Smed Cell 1,2&5 Updated (July)

PHASE I
Sundaram Brake Linings Limited,

Padi.
12/07/09
ANALYSIS TO REDUCE SETUP TIME IN CELL 1 DRILLING MACHINE FOR TVS/COM/1 TO TVS/HM/4
ELEMENTAL DESCRIPTION
TIME IN SECONDS
Sl.No.
ACTIVITY
CHANGE
TIME IN SECONDS (BEFORE)
BEFORE
PROPOSED
CURRENT
STATUS
40 80 120 160 200 240
Releasing clamp of cradle
32.55
32.55
32.55
Walking to take SMED trolley
30.26
30.26
Moving of trolley to m/c
36.24
Loading of cradle in trolley
22.68
22.68
22.68
Releasing of two bolts of Drill head
77.92
77.92
77.92
Releasing of drill head
8.96
8.96
8.96
Moving cradle to its location
55.87
Walking near to m/c

Taking the released drill head and placed in its
position
8.11
23.95
23.95
10
Placing of cradle to its place
18.38
11
Loading of required cradle in trolley
17.19
17.19
C
C
C
C
C
C
12
Searching of drill bit and taken
10.04
10.04
13
Moving of required drill head to m/c
15.62
15.62
14
Walking back to move cradle
7.12
7.12
15
Moving of required cradle to m/c
65.63
65.63
16
Loading of drill head
14.86
14.86
14.86
17
Tightening of drill head using two bolts
88.52
88.52
88.52
18
Loading of cradle
16.1
16.1
16.1
19
Clamping of cradle and tighten
26.24
26.24
26.24
20
Connecting all pneumatic hoses
12.73
12.73
21
Adjusting cradle with respect to drill head
278.25
70
278.25
22
Spindle adjustment
135.57
55
135.57
23
Down the bed and adjusting crimp height
78.47
30
78.47
24
Loosening of drill bush
25
Adjusting drill bush with respect to jig
26
Tightening of drill bush
27
checking of drill bit through bush with jig
7.25
7.25
7.25
18.83
18.83
18.83
14.4
14.4
14.4
56.17
56.17
C
C
C
C
C
C
C
C
C
C
C
320
PROPOSED TIME IN SECONDS

360
40
80
120 160 200 240 280 320 360
28
Fixing front side tool box
29
Connecting dust control hose
30
Air line on
31
32
26.74
26.74
26.74
17.99
17.99
17.99
8.03
Trial indexing
15.68
15.68
15.68
Tighten drill bit
25.93
25.93
33
Applying of lub oil on bush
18.83
18.83
34
Placing folded paper for dust
15.14
15.14
35
First piece trial
8.24
8.24
8.24
36
Inspection
52.05
20
52.05
37
Adjusting adapter
90.49
25
90.49
38
Second piece trial
39
Inspection
40
Third piece trial
41
Inspection
Total time in secs

Converted to Parallel activity
8.27
8.27
8.27
64.98
20
64.98
9.49
9.49
9.49
49.69
20
49.69
1589.46 670.72
C
C
C
C
C
C
C
C
C
C
C
C
1466.83
Converted to Pre-planning activity
BEFORE
PROPOSED
Time reduction through Kaizen
IMPROVEMENT
Off line setting of SMED trolley

Off line setting of SMED trolley
Provide SMED Trolley Back side of

Drilling M/C
TARGET DATE
20/07/09
20/07/09
15/07/09
parallel Activity
Quick coupler to be provided

Standardizing cradle Position
Provide lock pin
Provide Crimp height setting
gauge/ off line setting of adapter
Offline Setting
STATUS
11/07/09
15/07/09
25/07/09
28/07/09
18/07/09
COMPLETED
Placing air line nearer to operator
Off line setting of Drill bit

Offline lubrication
Dust hood modification
Placing Inspection table nearer to

m/c
off line setting of adapter
16/07/09
18/07/09
19/07/09
15/07/09
20/07/09
19/07/09

m/c
15/07/09

m/c
16/07/09
NO CHANGE
COMPLETED

Padi.
PHASE I
12/7/2009
ANALYSIS TO REDUCE SETUP TIME IN CELL 2 U LINE 1 DRILLING MACHINE FROM ALRF 5 TO ALRF 7
TIME IN SECONDS
S. No
CHANGE
BEFORE
PROPOSED
Removing the 5 inch drill bit
39
30
Loosening the drill head bolt for adjustment
78
50
Adjusting the spindle
76
76
Removing the pin for turning drill head
31
12
Turning drill head
29
29
Taking the removed pin and Locating it in drill head
80
20
Changing the 7 inch drill bit into drill adapter
Adjusting the drill bit
TARGET
DATE
IMPROVEMENT
ACTIVITY
Tightening the drill head bolt
28
28
265
109
80
10
Tightening the spindle
109
80
11
First good piece
135
135
12
Adjusting crimp height
35
13
Inspection
72
45
1086
585
Total time in secs

