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Indian Institute of Technology, Kanpur

JS Auto, Kanpur
Report on Design of new assembly line

By1. 2. 3. 4. Angshuman Sarkar Mangesh Dharwad Rahul Murkya Vidit Mehta 12125006 12125026 12125037 12125053

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Table of Contents
1. 2. 3. 4. 5. 6. 7. Acknowledgement ...................................................................................................................... 3 Introduction ................................................................................................................................ 4 Objective of our study................................................................................................................. 4 Assumptions................................................................................................................................ 5 Methodology used to collect data .............................................................................................. 5 Various operations and their time study data ............................................................................ 7 Analysis and work station design................................................................................................ 9

Annexure...............................................................................................................................................12

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1. Acknowledgement
The successful accomplishment of this project and the contentment it accounts for would be incomplete without the mention of people whose ceaseless cooperation made it possible, whose constant guidance and encouragement crowned all efforts with success. We are grateful to Dr. Deepu Philip for the guidance, inspiration and constructive suggestions that helped us in constant improvement and final preparation of this project. We also take this opportunity to thank Mr. Mukesh Jain, JS Auto for helping and supporting us in our study at the factory.

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2. Introduction JS Auto Pvt. Ltd. is a medium-scale firm, which primarily manufactures three-wheeler passenger and goods carrier. The owner of JS Auto Pvt. Ltd. is Mr. Suresh Puri, who is ably assisted by his son Mr. Sandeep Puri in the business operations. It is based in Kanpur, with the main production unit and offices at Panki Industrial Area. JS Auto was established in the year 1986 with employee strength of 20 and a basic production unit for Precision Sheet Metal Items, Fabricated Deep Drawn Items, Fabricated Items, Tubular & Tubular Fabricated Items, Machined Items with Close Tolerance, Assemblies & Shock Absorbers, etc. With the passage of time and advent of technology, it has rapidly expanded operations, and today it is a forerunner in the industry as an ISO 9001:2008 certified by UKAS (The United Kingdom Accreditation Service). It is known as the leading manufacturer, supplier and exporter of highly acclaimed JSA Three Wheelers (Diesel and CNG Models). JS Auto has also continued its old product line which is designed to provide adequate solutions to varied types of two and three wheelers and for other types of applications. Some of the reputed clients of JS Auto include Tata Motors, Telco, LML Ltd., etc. JS Auto has a market base spread all over the country and it also exports to Bangladesh, Sri Lanka and some of the African nations. With a monthly production capacity of 700-800 vehicles, it has a diversified product range comprising of:
        

Passenger Carrier with Hard Top (Diesel Variant) Load Carrier with Hard Top (Diesel Variant) Passenger Carrier and Chassis ( Diesel Variant) Load Carrier Pick Up Van Load Carrier (Petrol / CNG Variant) Tipper (Diesel Variant) Passenger Carrier (Petrol / CNG Variant) Pick Up Van (Petrol / CNG Variant) Passenger Carrier with Soft Top (Diesel Variant).

3. Objective of our study
JS Auto is coming up with a new plant which would be situated at a distance of 15 kms from its existing production unit at Panki. For this new plant JS Auto is planning to come up with an assembly line for manufacturing of three wheelers. Our project is to design a basic assembly line and work stations for Diesel passenger vehicles. It includes designing and

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combining assembly processes carried out on the chassis only. Time required for any subassembly is not included in our project. Our main objective is to reduce the time required for the assembly of the vehicle, by combining the various processes involved in to the same work station and sequencing them.

4. Assumptions
We have made the following assumptions while recording the time required for various processes and designing the assembly line:   All the sub-assemblies would be ready for the mounting on the main frame at the work stations. We are considering that the workforce would be available at the work stations dedicatedly for the work assigned to them.

