SCRAP REDUCTION IN PISTON MACHINING SHOP

Gautham T.C1 , Akshay Kumar K.P2, Anurag S.Wallepure3 Mashahed Abdul Hameed4
Rajesh S.M5, Srinivas Rao6
1

Student, B.E in Industrial Engineering and Management-5600781, email: gauthugautham@yahoo.co.in

2
Student, B.E in industrial Engineering and Management-56007, email: 2akshaykpkumar1@gmail.c,
3
Student, B.E in industrialEngineering and Management-5600783,email:anuragwallepure@gmail.com
4
Student, B.E in industrial Engineering and Management-560078
5

Asst. Professor of IEM, DSCE, Bangalore-560078

H.O.D of Quality, Federal Mogul Goteze, Bangalore.

II.

PROBLEM DEFINITION

AbstractThe resultant pistons are sent for cleaning up of surface of

the piston from risers and runners and later, the strength, hardness
and other foundry defects are evaluated. Then a bunch of piston is
placed in piston blank for its machining operations.

Rejection or the scrap is a threat to any manufacturing

industries. In a mass production company which aims to
produce around 800 per shift per line. Every single
rejection accounts to the loss of efficiency.

From the initial study, it reveals that FEDERAL MOGUL is

having a rejection rate of 8% overall of the products produced.
Possible causes for higher rejection rate may be due to the process/
method used, failure in analysing the quality of raw material
procured, on-job inspection in shop floor during production, damages
occurred during finishing process or secondary production.

As all products cannot be thrown out as scarp they are

inspected again and rework is carried out to bring about
difference in number of scrap thus bringing down of the
quality of the product manufactured, consuming extra man
and machine time

The aim of this project is to identify the possible causes for the
above said rejection and reducing the rejection rate with the help of
the quality techniques and the Quality Control tools.

III. METHODOLOGY

The Seven Quality (7 QC tools) Control tools include:

I. INTRODUCTION
Piston is one of the most important parts in the
reciprocating engine. With a huge development in the
automobile industries, there is increased demand for the
piston in the market.
Piston manufacturing involves various complicated process
to produce a piston. The quality level set to ensure
customer satisfaction has increased the degree of the
precession for the manufacturing product, thus increasing
the challenge for piston manufacturing industries.

Check sheet
Stratification
Pareto diagram
Cause and effect diagram
Histogram
Control charts
Scatter diagram

III.

DATA ANALYSIS

To survive in tough competition in the market the piston

manufacturing companies have to standardize the
production system to ensure high quality product and high
degree of customer satisfaction.
Due to very high rate of precision, various defects are
observed in the out coming process, which indicates the
nonconformity of product.
Figure.1: Pareto chart for cnc-1 line

Xbar Chart:

IV.
UCL

IMPROVEMENT PLAN
Table.1: Improvement plan

LCL

X- Axis= Sample number

Y- Axis= Control limits

PROBLEMS

PRESENT
CAUSES

SUGGESTIONS

STATUS

Chips
gets
embedded to
fixture

Manual
cleaning of
fixture in
machine

Motor will be put

with the brush,
use
air
compressor

Completed

Vibration
bed
machine

Temporary
packing
was used

Machining was
given
for
maintenance

Completed

in
of

Figure.2: X-bar Chart before implementation

UCL

LCL

Figure.6: X-Bar chart after implementation

Figure.3: R Chart before implementation

Figure.7: R chart after implementation

Figure.4: cause and effect diagram for compression height

Table.2: Implementation plan

Figure.5: cause and effect diagram for damage

on machine/ method, Rejection due to Damages has

been reduced by 5.17 %.
REFERENCES
1) Robinson, Harry (1977). Early detecting of defects
poka-yokhttp//facultywebberyed/igrout/pokasoft.html.may2012.
Figure.7: before and after implementation

V.

2) Shingo Shigeo. Andrew P Dillon (1989) a study of

Toyota production system for industrial
engineering view point.

RESULTS AND DISCUSSIONS

3) Oregon productivity press Johan R Gorat

production technology a brief tutorial on mistake
proofing, poka-yoke, and 7QC.
4) Manufacturing and processing system professor J
S Colton Georige institute of technology (2009).
5) Standard manufacturing process (piston) FMGIL
manual.
Figure.8: % Improvement in compression height

Figure.9: % Improvement in damage

CONCLUSION

The project titled REDUCING PISTON REJECTIONS

DURING
MACHINING
OPERATION
IN
MANUFACTURING is completed. And based on the
observation and analysis, the following conclusions were
drawn.
After providing the brush for cleaning machine fixture
seat and providing training for the operator of
machining process & Methodology, Rejection due to
compression height has been reduced by 8.19 %.
After providing grooves & appropriate space in
between the pistons and providing operative training