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TRANSCRIPT
UNDER THE GUIDANCE-NAME-SC NARULA
SUBMITTED BY:-NAME-DEVILAL SHARMAROLL.NO.- 10/FET/AU(S)/2009
CONTENTS
1) Acknowledgement2) Introduction3) Training detail4) Project detail
ACKNOWLEDGEMENTI take this opportunity to express my profound gratitude to express my profound gratitude & deep regards to my guide Mr.S.C Narula for his exemplary guidance ,monitoring & constant encouragement throughout this training period.The blessing ,help & guidance given by him time to time shall carry me a long way in the journey of life on which I am about to embark.
I also take this opportunity to express a deep sense of gratitude to Mr.N.K saxena (sr.manager production,Fabrication,JBMI) for his cordial support,valuable information & guidance,which helped me in completing this task through various stages.
I am obliged to staff members of JBMI company for the valuable information provided by them in their respective fields.I am greatful for their cooperation during the period of my assignment.
INTRODUCTION
About JBM INDUSTRIES•JBM group has its global presence in automotive,education,engineering services & renewable energy sectors,•Today the company has 33 manufacturing plants,5 engineering & design centres across 19 locations globally.•It has a turnover of USD 1.2 billion.•JBM Group caters to clients in Automobile OEMS like Ashok Leyland,bajaj,Fiat,GM,Hero,Honda,JCB,Mahindra,Maruti suzuki,Renault-Nissan,TATA,Toyota,TVS,VECV,VolksWagon,volvo & many more.•Products-Body Assembly,Body in white,Chasis and suspension system,Die casting,Engineering services,Exhaust systems,Fabrication,LPG &CNG Cylinders,Steel fastener,Skin panels,Steel processing,Tailored Welded Blanks,Tools,Jigs & Fixtures,Tubes & Tubular Manipulations,Welded Assemblies Systems.Wheel assembly.
TRAINING DETAIL
FABRICATION DIVISION
LINE:-1. H/T welding2. D/T welding3. H/T Assembly4. D/T Assembly5. Inner leg6. Outer leg7. S.S Foot 8. Cross box 9. Torsion tube10. Boom11. 2DX line12. Engine mount13. Axle yoke14. Export engine mount.
:- Cylinder formation.:- studied about MIG and TIG welding:- Studied about spm machines.:- Railway doors formation & its Fuel tank formation :- Type of welding done in railway doors.
JCB SECTION
Project NameProject Name:- Reduce In-house
Rework PPM-Outer leg
Outer leg formation
Parts
• U-channel plate• Closing plate• Saddle bracket• Backing plate• Thread bush• Big bush• Reinforcing plate• Small bush• washer
Dimension1) U-channel
Thickness=8mmLength=1233mmBreadth=153mm
2) Closing plateThickness=8mmLength=1233mmBreadth=153mm
3) Thread BushInternal dia=65mm
FLOW CHART
Raw material Raw material
shearingPlasma cutting
Bending Drilling
U-channel plate formed
Chamfering
Both closing plate & u channel plate welded together
Tagging
Welding(line welding on SPM)
2nd layer welding(23*3 Boss,small boss,big
boss,washer welding)
Saddle bracket weldedRNC plate
welded
Final welding
Grinding
Buffing
Punching Dispatch
Part wise contribution in overall PPM
Product Wise Rework PPM (AUG-2013)
Part NameHydraulic
tankOuter leg Diesel tank
Torsion
tubeCross Box S.S foot Inner leg
Total
Produce/R
ework Qty.
Produce
Qty.792 480 784 300 300 1415 1030 5101
Rework
Qty.27 29 21 8 9 7 0 101
PPM 34091 60417 26786 26667 30000 4947 0 19800
Part Name Defects Qty. Contribution in overall PPM
Hydraulic tank 27 5293
Outer leg 29 5685
Diesel tank 21 4117
Torsion tube 8 1568
Cross Box 9 1764
S.S foot 7 1372
Inner leg 0 0
Defects Wise Contribution in Overall PPM P
PM
Defects Name
Defect Qty. PPM
Undercut 12 2352
Overwelding 6 1176
Blow hole 5 980
Welding miss 2 392
Dent 2 392
Uneven welding bead 2 392
2352
1176980
392 392 392
0
500
1000
1500
2000
2500
Undercut Overwelding Blow hole Welding miss Dent Uneven welding bead
Concentration Diagram
Concentration Diagram
Day 1 Day 2
Day 5 Day 6
Day 3
Day 4
Concentration Diagram
Day 7 Day8 Day 9
Day 10
S. No Area
Defects
Welding
undercut
Welding
miss
Bow
holesDent
Over
welding
Uneven
welding
bead
Spatters Total
1 A 2 2
2 B 1 1
3 C 2 2
4 D 4 2 1 7
5 E 12 4 16
6 F
7 G
8 H 2 2
9 I 2 1 3
10 J
11 K
12 L 1 1
Total 16 3 4 2 7 1 1 34
Compilation of Data
Pareto - Zone wise
16
7
32 2 2
1 10 0 0 0
47
68
76
82
88
9497
100 100 100 100 100
0
10
20
30
40
50
60
70
80
90
100
0
5
10
15
20
25
30
E D I A C H B L F G J K
Pareto - Operator wise
98
3
1 1
41
77
9195
100
0
10
20
30
40
50
60
70
80
90
100
0
5
10
15
20
Nirmal Roshan Sunil Rajender Ranjeet
Area Identified On The Basis Of Pareto
Undercut In Area E& D (Thread Boss &Reinforcement plate)
Action Plan For Problem
S. No Cause Activity Responsibility Status
1Welding voltage too high.
Training to be impart to
operator through one
point lesson.
Trainer Completed
S.O.P to be display. Trainer Completed
Improvement To Control Undercut In Thread
Boss.
One point lesson not displayed. Now training given to operator through one point lesson.
Before After
S.O.P not displayed. Now training given to operator through S.O.P.
Before After
Improvement To Control Undercut In Thread
Boss.
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
14.02.13 15.02.13 16.02.13 18.02.13 19.02.13 20.02.13
Result Monitoring
679566 566
340226 226
113
0
500
1000
1500
2000
25002352
1176
980
392 392 392
0
500
1000
1500
2000
2500
Before After
Result