PROJECT SEMINAR

PROJECTS UNDERTAKEN

1. Development of master key system for PCML

cartridges.
2. Development of Paracentric latch lock.
Name: Kaushik Srinivasan

Place of Project: Locks Division,

Godrej & Boyce Mfg.Co.Ltd
Period : 18th June 2008 – 18th December
2008
Company Guide: Mr K.R Gaikar
Senior Manager - Product Design
College Guide: Prof. D.V Shirbhate
Godrej Group
• one of the largest engineering and consumer
products company
• Godrej is one of the largest privately held Industrial
Corporations
• high tech engineering solutions to world-class
consumer products
• core values of trust and reliability
• Annual turnover of above 4000 crores
• It employs a family of 10,000 employees.
• Most of the businesses are ISO 9001, ISO14001 &
OHSAS 18000 certified.
Locks Division
• 1897 - Godrej Introduces first lock with lever
technology (Anchor brand).
• A number of homegrown locks designed like Navtal,
Shakti, padlocks and many more with cutting edge
technologies like Ultra,wafer, mechatronic based.
• 2003 - Shifts strategy from selling locks to providing Godrej Products
Locking Solutions
Development of master key system for
PCML cartridges
 OBJECTIVE STATEMENT
1. To provide low cost master key systems

2. Compliance to European standards BS EN 1303:2005 for maximum

security and performance.

RESPONSIBILITY

1. Technology Assessment
2. Prepare master key chart
3. To make prototypes and related tools and fixtures
4. Production Recommendations
ORGANIZATION STRUCTURE AND
TEAM

Locks Division Design Department

 INTRODUCTION
• The main aim of developing GPI system is to make
affordable master keying facility and design it intricately
• The scope of the project concentrates on pin cylinder
mortise lock.
• These cartridges use pin technology wherein pins of
various sizes are assembled in the cylinder housing and
complementary to the pin sizes wards are cut in the key.
• The size of the lock considered is 60mm.
 INTRODUCTION
• Pin technology video
• Master Keying Facility
 PLANNING
• Technology Assessment
• Production Constraints
• Knowledge Gathering
• Workflow Chart
• Gantt Chart
 PLANNING
Technology Assessment
IDEAS TRANSFORMATION
 PLANNING
• New Technology Explanation

Preliminary Drawings: Profile + Pins

Representation of
cylinder key hole
profile
 COMBINATIONS
CYLINDER

KEY 1
KEY 2
 PLANNING
Production Constraints

1. Prototype Making
2. Production Plan

 Choice of process –Abrasive jet/Laser Cutting/Wire Cutting

 Availability of equipment
 Operation Sequence for the prototype and final product
WORKFLOW TABLE
 PLANNING
• Gantt Chart
 CONCEPT DEVELOPMENT
• Master Key system
 DESIGN IMPROVEMENTS

Design Improvement Reason Progress

Hardened armour plate insertion in Anti Drill in cylinder PASSED Drill test
cylinder & resistance to plug according to standards
extraction BS1303:2005

PASSED Plug extraction

test

CYLINDER : Hardened
Slit for hardened armour plate
plate insertion.
 DESIGN IMPROVEMENTS
Provision for two hardened pin onDrill resistance PASSED Drill test
either side in body according to standards

Cylinder housing:
Provision for
hardened pin
 DESIGN IMPROVEMENTS
3. Multi-Profile Keyhole in cylinder Increase combinations Testing on Master Key
and MK Viability for torque test
Multi Profile flutes in key In Process
 DESIGN IMPROVEMENTS
5. Nickel Silver Key
Better resistance to Opted for NS-12 over
twisting torque, non existing brass
reactive, more life
expectancy

Multi-profile Key
 Fixtures/Tools Developed

DRILL JIG CUM WIRE CUTTING FIXTURE

Brazing Fixture Key profile finishing Single point tools

tool cum Gauge for
multi-profile keys
 PROTO MAKING
CHALLENGES & SOLNS
Sr.No OPERATION PROBLEM SOLUTION

Wire Cutting Fillet radius of wire interfering in Single point cutting tools with required
1. insertion of key in cylinder radius and angle

Unable to insert key *3 HSS tools for the profile cuts

*Use the tool in milling machine as
shaper
Improper alignment b/w workpiece Manual filing to obtain desired clearance
and tool in milling m/c and obtain loose fit.

Desired dimension tolerances not Made finishing tool with required profile
maintained cut

Tendency to break or bending Made dimensional corrections in

increased due to excessive material drawings
removal

Partial insertion of key into cylinder Minor filing and passing through the
finishing tool ensured complete insertion.

Cutter is preferred. Developed cutter

Fishbone Diagram
REQUIREMENT: FORM CUTTER
1. Cutter must be mounted on milling machine arbor
2. Cutter must be clamped properly to prevent tilting while cutting.
3. Provision for quick change of tool for cutting the unsymmetrical profiles.
4. Down milling preferred.
 SUCCESS
• The cutter customized for making
prototype key was successfully made and
checked.

