SYNOPSIS

ON

PRODUCTIVITY IMPROVEMENT OF
CONVENTIONAL DRILLING MACHINE

FOR B.E. MECHANICAL ENGINEERING

OF
UNIVERSITY OF MUMBAI

PREPARED BY
Name of the students

HARSHAD V.SURYAWANSHI
 Bharati Vidyapeeth College of Engineering,
Navi Mumbai- 400 614

Certificate
This is to certify that

HARSHAD V.SURYAWANSHI

Have satisfactorily completed project entitled:

PRODUCTIVITY IMPROVEMENT OF CONVENTIONL
MACHINES (RADIAL DRILLING MACHINE)
In partial fulfillment of the Degree of B. E. in Mechanical
Engineering affiliated to the UNIVERSITY OF MUMBAI for the
academic year 2009-10.
 ACKNOWLEDGEMENT

In this partial fulfillment of our project, we present the synopsis of our

project. Sincere appreciation and warmest thanks are extended to the many
individuals who in their own ways have inspired us in the completion of
this project.

This task would not have been possible without the help and
guidance of our esteemed project guide Prof.L.Suryavanshi, without his
expert help and guidance, this project would not have reached this stage.
We are extremely grateful for his friendly support and professionalism.

We are also thankful to our project coordinator Prof.R.K.Agarwal for

his help and guidance.

We express our heartfelt gratitude to our Head of Department

Prof.Jadhav for her help and support.

We extend our thanks to Mechanical Department of B.V.C.O.E for

providing valuable resources needed for our project.
 ABSTRACT
In this project we have given the solution for different problems
occurring in radial drilling machine.
The problem such as like because of less speed the time taken for
drilling the hole is more ,chip removal & coolant application time is
more, cutting tool material have less specifications, clamping device is
poor etc.
On this problem solution may be like using specified speed of
machine, using chip breaker tool & automatic coolant flow, improved
cutting tool material with higher specification etc.
 INDEX

• INTRODUCTION TO COMPANY

• INTRODUCTION TO PROJECT

• LITERATURE REVIEW

• CAUSES & EFFECT ANALYSIS OF LESS

PRODUCTIVITY

• METHODOLOGY

• ANALYSIS

• BIBLIOGRAPHY
 CHAPTER 1-
INTRODUCTION
 INTRODUCTION TO COMPANY

Godrej is a part and parcel of every Indian’s life. From locks to

personal care. From appliances to air care. From furniture to construction.
There are innumerable ways we enrich quality of life - everyday,
everywhere. Godrej offer an entire spectrum of industrial solutions from
storage to material handling to process equipment and many, many more.
Whether clients are looking for standard equipment or custom engineering
solutions, the first name is Godrej.

The Godrej Group was established in 1897 and has since grown into a
US$1.875 billion conglomerate with a workforce of 18,000. Inseparable
from daily life in India, the Godrej name has been built on a spirit of
innovation that has made it one of the country's most remarkable industrial
corporations.
 WORKING DEPARTMENT

Process Equipment Division (ISO 9001)

Heavy Walled Reactors, High Pressure Vessels, High Pressure

Shell and Tube Heat Exchangers, Reactor/Tower Internals and Trays.

The Process Equipment Division (PED) of Godrej is a leader in

fabricating unit static equipment for process industries. Established in
1976, PED manufactures the entire range of process equipment for end-
users in core industry segments like Refineries, Petrochemicals,
Fertilizers, Oil & Gas, Chemicals, Pharmaceuticals and Power around
the world.

Located in the industrial garden township of Vikhroli, a northern

suburb of Mumbai, in India, the lush green Godrej complex and PED's
impressive manufacturing facilities strike the eye.

Product range –

• Heavy Walled Reactors

• Equipment Internals

• Fractionating / Distillation Columns

• High Pressure Shell & Tube Heat Exchangers

Custom built Equipment
 The bedrock of PED operations is its large, highly skilled
workforce.

Skilled workmen and trained, competent and highly

committed people have repeatedly been able to channelize the
knowledge and experience that PED has gained over the years,
through its robust systems, to ensure that projects are
successfully executed on time. Through continuous
improvement in quality, a deep commitment to on-time
 delivery and a clear policy of keeping
in step with the latest manufacturing
technology, PED is fully equipped to
meet the challenging demands of its
global customers for process
equipment.

