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SYNOPSIS

The purpose of this study is to analyse the work measurement in garment export industry of Tirupur. Work Measurement :It is the technique of establishing the proper time required in performing a job or work. Since it is concerned with measurement of time, it is also called time study. The time arrived for an activity through time study is called standard time. Time standards used under Standard Cost System reflect the amount of time it should take an average worker to do a job under typical operating conditions. The standards include expected activity time plus allowances for probable delays. Objectives of Work Measurement :To analyse the activities or job with the view to reduce or eliminate some unnecessary or repetitive activities so that the human effort is minimized. To compare the time of performance by alternative methods. To standardize the efficient method of performing a job. To standardize the conditions for efficient performance. To determine optimum number of men and machines. To determine man and machines ratio for effective and efficient utilization of both. To provide information and basis for production, planning and scheduling. To balance the work of all workers working in a group.

To determine the normal time for a job, to be used as a basis for wage incentive schemes for the workers. Hence a good work measurement system has many benefits. It helps to reduce labor costs, increase productivity, and improve supervision, planning, scheduling, performance appraisal, and decision making. Study in Tirupur :Tirupur is the knitwear capital of India and it contributes to a huge amount of foreign exchange. It has spurred up the textile industry in India for the past three decades. In 2007, an export worth Rs.12, 000 crores and domestic sales of Rs.14,000 crores was achieved by Tirupur. Nearly every International brand in the world has a strong production share from Tirupur. Knitwear industry in Tirupur is providing employment to over five lakh people. 56% of Indias total knitwear exports come from Tirupur. Hence a study of work measurement in export oriented Tirupur knitwear industry expected to reveal useful and interesting application results of work measurement.

CONTENTS TITLE CHAPTER 1 ABSTRACT INTRODUCTION COMPANY PROFILE OBJECTIVES OF THE STUDY RESEARCH METHODOLOGY LIMITATIONS CHAPTER 2 DATA ANALYSIS CHAPTER 3 FINDINGS SUGGESTION CONCLUSION BIBLIOGRAPHY PAGE.NO

LIST OF TABLES S.No 1 2 3 4 5 6 7 8 TABLES SPECIFICATION OF THE MACHINE HAAS MILL G-CODES HAAS MILL M-CODES BEFORE MODIFICATION MASTER LIST OF TOOLS MASTER LIST STANDARDIZED TOOLINGS WITH DIA X & LENGTH L MASTER TOOLINGTS WITH L & X FOR VF-5 AFTER MODIFICATION PAGE No.

INTRODUCTION INTRODUCTION: Work measurement is the application of techniques designed to establish the time for a qualified worker to carry out specified jobs at a defined level of performance. We have seen how total time to manufacture a product is increased by: adding undesirable features to product, bad operation of the processes, and ineffective time added because of worker and management. All this leads to decreased productivity. Method study is one of principal techniques by which work content in the product manufacture or process could be decreased. It is a systematic method of investigating and critically examining the existing methods, to develop the improved ones. Method study is, then, a technique to reduce the work content mainly by eliminating unnecessary movements by workers and/or materials and/or equipments. However, even after that, there could be substantial unnecessary time taken for the process because of lack of management control and/or inaction of worker. Work measurement (WM) is concerned with investigating, reducing and eliminating ineffective time, whatever may be the cause. WM is the means of measuring the time taken in the performance of an operation or series of operations in such a way that the ineffective time is shown up and can be separated out. In practice, proving existence of the ineffective time is the most difficult task. After existence is proved, nature and extent is easy to see WM is also used to set standard times to carry out the work, so that any ineffective time is not included later. Any addition the standard time would show up as excess time and thus can be brought to attention. Since, standard times are set for all the activities through WM, it has earned bad reputation amongst workers. Major reason for that has been the initial focus of the WM methods, which essentially targeted only the worker controllable ineffective times. Management controllable ineffective times were ignored traditionally.

Two Critical Issues in Work Study: Method study should precede the work measurement, always. Elimination of management controllable ineffective time should precede the elimination of the ineffective time within the control of the workers. Manufactured goods are typically divided into two cases: Consumer goods Producer goods The above goods are obtained from the raw material in different stage through the sequence of process. Thus by converting materials from one form to the other adds values to them. The more efficiently materials can be produced and converted into desired products that functions with the prescribed quality, the greater will be companys productivity and better will be the standard of living of the employees. PRODUCTIVITY: Productivity is simply a measure of the ratio between the output of the process and the input of the resources needed for it. It is usually expressed as output divided by input. CHANGING WORLD COMPETITION: During the earlier stage the competition among the manufactures and the demand from the customers, both internal and external, and the technology available are less. Due to this the production is limited and thus cannot produce satisfied customers. But in the modern world due to the increase in demand among the customers leads to Worldwide or global competition Advanced technology New manufacturing systems, structures, strategies and management These approaches increase the productivity without sacrificing the quality of the product, thereby ending in customer satisfaction.