PROTOTYPES

CUSTOMIZED KEY HOLDING

FORM CUTTER FIXTURE
Quality Function Deployment Chart
DESIGN DETAIL
TESTING AND REFINEMENT
 PRODUCTION
RECOMMENDATIONS

Prospective form cutter Key Design

 VARIANTS IN PRESENT SEQ OF OPERATION
SR.NO OPERATION
CYLINDER PROFILES
CP CP CP CP CP CP CP CP
1 2 3 4 5 6 7 8

1. Turning
COMMON TO ALL CYLINDERS

2. Broaching and Bowling X X X X X X X X

3. Pin hole drilling X X X X X X X X
4. Rear slot milling X X X X X X X X
5. Hardened pin hole drilling X X X X X X X X
7. Slitting X X X X X X X X
8. Finishing X X X X X X X X

VARIANTS IN PROPOSED SEQ OF OPERATION

SR.NO OPERATION

CYLINDER PROFILES
CP1 CP2 CP3 CP4 CP5 CP6 CP7 CP8

1. Turning
COMMON TO ALL CYLINDERS
2. Pin hole drilling
COMMON TO ALL CYLINDERS
3. Rear slot milling
COMMON TO ALL CYLINDERS
4. Hardened pin hole drilling
COMMON TO ALL CYLINDERS
5. Slitting
COMMON TO ALL CYLINDERS
7. Broaching and Bowling X X X X X X X X

8. Finishing X X X X X X X X

P.S The number of variants can be drastically reduced from 57

to 21 in the proposed Sequence of operation for production.
 ADVANTAGES OF
NEW PROCESS PLAN
Sr.No Advantage Reason
1. Reduction in Variants required for machining from 57 to Pin hole acts as reference for
21 locating the cylinder.
Variants/Fixtures on account
of different keyhole profiles
reduced

2. Reduction of load on broach teeth Pin Holes drilled before

broaching and milling done
before broaching for longer
cylinders
3. Deburring operation eliminated Burrs removed during the
broaching operation

4. Greater chip removal Chips in the pin holes are duly

removed during broaching

5. Better tool life Broach wear reduced on

account of less material
removal
 CONCLUSION
• The scope can be widened to
1. 1CK 60 mm PCML

2. 2C PCML Symmetric length ranging from 60 to 110mm

3. Variable length PCML – 1CK/2C

All the above can also be made available in different finishes

Development of Paracentric
latch lock
Development of Paracentric
latch lock
FEATURE TECHNICAL SPECIFICATION

RIGID & ROBUST MILD STEEL BODY, SILICON

BRONZE KEYWAY UNIT, KEY SIZE
14 cm

SECURITY 6 LEVER TECHNOLOGY

DIFFICULT TO PICK SIZE, PARACENTRIC KEYWAY AND

KEY DESIGN

SELF LOCKING WHEN DOOR FREE SPRING MOVEMENT OF

CLOSES LATCH BOLT
& KEY OPENING
 Task Enlistment
• Identify critical operations required
• Make preliminary drawings
• To release development drawings for prototype making
• Co-ordinate and make design changes
• Product Validating for performance
• Addition of new features
• Prototype testing for torque and durability
• Cost Estimation
• Sample Dispatch to marketing department with cost sheet
• Freezing of drawings
Prototype development
 Final product

• Specifications:
• Snap latch bolt locking and Unlocking by Key
• Corrosion Resistant Working Parts
• Latch bolt – Stainless steel
• Five Lever Tumblers
• Key Cylinder - One piece brass with paracentric keyway
• Bolt Size - 1½" x ¾"
• Bolt Throw - 5/8", projects 1/2" when retracted
• Finish - Painted or plated for corrosion resistance.
• Random depth key cuts impede picking.
 REFERENCES
1. Journal Papers
Kurt Prunbauer and Adalbert Paar, (1986), “Arrangement of cylinder locks”,
Patent application publication(US), Patent No.4612787
Harald Neumayer,( 2007),”Flat Key”, Patent application publication(US), Patent
no- 0295045
Akao. Yoji. Ed. 1990. Introduction to Quality Deployment. (In Japanese) Tokyo,
Japan: JUSE, ISBN 4-8171-0257-8
Hauser,John R and Don Clausing, (1988), “The House of Quality.” Harvard
Review 66, no. 3 (May-June): 63-73
2. Reference Book
R.S.Khurmi and J.K. Gupta, (2006), A textbook of Machine Design, Eurasia
Publishing House (PVT) Ltd, New Delhi.
Samuel Eilon, (1997), Elements of Production planning and control, Navneet
Prakashan Ltd., Mumbai
G.R. Nagpal, (1999), Machine Tool Engineering, Khanna Publications., Delhi.
THANK YOU