MANJU DOGRA Reg.

No70808545

Productivity Enhancement on the Cold Extrusion Press

BRIEF HISTORY OF THE PROJECT

Today, industries are reducing their cost in each area due to more compition We have decided to reduce Set up time on extrusion line because, we are manufacturing heavy items like Rear axle shaft etc. in which set up time is important thing We have already made different quality circle teams in different departments from initial process to final process so we are improving each area to reduce cost, improve productivity, improve safety etc. Here we have taken project To bring down the the Set Up time from current average 176 mins to 90 mins. To eliminate the Straightening Process after Cold Extrusion.

PROJECT TEAM Team Members

PROMOD KUMAR Extrusion Shop

Project in progress In pictures

HARJEET SINGH Extrusion Shop

Manju Dogra Team leader RAJINDER KUMAR Extrusion Shop

Project Start : Working Area

April 2011 : Extrusion Shop

Problem Statement
Low Productivity on the Extrusion Press 350T

Business Case
Company is having Two Extrusion Presses of 350T & 250 T. The Capital Cost of the machine is very high. There is strong demand for the extruded axle shafts. If we can increase the productivity by 10% we can create additional capacity of 20,000 axle shafts pa.

Goal Statement
To bring down the the Set Up time from current average 176 mins to 90 mins. To eliminate the Straightening Process after Cold Extrusion.

Mileston es
Month Sl. Activities No . 1 Identifying the Work Related Problem 2 Selection of Problem 3 Define Problem 4 Analysis of Problem 5 Identification of Causes 6 Finding out the Root Causes 7 Data Analysis 8 Developing Solution 9 Foreseeing possible resistance 10 Trial implementation & CHECK DO PLAN Apr - May Jun Jul 11 Aug-11 11 W W W W W W W W W W W W 1-2 3-4 1-2 3-4 1-2 3-4 1-2 3-4 1-2 3-4 1-2 3-4

Process Mapping

METHODOLOGY FOR PROBLEM SOLVING

Identification of different problems by team members & discussion of problems in meeting Selection of problem which have more rejection , more wastage & more cost effective Identification of concerned members to solve the problem & other departments help requirement. Brainstorming by different members to identify the root causes & identification of suitable root causes of the problems & analysis using different Q.C. Tools Action plan on the root causes identified as per the target dates decided by team Members Implementation of action plan as per the decided target dates After implementation, identification of status before & after on specified format Review & Follow up of action plan implemented

Problem Focus

Ishikawa Cause & Effect Analysis

MAN MATERIAL METHOD

ABSENTISM UNSKILLED MAN POWER

INADEQUATE SURFACE TREATMENT

HIGH SET UP TIME

INADEQUATE PROCESS QUALIFICATION

HIGH RUN OUT ON OUTPUT AXLE SHAFTS

LOW PRODUCTIVIT Y NON CALIBERATED INSTRUMENTS

NON CALIBERATED GAGES

LONG CYCLE TIME MACHINE BREAKDOWN

CUMBERSOME TOOLING IMPROPROPER TOOLING

MEASUREMENT

MACHINE

TOOLING

Root Cause Analysis-NGT

Set Up Symptoms

Set Up Process-As Is

Set Up Time Calculation

Month Total Availabl e Time Hrs 600 600 600 600 600 3,000 Run Product Set Down Waiting Number of Time ion Up Time Time (if Changeov ers Time any) Hrs Number Hrs Hrs Hrs No's s 464 491 475 473 490 2,393 19,500 21,263 20,536 21,277 21,210 103,786 81 76 79 62 67 366 51 26 6 10 2 7 45 31 39 39 36 190 25 24 25 25 26 125

Jan-11 Feb-11 Mar-11 Apr-11 May-11 TOTALS

Set Up Time Calculation

BEFORE

Actions Implemented
AFTER

1. Fixed Plate installed instead of movable to control the distortions. 2. This plate accommodate all models. 3. This reduced the Set Up time. 1. The thickness of the OCD ring increased 1. The thickness of the Die Clamping Plate reduced

