts.

A case study explains in detailed redesign of an existing production facility the

design of production differs from that of manufacturing layout and the analysis done

using group technology.

Existing practices of the organization in the area of study

1. Poka - Yoke

2. Cellular Manufacturing

3. Process layout

Poka – Yoke

• Poka – Yoke that help operators avoid mistakes in their work caused by

choosing the wrong part, leaving out a part , installing a part backwards etc.,

• It involve the implementation of fail – safe ways methods that detect or

prevent human machine error.

• It provides instant feedback and prevention of quality problems.

• It helps the operator and process work right the first time.

• Poka – Yoke refers to techniques that make it impossible to make mistake

and it also helps to drive defects out of product and process and substantially

improve quality and reliability.

• It helps the company of simple Poka – Yoke ideas and methods in product

and process design can eliminate both human and mechanical errors.



Cellular Manufacturing

Cellular manufacturing is a lean manufacturing approach that helps

company’s build a variety of products as little waste as possible. Equipment and

workstations arranged in a sequence that supports smooth material flow through

process with minimal transport or delay.

A manufacturing cell consists of people and machines of workstations

required for performing the process steps.

For example :

If a process for a product requires cutting, followed by drilling and

finishing, the cell could include the equipment for performing steps arranged in that

order.

It helps the company achieve to important goals of lean they are One-piece

flow and High-variety production.

One-piece flow

One-piece flow is the state that exists when products move through a

manufacturing process one unit at a time at a rate determined the needs of

customer.

High-variety production

By grouping similar products into families that can be processed on same

equipment in the same sequence. It helps to shorten change over time between

products.



Process layout

This type is generally used in systems where a product has to be

manufactured or assemble in large quantities. In process layout the machinery and

auxiliary services are located according to the processing sequence of the product

without any buffer storage within the line itself.

Design of the Study


Design of the Study

1. Objectives of the study

2. Scope of the Study

3. Tools and Techniques for collection of data

4. Operation definition of concepts

Objectives of the Study

� To study the current flow pattern and relation of overall plant layout

� Relocating the workstations for simpler flow and reduction in check points.

� To improve the efficiency of the plant layout using facility layout planning

� To increase production capacity of the plant.

� To ensure optimum utilization of workforce and equipment.

� To reduce movement of workers, raw materials and equipment.

Scope of the Study

Production and operations management concern with the conversion of inputs

into outputs, using physical resources, so as to provide the desired utilities to the

customer while meeting the other organizational objectives of effectiveness,

efficiency and adoptability. It distinguishes itself from other functions such as

personnel, marketing, finance etc., by its primary concern for conversion by using

physical resources.

Plant layout deals with the arrangement of machines and plant facilities. The

machines should be arrange that the flow of production remains smooth. There

should not be overlapping, duplication or interruption in production flow. Product

layout, where machines are arranged in a sequence required for the processing of a

particular product and in process layout, where machines performing the similar

process are group together are two popular methods of layout. The departments are

laid out in such a way that the cost of material handling is reduced. They should be

proper choice of material handling equipment. There are many software for planning

the process layout.

Group Technology, cellular manufacturing systems and flexible manufacturing

have made our concepts of layout planning undergo a tremendous change.

Design of the Study


In short, manufacturing facilities must be able to exhibit high levels of flexibility

and robustness despite significant changes in the operating requirements. However

the plant layout improvement, could be one of the tools to response to increasing

industrial productivity. Plant layout has became a fundamental basis of today’s

industrial plants which can influence parts of work efficiency. It is needed to

approximately plan and position employees, materials, machines, equipment and

other manufacturing supports and facilities to create the most effective plant layout.

Tools and Techniques for collection of data

1. Time study

2. String diagram

Time Study

Time study methods were originally proposed by Frederick Taylor and were

later modified two include a performance rating adjustments. They have now

became one of the most widely used means of work measurement. Basically by

using time study an analyst is taking a small sample of one worker’s activity and

using it to derive a standard for tasks of that nature time study or stopwatch, time

study is performed by timing a worker as the job is performed, summing the times for

the necessary element of the job, adjusting if an abnormal workspace was observed,

and then adding time for personal and rest breaks.

