AEIJST - August 2016 - Vol 4 - Issue 8 ISSN - 2348 - 6732

Time Reduction On Rear Transmission Assembly With Fool Proof JIG

*R S. Prakash
**D.Gobinath
***R. Soundharraj
****V.Srisairam
*****D.P.Vijay Aravind
*Assistant Professor, Mechanical Engineering, Kathir College of Engineering
** & *** & **** & *****UG Students, Mechanical Engineering, Kathir College of Engineering

Abstract Our paper deals with time reduction in an automobile industry and
improving the design of jig which is mounted on the conveyor. In automobile
assembling industries, the production rate is fully based on the speed and time of the
conveyor. In order to increase the production rate, the conveyor time is reduced. The
time taken for manual operation for assembling axles is high and so we made it semiautomatic by a DC motor drive which reduces the operation/assembling time for the
labours. The existing design of the jig is not safe and so we have developed the design
of the jig with fool proof to avoid careless accidents during operation.
I. INTRODUCTION

This paper is based on the common observations that has been made in industries. One of
the difficulty observation in the industries was manual rotation of jig for assembling rear
transmission assembly. So there is need of semi automated special purpose motor drive for
assembling rear axles. This lead for time reduction in mass production application.
Introduction To Lean Manufacturing
Lean manufacturing was introduced by Toyota nearly 50 years ago. Since then, it has come
to mean different things to different people. Talk about just in time deliveries, inline parts
sequencing, and smaller and more frequent deliveries and what you are really talking about is
lean-To that extent, lean is not a process or technology, rather lean is a philosophy aimed at
reducing waste by optimising process across an enterprise, from the point of order to the point
of delivery
If done right, lean manufacturing and distribution leads to;
Reduced cycle time
The ability to deliver every time at the same cost to the business
Predictable throughput times from better labour utilisation
Improved working capital positions from reduced inventory
Lower warranty and customer service costs from improved quality.
No More Waste
Taichi oh no, the father of lean manufacturing, identified seven deadly wastes that prevent
the value added flow from raw materials to finished goods. They are:

Over production

Waiting

Down time

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AEIJST - August 2016 - Vol 4 - Issue 8 ISSN - 2348 - 6732

Un necessary product movement

Excess inventory

Un necessary motion

Defective products

There are several things to be considered prior to investment in material handling

optimization. By following three simple concepts, plant managers can realize significant cost
savings from material handling systems and equipment.
Most plant managers grapple with the question-how do you reduce costs without hurting
output. One answer lies in optimizing current material handling systems and equipment. By
following a few simple steps, plant managers can prolong service life, minimize downtime and
cut capital expenditures and these strategies fall under three easy to remember approachesReduce Reuse and Recycle.
Reduce
To keep equipment running at peak capacity and thus reduce inefficiencies, managers
should implement a performance audit and adopt predictive, instead of reactive, maintenance.
These two strategies allow managers to maximize current material handling systems and
equipment without accelerating wear and tear or driving up maintenance costs.
A performance audit can help in zeroing in on productivity drains, evaluating such areas
as picking, queing, staging and sorting rates. Thus, managers can pin point and fix
inefficiencies, realising cost savings from improved productivity rates and system performance.
Reliable and cost effective, predictive maintenance is another way to get the most out of
material handling systems and a equipment, it can help you determine when components will
fail, so you can do corrective work on them before they break down. In particular, it allows you
to set base line failure rates over time.
Re-Use
To reuse existing equipment and avid the high cost of replacement, consider retrofitting,
that can boost efficiency by 15-20% or more by retrofitting, plant managers can allow systems
to function beyond initial capacity limits and to satisfy increased production demands. It can
involve incorporating new technologies, upgrading components or increasing capacity by
retrofitting equipment instead of replacing it managers can enjoy considerable savings. For
one thing the cost of reposing equipment is often less than 60 % of the new machines cost.
Re-Cycle
Instead of purchasing new equipment when production requirement change, plan
managers can buy remanufactured components. They can thus take advantage of lower
capital equipment costs, as manufacturing retains much of the original items value. A lean
system seeks the right balance of inventory, equipment, and manpower to support a built to
order environment rather than build to stock.
The first step to get lean is to develop a vision of where the company wants to go. The next
step is to roll lean out through a company. The next step is to evaluate what improvements
would have the greatest impact on the business. Materials handling enables lean through
solutions that lower picking costs, improve picking accuracy, increase throughput, reduce
injury related costs through ergonomics, or maximize floor space.
II. PROBLEM DEFINITIONS

We have identified the problem on rear transmission assembly. In which for assembling the
axles they have rotating the jig manually. It consumes much time so we converted into semi2
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AEIJST - August 2016 - Vol 4 - Issue 8 ISSN - 2348 - 6732

automatic by introducing of DC motor drive. There is a lack of safety in existing jig so we made
the development to avoid accidents and losses.

III. OBJECTIVES

To reduce time for lean manufacturing.

