TVS MOTOR COMPANY

“Optimizing Metal Working Process”

A Case study from

TVS Motor Company Ltd

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Company Introduction TVS Group of companies

TVS Group

Sundaram
SundaramClayton
Group companies
Clayton

Die Casting Harita Seating Sundaram

Brakes division TVS Motor TVS Electronics
Division Systems Auto Components

TVS Motor company is part of Sundaram Clayton group

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 PROJECT TITLE

“In-house manufacturing capacity augmentation of current

"Star “model crankcase line from 950/d to 1500/d
(60% improvement)”

Main theme of case study : Optimizing metalworking process ( Stream 4 )

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 PROBLEM IDENTIFICATION
Capacity vs. Utilization
83%
Identified for Productivity
Improvement
100%
92%

93%

Capacity Utilization

Capacity/
Model No.of parts No.of mcs No.of cells Capacity/d asset
110cc 5 159 13 2850 5
180cc 5 73 5 750 10
70cc 5 55 7 2000 14
90cc 5 82 7 1200 9

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 Business plan for 2009-10 – Star family
2,500 2,380
2,350 2,250 2,300 2,250
2,200
2,150 2,250
2,200

2,000 2,100
2,080
2,100 Plan for 2400/ day

1,500

1,000
Apr Jun Aug Oct Dec Feb
Existing capacity available for Star c’case RH No. of No. of No. of
Cell Capacity
1150 Machines CNCs SPMs
1200
950
Cell-1 1150 14 7 7
800
800
C'caseRH-1 Cell-2 800 12 9 3
C'caseRH-2
400 C'caseRH-3
Cell-3 950 17 12 5

0 Before –
Mar'08 3000/day Phase 1 – Phase 2 –
Target (3cells) 2450/day(2cells) 2650/day(2cells)
1600 1500
Ramping up cell 3 from 950 to 1500 1300
1150 1150 1150
1200
Eliminate cell 2 and release machines for NPD 950
800 800 800 C'caseRH-1
800
C'caseRH-2
C'caseRH-3
400

0
Mar'08 Jun'08 Sep'08
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 Analysis and development of solution

Capacity Enhancement through Capital Productivity Improvement

Efforts Vs Benefit Analysis

High

Existing
manufacturing
Cells Re-
engineering
New cell
Medium
Benefit

OEE formation
Improvement with
additional
investment
Low

Hourly
PDCA
De-
bottlenecking
Low Medium High
Effort
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 DATA COLLECTION

Existing Machine time & Manual time operation wise

Star Crank Case RH – Cell 3
Takt.time-67 sec Target Takt time – 47sec
Existing Capacity 950/day (for 1500/day)
90 in 3 shifts
80
7 10 7
70 8 8 10 8 7 9 10
7
8 8
Time in sec

60 16
16 7
50 8

40
30 8
30 57 57 57 56 56 57
52 52 52 54
48 47 49
20 36 39
33 32
10 33

0
10 20 25 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180

Above target takt time – 13 machines

Machine time - ( Auto cycle Man time
time)
Man time – 176 sec Load/Unload + Walking / occasional time -89 sec

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Approach
NVA Optimization

How ?

E - Eliminate C - Combine R - Reduce S - Simplify S - Substitute

E C R S S

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 Methodology adopted to eliminate NVA
Cycle Time

Machine time Manual time

Reduction Reduction

Optimal Elemental Provide Facility for

Utilization of Analysis of Easy Loading and
Machining Machine Un Loading
Parameters Movements

Reduce rapid Reduce feed By masking When F&B=0 When F&B=0,also

distance time distance time operation homing eliminated
F F
F

H H #a #b H

B B B

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 Implementation

Elemental Analysis

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 Implementation

Spindle Vibration Analysis Report for different tool diameters :

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 Implementation

Introduce combination tools & Casting improvement

BEFORE AFTER

• Combination PCD Reamers introduced • Machine time reduced 27 sec’s

•No.of tools from 6 to 3

• Ø9&Ø38chamfering operation • Open: 40 machine time reduced from 41 to 23

eliminated sec’s
• 2 Tool change time eliminated
• Die 4,12 corrected- Die 16& 17 under EJO