Design of the Study


The time study approach to work measurement use a stopwatch are other

timing device to determine the time required to complete given tasks. Assuming a

standard is being set the worker must be trained and must use the prescribed

method while the study is being conducted.

String Diagram

The string diagram is one of the simplest techniques of method study for

recording and examining movement of workers and materials. It is a tool for

analyzing the designing workspace in a such a way that the movement of material,

men, equipment etc., During a specified sequence of events the string diagram is

thus a form of flow diagram.

In this a thread is used to measure distance it is necessary that the string

diagram be drawn correctly to scale. It is most often used to supplement the flow

process chart. A string diagram can be used to plot the movement of material and is

done especially when a work study person wants to find out easily just how far the

materials travelled. The complete plan containing all the equipments, doorways,

pillars and partitions, which affect path of movement, are drawn to scale. A

measured length of thread is then taken and tide around the pins at the string points

of movement thus the string diagram is useful aid in explaining proposed changes to

company management, problem supervisors and employees.

1. Location of facilities

2. Plant layouts and material handling

3. Product design

4. Process design

5. Production and planning control

6. Quality control

Design of the Study


7. Materials management

8. Maintenance management.

LOCATION OF FACILITIES

Location of facilities for operations is a long-term capacity decision which

involves a long term commitment about the geographically static factors that affect a

business organization. It is an important strategic level decision-making for an

organization. It deals with the questions such as ‘where our main operations should

be based?’ The selection of location is a key-decision as large investment is made in

building plant and machinery. An improper location of plant may lead to waste of all

the investments made in plant and machinery equipments. Hence, location of plant

should be based on the company’s expansion plan and policy, diversification plan for

the products, changing sources of raw materials and many other factors. The

purpose of the location study is to find the optimal location that will results in the

greatest advantage to the organization.

PLANT LAYOUT AND MATERIAL HANDLING

Plant layout refers to the physical arrangement of facilities. It is the

configuration of departments, workcentres and equipment in the conversion process.

The overall objective of the plant layout is to design a physical arrangement that

meets the required output quality and quantity most economically.

According to James Moore, “Plant layout is a plan of an optimum

arrangement of facilities including personnel, operating equipment, storage space,

material handling equipments and all other supporting services along with the design

of best structure to contain all these facilities”. ‘Material Handling’ refers to the

‘moving of materials from the store room to the machine and from one machine to

the next during the process of manufacture’. It is also defined as the ‘art and science

of moving, packing and storing of products in any form’. It is a specialized activity for

a modern manufacturing concern, with 50 to 75% of the cost of production. This cost

can be reduced by proper section, operation and maintenance of material handling

devices. Material handling devices increases the output, improves quality, speeds up

the deliveries and decreases the cost of production. Hence, material handling is a

prime consideration in the designing new plant and several existing plants.

Design of the Study


PRODUCT DESIGN

Product design deals with conversion of ideas into reality. Every business

organization have to design, develop and introduce new products as a survival and

growth strategy. Developing the new products and launching them in the market is

the biggest challenge faced by the organizations. The entire process of need

identification to physical manufactures of product involves three functions: marketing,

product development, manufacturing. Product development translates the needs of

customers given by marketing into technical specifications and designing the various

features into the product to these specifications. Manufacturing has the responsibility

of selecting the processes by which the product can be manufactured. Product

design and development provides link between marketing, customer needs and

expectations and the activities required to manufacture the product.

PROCESS DESIGN

Process design is a macroscopic decision-making of an overall process route for

converting the raw material into finished goods. These decisions encompass the

selection of a process, choice of technology, process flow analysis and layout of the

facilities. Hence, the important decisions in process design are to analyse the

workflow for converting raw material into finished product and to select the

workstation for each included in the workflow.

PRODUCTION PLANNING AND CONTROL

Production planning and control can be defined as the process of planning the

production in advance, setting the exact route of each item, fixing the starting and

finishing dates for each item, to give production orders to shops and to follow up the

progress of products according to orders.

The principle of production planning and control lies in the statement ‘First

Plan Your Work and then Work on Your Plan’. Main functions of production planning

and control includes planning, routing, scheduling, dispatching and follow-up.

Planning is deciding in advance what to do, how to do it, when to do it and

who is to do it. Planning bridges the gap from where we are, to where we want to go.