METHODS TO INCREASE PRODUCTIVITY: The ultimate aim of increasing productivity is to increase the lot size of the product thereby coping up with the growing demand. But this should not be done compromising the quality. The productivity of the product can be enhanced by acting upon some of the following: Cycle time of the product Setup time of the product Down time of the product Manufacturing methods KEY ELEMENTS AND THEIR DEFINITION Key elements are the elements which are directly or indirectly involved in rate of production of goods. They are, Process Planning Setup Time Process time Feed Speed Material removal rate Depth of cut Machinability Process Planning It is the determination of sequence of process to convert the product from raw material to the finished state in an effective and efficient manner. It depends on the nature of the company, product, source available etc., Setup Time Setup time is something Shorter set-ups enable you to schedule smaller batches. Smaller batches reduce your inventory both in WIP and finished goods. Batch sizes are decreasing and the number of set-ups is increasing because customers the world over, in all industries, are demanding shorter lead times, more variety and

increased customization. The setup time can be considered in the following ways depends on the industrial production setups.

1. Fixture setup time 2. Tools setup time 3. Change over setup time Since our ways of production is varietys of jobs are more, we prefer the Tools setup time seems to be major areas need to be focused and taken it for this project analysis. Depth of cut (d) It is the amount of material removed per cut or per revolution of the job. Its unit is mm/cut. Its depends on tool and job material, Machinability, finishing requirements. When depth of cut increases, MRR increases and hence the productivity. Machinability It is defined as the ease with which the metal can be machined. It may be also defined by the relative cutting speed for a given tool life of the tool cutting some material , compared to a standard material cut with the same tool material.

MATERIAL SELECTION INTRODUCTION: The history of the man has been linked with his ability to work with materials, beginning with the Stone Age and ranging through the eras of copper and bronze, the Iron Age, and recently the age of steel, with our sophisticated ferrous and non-ferrous materials. As civilization develop, the range of engineering materials expanded. The success or failure of many engineering activities depends on the selection of engineering materials whose properties match the specific requirements of the application. When selecting a material, a primary concern of engineers is to assure that the material properties are consistent with the operating conditions of the component. The various requirements of each part or component are first estimated or determined. These may include mechanical characteristics (strength, rigidity, resistance to fracture, or the ability to withstand vibrations or impacts), physical characteristics ( weight, electrical properties, or appearance), and features relating to the service environment ( ability to operate under extremes of temperature or resist corrosion). The selection of appropriate engineering material is often based on the tabulated or recorded results of standardized tests. Although this information is usually readily available, it is important that it be used properly. The engineer must know which limitations should be placed on their use. COMPONENT MATERIAL: The objective of any practical work dealing with the manufacture of products is to produce components that will adequately perform their designated tasks. Meeting this objective implies the manufacture of components from selected engineering materials with the required geometrical shapes and precision and with companion material structures that are optimized for the service environment that the component must withstand. The ideal design is one that will just meet all requirements. Anything better tends to waste money and material. Anything worse and we have failed to manufacture an adequate product.

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PROPERTIES OF MATERIALS: The material which is used to manufacture the product (sub frame) is Grey Cast Iron grade 25. A fractured surface takes on a gray appearance due to graphite flakes and hence called gray cast irons. The graphite exists in the form of flakes which are normally surrounded by an ferrite or pearlite matrix. COMPOSITION AND PROPERTIES Grade: SAE G25 Composition: Carbon 3.3% Silicon 2.2% Other 0.7%Mn Properties: Applications: Tensile strength 173MPa Engine blocks, brake drums

CHARACTERISTICS OF CAST IRON: Strength and ductility are much higher under compressive loads. They are very effective in damping vibrational energy. Gray irons exhibit a high resistance to wear. They have a high fluidity at casting temperature which permits casting pieces having intricate shapes and also casting shrinkage is low. Gray cast irons are the least expensive of all metallic materials. TOOL MATERIAL: Success in metal cutting depends on selection of the proper cutting tool (material and geometry) for a given work material. A wide range cutting tool materials is available with a variety of properties, performance capabilities, and cost. These include high carbon steels and low/medium alloy steels, high-speed steels, cast cobalt alloys, cemented carbides, cast carbides, coated carbides, coated high-speed steels, ceramics, cermets, sialons, sintered polycrystalline cubic boron nitrate, sintered polycrystalline diamond.

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TOOL CHARACTERISITICS: The cutting tool is subjected to severe conditions. Tool temperatures of 1000 degree Celsius, severe friction, and high local stresses require that the tool have these characteristics. High hardness Resistance to abrasion, wear, chipping of the cutting edge High toughness High hot hardness Strength to resist bulk deformation Good chemical stability Adequate thermal properties High elastic modulus Consistent tool life Correct geometry and surface finish. TOOL SELECTION: In nearly all machining operations, cutting speed and feed are limited by the capability of the tool material. Speeds and feeds must be kept low enough to provide for an acceptable tool life. If not, the time lost changing tools may outweigh the productivity gains from increased cutting speed. Coated and uncoated high-speed steels and carbides are currently the most extensively used tool materials. Coated tools cost only about 15 to 20% more than uncoated tools, so even a modest improvement in performance can justify the added cost. About 15 to 20% of all tool steels are coated, mostly by the physical vapor deposition (PDV) process.

