welcome to bosch presentation · project overview productivity improvement in crp housing define...

Welcome to

BOSCH Presentation 1

Team Members : Product Development - Ms. Akansha Chauhan

Process Development - Mr. Naveen Reddy

Manufacturing - Mr. Mohan K V

Engineering - Mr. Gopinath/Mr. Sunil Kumar

Quality - Mr. John Victor

Strategic Partner - Mr. Ramsharan

Profile

Innovative approach using mould flow analysis for productivity improvement

In Common Rail Fuel Injection Pump Housings

Team Leader : Mr. Palanivel V

Video

BidP_Final.mp4

Products at Bidadi Plant

Inline Pumps Single cylinder Pumps Common Rail Pumps

Common Rail Fuel Injection Pumps

Passenger Cars

Light Commercial Vehicles

Project Overview

ControlImproveAnalyzeMeasureDefine

Productivity Improvement in CRP Housing

MAT cost reduction 7.45 MINR

Tool cost reduction 2.70 MINR

Output Increase 6795 Housings

Total cost savings 16.75 MINR

Challenges:

Pilot Batch manufacturing

“Q” Validation and approval

More material machined in

radial machining (OP20) on G320.

Generating high axial load to remove more

material stock

Vital cause for down time - Frequent alarm in

“A” Axis clamping tolerance

Leads to reduced output/high tool cost

Output Increase by 10%

MAE availability increase by 7%

Core hole in casting stage

Material weight reduction by 15%

Pre SC drill elimination in OP20

Initial Situation Manufacturing Feasibility : Core hole in casting stage

Target State Benefits & challenges Time Line

Functional Analysis

T9033 + T9435

Dia 20/21.5 drill

Phase 1

Phase 2

Phase 3

Pattern Ram/Swing check

Simulation check

Mould Flow AnalysisStep 2

Step 1 Centre axis offset by 1.5 mm

After Core longitudinal shift

(Import substitution avoidance 6.60 Mio INR)

(Recurring)

Start : 20.03.2017

Pilot Batch : 12.08.2017

‘Q” Validation : 03.09.2017

Bulk Trial : 21.11.2017

Approval &

Implementation : 14.01.2018

A B

A B

Housing Manufacturing Process Flow

Axial

Machining

Radial

Machining

Robotic

DeburringPre cleaning

Thermal

Deburring

Final

cleaning

Endoscopic

Inspection

Visual

Inspection

Finished Housing

Casting

High Speed HMC

Twin Spindle

17 Axes machine

90 bar coolant pressure

Modular Machining


5

Video


CP4 Gehäuse Fertigung.wmv

6


Cycle

Tim

e [

s]

Problem :

Delivery Takt > Customer Takt

Customer Takt = 39.5 secs

Delivery Takt = 44.8 secs

Line Takt = 39 secs


Need for Improvement

Technical Loss OEE trend chart

High Technical Loss - Avg. 10%

Impact on Customer fulfilment


Financial Impact through imports

to fulfil customer order

CPC Increase by 484 INR/pc

Jan'17 Feb'17 Mar'17 Apr'17 May'17 Jun'17 Jul'17 Aug'17 Sep'17 Oct'17 Nov'17 Dec'17

Cost 0.19 0.11 0.50 0.68 0.55 0.87 1.05 1.43 1.37 1.38 0.83 1.26

-

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

Mio

IN

r

Import Cost


Problem Definition

Machine frequent stoppage (“Alarm in G-320 m/c - “A -Axis clamping angle tolerance (±10˝) exceed”)