It makes it possible for things to occur which would not otherwise happen.

Design of the Study


Routing may be defined as the selection of path which each part of the

product will follow, which being transformed from raw material to finished products.

Routing determines the most advantageous path to be followed from department to

department and machine to machine till raw material gets its final shape.

Scheduling determines the programme for the operations. Scheduling may be

defined as ‘the fixation of time and date for each operation’ as well as it determines

the sequence of operations to be followed.

Dispatching is concerned with the starting the processes. It gives necessary

authority so as to start a particular work, which has already been planned under

‘Routing’ and ‘Scheduling’. Therefore, dispatching is ‘release of orders and

instruction for the starting of production for any item in acceptance with the route

sheet and schedule charts’.

The function to report daily the progress of work in each shop in a prescribed

proforma and to of follow-up is investigate the causes of deviations from the planned

performance.

QUALITY CONTROL

Quality Control (QC) may be defined as ‘a system that is used to maintain a

desired level of quality in a product or service’. It is a systematic control of various

factors that affect the quality of the product. Quality control aims at prevention of

defects at the source, relies on effective feed back system and corrective action

procedure.

Quality control can also be defined as ‘that industrial management technique

by means of which product of uniform acceptable quality is manufactured’. It is the

entire collection of activities which ensures that the operation will produce the

optimum quality products at minimum cost.

• The main objectives of quality control are:

• To improve the companies income by making the production more acceptable

to the customers i.e., by providing long life, greater usefulness,

maintainability, etc.

• To reduce companies cost through reduction of losses due to defects.

Design of the Study


• To achieve interchangeability of manufacture in large scale production.

• To produce optimal quality at reduced price.

• To ensure satisfaction of customers with productions or services or high

quality level, to build customer goodwill, confidence and reputation of

manufacturer.

• To make inspection prompt to ensure quality control.

• To check the variation during manufacturing.

MATERIALS MANAGEMENT

Materials management is that aspect of management function which is

primarily concerned with the acquisition, control and use of materials needed and

flow of goods and services connected with the production process having some

predetermined objectives in view.

The main objectives of materials management are:

• To minimize material cost.

• To purchase, receive, transport and store materials efficiently and to reduce

the related cost.

• To cut down costs through simplification, standardisation, value analysis,

import substitution, etc.

• To trace new sources of supply and to develop cordial relations with them in

order to ensure continuous supply at reasonable rates.

• To reduce investment tied in the inventories for use in other productive

purposes and to develop high inventory turnover ratios.

MAINTENANCE MANAGEMENT

In modern industry, equipment and machinery are a very important part of the

total productive effort. Therefore, their idleness or downtime becomes are very

expensive. Hence, it is very important that the plant machinery should be properly

maintained.

Design of the Study


The main objectives of maintenance management are:

1. To achieve minimum breakdown and to keep the plant in good working

condition at the lowest possible cost.

2. To keep the machines and other facilities in such a condition that permits

them to be used at their optimal capacity without interruption.

3. To ensure the availability of the machines, buildings and services required

by other sections of the factory for the performance of their functions at optimal

return on investment.

Operational definition of concepts

1. Job shop production

2. Batch production

3. Mass production

4. Continuous production

5. Effectiveness

6. Efficiency

7. Productivity

8. Lead-time

9. Work station

10. Material Handling

11. Benchmarking

12. Brainstorming

Job shop production

Job shop production are categories by manufacturing of one or few quantity of

products designed and products as per the specification of customers within prefixed

time and cost.

A job shop comprises of general purpose machines arranged into different

departments. Each job demands unique technology requirements, demands

processing on machines in a certain sequence.

Design of the Study


Batch production

Batch production is a form of manufacturing in which the job process through

the function departments or batches and each lot may have a different routing. It is

characterized by the manufacture of limited number of products produced at regular

intervals and stocked awaiting.

Mass Production

Manufacture of discrete parts or assemblies using a continuous process are

called Mass production. This production system is justified by very large volume of

production. The machines are arranged in a line or product layout. Product layout

and process standardization exists and all outputs follow the same path.