To make the rotation of handle automatic by a motor drive in order to reduce the time
taken to tilt the jig for mounting the Left hand and Right hand axle assembly.
To develop the design of the jig to make it fool proof for improved safety design.
To reduce the difficulty for the labours to adopt for the revised conveyor time and shift
hours.
IV. DC MOTOR

A DC motor like we all know is a device that deals in the conversion of electrical energy to
mechanical energy and this is essentially brought about by two major parts required for the
construction of dc motor, namely.
1)
2)

Stator The static part that houses the field windings and receives the supply
Rotor The rotating part that brings about the mechanical rotations

CONSTRUCTION OF DC MOTOR
Field Poles - The pole shoe acts as a support to the field coils and spread out the flux in the air
gap and reduce the reluctance of magnetic field.
Frame - The Frame is the stationary part of a machine in which poles and rotor are stationed.
Armature- The armature consists of core and winding. It is built up of thin lamination of low
loss silicon steel (0.4 to 0.5)
Commutator- A commutator converts alternating voltage to direct voltage. It is a cylindrical
structure built up of segment made drawn copper.
Brushes- The use of brushes is made for machines designed for large current at low voltage.
Armature Winding- The winding must be designated with the most advantages utilization of
the material in respect to weight and efficiency.
v. CALCULATION
DC Motor Requirements
Measured Torque
= 23 N-m
Minimum standard speed of motor
= 1500 rpm
Required speed
= 120 rpm
Transmission ratio for gear drive
= 1500/120
Transmission ratio
= 12.5
Torque will be increased 5 times from the motor to gear box spindle, since the transmission
speed is reduced 5 times.
Required motor torque
= 23/12.5
= 1.84 N-m
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AEIJST - August 2016 - Vol 4 - Issue 8 ISSN - 2348 - 6732

Required power of motor

=
= 2

= 289.026 Watts
= 0.3 kW
Power
= 0.384HP
Taking the standard motor power considering factor of safety
= 0.5HP =0.3
kW
For 0.5hp & 0.3kW Motor,
Torque of motor
=P
= 300
Tm
= 2.374 N-m
Torque attained in the spindle
= 2.374
Ts
= 29.675 N-m
For 24volts DC motor,
Current Rating
= Power / Voltage
= 300 / 24
I
= 12.5 amps
=Torque attained / Torque required
= 29.675 / 23
FOS
= 1.29
DC Motor Specification
Power
= 0.3kW= 1.5 HP
Speed
= 1500rpm
Volt
= 24v
Current
= 12.5amps
Torque
= 2.374N-m
Time Reduction
For 1500 rpm motor,
Speed reduced to 120rpm
= 2rps
No. of turns to rotate the jig 90o = 10
For 180o
= 20
Time taken to rotate the jig 90o = 10/2
= 5secs
For 180o
= 20/2
= 10secs
Time taken to rotate 180 manually
= 20secs
Time reduced
=20 - 10
= 10secs
Time reduction percentage
= 50%
For assembling one rear transmission case on the trolley completely, the jig is tilted one
180o rotation and two 90o rotation. Totally it takes 20seconds of operation per assembly.
Daily usage of motor
= 10times/shift
= 20times/day
Usage time taken/day
= 20 x 20
= 400 sec/day
Total Time saved per day
= 400secs
= 5.40 mins/day
Battery Requirements
Lead acid Battery
Current Rating
= 24amps
Volt Rating
= 24v
For consuming 12.5 ampere-hour, motor needs to run for 3600secs (1hour). Therefore,
for 24amps battery,
Battery Durability
= 24 / 12.5
= 1.92 hrs
= 6912secs
For 1.92hrs = 6912 / 400
= 17.28 days
NOTE:
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AEIJST - August 2016 - Vol 4 - Issue 8 ISSN - 2348 - 6732

Therefore battery stands for 17days
For safety purpose battery should be charged once in every two weeks by considering also

the idling power losses.

VI. CONCLUSION

Thus, we concluded by introducing an electrical DC motor drive by suitable calculations for

the required power source for tilting the jig.
It helps in time reduction in the assembly and also increases the productivity.
Also we have developed the design of the jig by providing a suitable fool proof attachment
which avoids the falling of casing when it is rotated upside down.
It ensures the safety operation in the assembly.
DESIGN OF DEVELOPED JIG

VII. REFERENCES
[1]

https://en.wikipedia.org

[2.] Xiangyang Zhu and Han Ding, Optimality Criteria for Fixture Layout Design A
Comparative Study , IEEE Transaction On Automation Science And Engineering Vol. 6, No 4,
October 2009.
[2]

[3.] YoulunXiong and XiaorongXiong, Algebraic Structure and Geometric Interpretation of

Rigid Complex Fixture Systems, IEEE Transaction On Automation Science and Engineering,
Vol 4, No. 2, April 2007.
[3]

[4.] Jean-Phillippe Loose, Shiyu Zhou, and DariuszCeglarek, Kinematic Analysis of

Dimensional Variation Propagation for Multistage Machining Process With General Fixture
Layouts, IEEE Transaction On Automation Science And Engineering, Vol 4, No.2, April 2007.
[4]

[5.] Qiao Lin, Joel W. Burdick, and ElonRimon, Constructing Minimum Deflection Fixture
Arrangement Using Frame Invariant Norms, IEEE Transaction On Automation Science And
Engineering, Vol 4, No.3, July 2006.
[5]

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