Higher Axial load during Ø20.0 cylinder bore pre drilling

Higher Stock removal in high speed machining centre

Impact on Cycle time


220 G

ram

s

Axes Load chart – Pearl softwareHousing– Ø20.0 Pre DrillAlarm History

Kg

A-Axis

clamping

angle >10˝


Problem Definition

Time study check sheetHourly monitoring chart

Operation Element Time Radial Machining-I

Running Quality Level


PEARL Software

Video


ViCTA Analysis

9033

Data Collection

ViCTA_CB28_ball pressing_Part A_315 hole__19.11.2018_V2.xls

48

33

2928

2324

2221

1918 18

17

1413

12 1211

10 10 109 9 9 9 9

87 7 7

6 6 6 6 6 6 6

0

20

40

60

80

100

120

0

10

20

30

40

50

60

Ø2

0 P

re d

rill

Form

Sin

ker

Mill

ing

Cu

tter

Form

dri

ll

End

Mill

dri

ll

Tap

Twis

t D

rill

Tap

Dri

ll

Pre

Dri

ll

Twis

t d

rill

Gu

n d

rill

Bal

l No

se

End

Mill

Tap

End

Mill

Form

dri

ll

Mill

ing

End

Mill

Flat

dri

ll

Dri

ll

Form

dri

ll

Form

dri

ll

Form

dri

ll

Form

dri

ll

Dri

ll

Dri

ll

Form

dri

ll

Form

dri

ll

Form

dri

ll

Form

dri

ll

Tap

dri

ll

Form

dri

ll

Form

dri

ll

Time consumption/tool (sec) Cumulative cycle time %

Radial Machining Elemental Time (ET)


Prioritization of the element times

Vital element times identified

Focussed for root cause analysis

Ø20 Pre drill

Vital ET Tool

Ø21.5 Form

sinker

Tim

e in “

SEC

”


Pareto Analysis

• Ishikawa diagram

Cause validation done for all probable causes

• Through simulation

• At Gemba

High significant causes identified for process optimization


Why? Why? Analysis

Why ? -

Why ? -

Why ? -

Why ? -

Why ? -

Higher cycle time at radial machining

More material stock removal

Casting stage pattern profile

Pattern drawing specification

Conventional casting method

Existing casting design


Root Cause Analysis

Casting180 (MH)

type283 (KD) type

Material Removal rate

Casting 4.70 Kg 3.50 Kg

After OP10 4.24 Kg 3.21 Kg 10%

After OP20 3.40 Kg 2.57 Kg 28%

Expected

MAT

Saving

~220 gms


Casting Weight Proportion


Short Term Intermediate Solution:Pre-determined Tool life - 60%

Impact on Tool cost Tool CPC increase by 3%

Process optimization

• Reduced cutting Speed of Drilling Increased cycle time

Output reduction Cost per part increase

Feasible to implement but not economical

Long Term Permanent Solution:

To introduce A-Axis external pneumatic clamping system

Resistance from OEM

Additional investment (1.30 Mio INR)

Not satisfied with outcome Need Out of box thinking Focus on Ø20.0 Drilling



Development of Solution

Idea : To Introduce shell type core (pre-cast hole) in casting process

Innovative Idea

Finish Hole : Ø21.5

Core Hole: Ø15.0

MMC 3.5 mm on radius

263 Type 180 Type Shell Type core

Casting shell Core


Potential Improvement


Foundry code 6043

Customer name BOSCH

Description PUMP HOUSING

Customer Part

NumberC445014952

Description PUMP HOUSING

Material N2580-1

Report sent date 14.07.2017

SolidificationPattern with core Feed flow check Porosity check Casting

Phase 1: Core with casting simulation check

Phase 2: Pattern Ram and swing check

Phase 3: Mould Flow Analysis

No Disconnection

- No Core breakage

- Orientation checked


No Shrinkage effect in mould flow analysis


Feasibility Study – Mould flow analysis

Axial

Ø40.0mm

Radial

Ø15.0mm

A B

- Offset of 1.50 mm in side cores wrt CH bores in OP20

Challenge : Disproportionate stock at cast hole Improper Tool wear


Stock MinMax Analysis


Functional Robustness Analysis

Centre axisCylinder bore axis

RH side pump offset


Pump centre axis to cylinder axis shift by 1.50 mm


Functional Robustness Analysis

SolidificationPattern with core Feed flow check Porosity check Casting

- Core axis Longitudinal shift by 1.50 mm

- Porosity analysis

- Mould flow analysis

Solution feasible for

manufacturing

Core shift


No Shrinkage effect in mould flow analysis


Feasibility Re Study – After core axis shift

Internal shrinkage

• No shrinkage defect seen

Feed Modulus

• Feeder feed well to casting

Copyright Brakes India Private Limited, Foundry Division

Simulation Report


No disconnection b/w feeder and casting

Core


Solidification

Copyright Brakes India Private Limited, Foundry Division

Simulation Report


Directional solidification towards feeder


Modified casting

After machining

Cylinder head bore in casting and machining are Co-axial

Uniform stock removal

Modified Casting Model Material Stock Distribution

Core Hole

Shell Core


No functional effect with modified casting


Functional Analysis –After core axis shift

Pulsation

Radial Machining

Chemical Composition

Brinell Hardness

Microstructure Analysis

Strength Properties

Magnetic Particle Inspection

Ultrasonic Testing

Dye Penetrant Testing

Validation Result

Chemical Composition

Mechanical Properties:

Hardness

Strength Properties

Microstructure Analysis

Crack Check : Magnetic

Particle Inspection

Internal soundness:

Ultrasonic Testing

Dye Penetrant Testing


Critical parameters found within Specification

Casting Validation


Pulsation Test results

Radial Machining

• Ppermissible (1020 bar) > Pqz (940 bar) (Max. fatigue strength)

• Fatigue strength of machining validated for High Pressure circuit

• High pressure pulsation test Passed


Initial samples machined &

subjected to Part Validation

Machining Validation – High Pressure Pulsation test


Pump label

Endurance test duration : 500hrsInitial visual inspection : OK Functional test : OK Dimensional check : OK Axial play : OKLow pressure leak : No leakage Loosening torque check : OK

PC-PDL test cycle:

Endurance Test Result : Passed

Test

point

Pump

speedCurrent

Rail

pressureFlow rate 0 hrs 500 hrs Remarks

Efficiency (RPM) (A) (bar) (l/h) (l/h) (l/h) Pump

flow rate

is OK2000 1.5 1600 >69 74.53 74.91

Housing bush Flange bush


Product validation – Endurance test


Trial Order

REPORT

Radial machining Project Report



Implementation

PDS

Hole Position

Hole Concentricity

• Critical

characteristic

analysed

through “Q”-

DAS

• Critical

dimensions

Cmk >1.66.

26

Hole Ø21.8


Quality Validation


• Cycle time Before Vs After

39

36

30

35

40

45

Before After

Cycle

Tim

e in s

ecs 280

260

250

255

260

265

270

275

280

285

Before After

INR

1700

1850

1600

1650

1700

1750

1800

1850

1900

Before After

Pcs

• Output per day Before Vs After

Radial machining

8% 7%

4.7

5.2

3

4

5

6

Before After

Pcs/

Manhour

9% 11%


MAT Cost

Productivity


Results

Productivity :

Housing output increased from 1700 to 1850 pcs/day

Capacity increased by 9%.P

Quality:

CmK achieved >1.66 for all critical Dimensions

FPY Improved from 98% to 99% through minimized tool breakage .Q

Innovation:

Innovative core design

Tool change cycle with macro program.

Cost :

MAT Cost saving through core hole 7.45 Mio INR

Cost saving through Import avoidance 9.30 Mio INR

Total cost saving through productivity improvement 16.75 Mio INR-Recurring

16.75 Mio INR


C

I

Dia 21.5 Form drill

Benefits


OEE improvement through technical loss reduction by 6%

Avoiding external clamping system 1.3 MINR

One magazine pocket available for process optimization

Employee fatigue reduction Morale improvement

Environment Reduce Iron ore consumption by 105 Tonne/Yr (7%)

Customer delivery fulfilment Output increase by 150 Housing/day

Vision-2021 KPR

Investment

DescriptionCash Out Flow

(Mio INR)

Sample Tooling and Housings 0.8

Series Tooling – Pattern and Core box 2.4

Project

Investment

3.2 Mio INR



Benefits

Inta

ngib

le B

ene

fits



• Before • After

Technical loss reduced by ~5% & OEE improved to 85%

OEE Trend


0

2

4

6

8

10

12

14

Mar April May Jun July Aug Sept Oct Nov Dec Jan Feb Mar Apr

Pilot LotProject Identification Bulk Trials Implementation

• High Technical Losses

• Focus on axial Load reduction

• Machining stock optimization

• Casting design Improvement

• Core hole introduced

in Castings

• Process optimization

(∅20 pre drill

elimination)

• PPAP

sample

trials

• Key parameters monitoring

(Spindle load, tool life)

• Sustenance of improvement

• Stabilization of OEEGO

ALS

Target Limit

Improvement

confirmed

Target condition is reached and

stability has been confirmed

Definition of time period

for the confirmation of

stability of standard

Positive trend

Technical Losses Trend




• Before • After

Cycle time & delivery takt improved by 8%

Takt Time Chart

Improvement deployed to CP1H ,CB18 & CB28 Common rail pump housing.

Actions shared with International Production Network (IPN)

CP1H Housing

CB18 Housing

Best Innovation award -2017


Horizontal Deployment

THANK YOU


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