Continuous production

Production facilities are arranged as per the sequence of production

operations from the first operation to the finished product. The items are made to

flow through the sequence of operation through material handling devices such as

conveyors, transfer devices etc.,

Definition of key terms

Effectiveness

Effectiveness means doing the right things to create the most value for the

company. It can be measured by the actual outputdivided with the expected output.

Efficiency

Efficiency means doing something at the lowest possible cost. It can be

measured by dividing resources planned to be used with resources actually used.

Productivity

Productivity is a common measure of how well a country, industry, or

business unit is using its resources. This can be measured by dividing the outputs

with the inputs.

Design of the Study


Lead-time

This is the time between placing an order and receiving the finished goods or

service.

Workstation

The space or area of a facility in which individuals or operators perform tasks.

This ranges from an assembly station in a factory to a cube in an office.

Material handing

Material handing is defined as providing the right amount of the right material,

in the right condition, at the right place, at the right time, in the right position, in the

right sequence, and for the right cost, by using the right methods.

Benchmarking

A tool to improve business processes by looking what other companies are

doing. It is often beneficial to observe firms in other branches.

Brainstorming

Brainstorming is one of the simplest and familiar creativity techniques. It helps

to generate the ideas for a solution of the problem. The outcome of brainstorming

can be a list of ideas, which lead to an approach or the solution itself.

Analysis of Data


Analysis of Data

Data Collection

To determine the effectiveness of the layout, the details regarding the

performance of the cell or needed. So by doing the times study, information is

collected. Time study was conducted by taking number or trails. The complete cycle

of events have been divided into work elements. The time required for carrying out

each element is measured using a stop watch in continuous mode. Trails were taken

in different periods to have a good accuracy. The results of the time study are shown

all the details regarding, the cell layout and ergonomics like loading and unloading

points were collected and presented. The table below shows the cycle time of each

station for the final product of their respective parts.

Cycle time details for machines :

S. No.

Work Element Machines

Machining Time (Sec)

Loading Time (Sec)

Unloading Time (Sec)

Cleaning Time (Sec)

Cycle Time (Sec)

1 PTO shaft press 110 5 5 4 124

2 Center Housing assembly 200 15 60 NA 275

3 OIB wheel axle bolt press 300 17 10 5 332

4 OIB axle housing assembly 150 12 7 NA 169

5 Axle housing sleeve press 360 7 10 NA 377

6 Turkey end cover assembly 240 8 5 NA 253

7 End cover assembly 170 5 5 6 186

8 HLC cylinder sub assembly 270 20 10 7 307

9 HLC assembly 650 10 15 NA 675

Table – 1 Cycle time details for machines

Analysis of Data


Production volume details for machines :

S. No.

Parts Cycle Time (sec)

Output per cycle

Total time available

(sec)

Production volume

per month (Nos.)

1 PTO shaft press 124 1 1310400 10565

2 Center Housing assembly 275 1 1310400 4765

3 OIB wheel axle bolt press 332 1 1310400 3947

4 OIB axle housing assembly

169 1 1310400 7754

5 Axle housing sleeve press

337 1 1310400 3476

6 Turkey end cover assembly

256 1 1310400 5180

7 End cover assembly 186 1 1310400 7045

8 HLC cylinder sub assembly

307 1 1310400 4268

9 HLC assembly 675 1 1310400 1941

0

100

200

300

400

500

600

700

800Cycle Time (Sec)

Analysis of Data


Calculation of cycle time and production volume

Cycle time = machining time + loading time + unloading time + cleaning time

= 110 + 5 + 5 + 4

= 124 seconds.

Production volume = Total time available (sec) cycle time (sec)

= 1310400 124

= 10568 parts

0

2000

4000

6000

8000

10000

12000

PTO shaft

press

Center

Housing

assembly

OIB wheel

axle bolt

press

OIB axle

housing

assembly

Axle

housing

sleeve

press

Turkey end

cover

assembly

End cover

assembly

HLC

cylinder

sub

assembly

HLC

assembly

Production volume per month (Nos.)

Analysis of Data


Comparison of Cycle time (sec) and Production volume per month (Nos.)

From the data collection phase, information are collected directly by observing

shop floor and it indicates performance of the shop floor (viz., man and machine,

utilization, part travel, production volume etc.,) Hence they have to be further

process to obtain the performance of cell.

