PROJECT SYNOPSIS

STUDY, ANALYSIS AND FIRST PASS YIELD

IMPROVEMENT IN PF-51 FUEL PUMP
ASSEMBLY LINE.

Under the guidance of

Satyaprasad R Shwethashree B
Engineer Lecturer
Bosch Limited East-West Institute Of
Hosur Road ,Adugodi Technology
Bangalore-30 Bangalore-91

Conducted at
Plant No.3,MFF Department
Bosch Limited
P.B.No. 3000
Hosur Road,Adugodi
Bangalore-560 030, India
By

PRITESH DEDHIYA-1EW07ME013
ARUN ANANTH-1EW07ME016
NEERAJ KRISHNAN-1EW07ME027
SANTHOSH R-1EW07ME042
 PROJECT DESCRIPTION
A fuel pump has become an indispensable part of an Internal Combustion Engine. The
basic objective of using a fuel pump is to pressurize the fuel before delivery to such large
pressures that the fuel becomes atomized and thereby making combustion more effective.
Better combustion leads to generation of more power, lower specific fuel consumption
and making the environment more clean with lesser wastage.
One such fuel pump series is the PF series of fuel pump manufactured by Global
leaders in automotive technology-Bosch Ltd.. The PF series of pumps manufactured by
Bosch cater to the varying needs of Diesel Engine systems especially the Common Rail
Diesel Engine systems. Bosch Ltd. started manufacturing of PF pumps – “Pumpen mit
Fremdantrieb” (Pump with a foreign drive) way back in 1954. Since then, Bosch Ltd. has
been catering to the needs of a large number of Engine manufacturers’ world wide. These
pumps cater to a wide range of applications from Gensets to Auotomobiles to
Locomotives.
Our area of concentration is the PF-51 variant fuel pump, a relatively new
addition to the series. Its compact size makes it a very popular choice among leading
automobile manufacturers. The PF-51 pump works basically on plunger and barrel
system with an external drive. The following diagram shows the cross-sectional view of a
PF-51 pump.
The assembly line of the PF-51 pump is a relatively new assembly line as compared to
the other fuel pumps. This assembly line basically consists of the following assembly
stations.
-O-ring assembly station
-Delivery-Valve Holder Tightening station
-Spring and spring seat assembly station
-Inlet and Overflow valve connector tightening station.
-Low-Pressure Tightness checking station
-Flushing and Calibration station
-Wet Tightness Checking Station.

The fuel pump once when it is assembled i.e. after the inlet and overflow valve
connectors are in place is subjected to various tests starting from low pressure tightness
checking to ensure that there is no body leakage or delivery valve leakage from the pump.
Once this is done it is subjected to flushing and calibration where in the pump is flushed
with ISOPAR-H liquid to get rid of any dirt particles and is calibrated using a pre-defined
set of values. It is then subjected to wet tightness operation where in the fuel pump with
an inlet of 4 bar pressure is dipped inside a fluid to check for air-bubbles indicating
leakage.

Due to various reasons the first-pass yield has been dangerously low with figures
touching as low as 81 per cent. Our objective over the course of this project would be to
study the behavior of the fuel pump under various conditions and take suitable actions to
increase the FIRST-PASS YIELD and also the OVERALL EQUIPMENT EFFICIENCY.