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COMPANY PROFILE AB Exports The company AB Exports is situated in Tirupur. The company has a strong background from textiles manufacturing textile machineries like dyeing, printing, and finishing machineries. The work study was conducted in this sections. They provide textile machineries for different customers all over India and abroad. The company is located in the heart of Tirupur, The city Tirupur is otherwise known for knitwear capital of India and it contributes to a huge amount of foreign exchange. It has spurred up the textile industry in India for the past three decades. In 2007, an export worth Rs.12, 000 crores and domestic sales of Rs.14,000 crores was achieved by Tirupur. Nearly every International brand in the world has a strong production share from Tirupur. Knitwear industry in Tirupur is providing employment to over five lakh people. 56% of Indias total knitwear exports come from Tirupur. Hence a study of work measurement in export oriented Tirupur knitwear industry expected to reveal useful and interesting application results of work measurement in tool setting by standardizing tools. Company has highly sophisticated machineries for dyeing, printing and finishing machineries like compacting, Mercerizing etc., The Company has grown to become the world's largest exporters of knitted garments and one of the leading exporters. With a global network the Company an outstanding reputation from customers worldwide. HEAD OFFICE Tirupur DIRECTORS: Chairman and representative Director : Mr. Ashok Kumar President and representative Director : Mr. Praveen Executive vice president and representative Director : Kiran Mohan
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MANAGING DIRECTORS: Shanmugavel Sundaresan EXPANDING CUSTOMER SATISFACTION ACTIVITIE: The ultimate goal of the company activities world wide is to satisfy the customers so that they will continue to come back for more textile quality products. To ensure this, we have implemented a vigorous customer satisfaction program covering all of our sales companies. This program aims to enhance customer satisfaction by strengthening our attention to detail in product and service activities through all stages of sales, delivery, and after sales service.

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OBJECTIVES OF THE STUDY Primary objective To Study the work measurement in material processing export industry (AB EXPORTS) in Tirupur Secondary Objectives 1. To know the different methods used in material processing 2. 3. To know the performance after implementing the methods To know the employees expectation towards the the processing

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RESEARCH METHODOLOGY RESEARCH PROCESS 1. 2. 3. 4. 5. 6. 7. Selecting the process which is to be analyzed. Recording all the events. To record sophisticated instruments should be used. Recorded events are analyzed. Using all relevant factors the suitable method is to be formed The selected methods time should be measured. Also the time to complete the process should be measured. New method is to be developed. And time should be Determined. This method should be managed by applying proper control Process.

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RESEARCH METHODOLOGY Research Methodology is a way to systematically solve the research problem. It may be understood as a science of studying how research is done scientifically and the steps that are generally adopted by a researcher in studying his research problem along with the logic behind them. Research methodology results in using research methods through which solutions are arrived for the problem of research.

RESEARCH DESIGN This research is based on DESCRIPTIVE method. DESCRIPTIVE RESEARCH studies are those studies, which are concerned with describing the characteristics of a particular individual or of a group. Consumer profile studies, market potential studies, product usage studies, attitude surveys, sales analysis, media research and priced surveys are the examples of descriptive research. In descriptive research, the researcher must be able to define clearly, what he wants to Measure and must find adequate methods for measuring it along with a clear cut definition of Population he wants to study. POPULATION Population here includes all the export industries of Tirupur District. SAMPLE Sample means the particular items which are selected from the population.

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SAMPLING DESIGN Sampling design means the process of selecting the samples from the population. Convenience sampling design is used for the study.

SAMPLE SIZE The sample size taken for the study is 100 respondents. They have been selected from A.B.Exports, Tirupur.

SOURCES OF DATA Both primary and secondary data will be collected. Primary Data Primary data will be collected by orderly designed questionnaire from the respondent. The primary data is playing vital role in solving the research problem. Secondary Data Secondary data on the product profile will be collected from the Websites and from the books.

DATA PROCESSING The collected data will be edited, coded and tabulated for the purpose of using statistical tools.

STATISTICAL TOOLS Simple percentage analysis and Chi-square methods are used for the analysis of data that is collected for the research work. Percentage is often used in data presentation for the simplified numbers. Use of percentage the data had reduced in the standard form with base equal to which facilitate relative comparison. Tabulation Method Formula for simple percentage analysis: Number of respondents for the particular factor
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--------------------------------------------------------------Total number of respondents

X 100

ANALYSIS & INTERPRETATION The analyzed results will be interpreted and findings will be noted. Viable measures and suitable suggestions will be recommended.

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LIMITATIONS This setting up time and standard time is only applicable for that particular tools only. This study is not applicable for other tools.

