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  • Lean Manufacturing

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    Sudip Roy
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    This document discusses various lean manufacturing improvements made at a machine shop. It presents examples of eliminating muda (waste), reducing mura (process variation), and preventing muri (operator fatigue). Specific changes included standardizing nut sizes to reduce fatigue, introducing laser calibration to reduce radial offset errors, switching to a 2-flute ball nose to prevent mould breakage, using interchangeable carriers to reduce waiting time, developing internal gear cutting capabilities to reduce lead times, and balancing production lines. Additional kaizen activities optimized machining strategies, introduced last piece inspection, improved cutter performance, and eliminated cutter runout. The improvements contributed to on-time delivery of parts for a gear box manufacturing project.

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    Lean Manufacturing (1)

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    This document discusses various lean manufacturing improvements made at a machine shop. It presents examples of eliminating muda (waste), reducing mura (process variation), and preventing muri (operator fatigue). Specific changes included standardizing nut sizes to reduce fatigue, introducing laser calibration to reduce radial offset errors, switching to a 2-flute ball nose to prevent mould breakage, using interchangeable carriers to reduce waiting time, developing internal gear cutting capabilities to reduce lead times, and balancing production lines. Additional kaizen activities optimized machining strategies, introduced last piece inspection, improved cutter performance, and eliminated cutter runout. The improvements contributed to on-time delivery of parts for a gear box manufacturing project.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    6 views13 pages

    Lean Manufacturing

    Uploaded by

    Sudip Roy
    This document discusses various lean manufacturing improvements made at a machine shop. It presents examples of eliminating muda (waste), reducing mura (process variation), and preventing muri (operator fatigue). Specific changes included standardizing nut sizes to reduce fatigue, introducing laser calibration to reduce radial offset errors, switching to a 2-flute ball nose to prevent mould breakage, using interchangeable carriers to reduce waiting time, developing internal gear cutting capabilities to reduce lead times, and balancing production lines. Additional kaizen activities optimized machining strategies, introduced last piece inspection, improved cutter performance, and eliminated cutter runout. The improvements contributed to on-time delivery of parts for a gear box manufacturing project.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    of 13

    Lean Manufacturing

    Improvements.
    Presenting By Sudip Roy
    Lean Aim – Waste Elimination / Reduction

    Muda ( NVA – TIMWOOD)


    Mura – Process Variation
    Muri- Fatigue ( Ergonomics )
    Muri
    Aim – Operator fatigue Elimination ( Machine Shop )

    BEFORE SITUATION –
    DIFFERENT SIZES OF NUTS.
    TO OPEN / CLOSE IT REQIRES
    DIFFERENT SIZE SPANNER .

    AFTER SITUATION –
    COMMONIZATION OF NUT .
    SAME SIZE . SINGKE SOCKET
    HELPING TO OPEN / CLOSE IT
    .
    Mura
    Aim – Reduced Process variation radial offset G54 ( Machine Shop )

    BEFORE SITUATION –
    IN HOBBING MACHINE X
    OFFSET ERROR ( Radial
    Offset ) – ERROR 0.08 mm

    AFTER SITUATION –
    ERROR 0.0 mm .
    INTRODUCED LASER
    CALIBRATION .
    Mura
    Aim – Mould flow cavity breakage prevented ( Process Improvement )

    BEFORE SITUATION –
    4 FLUTE BALL NOSE USED
    RESULT MOULD BREAKAGE .

    AFTER SITUATION –
    2 FLUTE BALL NOSE USED
    WITH SAME RPM/ FEED .
    RESULTS NO BRAEKAGE IN
    MOULD ( SAND EVACUATION
    EASY ) .
    Muda
    T I M W O O D ( Reduced waiting time )
    Lean Tool Used – SMED

    BEFORE SITUATION –
    ONE CARRIER . AFTER
    ONE CYCLE WAIT FOR
    SETTING .

    AFTER SITUATION –
    INTERCHANGABLE 2NOS
    CARRIER USED . WAITING TIME
    REDUCED
    Muda
    I
    T M w O O D ( Reduced Lead time )

    BEFORE SITUATION –
    HOBB TOOL MANUFACTURING
    LEAD TIME SUPPLIER MIN 3
    MONTHS

    AFTER SITUATION –
    WE CAN CUT ANY GEAR
    TERMINOLOGY ( MIN
    LIMITATION ) WITH HELP OF
    FROM CUTTER & BALL NOSE .

    Note – GEAR CNC BLANK TURNING SUPPLIER & US CREATED MOM FOR
    SELF CERTIFIED PRODUCT – REDUCED WIP IN INCOMING STAGE .
    Muda
    TI M w O O D ( Line Balancing )
    BEFORE SITUATION – AFTER SITUATION –
    UNBALANCE LINE BALANCE LINE
    BOTTLE NECK – SINGLE ACTION TAKEN – THREE
    WASHING MACHIE WASHING MACHINE
    LAYOUT – PRODUCT LAYOUT LAYOUT – PROCESS LAYOUT

    • TOOL USED FOR MOTION CAPTURING – SPAGHETTI DIAGRAM


    KAIZENS
    • Reduced Step over in Machining 0.5 to 0.3 mm in Finishing strategy in CNC
    Programming (Surface Roughness N8 )
    • Last piece Inspection introduced for Job & Fixture – IATF 16949
    • Used Hitachi make Coted insert instead of solid carbide Ball nose ( Ra Value
    achieved & Fast Machining ).
    • Utilization of Shrink fit adaptor to eliminate cutter Run out ( with in 0.01 mm) .
    • Clinometer Introduced to quick Checking Hobbing Machine axis .
    APPLICATION OF CAM PROGRAMMING – MASTER CAM

    SKILL SET
    INDEPENDLY
    OPERRATE BOTH
    PROGRAMMING
    & OPERATING
    Major contribution for manufacturing of G5220 Gear Box Parts
    Manufacturing several parts like Gears , Shaft on time delivery in
    Tata Motors
    NON ROTUINE ACTIVITIES
    1. ASSOCIATES WITH BHARAT SEVASHRAM SANGHA .
    2. GIVING TECHNICAL TRAINING IN TEPL FOR UNDER DEVELOP GIRLS WITH COLABORATION NTTF .

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