Gear Box Productivity 30 To 33 Nos Per Hour.pdf

PDC DEEP DIVE – PRODUCTIVITY IMPROVEMENT

Shots per hour

Part Name : GEAR BOX HOUSING 40 35 30 25 20 15 10 5 0

1

30

Baseline

Optimize Machine Parameter

1

3

36

1

Robot sprayer Internal and Shots to be As per NADCA Optimization External spray increased to optimization meet NADCA

33

Achieved Output

Ideas 1. To increase the effectiveness of heat transfer at bottom/side core by modifying the internal cooling design in CFT.

2.Reduce heat check mark in high temp. spots by introducing loose pieces wherever required. NADCA STANDARD.  NADCA Cycle time =26.90 + (0.0365 * Machine Locking Force in Tons) =26.90+(0.0365*2000) =100 sec 36 shots/Hour  Considering 90 % Of NADCA Cycle time we should achieve 33 shots/Hour  We Planning to achieve Cycle time by New Innovation and ideas In Future

Inference : We have improved 10 %from the baseline.

Kaizen No. & Date : 19.02.2019

KAIZEN IDEA - SHEET Category

P

Q

C

D

Kaizen Theme:

Kaizen Start : 23.01.2019

To Improve Productivty in Gear Box housing

Kaizen Finish : 19.02.2019

Problem / Present Status 1) Cycle time of auto sprayer is around 55sec.

Department

S

M

: HPDC

Team Members M.Gopi, Sivanesan, Raymond furdato, Srinath, Praveen, Aravind, Dharani Babu

Countermeasure/ After improvements 1. Machine Parameter Optimised.

Benefits 1) Productivity improved 30 nos to 33 nos.

2. Auto spray lubrication on both the dies at same time and program optimised according to the requirements.

2) Cycle time reduced 120 sec to 109 sec.

3. External Spray position modified for effectivness.

4) Auto spray and Die life increased

3) Auto spray is given in required area.

4. Die temp. attained to 180±30°c rapidly, by this activity at after spray condition.

Sep'18 40

Before

After

* This Kaizen is

30

30

Reversible If reversible updated in Process sheet

20 10

Ir-reversible

JH Check sheet

0

shots/Hour

Timer cooling given at 7 different spots of the die at less volume and pressure

Analysis Auto Sprayer Cycle time high

3) Ouptut per hour increased from 30 to 33 No's.

shots/Hour 32

Scope & Plan for Horizontal Deployment: S.No.

Item

Target Date

Responsibility

Status

1

Ladder Frame

March '19

M.Gopi

on Going

33

34

30

IF IT IS POKA YOKE WHAT TYPE & FUNCTION

30

Use forced extermal cooling at specific spots

QM check sheet

1) Less No.of interpolations in Auto sprayer.

Before spray temperature of the die is high Differnence of Die temp. at specific spots

Eqpt/ fixture Drawing

Results 2.Cycle time reduction from 55sec to 48sec.

More spray required to cool and lubricate the die

PM Check sheet

Timer cooling given at 5 locations of Die at High pressure and volume.

28 Sep'18

Feb'19

1. To increase the effectiveness of heat transfer at bottom/side core by modifying the New Ideas to reach 100 internal cooling design in CFT. % Nadca Cycle time 2.Reduce heat check mark in high temp. spots by introducing loose pieces wherever required.

Prevention

Shutdown

Detection

Warning Control

1