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ANALYSIS AND INTERPRETATION TOOL DIAGRAM AND ITS SPECIFICATION: SPECIFICATION OF THE TOOLS Sl. No Hole size (mm) Tool no and its Description (Material and Grade) Cutting Speed (in m/min) 40 50 25 25 30 40 10 10 10 40 60 80 60 40 50 100 80 80 Speed (rpm) Feed (mm/min)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

TCN000000006570, Solid carbide, GCI 25 TCN000000006560, Solid carbide, GCI 25 TCN000000004660, Solid carbide, GCI 25 5 Drill TCN000000004660, Solid Extra Long carbide, GCI 25 6.8 Drill TCN000000001810, Solid carbide, GCI 25 11.8 Drill TCN000000001820, Solid carbide, GCI 25 M6 Tap TCN000000001600, Tin Coated Spiral flute tap M6 Tap TCN000000001600, Tin Extra Long Coated Spiral flute tap M8 Tap TCN000000001610, Tin Coated Spiral flute tap 7.8 Drill TCN000000006820, Carbide, GCI 25 13 Drill TCN000000007110, Carbide, GCI 25 12 End TCN000000007340, Tialn mill Long Coated, GCI 25 8 End TCN000000007350, Tialn mill Coated, GCI 25 8 H7 TCN000000005020, Carbide Reamer reamer 12 H7 TCN000000006250, Carbide Reamer reamer 16 End TCN000000005050, Insert mill cutter type, GCI 25 19.5 U TCN000000000080, Insert Drill type, GCI 25 23 U TCN000000000100, Insert Drill type, GCI 25

8 Spot Drill 12 Spot Drill 5 Drill

1500 1400 1500 1500 1400 1100 250 250 375 1600 1500 2000 1800 1000 1000 1200 1300 1100

60 60 60 60 80 85 250 250 300 80 75 800 600 50 150 1200 105 88

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19. 20. 21. 22.

41.5 RB bar 35.5 & 42 FB 60 & 65.5 H7 FB bar 50 End & Face mill cutter

TCN000000000590, Insert type, GCI 25 TCN000000001190, Insert type, GCI 25 TCN000000004510, Insert type, GCI 25 TCN000000001320, Insert type, GCI 25

60 100 80 60

600 750 550 1200

50 60 45 300

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MACHINING PROCESSES: Machining is the process of removing unwanted material from a work piece in the form of chips. If the work piece is a metal, the process is often called metal cutting or metal removal. The vast majority of manufactured products require machining at some stage in their production, ranging from relatively rough or non precision work to high precision work or high-quality finishes. So over the past 80 years, the process has been the object of considerable research of experimentation that have led to improved understanding of the nature of both the process itself and the surfaces produced by it. Thus machining undoubtedly is the most important of the basic manufacturing process. There are seven basic chip formation processes: Shaping, turning, milling, drilling, sawing, broaching and grinding. The machining processes involved in manufacturing the sub frame are, Casting Rough Machining Drilling Boring Reaming Tapping Chamfering

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SPECIFICATIONS OF THE MACHINE: Machine Name : Haas VF-2 S. No Description 1 X axis Y axis Z axis 2 Length X axis Length Y axis Max weight on table 3 4 5 6 Machine Make : USA, 2008 Specification Unit TRAVEL 762 mm 406 mm 508 mm TABLE 914 mm 457 mm 1360 kg SPINDLE Taper size # 40 BT Speed 7500 rpm Max torque NM @ rpm 102 Nm @ 1400 Nm/rpm FEED RATE Max rapid - X Axis 25.4 m/min Max Rapid - Y& Z Axis 25.4 m/min TOOL CHANGER Capacity 24+1 NOS Type SMTC CT ACCURACY Positioning 0.005 Mm Repeatability 0.002 Mm

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HAAS MILL G-CODES G00 G01 G02 G03 G04 G09 G10 G12 G13 G17 G18 G19 G20 G21 G28 G29 G60 G61 G64 G65 G68 G69 G70 G71 G72 G73 G74 G76 G77 G80 G81 G82 G83 G84 G110G129 G136 G141 G150 G154 G174 Rapid Positioning Motion Linear Interpolation Motion Circular Interpolation CW Circular Interpolation CCW Dwell Exact Stop, Non-Modal Programmable Offset Setting CW Circular pocket milling CCW Circular pocket milling Circular motion XY Circular motion YZ Circular motion XZ Verify inch coordinate psng Verify metric coordinate psng M/C 0 return thru reference pt Move to location thru G28 Unidirectional positioning Exact stop, modal Exact stop cancel Macro subroutine call Rotation Rotation G68 cancel Bolt hole circle Bolt hole arc Bolt hole along an angle HS Peck drilling canned cycle Reverse tapping caned cycle Fine boring canned cycle Back boring canned cycle Cancel canned cycle Drill canned cycle Counter bore canned cycle Peck drill hole canned cycle Tapping canned cycle Offset positioning coordinate Automatic offset center measure 3D+ cutter compensation General pocket milling routine Select Work offset positioning coordinate Non vertical rigid tapping CW G31 G35 G36 G37 G40 G41 G42 G43 G44 G47 G49 G50 G51 G52 G53 G54-59 G85 G86 G87 G88 G89 G90 G91 G92 G93 G94 G95 G98 G99 G100 G101 G102 G103 G107 G164 G165 G166 G167 G153 G155 Feed until skip function Automatic tool dia measure Work offset measurement Auto tool length measure Cutter comp cancel Cutter comp left Cutter comp right Tool length comp + Tool length comp Target engraving Tool length comp cancel Scaling G51 cancel Scaling Global coordinate offset M/C positioning coordinate Work offset coordinate Bore in & out canned cycle Bore in stop canned cycle Bore in manual out canned Bore in dwell canned cycle Bore in dwell & out canned Absolute position command Incremental positioning Global coordinate system Inverse time feed mode ON Feed per Minute Feed per revolution Canned cycle initial return Canned cycle, plane return Mirror image G101 cancel Mirror image Programmable output Limit block look ahead Cylindrical Mapping 5-Axis Tap canned cycle 5-Axis Bore in & out cycle 5-Axis Bore in stop cycle 5-Axis Bore in dwell cycle 5-Axis HSP Drill 5-Axis Rvrse tap canned cycle

