CHAPTER 1

INTRODUCTION

The topic of the project report is to study and reduce the rejection of the HSS blades on
slotting machine in the industry. Hss Blade is a part which is used in the making a die. The
industry was facing the problems in the rejection i.e. the product HSS blades and the project
is based on establishing a control over the defects that has been occurring in the product.

The Rejection Analysis allows expertise on reworking failed parts to be shared with all
operators and with the supervisors. Rejection analysis helps us to establish a control over the
defects occurring in the given product. The rejection analysis helps us to find us the root
cause of the defect why the defect has occurred and help us to find the way to minimize it.
For the given project topic to get a keen view of the rejection analysis research is also done
on the project topic.

The manufacturing process in detail is described in the chapter 4 and discussed in detail and
the diagram design of the bearing support is also shown in this chapter. Also in this chapter
the data is collected which is necessary for the project study and data is analysed and is
interpreted. Graphical representation is also shown in the given chapter. The findings and
suggestions is described in the last chapter.

So we are going to make an Automatic slotting machine for SHIVA ENTERPRISES

PVT.LTD., a industry which made a die making work for cardboard, gasket make it
multipurpose & should be used as slotting HSS blades for dies. The machine is simple to
maintain easy to operate. Hence we tried our hands on “Automatic slotting machine”
slotting Machine is one of the principal machines in die making industry. It is mainly used as
the name indicates to make a slots in HSS Blades up to 1 mm thickness & it made automation
in small scale industrial processes.

Rejection Analysis Summary

The Rejection Analysis application allows expertise on reworking failed parts to be shared
with all operators. It captures detailed results of product failings from the factory. Operator
actions are suggested based on the failure(s).

1
Rejection Analysis Benefits

 Operator views history of calibration/testing attempts and is advised as to part

disposition.
 Better utilization of operator time because of level of information available.
 Suggestions can be based on best knowledge giving operators benefit of experience.
 Eliminates scrapping all failures, you can tell if part is able to be re-worked.

Rejection Analysis Function and Use

Calibration and test data is transferred automatically to reject analysis when the product is
marked as failing by a calibration or test process. A detailed database is maintained of
calibration and test results linked to the tracking number. Production personnel can request
displays of calibration/test history based on the tracking number. Suggestions are displayed
for the operator based on the test history. Quality analysis personnel can utilize a wide variety
of tools to perform more detailed investigations into failures.

Rejection Analysis Features

Suggested recovery actions are displayed when the operator enters the product tracking
number. These actions are based on the type of failure and the number of calibration or test
re-runs for the individual product. Intermediate testing or calibration results can be associated
with the part runs. This allows capture of test equipment settings or number of calibration
retries by automated machinery.

A reject analysis station accepts the product tracking number and can display a summary
screen of the most recent failure for the product or a history of all failures for the product.
The most recent failure screen displays the suggested resolution.

The reject station does not require a keyboard for operation if the product or holder is
barcoded. A barcode reader can be used to select the product and switch displays.

2
 CHAPTER 2

COMPANY PROFILE

MAHINDRA SONA LTD.

The manufacturing unit is situated at Nashik about 180 kms. North-east of Mumbai
and employs about 370 people. Its constructed area is around 10000 Sq. meters.
The Nashik Plant commenced production in 1979 following a technical and financial joint
venture between Mahindra & Mahindra Limited and Dana Corporation USA, named
Mahindra Spicer Limited. In 1984, Mahindra Spicer Limited merged with its parent company
Mahindra& Mahindra Limited and became MSL Division of the parent company. In March
1995, Mahindra & Mahindra Limited and Sona Koyo Steering Systems Ltd formed a new
company MAHINDRA SONA LIMITED to take over the automotive component business of
MSL Division of Mahindra & Mahindra Ltd.