Any manufacturing cell includes, all the resources needed for product

manufacturing. The resources have to be utilized to maximum extent to obtain the

desired output from the cell. Hence to evaluate the performance of cells, the

utilization of resources, along with the factors that affects the utilization of the

resources. In order to do so, the following factors have to be considered to know

about the performance of the cell.

1. Man activity chart

2. Cell Ergonomics

0

2000

4000

6000

8000

10000

12000

PTO shaft

press

Center

Housing

assembly

OIB wheel

axle bolt

press

OIB axle

housing

assembly

Axle

housing

sleeve

press

Turkey

end cover

assembly

End cover

assembly

HLC

cylinder

sub

assembly

HLC

assembly

Cycle Time (Sec)

Production volume per month (Nos.)

Analysis of Data


Man activity chart

In the man activity chart we will look at the following stations, how they were

efficient and it also represent the ergonomics, movements of operator, distance

travelled and production volume. The data collected using the stop watch study and

string diagram.

Cell Ergonomics

The job of the operator is primary loading and unloading parts. Hence

ergonomics concern with lifting and placing parts in machines and operating work

holding devices. In this system, human performance in detecting and correcting cell

malfunctions will establish utilization and thus the production efficiency. The existing

cell has been studied and the ergonomics of a worker is designed. There are no

unnecessary movements and operator fatigue is less, when working continuously.

As far as the ergonomic concern in the company, they have been following

the standards which is feasible to the workers with less fatigue and strain. They were

following some techniques in order to enhance the productivity. They are

1. Machinery and controls, so as to minimize mental and physical strain on

the worker to enable the improvement in efficiency.

2. They were maintaining a peaceful environment for performing the task

most affectively and conducive.

3. They have designed the working environment in such a way that lighting,

ventilation, temperature, noise, vibrations, color, safety etc.,

Analysis of Data


OIB AXLE HOUSING ASSEMBLY ( in mts.,)

Operations Sequence Tools used Forward Backward Right Left Bending Down

Stretching up Remarks

To Fro To Fro To Fro To Fro To Fro To Fro

Taking OIB from TOD

Scanning the sticker on the moniter

Barcode Scanner 0.5 0.5

Stretching forward to pick up the barcode scanner

Taking axle shaft from the trolley

0.5 0.5 Turning back to pick up the axle shaft

Taking friction plate and intermediate plate from the trolley

0.5 0.5 Turning back

Checking disc length Disc guage 0.5 0.5

Stretching forward to pick up the guage

Taking reaction pin from the storage rack

0.5 0.5 0.75 0.75

Stretching forward to pick up the reaction pin

Taking accutator from the trolley

0.5 0.5 Turning back to take the accelator

Cont…

Analysis of Data


Taking friction plate and intermediate plate from the trolley


Putting grease and 'O' ring and again applying grease

0.75 0.75 1.00 1.00 Stretching towards left for taking 'O' ring

Taking brake boot bracket from the trolley

1.5 1.5 1.00 1.00

Operator is bending down to pick up boot bracket in the trolley

Scanning the brake boot bracket for checking hours (4 hrs) curing time


Putting Gasket 0.5 0.5

Applying loctite 0.5 0.5

Bending down to pick up loctite

Cont…

Analysis of Data


Putting brake lever from the trolley

0.5 0.5

Putting fasteners and washers from the storage rack

0.5 0.5

Tightening fasterners using Nut runner

Nut runner (Power tool) 0.5 0.5

Bending down to pick up the Nut runner

Tightening the stud using torque wrench

Torque wrench 0.6 0.6

Putting Nut and cotter pin 0.5 0.5

Taking carrier plate from the pressing machine

1.5 1.5

Travel back to carry tip carrier (heavy weight)

Putting screw and tightening

Power screw driver 0.5 0.5 0.5 0.5

Stretching up to catch the power screw driver

Cont…

Analysis of Data


Punching the screw

Hammer and rod 0.5 0.5

Checking the gap with filler gauge

Filler gauge

Moving to the trolley for main assembly line

Cycle time = 169 seconds

Production volume = 7754 parts

Distance travelled by the operator = 31.2 meters

Analysis of Data


OIB WHEEL AXLE BOLT PRESS ( in mts.,)