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G184 G187 G188

Non vertical rigid tapping CCW G161 Accuracy control high speed G162 machining Get program from pallet schedule G163 table

5-Axis Drill canned cycle 5-Axis Spot drill 5-Axis peck drill canned cycle

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HAAS MILL M-CODES M00 M01 M03 M04 M05 M06 M08 M09 M10 M11 M12 M13 M16 M17 M18 M19 M21-M28 M79 M80 M81 M82 M83 M84 M86 M88 M89 M93 M94 Program stop Optional Program stop Spindle on CW Spindle on CCW Spindle stop Tool change Coolant ON Coolant OFF 4th Axis brake ON 4th Axis brake release 5th Axis brake ON 5th Axis brake release Tool change Unclamp APC and open door Clamp APC and close door Orient Spindle Optional M code interface Alarm if skip not found Automatic door open Automatic door close Tool unclamp Auto air jet ON Auto air jet OFF Tool clamp Coolant through spindle ON Coolant through spindle OFF Axis position capture start Axis position capture stop M31 M33 M34 M35 M36 M39 M41 M42 M50 M51-58 M59 M61-68 M69 M75 M76 M77 M78 M97 M98 M99 M109 M95 M96 Chip auger forward Chip auger stop Coolant spigot down Coolant spigot position up Pallet part ready Rotate tool turret Spindle low gear override Spindle high gear override Execute pallet change Optional user M code Output relay set Optional user M code Output relay clear Set reference point Control display inactive Control display active Alarm if skip command found Local sub program call Sub program call Sub program return Interactive user input Sleep mode Jump if no signal

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ON ANALYSIS THE FOLLOWING ARE BEING EFFECTED Master list of standard toolings have been listed. Master list of tool operation sheet has been prepared for the standard components and list in through tos. Toolings are being numbered and placed in a assembled condition in a separate racks. All the standardized toolings have freezed with the dia as x and length as l. Before modification the setup time is anaylsed. After modificastion the setupo time is anaylsed.

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MASTER LIST OF TOOLS S.NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 DOC.NO CNC/ PRO/ D / 01/ 001 CNC/PRO/D / 01/ 002 CNC/PRO/D / 01/ 003 CNC/PRO/D / 01/ 004 CNC/PRO/D / 01/ 005 CNC/PRO/D / 01/ 006 CNC/PRO/D / 01/ 007 CNC/PRO/D / 01/ 008 CNC/PRO/D / 01/ 009 CNC/PRO/D / 01/ 010 CNC/PRO/D / 01/ 011 CNC/PRO/D / 01/ 012 CNC/PRO/D / 01/ 013 CNC/PRO/D / 01/ 014 APPLICATION CODE MASTER TOOL LIST APPLICATION MASTER TOOL LIST OPERATION 10 10 10 10 10 10 10 10 10 10 10 10 10 REVISION. NO 0 0 0 0 0 0 0 0 0 0 0 0 0 0

MFL01B00B020010 COLT MAIN FRAME (R) MFL01B00B020020 MPT02B00B020030 MPT02B00B020040 MPT02B00B020060 MPT02B00B020050 MKC02B00B020150 MKC02B00B020030 MKN01B00R010010 & MKN01B00R010020 MKN01B00B020020 MKN01B00B020010 MPT02B00B020010 MPT02B00B020020 COLT MAIN FRAME (L) COLOUR HEAD - I (L) COLOUR HEAD - I (R) COLOUR HEAD - II (R) COLOUR HEAD - II (L) KNIGHT COLOUR HEAD - II (R) KNIGHT COLOUR HEAD - II (L) FEEDER FRAME ( L & R) KNIGHT MAIN FRAME (L) KNIGHT MAIN FRAME (R) PTP MAIN FRAME 7000 (L) PTP MAIN FRAME 7000 (R)
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15 16 17 18 19 20