The Company is engaged in designing and manufacturing a wide range of auto

ancillary products such as propeller shafts, clutches, universal joint kits, steering joints,
steering column parts and axle shafts. The company is original equipment supplier to almost
all vehicle manufacturers in India and caters to the spare parts market through a wide
distribution network. The company also supplies to vehicle manufacturers and Tier 1
suppliers outside India. The Company has been certified for ISO-9001 in 1995 and QS-9000
in 1999. The Company firmly believes that the high standards of quality can only be achieved
through strong systems and the support of its people. Mahindra Sona Limited manufactures
Propeller Shafts / Cardan Shafts and components for Automotive Applications like Passenger
Cars, Multi Utility Vehicles, Sports Utility Vehicles, Light Commercial Vehicles, Medium
Commercial Vehicles and Heavy Commercial Vehicles.

MSL Drive Shafts also cater to vide Industrial Applications like Earth Moving
Equipment, Engine Dynamometer Testing , Radiator Fan Drive for Railways, Steel Rolling
Mills, Printing Machineries etc. MSL’s products include Steering Universal Joints for
Automotive Applications like Passenger Cars, Multi Utility Vehicles, Sports Utility Vehicles,
Light Commercial Vehicles, Medium Commercial Vehicles and Heavy Commercial
Vehicles.

3
 MSL also manufactures Spindle and Sleeves of Steering Column Intermediate Shafts for
the following categories:

 Multi Utility Vehicles / Sports Utility Vehicles

 Light Commercial Vehicles
 Medium Commercial Vehicles
 Heavy Commercial Vehicles

Recent addition in Mahindra Sona Limited’s’ product range is Rubber Coupling for
Steering Application for Multi Utility Vehicles, Sports Utility Vehicles and Earth Moving
Equipment’s . The product line of Mahindra Sona Limited is for the Automotive Clutches.
This includes the world’s latest Diaphragm Type (DST as well as Ring Type) and the
conventional lever type for Passenger Cars, Multi Utility Vehicles, Sports Utility Vehicles,
Light Commercial Vehicles, Medium Commercial Vehicles, Heavy Commercial Vehicles
and Farm Tractors.

Various models of Driven Plate Assemblies are used in

 Passenger Cars
 Multi Utility Vehicles / Sports Utility Vehicles
 Light Commercial Vehicles
 Medium Commercial Vehicles
 Heavy Commercial Vehicles
 Farm Tractors

Name of the company : - MAHINDRA SONA LIMITED

Address : - Mahindra Sona Ltd, Plot No. 89/1 MIDC Satpur, Nashik- 422007

Phone No. : - 0253 6610500

Fax no. : - 0253 6610504

Strength of Employee : - 370 {approx.}

Product : - propeller shaft, Universal Joints, Steering Joint, Clutch, Axle Shaft

4
Establishment : - 1979

Mission And Vision :- Mahindra Sona ltd are committed to satisfied our customers by
Designing manufacturing and delivering product through a well-defined quality system
meeting TO/TS 16949 standard and continuously Improve our products process and
system.

Vision- Mahindra Sona Ltd is guided by its powerful vision to be a "Supplier of

Choice" to global customers.

Mission –We at Mahindra Sona Ltd are committed to satisfy our customers by
designing, manufacturing and delivering products through a well-defined quality
system meeting ISO/TS 16949 standard and continually improve our products,
processes and systems.

Values - "Mahindra Sona Ltd recognizes its employees as its vital strength for
combating competition and ensuring continual growth. MSL strives to create a work
environment that nurtures respect for individuals, excellence in the pursuit of goals and
dedicated service to the customer. MSL endeavours to direct the energies of its
employees to make MSL a "Supplier of choice" to Global customers."

5
Products Application Products picture

1} CLUTCHES  Malty Utility vehicles

 Passenger cars
 Trucks
 Jeeps

2} AXLE  Malty Utility vehicles

 Jeeps
 Trucks
 Light commercial
vehicles

3} CV JOINT  Heavy duty vehicles

trucks
 Light commercial
vehicles
 Passenger cars three
wheelers

4} UNIVERSEL JOINT As a components for

propeller shaft

 Heavy duty trucks

 Light trucks

TABLE 1.1 PEODUCT & SERVICE OF ORGANISATION

6
 CHAPTER 3

Research Methodology

3.1 Research Methodology

Research as a means for gaining knowledge can carried out arbitrarily or in a
systematic fashion. Research is a way of looking at familiar things in order to explore
ways of changing it. Research concerns itself with obtaining information through
empirical observation that can be used to systematically develop logically related
propositions so as to attempt to establish causal relationships among variables.
“Defining the research analysis of obtained information in order to analyze the
results of research, both quantitative and qualitative measures can be used.”
A research designs is the logical and systematic planning and directing of a piece
of research. The research design attempts to integrate various aspects of the research
study. In planning and designing a specific research project, it is necessary to
anticipate all the steps that must be reliable and informative.