40 80 120 160 200 240 280 320 360
40
80
120 160 200 240 280 320 360
C1`
To provide drift type for

easy removal
17/07/09
Ratchet Spanner
16/07/09
Provide
pin
welded chain link
with
20/07/09
Provide pin with

welded chain link
20/07/09
Off line setting of

adapter
18/07/09
Ratchet Spanner
16/07/09
Ratchet Spanner
16/07/09
C
C
To be studied
18/07/09
Off line setting of Drill
bit
15/07/09
C
C
BEFORE
AFTER
No change
SUNDARAM BRAKE LININGS LIMITED
Phase 1
Padi.
ANALYSIS TO REDUCE SETUP TIME IN CELL 2 U-LINE 4 DRILLING MACHINE FROM ALRF TO EICHER
TIME IN SECONDS
SL. No
ACTIVITY
CHANGE
BEFORE
PROPOSED
Removing Drill head assembly.
70
Walking to trolley
18
40 80 120 160 200 240 280 320 360
40
80
120 160 200 240 280 320 360
E/I
Moving trolley with drill head to the rack
49
Searching for drill adapter and spindle adjuster
51
Moving trolley to the machine
15
Moving cradle(off line set) to machine
26
Loading to the machine bed.
24
10
Adjusting the spindle
77
30
Checking spindle key way with spindle shaft top locater
41
1
2
3
4
5
6
7
10
Moving trolley to the machine for placing the drill head
C
C
Fitting and locating spindle key
50
Fixing cradle
87
30
Moving spindle up.
16
Raising the bed.
22
15
17
Spindle Up/Down Movement.
11
11
18
Lifting Drill Head
62
Adjusting and fixing drill head
57
Drill head rotating for alignment
31
Fixing with 10 mm bolt
37
19
Searching for tools.
17
251
40
Adjusting Drill head key.
18
15
25
rotating spindle.
25
12
26
Spindle adjusting.
12
Drill bit setting
33
12
13
14
15
16
19
20
21
22
23
24
27
Moving spindle down
Tightening using Allen key.
E
E
To use same drill head
To design a new improved SMED tro

which wil be able to take up remov
assembly and the assembly to b
mounted along with place for dri
adaptor and necessary tools for th
concern change over.
11
Searching for tool
IMPROVEMENT
E
I
E
I
E
C
C
To arrange rollers in SMED trolley

To arrange setting gauge in SME
trolley.
E
I
To arrange al necessary tools for C/

SMED trolley.
To standardize the Key pin
To arrange roller type trolley
I
I
I
To give location for keeping the le

fixed.
I
I
I
I
E
I
Bolting will be done

To provide the tools near by the
machine
To use rachet spanner instead of al
key.
I
I
I
E
off line setting of drill bit
28
Adapter setting.
19
15
29
Adapter fixing.
19
15
Adjusting Drill bit.
24
112
Tightening drill using Allen key.
63
23
Adjusting cradle
32
24
Adjusting drill head bolt.
41
20
Drill head adjusting
19
36
Checking for hole position.
10
10
37
Cradle adjustment with hammer
23
Adjusting CED plate
40
12
Adjusting spindle for hole position.
30
31
32
33
34
35
38
Adjusting drill adapter.
17
17
Connecting Airline to cylinder
116
20
Trial checking drill movement.
35
19
Drill up down position checking
13
10
Drill hole position checking in reverse direction.
18
44
Adjusting top limit switch for drill hole depth.
33
26
45
Indexing limit switch adjusting.
87
18
46
Setting of first piece
20
13
Trial piece check
16
16
Inspection of crimp height
15
15
Moving to hole position gauge
17
Hole position checking
35
22
Plug gauge checking
20
20
Counter Bore Dia Checking
15
15
53
Moving back to machine
14
54
Checking CED
20
Fine tuning the Adapter
33
Setting of second piece
20
13
Trial piece check
16
16
Inspection of crimp height
15
15
2097
590
39
40
41
42
43
47
48
49
50
51
52
55
56
57
58
E
I
E
E
To arrange setting gauge in SMED

trolley.
To arrange setting gauge in SME
trolley.
I
I
I
I
I
I
I
To provide easy locator
I
I
Common airline connecting junctio
I
I
I
I
I
Standardizing the limit switch for e

product
I
I
I
I
To place the hole position gauge

SMED trolley based on the produc
I
I
I
I
I
standardizing CED plate
off linesetting of adapter
I
I
I
BEFORE
AFTER
34.95
9.833333
No change
UP TIME IN CELL 2 U-LINE 4 DRILLING MACHINE FROM ALRF TO EICHER
Date :12/07/09
IMPROVEMENT
Target Date
15/07/09
To design a new improved SMED trolley

which wil be able to take up removing
assembly and the assembly to be
mounted along with place for drill
adaptor and necessary tools for the
concern change over.
To arrange rollers in SMED trolley.