CNC/PRO/D / 01/ 015 CNC/PRO/D / 01/ 016 CNC/PRO/D / 01/ 017 CNC/PRO/D / 01/ 018 CNC/PRO/D / 01/ 019 CNC/PRO/D / 01/ 020

MPT02B00B040010 MPT02B00B040020 MPS01B00B020020 MPS01B00B020010 MRE01B00B020020 MRE01B00B020010

PTP MAIN FRAME 10000 (L) PTP MAIN FRAME 10000 (R) PTP SINGLE MAIN FRAME PTP SINGLE MAIN FRAME(R) REACKONER MAIN FRAME(L) REACKONER MAIN FRAME (R)

10 10 10 10 10 10

0 0 0 0 0 0

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BEFORE MODIFICATION Standard Cycle Time Before Tools Standardization in VF 5 S.NO ERP CODE MFL01B00B0200 10 MFL01B00B0200 20 MPT02B00B0200 30 MPT02B00B0200 40 MPT02B00B0200 60 MPT02B00B0200 60 MPT02B00B0200 50 MPT02B00B0200 50 MKC02B00B020 150 MKC02B00B020 150 MKC02B00B020 030 MKC02B00B020 030 MKN01B00R010 010 & REV . NO 7 7 3 3 2 2 2 2 2 2 2 2 2,4 PART NO / PART NAME COLT MAIN FRAME LEFT-A24 B02 02 COLT MAIN FRAME RIGHT-A24 B02 01 COLOUR HEAD-I LEFT E21 B02 03 COLOUR HEAD-I RIGHT E21 B02 04 COLOUR HEAD II RIGHT E21 B02 6 COLOUR HEAD II RIGHT E21 B02 6 COLOUR HEAD II LEFT E21 B02 05 COLOUR HEAD II LEFT E21 B02 05 250CB COL. HEAD II RIGHT D21 B02 15 250CB COL. HEAD II RIGHT D21 B02 15 250 CB COLOUR HEAD II LEFT D21 B02 03 250 CB COLOUR HEAD II LEFT D21 B02 03 FEEDER FRAME-RIGHT & LEFT DRG NO A26R01 01-2 A26R01 02-4
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Setting Time before Tools Standardization SETTING TIME 240 240 180 180 180 180 180 180 180 180 180 180 180 CYCLE TIME. 110 80 70 60 60 10 70 10 60 10 70 10 40

OPERN.NO.

1 2 3 4 5 6 7 8 9 10 11 12 13

10 10 10 10 10 20 10 20 10 20 10 20 10

14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

MKN01B00R010 020 MKN01B00B020 020 MKN01B00B020 020 MKN01B00B020 010 MKN01B00B020 010 MPT02B00B0200 10 MPT02B00B0200 20 MPT02B00B0400 10 MPT02B00B0400 20 MPS01B00B0200 20 MPS01B00B0200 10 MPS01B00B0200 10 MRE01B00B0200 20 MRE01B00B0200 10

6 6 6 6 4 3 2 1 2 2 2 3 3 2 2

KNIGHT MAIN FRAME LEFT A26B0202 KNIGHT MAIN FRAME LEFT A26B0202 KNIGHT MAIN FRAME RIGHT A26 B02 01 KNIGHT MAIN FRAME RIGHT A26 B02 01 PTP 7000 MAIN FRAME LEFT E21 B02 01 PTP 7000 MAIN FRAME RIGHT E21 B02 02 PTP 10000 MAIN FRAME LEFT E21 B04 01 PTP 10000 MAIN FRAME RIGHT E21 B04 02 PTP SINGLE COLOUR LEFT E24 B02 02 PTP SINGLE COLOUR RIGHT E24 B02 01 PTP SINGLE COLOUR RIGHT E24 B02 01 REACKONER MAIN FRAME(L) REACKONER MAIN FRAME (R) 250CB COLOUR HEAD I -RIGHT D21 B0214 250 CB COIOUR HEAD I LEFT D21 B02 02
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240 60 240 60 180 180 180 180 240 240 60 180 180 180 180

110 18 100 18 60 70 60 70 120 105 20 100 90 70 60

10 20 10 20 10 10 10 10 10 10 20 10 10 10 10

CONTINUE WITH PART II

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MASTER LIST STANDARDISED TOOLINGS WITH DIA X & LENGTH L DOC.NO REV.NO DATE CHANGE D TOOLS CNC/PRO/D/32

MASTER TOOLING LIST WITH L & X TOOL POCKET T01 T02 T03 T04 T05 T06 T07 T08 T09 T10 T11 T12 T13 T14 TOOL CODE A01 A02 A03 A04 A05 A06 A07 A08 A09 A10 A11 A12 A13 A14 TOOL HEIGHT L 118.10 108.64 117.10 171.25 124.00 142.00 153.10 179.00 154.00 145.17 147.07 139.40 149.60 123.62 TOOL DIA X 10.00 CD 5.80 DR 7.80 DR 9.80 DR 11.80 DR 16.00 UD 17.50 UD 21.50 UD 24.50 UD 27.50 UD 6.00 RE 8.00 RE 10.00 RE 12.00 RE

FOR VF 5 TOOLS PERMENANT TOOLS TO BE CHANGED X X X X X X X X X X X X X X

S.NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14

CHANGED TOOLS -

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15 16 17 18 19 20 21 22 23 24 25 26 27 28