The data collected are facts, figure and relevant materials, past and present servings as
basis for study and analysis.
Primary Data: Data that is collected for the specific purpose as hand is called as
primary data. It calls for greater planning and co-ordination. In situations it is
impossible to use secondary data keeping in the view the requirement of the study or
in cases no secondary data available, only way out is to collect the primary data.
Sources of collecting primary data
Primary Data is the data which is not readily available. The primary data is
collected by questionnaire method, interviewing method and observation. This data
one has to collect on his own.
With the help of the Primary Data I collected the information about the
“INVENTORY MANAGEMENT AND COST ANALYSIS” with the help of work in
store, purchase department and finance department.
Following are the information related to this data:

7
 Questionnaire Method:
With the help of questionnaire method I made a question in a set of forms. From
which I conducted survey for the information about INVENTORY AND COSTING.
The respondents answer the question according to their knowledge on such products.
It helps me to know the product information by which I can analysis into my project.
Observation Method:
Observation method is of two types: participative and non- participative. I used
non-participative method to know the Operation of the company, working of the store,
maintenance, egg. Finance department, etc.
Secondary Data: Data that has been collected earlier for some purpose of his than the
present study is called secondary data. Secondary sources of data provide wealth of
information to research is. It acts as reference for the present study.
 Internet
 Data from company brochure
 Magazines
 Books.

Literature review -

Research Paper on

A) Management of inventory under market fluctuations

(The case of a Canadian high tech company by Malgorzata Plaza*, Iulian David, Farid
Shrazi)
 This research focuses on improving the control over a lead time. The improvement is
measured by observing the inventory levels and measuring inventory turnover.
 Cycle times and warehouse handling has been improved, because sometimes in high
period consumption the batch was bypassing the warehouse altogether, going into
production for assembly.
 When the proper training was not provided to some of the employees, the work flows
were negatively impacted. The affected personnel were able to easily adjust their
working habits when the proper training was provided.

8
B) Optimal Production, Replenishment, Delivery, Routing and Inventory Management
Policies for Products with Perishable Inventory
(By Yuzhuo Qiu, Jun Qiao, Panos M., Pardalos)
The contributions of this paper are (i) to describe a modelling approach enriching the lot-
sizing part of production routing problems with perishable inventory and corresponding
inventory management policies; (ii) to offer a mixed integer linear programming formulation
for PRPPIs and extended formulations for different inventory management policies; (iii) to
provide branch-and-cut algorithms based on logical, strengthened lot-sizing, and lifted MTZ-
type valid inequalities; and (iv) to present extensive computational analyses that capture the
effects of these valid inequalities and different combinations of inventory management
policies in various scenarios, from which managerial insight can be drawn.

C) Inventory Management in Supply Chain

(by Deepesh Singh, Ajay Verma)
The paper presents a conceptual methodology for Inventory issue. There is a need for an
empirical validation of the proposed methodology. The bi-directional information at different
levels will have affected the supply chain at all levels and it should be managed to reduce the
information distortions. If a company wants to survive in the long run it should pay special
attention to the area of supply chain and Inventory.

9
3.3 Objectives of Project

1. To study the types of inventory control such as ABC analysis, vital Essential
desirable analysis, fast moving non-moving slow moving dead analysis etc.
2. To study inventory management of the company.
3. To analyse various inventory levels such as economic order quantity, Maximum level,
minimum level, re-order level, etc.
4. To minimize investment in inventory implies that maintaining inventory involves
costs, such that the smaller the inventory, the lower is the cost to the firm.

Universe: MAHINDRA SONA LIMITED.