Wheel Axle Pressing

Taking wheel axle from trolley 2 2 0.5 0.5 Operater is

bending down

Taking seal labrith plate from storage rack

0.5 0.5 1 1 Stretching upward towards left

Taking Bolt from storage rack and putting on wheel axle

0.5 0.5

Taking bearing from the trolley and inserting on the wheel axle

0.75 0.75

Travelling towards right side to pick up bearing

Operating Hydraulic machine for pressing bolt

Taking drive cover from right side

Bearing press tool 2 2 Carring heavy

weight

Pressing the bearing with machine

Putting half ring from storage rack

Using hammer and screw driver

0.5 0.5

Cont…

Analysis of Data


Checking the half ring

Adjusting the half ring

Filler gauge tool 0.5 0.5

Putting 'O' ring from storage bin

0.5 0.5

Locating 'O' ring Spanner

Putting wheet axle in carrier press

Taking carrier from trolley using hoist

1.5 1.5

Putting bearing

Taking bearing from bearing stand

1 1

Pressing the carrier and bearing using pressing machine

Forwarded to the shim size stickering

1 1 0.5 0.5 Stretching upward to pick up the sticker

Cycle time = 332 seconds Production volume = 3947 parts


Analysis of Data


AXLE HOUSING SLEEVE PRESS ( in mts.,)




Scanning the shim using scanner

Using barcode scanner travelling to shimming gauge


Moving backward diagonally

Putting shim on axle according to the size mentioned

0.5 0.5

Putting 'O' ring from the storage rack and locating

Spanner 0.5 0.5

Moving to the sleeve press machine

0.5 0.5

Pushing the wheel axle and carrier to left

Pressing the axle sleeve with 40kg/cm2

Mounting Ring gear

Taking ring gear from trolley

2 2 Travelling in backward direction

Cont…

Analysis of Data


Mounting Carrier on Ring gear

Taking Carrier from carrier press trolley

Hoist 1 1 Turning back to pick up the carrier

Putting washers and bolts from storage rack

0.5 0.5

Tightening stud with Nut runner

Nut runner (Power tool) 0.5 0.5 0.5 0.5

Bending down to pick up the Nut runner

Locking the bolt with Torque wrench from storage rack

Torque wrench 0.5 0.5




Analysis of Data


Turkey end cover assembly ( in mts.,)

Operations Sequence Tools used

Forward Backward Right Left Bending Down



Turkey end cover assembly

Picking end cover from the trolley and keeping on the pressing machine

0.5 0.5 Operator carrying heavy weight

picking bearing from stroage rack and inserting on the end cover

0.5 0.5 Streching forward to pick up the bearing

Picking lock tool and pressing bearing using pressing machine

End cover lock tool

0.5 0.5

Picking end cover lock from storage rack and inserting in the end cover over bearing

0.5 0.5

Taking bearing pressing guide tool and keeping over the bearing

Bearing pressing guide tool

0.5 0.5

Picking heavy weight of bearing press tool

Cont…

Analysis of Data


Turning back side of the end cover

Picking end cover oil seal from storage rack

0.5 0.5

Applying loctite (603) inside the oil seal

0.25 0.25 Bending down to pick up the loctite

Inserting oil seal in the end cover and pressing with oil seal pressing tool

Oil seal pressing tool

Pasting the barcode sticker and waiting for to dry the loctite (15 minutes)