T15 T16 T17 T18 T19 T20 T21 T22 T23 T24 T25 T26 T27 T28

A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27 A28

151.50 175.85 142.565 145.60 119.70 111.99 113.30 121.20 124.50 123.50 124.70 132.80 142.30 136.50

16.00 RE 18.00 RE 22.00 H7 25.00 H7 28.00 M6 32.00 M6 35.00 H7 38.00 H7 47.00 M6 52.00 M6 55.00 M6 62.00 H7 62.00 M6 72.00 H7

X X X X X X X X X X X X X X

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S.NO 29 30 31 32 33 34 35 36 37 38 39 40

MASTER TOOLING LIST WITH L & X FOR VF 5 TOOL TOOLS TOOL TOOL TOOL TOOLS HEIGHT TO BE POCKET CODE DIA X PERMENANT L CHANGED 1.30 T29 A29 140.67 X GR 1.90 T30 A30 170.30 X GR 31.50 T31 A31 183.40 X UD 34.50 T32 A32 150.20 X UD 37.50 T33 A33 186.25 X UD 46.50 T34 A34 217.15 X UD 51.50 T35 A35 227.15 X UD 54.50 T36 A36 232.97 X UD 61.50 T37 A37 120.25 X TB 71.50 T38 A38 195.37 X TB 16.00 T39 A39 122.86 X IC T40 A40 25 J7 X

DOC.NO REV.NO DATE CHANGE D TOOLS A41 A42 A43 A44 A45 A46 A47 A48 A49 A50

CNC/PRO/D/32

CHANGED TOOLS A31 ,A41 A32 , A42 A33 , A43 A34 , A44 A35 , A45 A36, A46 A37 , A47 A38 , A48 A39 , A49 A40 , A50

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41 42 43 44 45 46 47 48 49 50

A41 A42 T43 T44 T45 T46 T47 T48 T49 T50

A41 A42 A43 A44 A45 A46 A47 A48 A49 A50

6.6 DRILL 79.5 TBB R.B.B 25.5 26 K6 32 H7 52 H7 62 TO 85 FBB 55 H7 R.B.B 45 TO 60 4.2 DRILL

X X X X X X X X X X

A31 A32 A33 A34 A35 A36 A37 A38 A39 A40

A41 , A31 A42 , A32 A43 , A33 A44 , A34 A45 , A35 A46 , A36 A47 , A37 A48 , A38 A49 , A39 A50 , A40

37

AFTER MODIFICATION Standard Cycle Time After Tools Standardization in VF 5 Setting Time before Setting Time after Tools Tools Standardization Standardization SETTING CYCLE SETTING CYCLE TIME TIME. TIME TIME. 240 110 120 100 Savings in Setup Time 120

S.NO

ERP CODE

REV . NO

PART NO / PART NAME COLT MAIN FRAME LEFT-A24 B02 02 COLT MAIN FRAME RIGHT-A24 B02 01 COLOUR HEAD-I LEFT E21 B02 03 COLOUR HEAD-I RIGHT E21 B02 04 COLOUR HEAD II RIGHT E21 B02 6

OPERN.N O.

MFL01B00B020010

10

MFL01B00B020020

240

80

120

70

10

120

MPT02B00B020030

180

70

120

70

10

60

MPT02B00B020040

180

60

120

60

10

60

MPT02B00B020060

180

60

120

60

10

60

38

MPT02B00B020060

MPT02B00B020050

MPT02B00B020050

MKC02B00B020150

10

MKC02B00B020150

11

MKC02B00B020030

12

MKC02B00B020030

COLOUR HEAD II RIGHT E21 B02 6 COLOUR HEAD II LEFT E21 B02 05 COLOUR HEAD II LEFT E21 B02 05 250CB COL. HEAD II RIGHT D21 B02 15 250CB COL. HEAD II RIGHT D21 B02 15 250 CB COLOUR HEAD II LEFT D21 B02 03 250 CB COLOUR HEAD II LEFT D21 B02 03

180

10

40

10

20

140

180

70

120

70

10

60

180

10

40

10

20

140

180

60

120

60

10

60

180

10

40

10

20

140

180

70

120

70

10

60

180

10

40

10

20

140

39

13

MKN01B00R010010 & MKN01B00R010020

2,4

14

MKN01B00B020020

15

MKN01B00B020020

16

MKN01B00B020010

17

MKN01B00B020010

18

MPT02B00B020010

FEEDER FRAMERIGHT & LEFT DRG NO A26R01 01-2 A26R01 02-4 KNIGHT MAIN FRAME LEFT A26B0202 KNIGHT MAIN FRAME LEFT A26B0202 KNIGHT MAIN FRAME RIGHT A26 B02 01 KNIGHT MAIN FRAME RIGHT A26 B02 01 PTP 7000 MAIN FRAME LEFT E21 B02 01