3.4 Scope and Limitations of the Study:-

 This project has a very wide scope in every organization. The project focus on set
of concepts, tools and techniques within the supply chain management paradigm,
which can be understood and used by practicing material managers, and this
members of management team. Supply chain encompasses the coordination,
control and profit initiatives or cost associated with the flow of materials,
information and cash transactions across partners to which enterprise is related.
 It includes vendors, customers, their channels, (logistics) operations and
capabilities to integrate with (company) core enterprise. By implementing the
project it will formalize rules and procedure to guide day-to-day operations and
develop flexible response.
 It shows how and why costs are incurred in supply chain systems, what costs are
avoidable and what are not. It’s helpful to organization towards achieving an
integrated approach and strategic alliances between the various entities that form
the supply chain become critical to information access, connectivity and
formalization beyond basic documents.

10
Limitation:
Generally company does not allow outsiders to conduct any study or research work in
company.

Therefore, get the projects get in the company itself was very difficult.
The Project is based on the Data provided by the organization.
The project is based on theoretical guidelines and as per the situation prevalent time of the
practical training. Hens it may not be applicable to difference situations.

11
 CHAPTER 4
DATA COLLECTION & DATA ANALYSIS
Data Analysis:
In financial year April 2018 to March 2018 Target of Inventory raw material is 14days means
every month company kept minimum raw material is 14.in the month of April 2018 company
bring 25 days raw materials while in the month of May 2018 company bring 27 days raw
materials as per their requirements. In the month of September2018 Company bring 30 raw
materials and in the next month October Company bring 26 days raw materials as per their
requirements. This shows company requiring more raw materials for their inventory material
target 14days. This shows company required more capital and more finance for its spare
parts.

Data Interpretation:
In the financial year company required more raw materials more than their inventory target
14days. This shows company’s production is high and due to high production capacity and
heavy quality system and heavy production cost, material cost, overhead expenses that’s why
they require more raw materials in every month.
This also shows that they bring raw material on based on their financial cost. In august and
September 2018 they are spending their 30 days to complete 14 days raw material target so
that they required more time .while in march 2015 they spending only 20 days to complete
14days raw material target so that they required short time due to sufficient material and
better financial condition.

Objective and scope

Based on the need for well-defined experiments and accurate experimental data for model
validation, the research question is formulated as: “What are the requirements on an
experimental shear cutting procedure to allow accurate high sensitivity studies of small
process parameter variations?”. This work aims to develop a procedure for experimental
evaluation of shearing and includes the design, build and evaluation of an experimental set-up
with high measurability and consistent and predictable output. Finally, three material grades,
representative for low, medium and high strength steels, are selected for the study of
clearance and clamp configuration, two shear parameters identified as important to the shear
process.

12
 PROCESS FLOW CHART:

The below flow chart shows the sequential operation/steps that will be performed during the
project process.

Project Selection Concept Data Collection

Development

Concept Design

Final Design Data Analysis

Design Analysis Material Machining

Procurement Process

Documentation Complete
& Costing Manufacturing
Testing

Fig 1.6 Process Flow Chart

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Shear cutting of sheet metal

Shearing in general
Shearing is a process for mechanical straight cutting of sheet metal withoutchip formation
between two, against each other, moving tools. After thetools are in contact with the sheet,
penetration starts and the sheet materialexperiences high shear stresses and ultimately failure.
After a plastic penetration into the sheet, cracks will start and propagate from both tools.
Depending on sheet material properties and shear settings, the amount ofplasticity and
penetration before crack initiation will vary.
Shearing is most commonly used to produce rectangular shapes andthe sheared pieces of
sheet metal generally have high tolerances and areused without further machining. Material
waste and energy consumptionin shearing are low compared to chip forming cutting and
melting cutting.The work required for shearing are commonly applied either manual,
mechanical,hydraulic or pneumatic, where the manual and pneumatic typesare used for
lighter shearing. High production rate is featured by the mechanicallyeccentric shears but the
hydraulic shears are more flexible andadjustable.

Fig 1.7 : Schematic 3D representation of shear geometry with definition of the

coordinate system used.