MACHINE SHOP DEPARTMENT :-

PED has fabrication shops dedicated to manufacturing of

Heavy, Medium & Light equipment, spread across an area of
50,000 m2 (under
Cranage). The shops are
laid out for fabricating
Process Equipment
category-wise i.e.
Column, Pressure
Vessels, Reactors, Heat
Exchangers, Reactor
Internals, Trays & Tower Internals and Heavy Equipment. PED
manufactures critical equipment of:
 CHAPTER 2-
INTRODUCTION TO PROJECT
TITLE:-
PRODUCTIVITY IMPROVEMENTS IN CONVENTIONAL
MACHINES (RADIAL DRILLING MACHINE)
RADIAL DRILLING MACHINE:-
 Description of machine
It’s a design for operation conveniences and high production in
applied such as drilling, reaming, tapping, countering etc.
Base plate

This is rigid structure on which there columns and sleeve assemble is

fixed this also contain the coolant chamber .three T slot running length
wise facilities fixed of the work piece or auxullatre work table.

Colum and sleeve

The sleeve is suspended top of the truest ball bearing 32 through a

heavy spring table plate 33. It’s a centered by a ball bearing 34 or roller
bearing at the top & specially roller bearing 35 at the bottom .thus the
arm which is mounted on the sleeve swings easily to the light figure
touch the sleeve is also suspected and there will be the clearness of 0.05
mm between the lower annular surface of the sleeve and corresponding
surface of the column in the unlocked condition .the cleanse which has
been adjust screw 36, 37 climbing ring -38 spring plate 33 , eccentric
shaft 39. Ship ring and brush ring is also housed in the top chamber of
the sleeve.

Arm

The liberally proportioned arm of diagonally ribbed box section is

designed for maximum rigid .the climbing machine is amounted at rear
arm .The arm housing which surrounded this mechanism has the oil tank
integral with it.
Drilling head

The drill head balanced on two ball bearing roller 46 runs on a

hundred steel taps stretched on the top guide away of the arm. The
drilling head housed the main drive feed mechanism, main drive control
and drilling spindle, countering balanced mechanism

Main drive

Spindle speed are provided through the selective arrangement of

one three position sliding gear block 47 one mute disc ,double clutch 48,
two spread revisable motor 49,with this arrangement the number of shaft
and gear have been reduces to minimum . The speeds cover most the
operation like drilling reaming and tapping within the capacity of the
m/c .engagement of the clutch is smooth in the both direction and
provide an increase reveres speed for a rapid withdraw of tap while
tapping .the clutch also proceed the machine against over loads

Feed mechanism

The feed drive housed in a separate housing which in turn is

housed in a front of the drill head .6 feed are obtain by a single level.
The warm drive assures uniform drill thrust at the drilling spindle the
feed mechanism is protected from any adverse over load by a spring
loaded safety clutch situated between the feed drive and warm drive.
 The feed mechanism offer three type of feeds viz. automatic feed. Fine
feed, by hand and coarse feed is obtained by them.

SPECIFICATION OF RADIAL DRILLING MACHINE:-

MACHINE CODE:- RM65

CAPACITY STEEL CAST IRON

Drilling in solid 50 60
Drilling in solid with 75 85
reduced speed & feed
Tapping (metric fine 56 70
threads)
Tapping (with worth) 1.25inches 2.5inches

WORKING RANGE:-ALL IN MM

Max. drilling radius 2350

Min. drilling radius 550
Dia. of sleeve 400
Max. distance (sleeve to spindle) 2150
Min. distance (sleeve to spindle) 350
Spindle traverse 325
Max. distance base plate to spindle 1645
Min. distance base plate to spindle 380
Working surface of base plate(length) 2330
Working surface of base plate (width) 1000
Std. box table 600*500*500
DRILLING SPINDLE:-

Morse taper in spindle nose MT5

Spindle speed 12 no.
Range of speed (standard) 40-1800 rev/min
Range of speed (on request) 50-2240 rev/min
Feeds 6 no.
Range of feeds 0.125-1.25 mm/rev
Max. drilling thrust 1650 kg.

POWER:-

Drilling head motor at 1500/3000 rpm 4.5 kw

Elevating motor 3 kw
Coolant pump motor 0.11kw
Approx. weight of machine 4560 kg.