trolley.
To arrange al necessary tools for C/O in
SMED trolley.
To standardize the Key pin
17/07/2009
18/07/2009
21/07/2009
18/07/2009
20/07/09
To arrange roller type trolley

20/07/09
To give location for keeping the lever
fixed.
20/07/09
18/07/09
18/07/09
18/07/09
Bolting will be done

To provide the tools near by the
machine
To use rachet spanner instead of allen
key.
18/07/09
completed
off line setting of drill bit
18/07/09
17/07/09

trolley.
trolley.
To provide easy locator
19/07/09
19/07/09
24/07/09
22/07/09
Common airline connecting junction.
18/07/09
Standardizing the limit switch for each

product
26/07/09
To place the hole position gauge in

SMED trolley based on the product.
20/07/09
standardizing CED plate
24/07/09
off linesetting of adapter
24/07/09
No change

Padi.
ANALYSIS TO REDUCE SETUP TIME IN CELL -5 IN DRILL 08 FROM 280DIA to 10/MB/1A

S.No.
ACTIVITY
TIME IN SECONDS
CHAN BEFORE
PROPOSED
GE

IMPROVEMENTS
50
100
150
200
250
300
50
100
150
200
250
300
Cleaning the machine
32
32
Taking the spanner
16
60
60
Fixing the tools with in the machine
Searching and taking cotton waste
26
59
59
Off-line arrangement
58
Cleaning the machine
58
Removing the Jig clamp bolts(2 Nos)
57
57
15
56
56
Reducing the no of turns
55
55
Fixing c-washer within the machine
54
54
Provision done for keeping the guide rod with

in the head itself
53
53
52
52
51
51
50
50
49
49
48
48
47
47
46
46
6
7
8
9
Removing the jig bolts(3 Nos)

Loosening guide rod bolts and taking CWasher
29
16
10
Removing the guide rod

Removing jig from m/c and keeping in offline
trolley
30
10
20
20
10
Moving to the drill head c/o trolley
16
11
Moving the trolley to machine
29
12
13
Adjusting the trolley to position

Moving the inner trolley to m/c and climping
to top
14
Taking tool
15
10
10
Off-line arrangement/trolley to be serviced

64
40
55
15
45
45
44
44
44
18
Loosening bolts and c-washer

Lowering drill head and moving the inner
trolley back
Moving the trolley back and bringing the new
trolley
Moving the inner trolley to m/c and climping
to top
12
12
43
43
19
Adjusting for bolt position
25
10
42
42
20
Tightening the bolts
79
40
41
41
21
Coming down and taking inner trolley back
10
10
40
40
22
Moving the trolley back to its position
16
39
39
23
Bringing the offline trolley to machine
23
38
38
24
Taking the jig from trolley and keeping in m/c
14
14
37
37
25
Connecting the pneumatic hoses
25
10
36
36
35
35
34
34
33
33
32
32
31
31
30
30
16
17
26
Putting jig bolts and tightening(3 Nos)
38
20
27
Keeping spacer in jig
15
Fixing the tools with in the machine

C-Washer to be changed
Problems in drill head to be corrected
Stopper to be provided
C-Washer to be changed
Quick coupler provided

Reducing the no of turns
Provision to be done in bush holder to locate
without using spacer
28
Bed up and taking C-washer and loading the

bush holder in Off trolley from machine
33
33
29
Loosening drill adaptor bolts and taking out
58
30
30
Keeping spacer
10
31
Keeping the bush holder from trolley to m/c
32
Taking guide rod and putting it (2 sides)
47
10
37
37
36
36
35
35
34
34
33
33
32
32
31
31
30
30
29
29
28
28
27
27
26
26
25
25
24
24
Lever type arrangement provided instead of

using hand tolls
Bed movement rod to be serviced and
provision to be done for reducing hand tools
Lever type arrangement provided instead of
using hand tolls
Seperate sensors provided for each cylinder
33
Putting stopper for guide rod
11
34
Loosening bed movement lock bolts
32
10
35
Adjusting bed for guide rod free movement
90
40
36
Tightening bed movement bolts
28
10
38
Changing indexing cylinder sensors