0.5 0.5

Streching forward to pickup the barcode sticker

Picking shaft from the trolley Hoist 0.5 0.5

Turning back to pick up the shaft

Inserting shaft into the end cover and pressing with machine

Cont…

Analysis of Data


Removing the end cover from pressing machine and putting into TOD

0.5 0.5

Operator is carrying heavy weight of end cover

Putting lock washer into the shaft

0.25 0.25 Bending down to pick up lock washer




Analysis of Data


END COVER ASSEMBLY ( in mts.,) Operator 1





End cover assembly

Collecting end cover from the washing machine using conveyor

1.5 1.5

Pulling the end cover from the right side to the pressing machine

Putting end cover in the pressing machine

0.5 0.5

Putting bearning over the green oil seal over the end cover from the trolley

0.5 0.5

Putting shim over the bearing from the storage rack

0.25 0.25 0.75 0.75

Putting circlip guide tool over the end cover

Putting circlip from the trolley 0.5 0.5

Turning back to pick up the circlip

Pressing the bearing

Bearing press tool

0.25 0.25

Cont…

Analysis of Data


Putting green oil seal from the trolley

0.5 0.5 Turning back to pick up the green oil seal

Pressing using the machine

Oil seal guide tool

0.25 0.25

Stretching forward to pick up the oil seal guide tool

Turning backside of the end cover

Putting mud block after turning the end cover

Bearing press tool

0.25 0.25 0.5 0.5

Turning back to pick up the mud block from the trolley

Taking shaft from the trolley putting on the end cover

Hoist 0.5 0.5 Turning back to collect the shaft from the trolley

Pressing the shaft using press machine

0.25 0.25

Pusing end cover with shaft into the pressing machine

Forwarded to TOD

Cont…

Analysis of Data


Operator 2





End cover sub assembly

Collecting from the TOD 0.5 0.5

Pulling end cover with shaft from the TOD

Taking 'O' ring from storage rack 0.75 0.75

Stretching forward towards right to pick up 'O' ring

Taking sleeve from the storage rack and putting over the shaft

0.75 0.75 Stretching forward to pick up the sleeve

Applying loctite from the storage rack

0.5 0.5 Stretching forward to pick up the loctite

Putting sleeve over the shaft and tightening the sleeve

Nut tighter tool

0.5 0.5 0.75 0.75 Stretching up to catch the nut tighter tool

Taking sleeve nut from the storage rack

0.5 0.5

Stretching forward to collect the sleeve nut

Cont…

Analysis of Data


Tightening the Sleeve nut

Nut tighter tool

0.5 0.5 0.75 0.75 Stretching up to pick up the tool

Moving end cover to the main assembly line




Analysis of Data


HLC CYLINDER SUB ASSEMBLY ( in mts.,)





HLC cylinder sub assembly

Taking piston from the trolley 0.75 0.75

Turning back to pick up the piston

Taking piston seal ring and inserting over the piston

0.5 0.5

Taking seal ring guide tool and putting over the piston

0.6 0.6 Bending down to pick up the tool

Taking seal ring from storage rack and putting over piston

Fitting the piston using seal ring guide tool

Seal ring guide tool

0.5 0.5

Taking cylinder (outer body) from the trolley

0.5 0.5 Carring heavy weight

Cont…

Analysis of Data


Apply grease 0.5 0.5

Inserting piston into the cylinder

Piston guide tool and insert tool

0.5 0.5

Putting stud into cylinder from storage rack

0.5 0.5 Stretching forward

Tightening the stud

Nut runner (Power tool)