14
Shear geometry
Fundamental shear geometry is represented in fig. where thesheet metal is sheared between
two shear tools and held in place by clamps.Here, the geometric properties defined are sheet
thickness h, clearance cand shear tool radius r. Shearing of wide sheet strips generally
includes
the rake angle, created by rotation of one shear tool around the x-axis infig. Use of rake
angles limits contact length and forces but inducesadditional strains in the sheared material.
With more three dimensionalstrain state, distortion of the sheared piece may occur. To
minimize thestrains, thorough clamping of the sheet as close as possible to the sheartools is
important.
In general, existing shear settings effect the sheared edge geometry,which in turn is important
for aesthetics, sharpness and the tendency toinitiate cracks. Sheared edges have four
characteristic zones i.e. rollover,shear, fracture and burr zones, fig. Rollover and shear zones
arisefrom the plastic deformation of the sheet when penetrated by the sheartools, while the
appearance of fracture and burr zones are determined bythe crack propagation characteristics
during fracture. Specific for shearingof high strength steel, are a small shear zone and large
fracture zone. Burrsand rough fracture zones complicate the following processing through
inadequatetolerances that may imply additional machining and sharp edgesthat may damage
equipment or even cause injuries.

Fig.1.8 : Sheared edge characteristic zones shown on sheet cross-section.

serve as initiation spots for cracks in later processing steps. Characterizationof sheared edges
from sheet metal trimming is discussed in, where amethod for post shear strain evaluation
through analyses of sheet edge microstructure, is developed. Further, sub-cracks in the
sheared edge surfacewere observed.

15
Within most shear processes, the clearance between shear tools is usuallyadjusted along with
changed sheet metal grade or thickness, and isgenerally specified relative the sheet thickness.
Clearance and clampinghave large impact on the sheared edge geometry. Ideally, cracks will
startfrom each tool radius and meet inside the sheet. Depending on size of thefracture zone
and the materials desired crack propagation angle, clearance isadjusted for the cracks to meet
without overlap .Experimental studieson blanking suggest 10% clearance to minimize the
required force and tool wear. Observations in sheet metal trimming show that both rollover
andburr increases with greater clearance, especially when approaching 20%

Sheet metal processing

The raw material for sheet metal manufacturing processes is the output of the rolling process.
Typically, sheets of metal are sold as flat, rectangular sheets of standard size. If the sheets are
thin and very long, they may be in the form of rolls. Therefore, the first step in any sheet
metal process is to cut the correct shape and sized ‘blank’ from larger sheet.

Sheet metal processing is an important process for many HK industries, which are one of the
largest manufacturers of products such as home appliances (fridge, washer, dryer, vacuum
cleaners etc.), electronics (DVD- and CD-players, stereos, radios, amplifiers etc.), toys and
PC’s. Most of these products have metal casings that are made by cutting and bending sheet
metal. We look at some the basic sheet metal cutting and forming processes.

Shearing and Punching

Shearing is similar to the process by which you cut a sheet of paper using scissors. However,
the machinery used is a little different. The image below shows two typical machines used to
cut sheet metal – the first is a shearing machine which has a long blade to make straight line
cuts; it is used to cut long sheets of metal into smaller sheets. This operation is similar to that
of a paper-cutting machine: the metal sheet is held on top of a hardened die, and the shearing
blade cuts downward, usually driven by an electrical or hydraulic punch. The second image is
a sheet metal punching machine – the cutting tool is a punch, a piece of hard tool steel which
is punched down on the sheet to cut a hole. The punch in the image is a turret punch – the
turret is a rotating tool holder that can hold tens of different shapes and sizes of punching
dies. Typical shapes are rectangular and circular. By punching in a series of steps, a long slot

16
can be cutout. A typical punching operation is similar to that of a paper punch that you may
have used to cut holes to hold paper in a 3-ring binder.

Fig 1.9 Hydraulic sheet metal shearing machine.

Fig.1.10 A CNC turret-type sheet metal punching machine

17
 Fig.1.11 Typical punched part

Cutting metal by punching utilizes almost pure form of failure in shear; therefore, the cutting
forces and the energy required are functions of the shear strength of the material. The figure
below shows a schematic of how the metal is sheared between the cutting edges of the punch
and the die.