180

40

120

40

10

60

240

110

120

110

10

120

60

18

40

16

20

20

240

100

120

100

10

120

60

18

40

16

20

20

180

60

120

60

10

60

40

19

MPT02B00B020020

20

MPT02B00B040010

21

MPT02B00B040020

22

MPS01B00B020020

23

MPS01B00B020010

24

MPS01B00B020010

25 26

MRE01B00B020020 MRE01B00B020010

3 3

PTP 7000 MAIN FRAME RIGHT E21 B02 02 PTP 10000 MAIN FRAME LEFT E21 B04 01 PTP 10000 MAIN FRAME RIGHT E21 B04 02 PTP SINGLE COLOUR LEFT E24 B02 02 PTP SINGLE COLOUR RIGHT E24 B02 01 PTP SINGLE COLOUR RIGHT E24 B02 01 REACKONE R MAIN FRAME(L) REACKONER MAIN

180

70

120

70

10

60

180

60

120

60

10

60

180

70

120

70

10

60

240

120

150

120

10

90

240

105

150

105

10

90

60

20

40

20

20

20

180 180

100 90

120 120

100 95

10 10

60 60

41

FRAME (R) 250CB COLOUR HEAD I -RIGHT D21 B0214 250 CB COIOUR HEAD I LEFT D21 B02 02

27

--

180

70

120

70

10

60

28

--

180

60

120

60

10

60

42

FINDINGS 1. Setting Time for MFL01B00B020010 before tools standardization in VF5 is 240 After tools standardization is 120 2. Setting Time for MFL01B00B020020 before tools standardization in VF5 is 240 3. After tools standardization is 120 4. Setting Time for MPT02B00B020030 before tools standardization in VF5 is 180 5. After tools standardization is 120 6. Setting Time for MPT02B00B020040 before tools standardization in VF5 is 180 7. After tools standardization is 120 8. Setting Time for MPT02B00B020060 before tools standardization in VF5 is 180 9. After tools standardization is 120 10. Setting Time for MPT02B00B020060 before tools standardization in VF5 is 180 11. After tools standardization is 40 12. Setting Time for MPT02B00B020050 before tools standardization in VF5 is 180 13. After tools standardization is 120 14. Setting Time for MPT02B00B020050 before tools standardization in VF5 is 180 15. After tools standardization is 40 16. Setting Time for MKC02B00B020050 before tools standardization in VF5 is 180 17. After tools standardization is 120 18. Setting Time for MKC02B00B020050 before tools standardization in VF5 is 180 19. After tools standardization is 40

43

20. Setting Time for MKC02B00B020030 before tools standardization in VF5 is 180 21. After tools standardization is 120 22. Setting Time for MKC02B00B020030 before tools standardization in VF5 is 180 23. After tools standardization is 40 24. Setting Time for MKN01B00R010010 before tools standardization in VF5 is 180 25. After tools standardization is 120 26. Setting Time for MKN01B00B020020 before tools standardization in VF5 is 240 27. After tools standardization is 120 28. Setting Time for MKN01B00B020020 before tools standardization in VF5 is 60 29. After tools standardization is 40 30. Setting Time for MKN01B00B020010 before tools standardization in VF5 is 240 31. After tools standardization is 120 32. Setting Time for MKN01B00B020010 before tools standardization in VF5 is 60 33. After tools standardization is 40 34. Setting Time for MPT02B00B020010 before tools standardization in VF5 is 180 35. After tools standardization is 120 36. Setting Time for MPT02B00B020020 before tools standardization in VF5 is 180 37. After tools standardization is 120 38. Setting Time for MPT02B00B040010 before tools standardization in VF5 is 180 39. After tools standardization is 120

44

40. Setting Time for MPT02B00B040020 before tools standardization in VF5 is 180 41. After tools standardization is 120 42. Setting Time for MPS01B00B020020 before tools standardization in VF5 is 240 43. After tools standardization is 150 44. Setting Time for MPS01B00B020010 before tools standardization in VF5 is 240 45. After tools standardization is 150 46. Setting Time for MPS01B00B020010 before tools standardization in VF5 is 60 47. After tools standardization is 40 48. Setting Time for MRE01B00B020020 before tools standardization in VF5 is 180 49. After tools standardization is 120 50. Setting Time for MRE01B00B020010 before tools standardization in VF5 is 180 51. After tools standardization is 120

45

SUGGESTIONS If the company uses advanced technology it can eliminate unwanted process. For this employee should have been trained. The company has sophisticated machineries. It should be used for further process. So that the time for setting up and processing can be minimized. If an effective forecast could be done with the help of software like ERP, SAP etc., the cost and time for processing materials can be minimized.

46

CONCLUSIONS This study reveals that the tool setting time is reduced by standardizing tools. Company has highly sophisticated machineries. It should be used by proper trained

personnel. Training are given every personnel monthly once. Both Hard and soft skill is being given to all employee with the help of internal and external trainers. Otherwise there is chance of getting problem in machineries and tools. Also, usage of tooling and effective utilization of the machine if reviewed every month in MRM (Monthly Review Meeting). Tools consumption is also monitored thro ERP. machineries should have be known by each personnel those who operates it.

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BIBLIOGRAPHY 1. 2. 3. Company records www.google.com www.autoprint.net

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