Taking setting bracket 0.5 0.5

Turning back to correct the setting bracket

Taking fasterners from the storage rack


Putting fasterners over setting bracket from the storage rack

0.5 0.5

Cont…

Analysis of Data


Tightening the Fasterners


0.5 0.5 Stretching forward to pick up Nut runner

Taking PC and DC lever from the trolley


Tightening fasterners of PC and DC levers


0.5 0.5 Stretching forward to pick up Nut runner

Moving to HLC main assembly




Analysis of Data


HLC ASSEMBLY ( in mts.,) Operator 1





HLC assembly

Taking HLC from the trolley using hoist

2.5 2.5 0.5 0.5

Travelling in backward direction and bending down

Putting HLC in washing machine

Operator is training due to heat

Taking the HLC from the washing machine and putting on the trolley

1.5 1.5 Travelling in backward direction

Mounting washers and bolt the storage rack on the HLC

1.00 1.00

Tightening the bolts Spanner, Torque wrench

0.5 0.5

Bending down to take the washers and bolts

Taking trolley from behind the washing machine

1.00 1.00 3.00 3.00

Traveling left and then forward to get the trolley

Picking the cylinder from trolley and putting into washing machine

Cont…

Analysis of Data


Picking cylinder from washing machine and again keeping in trolley

2.00 2.00 Operator is carrying heavy weight

Removing water droplets using air gauge

Air gauge 0.5 0.5

Again moving trolley to the respective station

1.00 1.00 1.5 1.5

Taking kitting trolley and washing the parts

1.5 1.5

Pulling kitting trolley near to washing machine

Picking parts from washing machine and keeping in the kitting trolley

0.5 0.5 Turning back to keep parts in the trolley

Picking end cover from the end cover tray and putting in the washing machine

Hoist 1.00 1.00 0.5 0.5

Operator is bending down to pick up end cover

After washing picking the end cover using hoist and keeping on the conveyor

Hoist 0.75 0.75 Operator is straning due to heat

Cont…

Analysis of Data


Operator 2





Putting bolt and washers from storage rack to fix the HLC

0.5 0.5

Putting 'O' ring and disc over load plate from storage rack

0.4 0.4 0.35 0.35

Operator is bending to take disc cover load plate

Taking kitting trolley from the trolley line to station

2.5 2.5

Operator is travelling straight and right to take the kitting trolley

Taking Arm Ram and connecting rod pressing using machine

1.5 1.5 Turning back for pressing

Putting allen screw on HLC from storage rack

1 1

Putting washers from trolley 0.5 0.5

Inserting lift shaft into HLC from trolley

0.5 0.5

Cont…

Analysis of Data


Locating DC link and PC link from the trolley to the HLC

Hammer and rod 0.5 0.5

Putting link shaft from storage rack 0.75 0.75

Putting bush from storage rack and locating it

Bush guide tool

1 1 Turning back to pick up the bush

Putting 'O' ring and seal ring

Bush guide tool

0.5 0.5

Putting lift arm from the trolley 0.75 0.75

Putting load washer from storage rack

0.5 0.5

Putting control spring from the trolley and locating it

Screw driver 0.5 0.5

Locating HLC cylinder from the HLC sub assembly line

Hammer 1 1 Operator is carring heavy weight

Locating quardant from the storage rack

Screw driver and centre screw allen key

3 3

travelling in backward direction carring heavy load

Cont…

Analysis of Data


Checking draft control and position control

Pounds and checking tool

1.5 1.5

Moving to the main assembly line

Putting bolt and washers from storage rack to fix the HLC

0.5 0.5

Putting 'O' ring and disc over load plate from storage rack

0.4 0.4 0.35 0.35

Operator is bending to take disc cover load plate

Taking kitting trolley from the trolley line to station

2.5 2.5

Operator is travelling straight and right to take the kitting trolley

Taking Arm Ram and connecting rod pressing using machine

1.5 1.5 Turning back for pressing



Distance travelled by the operator = 72 meters

Findings and Recommendations


Findings

With the best knowledge of available techniques the solution to these type of

layout become more acceptable with the good points of different approach were

brought together.

� As it was noted there are several points which make the problem more real.

The data that are posted in the operated movement chart has been carefully

collected and summarized.

� The important factors should be assigned accurately to the type of movement

so that adjustment of the numbers in the travel chart could be affected

accordingly.

� The data collection and posting into the operator movement chart is the most

important step before starting the analysis, because the techniques of

evaluation of layouts depends on the accuracy of the operator movement with

keeping the restrictions and assumptions in the mind.

� we can find the effectiveness of the existing layout. From the data collected

using the methodology the existing layout of the rear axle assembly was doing

good in terms of productivity and ergonomically. Now the existing layout they

were achieving the peak of the desired production level in the rear axle

assembly.

Recommedations

� For the main assembly line of tractor they can adopt the robotic technology.

� By adopting the robotic technology they can reduce the human error and can

achieve the high precision.

� With the help of robotic technology they can reduce the takt timeand the

production volume can be increased.

Bibliography


Bibliography

1. Dr.M.Khoshnevisan Francis, “Facility layout and location: An analytical

approach”, Prentice Hall, 2/E, Engle wood cliffs, NJ, 1993.

2. Shikdar A. Al-Hadhrami M., (2007) “Smart workstation design : an ergonomics

and methods engineering approach” International Journal of Industrial and

System Engineering.

3. Dr.V.Jayakumar, “Process planning and cost estimation”, Lakshmi

Publications, OMAN, 2011.

4. G.Sundaraja, Improving productivity of manufacturing using lean concepts,

International Journal of Lean Thinking.

project report tafe final

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