Fig. 1.12 Schematic of the shearing process.

18
The clearance is typically between 2% and 10% of sheet thickness, t; if the clearance is
larger, the part that is sheared away, called the slug, may just flow through the clearance
without separating from the sheet.

Other methods of cutting sheets

These include flame cutting, sawing, laser cutting, and water-jet machining, some of which
we shall cover later.

Bending

A large percentage of sheet metal parts are bent along some lines to get them into the desired
shape for use (for example, think of the metal case for a computer). The sheet metal part
before it is bent is called a blank. Here, we shall also look at a special case of bending of
wires or rods – the reason this is interesting is that one of the most important mechanical
component: springs.

Bending induces plastic deformation in the material, so the part retains its shape after the
bending force is released. However, on studying the stress-strain curves for materials, you
will notice that when a material is deformed into the plastic region and then released, some
portion (the elastic part) of the strain is released. This phenomenon causes an action called
spring-back in the part that we want to bend. Thus, the bending dies must account for the
spring-back.

Fig. shows a simple bend on a rectangular blank. The top profile of the blank undergoes
extension – a thin element along the top surface will be longer after the bending than the
initial length; likewise, the bottom portion experiences compression. Thus, as we travel from
the bottom to the top, there is some layer in the middle which retains its original length – this
forms the neutral axis. The location of the neutral axis, and therefore its length, determines
the length of the blank we must begin with, in order to get the final part with the correct
geometry.

19
 Fig.1.13 Schematic of bending mechanics.

Rule processing equipments

An manufacture offers wide range of manually-operated machines and accessories for the
steel rule die making industry. These benders, Notcher & cutters machines have a long-
standing history of quality ools have been used in the field since the technology began.

Today, manufacture offers several models of these machines to suit a variety of applications.
So whether we need a good piece of starting equipment, a slightly modified version of old
trusted tool, or a tool with the latest design enhancements that increase production, of a
bender, Notcher, and cutter machine for die making industries.

Rule Cutter

Rule Cutter is designed for accurately cut steel rule to length, the Rule Cutter is an extremely
powerful, rigidly-constructed tool that will cut up to 6-point tempered rule. It is equipped
with front and rear gauges that are graduated by sixteenths. The short front gauge allows a
cut of 6 1/2" and the long back gauge a cut of up to 25". The Rule Cutter’s knives are readily
removable for sharpening. Replacement knives are also available.

20
 Fig.1.14 Rule Cutter
Rule Bender

Standard.Rule.Bender
In use wherever steel rule dies are made, the Standard Rule Bender’s
interchangeable male and female dies are used in forming rule to the desired shape without
disturbing previously made bends. The Standard Rule Bender is equipped with an adjustable
stop which may be instantly set, limiting the amount of die movement and enabling the user
to readily make duplicate symmetrical bends. The Standard Rule Bender is also equipped
with an adjustable gauge which can be used on either side of the machine to locate the
position of the rule relative to the dies.

Also available are the Heavy Duty Attachment, Bending Die Sets, and SI Notching Die
(turns bender into notcher.)

21
 Fig.1.15 Rule Bender.

Rule Notcher

Standard.Notcher
Used for notching and bridging rule, the Standard Notcher comes equipped with an
adjustable link so that the knife can be reset after sharpening for entry into female knife.
Also available: Heavy Duty Notcher. Special size notches can be made to order.

Standard size notches of 1/4" x 5/8" or 5/16" x 3/4" are available for use with up to 3-point
rule.

Notcher
􀀁Used to process the bridge portion
􀀁􀀁Adjustment of bridge depth is made with a single motion, just by turning the dial.
􀀁􀀁Small / Large type
􀀁􀀁Standard groove 9mm

22
 Fig. 1.16 Rule Notcher

TYPES OF STEEL RULES:

1)Special cutting rule:
The Special Cutting Rules are steel cutting rules used to die cut plasticmolded products
having substantial depth and height such as food traysand plastic containers as well as
honeycomb boards having substantial thickness. These Rules are excellent in both bending
workability and
elastic strength that apply the characteristics of ground edge and binatetreatment.