5. Methodology used to collect data
We visited JS Auto factory at Panki, Kanpur four times to study all the manufacturing processes and assemblies. In our first visit we explored the complete factory and tried to understand the functioning of various departments and operations carried out at JS Auto. In subsequent visits we focussed our study only on the assemblies carried out on the chassis. As no one from our group had prior experience in automobile manufactory industry before, each and every step and process was a new learning for us. In our second visit we studied the assemblies broadly and tried to get the time required for various operations carried out on the chassis from the workers. We enquired 6 to 7 workers in our second visit and asked how much time they require for each operation but we were not able to get the exact details and time data required for the small sub-assemblies as workers only provided us with overall times for front show assembly, rear wheels assembly, front wheel assembly, engine mounting etc. Before our third visit we decided to record the time required for each operation personally and also note down all the small steps involved. For this we visited the factory at 9:00 AM and started our work with five Diesel passenger vehicles chassis. During our third and fourth visits we formally recorded the operations carried out by the workers along with their specific times taken on the chassis. We did not miss even a single assembly process on the chassis and noted the time required for all of them. We gathered data for chassis of five Diesel passenger vehicles on which different operators were working. We kept taking notes and whenever we had a doubt or a query with respect to any of the operations, we got them clarified from the workers and the supervisor present at the shop floor. Parallely our team recorded data and

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times taken for the five chassis that were being worked upon. In the end we collated the data and averaged it out.

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6. Various operations and their time study data
Time data collected for the different operations on chassis of Diesel passenger vehicle. Five chassis were studied. [Table 1]
After rounding of average time

Sr. No.

Operations

Chassis 1

Chassis 2

Chassis 3

Chassis 4

Chassis 5

Average Time

Time (mins) 1 2 Master Cylinder setup Upper cone and Lower cone Setup Reverse Gear Lever setup Air cylinder with stand Diesel Filter Steering wheel assembly Hydra mounts (2 Nos) Rear Shock absorbers (2 nos) Gear lever stand (Floor gear mount) FGM Gear lever Hand break Paddle assembly Leaf springs (2 Nos) Air filter to host pipe Master Cylinder to breaking cables Ball bearing Mounting on upper cone Ball bearing Mounting on lower cone Screw tightening with pneumatic machine D cable to compressor Choke cable Reverse gear cables Accelator cable Break cables Clutch cable Starter cable stopper cable 1.5 2 2 2 1.5 1 2 2 2 2 1.80 1.80 2 2 5 6 5.5 5 5 5.30 6 1 6 5.5 1.5 3 3 3 4 1.5 5 5 2 3.5 3.5 4 5 1 6 6 2 3 3 3.5 5 2 7 5 2 3 3 4 4 1.5 6 5 1.5 4 4 4 4 1.40 6.00 5.30 1.80 3.30 3.30 3.70 4.40 2 6 6 2 4 4 4 5 1.5 1 2 2 2 1.5 1.5 2 1 2 1.60 1.70 2 2

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3

2

2.5

3

2.5

2.60

3

4 5 6 7 8

2 1 4 2 2

2.5 1.5 4 2 1.5

2.5 1 5 2.5 2

2 2 7 2 1

2 1 5 2 1.5

2.20 1.30 5.00 2.10 1.60

3 2 5 3 2

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

4

5

5

4

6

4.80

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8 After rounding of average time 3 2 9 3 5 17 2 8 2 3 15 5 2 6 11 5

Sr. No.

Operations

Chassis 1

Chassis 2

Chassis 3

Chassis 4

Chassis 5

Average Time

27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Oil filling in Air filter Oil filling in stearing box Front show assembly Stand for Diesel tank Diesel tank mounting Rear wheel and cable assembly (with tyres) Battery mounting Tack welding of platform on frame Exhaust Pipe assembly Engine mounting Engine assembly with other cables Engine shocker Bracket welding Engine shockers to frame Inner dome Front wheel assembly Front mudguard assembly