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 Implementation

E-Probing for Thermal Growth Compensation

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 Implementation

Introduce low Cost Automation

Operation :10,40,60,70,90,100,110&130
BEFORE AFTER

• Manual Unloading • Auto Unloading

IMPROVEMENT BENEFITS
• Man time reduced from 8 to 4 sec’s
• Auto Unloading LCA introduced
in each m/c

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 Implementation

Introduction of Auto Deburring

Operation :25
BEFORE AFTER

Auto De-burring
introduced in opn:40 &
Manual
opn:70

IMPROVEMENT BENEFITS
• AutoDeburring introduced in •SMS reduced from 26 secs to 0 secs
CNC machines

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 Implementation

Introduce low Cost Automation

Operation :165
BEFORE AFTER

• Manual pin pressing • Auto setup pin pressing m/c

IMPROVEMENT BENEFITS
• Pin pressing machine is introduced • Manual time saving – 20 sec
•Safety of Operator

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 Implementation

Current Machine time & Manual time operation wise

( Star Crank case RH – Cell 3 )
Present
115 Capacity
Parallel 1502/day
machine in 3 shifts
94
6 6 Current takt time – 47
73 secs
T im e in sec

52 8 5 7 5
5 8 5 7 73
6 5 5 5
73 7
31 36
39 39 41 38 35 36 39 8
32 0 32 34 34 34 32
10 0 8
30 0

-11 10 20 25 30 40 50 60 70 80 85 90 100 110 120 130 140 150 155 160

Machine time - ( Auto cycle
Man time
time)
Man time – 106 sec Load/Unload (Walking / occasional time -67 secs,total =173
secs)
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 Validation Implementation

Quality parameter
Impr ov e me nt S umma r y on P r o duc ti v i ty - S ta r C r a nk c a s e
Ho = No Significant Difference

A fter C D
Ha = Significant Difference is there
Subscripts

Hence P>0.05 accept

B efo r e C D
“Ho” and reject “Ha”
F - T est
0.00150 0.00175 0.00200 0.00225 0.00250
9 5 % B onfe r r o ni C onfide nce I nte r v a ls fo r StD e v s
T est S tatistic
P - V alu e
0.92
0.808 With the above
L ev en e's T est
T est S tatistic 0.04 declaration(P>0.05) – it is
P - V alu e 0.834
A fter C D
inferred that there is “no
Subscripts

B efo r e C D
significant difference in process
variance”
76.010 76.012 76.014 76.016 76.018 76.020
B o r e C e ntr e D istance

Delivery

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 Financial benefits Benefits to organization
COST SAVINGS CERTIFICATE FOR RELEASE OF MACHINES FROM LINE-2

RS.6,11,58,000

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 BENEFITS Benefits to organization

Quality Cost Cost

Productivity Sets/Man/Day Delivery Capacity

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 Institutionalization

EJO – EXPERIMNET JOB ORDER APPROVAL

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 Institutionalization
Process FMEA Process Flow Diagram

Operation standard Control plan

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 Scope for horizontal deployment

The project being unique and having resulted with high benefits, it was shared and horizontally
deployed in the applicable areas. The snap shot of online sharing through intranet is shown below

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 Learning

Productivity

MACHINE METHOD MATERIAL MEASUREMENT MAN

Tap the maximum Tools Maintain minimum Multi gauging LCA

capacity of mc High speed Tooling material stock for system
PCD-CBN machining Deskilling the
Spindle speed–rpm Multi point cutting Online SPC manual operation
Traverse speed– edges As cast
m/min Multi stepped Core holes
Multi process tool Casting chamfer
Multi axis operation Fixture
4th & 5th axis Auto un-loader
Multi part loading

Monitoring through
DAQ

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 Learning

TVSM Guidelines followed to reduce Takt time:

Machine cycle time reduction
1. Map the existing cell for process parameters used.
2. Optimize cutting parameters by using best of tool/holder technology available.
3. Reduce non cutting time.
4. Combine tools wherever possible.
5. Use hydraulic fixtures to utilize full cutting capability of tools.
6. Optimize stock removal by design modification in incoming raw material.
7. Mapping of NVA activities related to machining and apply ECRSS
8. Line balancing.

Man time reduction

1. Conduct video analysis and identify NVA activities.
2. Make operation easy.
3. Combine operations.
4. Provide LCA to achieve Man – Machine separation.
5. Combine inspection gauges to reduce the inspection time.
6. Optimize cell layout for efficient men grouping.

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