Fig 1.17 :Special Cutting Rule

23
2) Creasing rule

The Creasing Rules are used to crease cutting sheets. The creasingprofile, height and
thickness are chosen taking into account the material,thickness, and batch size of cutting
sheets. The choice of creasing rulesis an important component in manufacturing packages. In
thisconnection, we have established high quality standards to ensure flexibleresponse to
supply of suitable creasing rules to customers.

Fig.1.18 :Creasing Rule

3) Perforation rule
The Perforation Rules are steel cutting rules that are used for processingof cut portion or
creasing process, and are available in a variety ofperforates spacing to respond to diverse
requests from customers. Inaddition, these Rules support perforation of materials with
randomgrooves.

Fig 1.19 : Profile Of Perforation Rule

24
 Table 1.1.Perforation Scale

4) Combination rule
The Combination Rules are steel cutting rules that perform cutting andcreasing at one time,
and used to cut the creases of cardboards andpaperboards through the choice of the length
and depth of cutting bladeand creasing according to the thickness and kind of materials to be
diecut. We provide a lineup of several types of manufacturing tools to finishsteel cutting rules
to any requirements for creasing pitch, profile andheight.

Fig 1.20 Combination Rule

25
CONVENTIONAL STEEL RULE NOTCHER

Fig 1.21 Conventional Steel Rule Notcher

26
Heavy-Duty Notcher

1) Heavy Duty Notcher Parts (2-Hole & 4-Hole)

Fig. 1.22 : Heavy Duty Notcher Parts

27
2) Standard Notcher Parts

Fig. 1.23 : Standard Notcher Parts

28
29
Working Of Conventional Steel Rule Notcher

1. In the process worker has to held the HSS blade by one hand in position by keeping the
part to be slotted on the marking and operate the heavy handle by one hand.
2. After positioning manually he has to press the handle forcefully downwards so that the
machine can make the slot to the blade.
3. For a skilled labor one push is sufficient, but for others two cycles were necessary to make
the slot.
4. For each slot every time we need to position the HSS blade and make the slot.

Fig 1.24 : Conventional Steel Rule Notcher Actual View

30
Data Collection For Objective No .1

1) As one has to press handle forcefully more effort is required during slotting, that also
affects the energy of worked and makes it difficult and they feel tired.

2) Due to human errors less accuracy & more scrap during slotting, which increases
company’s expenditure on the HSS blade

3) As slots are required to be specific in size ,skilled worker is required to handle the machine
,which increases company’s expenditure on salary

4) For 1 Slot Conventional machine Takes 4-5 minutes right from setting blade to make a slot
and remove it from machine .

5) Without any automation unit for the blade slotting, this m/c cannot be adopted in today’s
automated die making plants.

6) To perform the most rigid operation with high speed we needed automation in slotting
machine.

31
Data Collection for Objective No 02 :

Rejection rate:-

Months Total Qty. Rejection Rejection %

January 300 32 10.66%
February 300 30 10.00%
March 280 24 8.57%
April 350 32 9.1%
May 360 31 8.6%
June 320 29 9.06%
July 330 33 10.00%

Table 1.3 showing the rejection rate monthly.

(Note : Data From Jan 2018 To April 2018 is collected approximately From Worker On
Manual Steel Rule Notcher

Rejection Rate Monthly

400
350 350 360
320 330
300 300 300
280
250
200 Total Qty.

150 Rejection %

100
50
0 10.66% 10.00% 8.57% 9.10% 8.60% 9.06% 10.00%
January February March April May June July

Graph 1 : Rejection Rate Monthly

32
Data Collection For Objective No 03

MAN MACHINE

STEEL RULE
UNSKILLED
NOTCHER
EMPLOYEE
Conventional
Slotting
LACK OF Machinne
COORINATION