1.5 2 8 3 6 18 2 8 1 2 14 5 1 6 `12 5

2 2 7 2.5 6.5 15 2 7 1.5 2.5 16 4 2 5 14 4

2.5 1 9 2 5.5 15 1.5 7 1 3 14 4 2 5 12 4

Time (mins) 2 2 9 2 6 17 2 8 1 2 14 5 1 6 12 4.5

2.5 1 8 3 6 16 2.5 8 2 2 15 5 1 6 13 4

2.1 1.6 8.2 2.5 6 16.2 2 7.6 1.3 2.3 14.6 4.6 1.4 5.6 10.2 4.3

Total time = 168 minutes

Work station Number 1 2 3 4 5 (only 1 team)

Team 1

Team 2

Total time at work station per team 19 20 19 18 20

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7. Analysis and work station design
To design a basic assembly line for the three wheeler Diesel Passenger vehicle we are considering the following work stations with processes and timings taken from Table 1. At the work stations 1, 2, 3, 4 and 5 two teams (team 1 and team 2) of workers would be working simultaneously on the chassis of vehicle. Two teams will consist of 3 workers. [Serial Nos. In square bracket from Table 1] WORK STATION 1 Team 1 1) Upper cone and Lower cone Setup [2] 2) Reverse Gear Lever setup [3] 3) Ball bearing mounting on upper cone [16] 4) Ball bearing mounting on lower cone [17] 5) D cable to compressor setup [19] 6) Choke cable setup [20] 7) Reverse gear cable setup [21] 8) Accelerator cable setup [22] 9) Break cables setup [23] 10) Clutch cable setup [24] Total time required for Team 1 = 17 minutes Total time required for Team 2 = 19 minutes Team 2 1) Master Cylinder setup [1] 2) Air cylinder setup with stand [4] 3) Diesel filter setup [5] 4) Hydra mounts setup (2 Nos) [7] 5) Gear lever and its stand (Floor gear mount) FGM setup [9 & 10] 6) Hand break setup [11]

WORK STATION 2 Team 1 1) Steering wheel assembly [6] 2) Rear Shock absorbers (2 nos) setup [8] 3) Paddle assembly [12] 4) Air filter to host pipe setup [14] 5) Master Cylinder to breaking cables [15] Total time required for Team 1 = 19 minutes Total time required for Team 2 = 20 minutes Team 2 1) Leaf springs (2 Nos) setup [13] 2) Screw tightening with pneumatic machine [18] 3) Front show assembly [29]

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WORK STATION 3 Team 1 1) Starter cable setup [25] Starter cable 2) stopper cable setup [26] 3) Oil filling in Air filter [27] 4) Oil filling in steering box [28] 5) Stand for Diesel tank [30] 6) Diesel tank mounting [31] 7) Battery mounting [33] Total time required for Team 1 = 19 minutes Total time required for Team 2 = 19 minutes Team 2 1) Rear wheel and cable assembly (with tyres) [32] 2) Exhaust Pipe assembly [35]

WORK STATION 4

1) Inner dome [40] Starter cable 2) Front wheel assembly [41]

1) Engine mounting [36] 2) Engine assembly with other cables [37]

Total time required for Team 1 = 17 minutes

Total time required for Team 2 = 18 minutes

WORK STATION 5

1) Engine shocker Bracket welding [38] 2) Tack welding of platform on frame [34] 3) Engine shockers to frame [39] 4) Front mudguard assembly [42] Spare team at the work station 5

Total time required for Team 1 = 20 minutes

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Analysis As per our observational study with current setup (Batch production) at JS Auto, with all sub assemblies ready and 3 workers it takes 168 minutes (as per table 1) to assemble all the components on one chassis. If we assume that there is increase in the work force by five times i.e. to 15 it will take 34 minutes to assemble all the components described in table 1 on one chassis. With design of new assembly line, work stations and 15 workers the time required for assembly of components on the chassis of one vehicle will come down to 20 minutes.

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Annexure
Master Cylinder Gear lever and Floor gear mounting

Rear wheel assembly

Hydra mount

Reverse gear lever

Hand break

13 Air filter to Host pipe Paddle assembly

Steering wheel assembly with paddles

Ball bearing mounting on upper cone

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Exhaust Pipe assembly

Engine assembly