Straightening
Run Out on Extruded Axle Shafts found varying from 4~5 mm against the required 1~1.5mm

High Run Out is on account axle shaft being dragged by ram non-uniformly after cold extrusion.
Average Production per month 20,757 Cost of Straightening Rs 2.00 Total Monthly Cost Rs 41,514.4 0

Yearly Saving

Rs Lacs

Distortion Analysis
Distortion on pieces on account of pieces getting dragged by Top and Bottom movable Plates. This demands for the Straightening operation after Cold Extrusion Fixed Plate placed that does not allow any transverse movement of axle shaft during the backward movement of RAM.

BEFORE

AFTER

Before

After

19

S.N Set Up Activities Time in o. Mins 1 UNSCREWING OF MOVABLE PLATES (2 IN 10.00 NO.) 2 UNSCREWING OF RESTING BLOCKS(4 IN 36.00 NO.) 3 UNSCREWING OF OCD RINGS 10.00 4 UNCREWING OF DIE CLAMPING PLATES 12.00 5 UNLOADING OF SPACERS/DIES 20.00 6 LOADING OF NEW DIES/SPACERS 20.00 7 SCREWING OF DIE CLAMPING PLATES 10.00 8 SCREWING OF OCD RINGS 10.00 9 SCREWING OF RESTING BLOCKS(4 IN NO.) 40.00 10 SCREWING OF MOVABLE PLATES (2 IN NO.) 10.00 176

Set Up TimeBefore/ Time in Mins Proposed Actions After

UNSCREWING OF OCD RINGS UNCREWING OF DIE CLAMPING PLATES UNLOADING OF SPACERS/DIES LOADING OF NEW DIES/SPACERS 15.00 10.00 20.00 20.00

SCREWING OF DIE CLAMPING PLATES SCREWING OF OCD RINGS

10.00 15.00 -

90

Gains

1 2 3 4 5 6 7

SET UP TIME REDUCED FROM AVG 176 mins TO 90 mins REDUCING SET UP TIME ON AN AVERAGE CREATED CAPACITY OF ADDITIONAL 20,000 AXLE SHAFTS PER YEAR. ELIMINATION OF THE STRAIGHTENING PROCESS THAT LEADS TO ANNUAL SAVING OF AROUND Rs. 5 LACS PER ANNUM LEAD TIME FOR THE TOTAL PROCESS REDUCED COST OF THE SET UP REDUCED ON ACCOUNT OF LESS CONSUMTION OF TOOLINGS SIMLIFICATION OF THE SET UP PROCESS LEADS TO HIGH MORALE OF OPERATORS. THE RESULTS CAN BE IMPLEMENTED ON 250 T PRESS ALSOHORIZONTAL DEPLOYMENT

Cost of Project

S. No.

Equipment Material cost of new Plates Fabrication of Plates Cost of Ring Plates-new

Cost-Rs 8000.00 4050.00 2000.00

1 2 3

Total

14,050.00

NEW PLATE

RING PLATE

Month

Total Available Time Hrs

Run Time

Producti Set Up on Time

Down Time

Waiting Number of Time (if Changeov any)

ers

Impact of the Actions

No's Set Up Produc Time/ tion/hr Chang eover mins No's 25 24 25 25 26 195 189 190 149 156 42 43 43 45 43

Hrs

Numbers

Hrs 81

Hrs

Hrs

Jan-11 600 Feb-11 600 Mar-11 600 Apr-11 600 May-11 600

464 491 475 473 490

19,500 76 21,263 79 20,536 62 21,277 67 21,210

10 2 7 26 6

45 31 39 39 36

TOTALS 3,000 2,393 103,786

366 51 190 125 176 43

Month

Total Available Time Hrs

Run Time

Producti Set Up on Time

Down Time

Waiting Number of Time (if Changeov any)

ers

Hrs

Numbers

Hrs

Hrs

Hrs

No's

Set Up Produc Time/ tion/hr Chang eover mins No's

JUL-11

600

524 32,55 8

42

25

26

97

62

THANKS