IMPROPER IMPROPER
MATERIAL MACHINE
HANDLING SETTING

VARIATION IN
DEPTH
Slotting

MATERIALS METHODS

Fig 1.25 : Fish Bone Diagram

33
Factors Cause Effect

1. Man Unskilled employee Consuming more time

Lack of coordination Defective Slot

2. Machines Conventional Steel Rule Cutting Problem

Notcher
Irregular shape

3. Materials Variation in alloy material Low quality of product

Improper material handling Wastage of material

4. Methods Handle Pressing Rejection of the product

Improper machine setting Improper operation

Table 1.2: Cause and effect analysis

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Data Collection For Objective No 04

Voldy’s Automatic Slotting machine

Fig 1.26 Voldy’s Automatic Slotting Machine

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 WORKING

This project is consists of slotting tool which is mounted on top sides M.S. sliding structure
on upper slider & at the middle of the frame. When we want to do a slotting on blade then we
push the foot pedal that start the supply electricity to motor & other driver units.

An electronic controller is provided with limit switch to off the motor after one rotation of
shaft that is after slotting of blade. When we insert the blade in between slotting tool and
push the foot pedal then, the electricity is supply through control panel to make one rotation
of motor & after cutting of blade the control panel will stop the motor. The project working is
depending on principal of slider crank mechanism & cam operation.

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 COST ESTIMATION

Total Cost

= Cost Of Machine + Cost Of Transportation

= 65,200 + 4000

= Rs. 69,200

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 CHAPTER 5

Finding and suggestion

Findings For Objective No 1

1. Time required to make 1 slot – Approx. 2-3 min.

2. Each Blade ready to mount on a die contains 4-5 slots so in the process ,it takes about
10-15 minutes to complete slotting of 1 HSS blade.
3. If any of the slot gets improper or not in a dimension, worker has to replace blade.
This replacement is not limited only to slotting ,but again we have to measure it
according to dimensions and went through bending process and then slotting
4. This not only increases rejection but also time required to make a perfect die.
5. Also while making slot worker has to press the Heavy duty handle forcefully so that
he can obtain a perfect slot .This Increases the energy required to make the slot and
also he gets tired early resulting in output from a worker.
6. Also while making a slot he has to hold the Blade by one hand and press the handle
by one hand ,so while doing this if due any disturbance if he gets distracted there is
chances of irregular slot on HSS blade which can result into rejection.

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Suggestion
Following are suggestion by which the defects in the product is controlled and minimized and
ultimately the rejection would be minimized.

In This Section we need to atomize the Slotting Function Which Will Help In Following
ways:;

1.Working Time:

It will decrease working time as for 1slot time required will be very less as compared to
manual Slotting machine

2.Work Output :

It will increase Work output ,as worker will require less force and energy to perform
operation and also slots covered in given span will be much more than earlier

3. Also it will reduce work load and stress of worker, and there will be no requirement of
skilled worker.

4. Rejection:

The main objective is to reduce rejection and automation will reduce rejection .

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 CHAPTER 6

CONCLUSION

Conclusion

1)The operation of the new machine is well controlled.

2) Most important rejection is very less compared to conventional machine ,as only 1-2
pieces get rejected in a lot of 300 blades.

3) Machining Time Is approximately in the ratio 1:5 compared to old slotting machine,
Automatic slotting machine makes 5-6 slots in a same time in which Conventional machine
makes 1 slot.

4) There is no requirement of skilled manpower as only foot pedal pressing and alignment is
required. Hence expenditure on manpower is less.

5) It is a faster process. So output is more than before .

6) More accurate and economical in mass production.

7) It minimizes misalignment & less floor space is required.

8) It increases the safety and working condition.

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 APPLICATIONS

1) It is mainly used for slotting the HSS blade in Die making Industries.

Fig 1.27 Applications Of Automatic Slotting Machine

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 REFERENCES

Reference Book

1) Khurmi and Gupta “Theory of Machine” Edition Reprint 2007. Page no. 106-107

2)Khurmi and Gupta “Machine Design” Edition 2005. Page no. 261- 280 and 558-570

3) Design of machine Elements: - Prof. V. B. Bhandari, Tata Mc .Grew Hill Publishing Co. New
Delhi.

4) Workshop Technology,HajaraChaudhari.

5) Production Technology, R.K. Jain.

6 )PSG Design Data Book.

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