GOAL REPORT: PROJECT SEMESTER

on
Title of the Project
(VALUE ANALYSIS & VALUE ENGINEERING TO
INCREASE PRODUCTIVITY AND EFFICIENCY OF THE
LINE)

Submitted by
Name of the student (Rohan Malhotra)
Registration No. (101504103)

Under the Guidance of

Host Mentor Faculty Supervisor

Er. Anoop Kumar Jitender Kaushal
Senior Production Engineer Lecturer
Luminous Power Technologies Pvt. Ltd TIET

2019

Electrical and Instrumentation Engineering Department

Thapar Institute of Engineering and Technology, Patiala
(Declared as Deemed-to-be-University u/s 3 of the UGC Act., 1956)
Post Bag No. 32, Patiala – 147004 Punjab (India)

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Introduction:

Assembly line: An assembly line is a manufacturing process in which parts are

added as the semi-finished assembly moves from workstation to workstation
where the parts are added in sequence until the final assembly is produced.

1. Engineering Problems/ Opportunity being addressed:

1.1 Some line unbalancing problems:

 Small part casting defects due to human error: A casting

defect is an undesired irregularity in a metal casting process.
Some defects can be tolerated while others can be repaired,
otherwise they must be eliminated.

Fig 1: Different types of casting effect

 Intercell short circuit of battery: PE separators are used as

insulation between plates and plastic buffers for insulation
between the cells. PE separators are made up of polyethene and
fine silica powder. These cells undergoes short circuit testing.
110A current made to flow through the cells. In case of
insulation failure cells are rejected. Therefore, quality check is
must.


 Change in specific gravity of H2SO4 during charging:
Battery undergoing charging is prone to heat. As a result,
temperature increase which in turn changes the specific gravity
of the acid which is used in battery. Acceptable specific gravity
limit is 1.220-1.240. Any battery violating this limit will be
rejected.

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  HRD (High Rate Discharge) Test failure: It is short test on
each battery to find defects such as poor welds, reversed plates
and poorly formed batteries. Batteries with open circuit voltage
between acceptable limit of 12.50 to 12.90V have to undergo
this test. Current is set to be 560A with 3 seconds of discharge
time. HRD voltage limit is set to be within 6.05V to 12.90.
Batteries violating this limits are rejected.



 Low OCV(Open circuit voltage): Required time for charging of
150AH battery is 10hrs 20 minutes. In case battery is
undercharged it may not be acceptable. The required open
circuit voltage for a battery is within 12.50V to 12.90V.
Batteries violating this limits are rejected.

1.2 Opportunities being addressed:

 To grab the detailed knowledge of casting defects and other assembly line
processes.

 Meeting with different assembly line workers gives opportunity to
understand various technical and non-technical problems.

 To have knowledge about testing equipments and machines.




3. Project Goals and Objectives:
 To grab the detailed knowledge of processes going under assembly line,
charging section, acid filling section and packing line.

 To do analysis of various reasons for line unbalancing.

 To do before and after analysis of corrective actions taken using Pareto
charts and distribution histograms.

 To increase the productivity and efficiency of the assembly line by
implementation of corrective actions.

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3.PROPOSED METHEDOLGIES
3.1 Flow chart of adaptable root cause analysis process

FIG 2. Flow chart of adaptable root cause analysis

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 3.2 KAIZEN Rule implementation
 KAIZEN refers to small activities that continuously improve all functions
and involve all employees from the CEO to the assembly line workers.



 Example of KAIZEN Implementation

 Problem details: Earlier, air washer found to be in running condition even

machine is idle. During tea time air washer is in running condition.

 KAIZEN Idea: Air washer to be interlocked with brushing machine.

 Results and Benefits:

Total saving = 8.5 units/hour, 204 units per

month. Price of 1 unit = Rs.6


Total saving in rupees= Rs. 1224/month

4. PLAN FOR THE COMPLETION OF THE PROJECT SEMESTER:

 1 month dedicated for understanding the basic parts of assembling of all

types of batteries.

 2 month dedicated for understanding the basic processes involves in
testing of batteries.

 1 month dedicated for designing Process failure mode analysis (PFMEA)
& Pareto charts.

 2 months for corrective actions using fault tree analysis, affinity tables
and relation digraph and implementation part.

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