Checking spindle for hole position in bush
holder
Loosening universal joint bolts and replacing
joints
66
23
23
68
20
22
22
280
21
21
31
20
20
39
40
41
43
Putting bolts
Checking drill bit free movement in the bush
holder and placing the drill bit(6 Nos)
Adjusting spindle for drill bit position and
insertig the drill bit in to the spindle
103
18
44
Tighteneing drill bits with spindle
86
86
17
17
45
Putting bush holder c-washer
17
17
16
16
46
Adjusting spindle
150
15
15
47
Putting jig clamp
33
33
14
14
48
Searching for Jig clamp stud
18
13
13
12
12
11
11
42
74
20
19
19
103
18
49
Tightening the clamp bolts
14
14
50
Putting guide rod c-washer
22
10
Checking indexing and cycle start
26
52
Checking crimp height
43
53
Adjusting bed up and down travel
27
10
54
30
10
24
10
57
1st trial
37
37
58
Adjusting crimp height limit switch
22
59
2nd trial
15
15
60
17
17
To be done in Offline
Bed height to be standardised for each
product
To be done in Offline
product
Lock nut to be provided for using the 2nd limit
switch
Adjusting crimp height limit switch
Offline crimp height adjustment to be done
Adjusting bed up and down travel
56
It should be standardized instructed to fix
atleast 10 joints in the head
Lever type arrangement for loosening the
bolts instead of hand tools
Fixing c-washer within the machine
55
Provision done for keeping the guide rod with

in the head itself
10
10
51
Drill adaptors to be serviced for free

movement
Provision to be done in bush holder to locate
without using spacer

product
50
100
150
200
250
300
50
100
150
200
250
300
19
19
18
18
17
17
16
16
15
15
14
14
13
13
12
12
11
11
10
10
1
0
61
First off approval
Total time in secs

20
20
2216
833
50
100
150
200
BEFORE
250
300
50
100
150
200
250
300
Proposed
No change
12/7/2009
UP TIME IN CELL -5 IN DRILL 08 FROM 280DIA to 10/MB/1A
TARGET DATE
25/07/2009
20/07/09
Completed
30/07/09
Completed
Completed
10/07/09
25/07/2009
20/07/2009
Completed
20/07/09
15/07/2009
20/07/09
20/07/2009
20/07/2009
Completed
Completed
25/07/2009
30/07/2009
25/07/2009
Completed
Completed
Completed
Completed
Completed
20/07/09
20/07/2009
Completed
20/07/09
20/07/2009
20/07/09
20/07/09
20/07/09
25/07/2009
20/07/09
25/07/2009
Completed
25/07/2009
No change

Smed Cell 1,2&5 Updated (July)

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PHASE I

Sundaram Brake Linings Limited,

TIME IN SECONDS (BEFORE)

40 80 120 160 200 240

Releasing clamp of cradle

Walking to take SMED trolley

Moving of trolley to m/c

Loading of cradle in trolley

Releasing of two bolts of Drill head

Releasing of drill head

Moving cradle to its location

Walking near to m/c

Placing of cradle to its place

Loading of required cradle in trolley

Searching of drill bit and taken

Moving of required drill head to m/c

Walking back to move cradle

Moving of required cradle to m/c

Loading of drill head

Tightening of drill head using two bolts

Clamping of cradle and tighten

Connecting all pneumatic hoses

Adjusting cradle with respect to drill head

Down the bed and adjusting crimp height

Loosening of drill bush

Adjusting drill bush with respect to jig

Tightening of drill bush

checking of drill bit through bush with jig

PROPOSED TIME IN SECONDS

120 160 200 240 280 320 360

Fixing front side tool box

Connecting dust control hose

Tighten drill bit

Applying of lub oil on bush

Placing folded paper for dust

First piece trial

Second piece trial

Third piece trial

Total time in secs

Converted to Pre-planning activity

Time reduction through Kaizen

Off line setting of SMED trolley

Provide SMED Trolley Back side of

Quick coupler to be provided

Placing air line nearer to operator

Off line setting of Drill bit

Placing Inspection table nearer to

Placing Inspection table nearer to

Placing Inspection table nearer to

Sundaram Brake Linings Limited,

TIME IN SECONDS (BEFORE)

PROPOSED TIME IN SECONDS

Removing the 5 inch drill bit

Loosening the drill head bolt for adjustment

Adjusting the spindle

Removing the pin for turning drill head

Turning drill head

Taking the removed pin and Locating it in drill head

Changing the 7 inch drill bit into drill adapter

Adjusting the drill bit

Tightening the drill head bolt

Tightening the spindle

First good piece