APPROXIMATE SHIPPING DIAMENSIONS:-

Length 3.60 m
Width 1.32 m
Height 3.30 m

WORKNG AREA:-

T H S R

3065 1016 436 2750

Total Quality Management (TQM)
Total quality management (TQM) tools help organizations to
identify, analyze and assess qualitative and quantitative data that is
relevant to their business. These tools can identify procedures, ideas,
statistics, cause and effect concerns and other issues relevant to their
organizations. Each of which can be examined and used to enhance the
effectiveness, efficiency, standardization and overall quality of
procedures, products or work environment.
TQM tools illustrate and aid in the assimilation of complicated
information such as:
• TQM Tools

The following are some of the most common TQM tools in use
today. Each is used for, and identifies, specific information in a specific
manner. It should be noted that tools should be used in conjunction with
other tools to understand the full scope of the issue being analyzed or
illustrated. Simply using one tool may inhibit your understanding of the
data provided, or may close you off to further possibilities.
1. Pie Charts and Bar Graphs
Used to identify and compare data units as they relate to one issue or the
whole, such as budgets, vault space available, extent of fonds, etc.
2. Histograms
 To illustrate and examine various data element in order to make
decisions regarding them. Effective when comparing statistical survey or
questionnaire results.

3. Pareto Charts / Analysis (designed by Vilfredo Pareto)

Rates issues according to importance and frequency by prioritizing
specific problems or causes in a manner that facilitates problem solving.
Identify groupings of qualitative data, such as most frequent complaint,
most commonly purchased preservation aid, etc. in order to measure
which have priority.
Can be scheduled over selected periods of time to track changes. They
can also be created in retrospect, as a before and after analysis of a
process change.
4. Cause and Effect, Ishikawa or Fishbone Diagrams (designed by
Kauro Ishikawa)
Illustrates multiple levels of potential causes (inputs), and ultimate
effects (outputs), of problems or issues that may arise in the course of
business. May be confusing if too many inputs and outputs are
identified. An alternative would be a tree diagram, which is much easier
to follow.

5. Tree Diagram
To identify the various tasks involved in, and the full scope of, a
project.
To identify hierarchies, whether of personnel, business structure, or
priorities. To identify inputs and outputs of a project, procedure, process,
etc.

6. PDCA
 The Plan-Do-Check-Act style of management where each project or
procedure is planned according to needs and outcome, it is then tested,
examined for efficiency and effectiveness, and then acted upon if
anything in the process needs to be altered.
This is a cyclical style to be iterated until the process is perfected.
 CHAPTER 3-
LITERATURE REVIEW

Drilling
 Drilling is the operation of producing circular hole in the work-
piece by using a rotating cutter called DRILL.
 The machine used for drilling is called drilling machine.
 The drilling operation can also be accomplished in lathe, in which the
drill is held in tailstock and the work is held by the chuck.
 The most common drill used is the twist drill.
Types of drilling machine:-
1) Based on construction:
Portable, Sensitive, Radial, up-right, Gang, Multi-spindle
2) Based on Feed:
Hand driven, Power driven
Drill Materials:-
The two most common types are
1. HSS drill
- Low cost
2. Carbide- tipped drills
- High production and in CNC machines
Other types areSolid Carbide drill, Tin coated drills, carbide coated
masonry drills, parabolic drills, split point drill.

Drill fixed to the spindle

 Fig. 5 Drill fixed to a spindle

Tool Nomenclature

The

different methods used for holding drill in a drill spindle are

• By directly fitting in the spindle hole.

• By using drill sleeve
• By using drill socket
• By using drill chuck

Cutting data
 Effects of cutting speed:
• the main factor in determining tool-life
• affects power consumption
 Excessive cutting speed can lead to:
• rapid flank wear on drill
• plastic deformation of cutting edges
• poor hole quality
• out of tolerance
 Cutting speed too low:
• built-up edge formation on drill
• negatively affect chip evacuation
• poor productivity/high cost per hole
 Effects of feed rate:
• decisive for chip formation
• affects power consumption
• contributes to mechanical and thermal stress

 High feed rate leads to:

• good chip control
• less time in cut
• less tool wear
• higher risk of drill breakage
• hole quality can deteriorate
 Low feed rate leads to:
• longer chips
• quality improvement
• accelerated tool wear
• longer time in cut/higher cost per hole
 Importance of chip control:
• Poor chip control can lead to unsatisfactory
• hole-finishes and possible breakage of the Delta-C drill.
 CHAPTER 4-
CAUSES & EFFECT ANALYSIS OF LESS
PRODUCTIVITY
 Time study on radial drilling machine
 JOB DETAILS:-
1. MACHINE NO. :- DR-02
2. NAME OF JOB:- Tube sheet
3. ITEM CODE:- 105
4. PROJECT NO.:-130640
5. JOB-M.S.
6. DIA OF HOLE REQUIRED: - D-54mm
7. SPEED:-45rpm
8. FEED:-0.8mm/min
9. RAW MATERIAL:-Tool- HSS
SR.N TIME at am OPERATIONS DETAILS
O.
1 10.00-10.57 Idle Clamping of job(setting
of job)
2 10.58-11.06 Drilling Drilling
3 11.06-11.08 Idle No work
4 11.08-11.10 Drilling Drilling
5 11.10-11.11 Idle Chip removal & using
coolant
6 11.11-11.14 Drilling Drilling
7 11.14-11.15 Idle Chip removal
8 11.15-11.20 Drilling Drilling
9 11.20-11.21 Idle Chip removal & coolant
10 11.21-11.30 Drilling Drilling
11 11.31-11.40 Idle Chip removal
12 11.40-11.50 Drilling Drilling
13 11.51-12.45 Idle Lunch time
14 12.45-12.47 Idle Position of tooling
15 12.47-01.05 Drilling Drilling
16 01.06-01.07 Idle Chip removal & using
coolant
17 01.08-01.17 Drilling Drilling
18 01.17-01.20 Idle Chip removal & using
coolant
19 01.21-01.31 Drilling Drilling
20 01.31-01.32 Idle Chip removal & using
coolant
21 01.32-01.44 Drilling Drilling
22 01.44-01.46 Idle Chip removal & using
coolant
23 01.46-01.51 Drilling Drilling
24 01.51-01.52 Idle Chip removal & using
coolant
25 01.52-02.02 Drilling Drilling
26 02.02-02.03 Idle Chip removal & using
coolant
27 02.03-02.15 Drilling Drilling
28 02.15-02.17 Idle Chip removal & using
coolant
29 02.17-02.28 Drilling Drilling
30 02.28-02.30 Idle Chip removal & using
coolant
31 02.30-02.40 Drilling Drilling
32 02.40-02.42 Idle Chip removal & using
coolant
33 02.43-02.56 Drilling Drilling
34 02.57-03.00 Idle Chip removal & using
coolant
35 03.00-03.15 Idle Machine off no work
 RESULT:-
1. Idle time: - 162min
2. Working time:- 145min
3. Total time:- 307min

METHO TOOL
D MATERIAL

Chip
Delay in clamping delay in cooling breaker less specification

CAUSE IMPROVEMEN
T
Less speed
Lack of
overview less feed
Lack of knowledge
maintenance
MACHI
MAIN NE

CAUSE & EFFECT ANALYSIS

CAUSES & EFFECT ANALYSIS OF Radial Drilling
Machine:-
 Time taken for manual cooling- workers are using manual
cooling by stopping machine.
 Time taken for removing chips from job- chips are getting
around tool so worker used to stop the machine & then removing chips
from tool.

 The workers are not using specified speed of machine-to get

smooth finishing & to minimize the wear of the tool.

 Tool material is HSS (high speed steel) which have lesser

specification & low qualities-

 Clamping system is not proper-taking too much time to set the

job

 Worker tendency –using low specification.

 CHAPTER 5-
METHODOLOGY
 METHODOLOGY:

Various TQM tools are to be used to achieve the objectives by adopting

following procedure,

1. Brainstorm the quality characteristics and design parameters important

to the project or process In radial drilling machine

2. Draw cause and effect diagram for deciding the key factors.

3. Decide various solutions for removing problems.

4. Run confirmation test using the specified conditions.

5. Analyze the results to determine the improved productivity.

6. Conclusions.
Scope of Project:-
Productivity improvement in radial drilling machine gives following
scopes:-
1. It the objectives of owner and workers.

2. It contribute towards increasing production through efficient

utilization of resources and input rather than making workers to work
hard.

3. It strives to minimize human hazards and human efforts with the

view to utilize them to those areas where they can contribute maximum
to the output.

4. It results in lower cost per unit by effective utilization of all the

resources and reducing wastage.
CHAPTER 6-

ANALYSIS
SUGGESTIONS

 Use chip breaker in tool

 Use pump for cooling system

 Increase speed of spindle according to specification

 Use carbide tool instead of HSS tool

 Change the spindle motor for increasing speed

 Use new clamping system

 Change worker tendency

 BIBLIOGRAPHY
 WWW.GOOGLE.COM

 WWW.WIKIPEDIA.COM

 WWW.GODREJ&BOYCE.COM

 WWW.HMT.COM

 BOOK:- INDUSTRIAL ENGG. &

PRODUCTION MANAGEMENT-
Marten Telsang