Part details

1. Crank case LH

Part flow : Stores  Paint shop  Machine shop Engine assembly

POM : Paint shop (VA – Painting)

POS : Trolley

POC : Machine shop (VA – Machining)

POS : Trolley

POM : Engine assembly (VA – Sub assembly and main assembly)

TVSM / PED / MSE / MHSE Slide 71

 Part details

2. Front panel top

Part name : Front panel top

250
Part number : K62210100D

Part type : Metal part

Material : Steel

Part profile : Odd

500
Classification : ‘A’ Class

Part weight : 1.5 kg

Category : MIW 450

Part dimension : 500 x 450 x 250 mm

Nature : Painted part (More sensitive)

TVSM / PED / MSE / MHSE Slide 72

 Part details

2. Front panel top

Part flow : Press shop Welding shop  Paint shop Vehicle assembly
POM : Press shop (VA – Pressing)
POS : Trolley
POM : Welding shop (VA – Welding)
POS : Trolley
POC : Paint shop (VA – Painting)
POS : Trolley
POM : Vehicle assembly (VA – Sub assembly and main assembly)

TVSM / PED / MSE / MHSE Slide 73

 Part details

3. Cover frame LH

Part name : Cover frame LH

Part number : N8220059

80
Part type : Plastic part

Material :-

Part profile : Odd

260
Classification : ‘A’ Class

Part weight : 0.4 kg

Category : MIW 380

Part dimension : 380 x 260 x 80 mm

Nature : Painted part (More sensitive)

TVSM / PED / MSE / MHSE Slide 74

 Part details

3. Cover frame LH

Part flow : Paint shop Vehicle assembly

POC : Paint shop (VA – Painting)

POS : Trolley

POM : Vehicle assembly (VA – Sub assembly and main assembly)

TVSM / PED / MSE / MHSE Slide 75

 Sample Parts for Design

TVSM / PED / MSE / MHSE Slide 76

 Design of Material Handling
Facility for “B” & “C” Class
Parts - Crates

TVSM / PED / MSE / MHSE Slide 77

 Design of crates

Design of crates

Crate is a large basket to store material and move material from point of
storage to point of consumption. Crates are mostly preferred for ‘B’ class parts.

Product

Partitions

Tote pan

Crate with partition

TVSM / PED / MSE / MHSE Slide 78

 Factors for Crate design

 Criteria for designing of crates:

1. Quality:
• Component should not touch one another –during loading & unloading.
• The crates should not make any mark or impression on components
• The Trays material shall not peel off when the metal part is loaded / unloaded from
Tray.
• No sharp corners in any pocket
• No weld in the Trays

2. Safety & Ergonomics:

• Component should not protrude outside
• No sharp points or trapping of fingers while lading / unloading parts in crates
• The weight shall not exceed the ILO guidelines, which is 14 kgs Male.

3. Ease of operation:
• Easy to load / unload part
• Ease of lifting

TVSM / PED / MSE / MHSE Slide 79

 Factors for Crate design

4. Ease of Maintenance:
• Easy to clean
• Easy to remove partition and replace

5. Flexibility:
• Design must be common for each part per model
• Remove partition and change design for any other part

6. Cost:
• Utilize maximum volume of space within the crate and reduce cost of storage per
part

7. Repair & replacement:

• Life of crate is expected for minimum 5 years
• Life of HDPE partition should be minimum for 2 years

TVSM / PED / MSE / MHSE Slide 80

 Elements for Crate design

The elements of designing a crate are explained in detail below,

1. Material:
• Material used for crate & partition
• HDPE – High density polyethylene with recycling symbol of 2.
• Yield strength - 26-33 MPa
• Temperature it can withstand – 110° C continuously &
• 120° - short period

2. Size:
• 650 X 450 mm
• 600 X 400 mm
• 400 X 300 mm
• 300 X 200 mm
• Height should be between 80 to 320 mm max.
• Partition should be 3-5mm thick

TVSM / PED / MSE / MHSE Slide 81

 Elements for Crate design

3. Color:
• Blue color for use inside Plant
• Yellow for Hosur to other plants
• Green for supplier B/O parts
4. Capacity:
• Factors of 6 (6,12,18,24,30,36,42,48,54)
5. Identification and Labeling:
• The identification should have the features mentioned below.
• Part name
• Capacity
• Model
• Process linkage
• Company name
6. Other features:
• Crates shall have lids to prevent dust
• Provide handle to carry

TVSM / PED / MSE / MHSE Slide 82

 Drawing Standardization

Crate detail design

BOM

Drawing
Standardization

Name board details

TVSM / PED / MSE / MHSE Slide 83

 Design of Kitting crates

Design of kitting crates

Kitting Tray is a large container to store material pertaining to one engine or one vehicle
for a specified zone and transfer the Tray within the zone to perform assembly process.

Kitting crate with partition

TVSM / PED / MSE / MHSE Slide 84

 Elements of Kitting crates design

 Kitting crate design:

The different levels of designing a kitting crates are explained in detail below,
1. Material:
• PU – Poly Urethane
• HDPE Foam
2. Size:
• 650 X 450 mm
• 600 X 400 mm
3. Color:
• Dark Grey color
4. Capacity:
• Not applicable

TVSM / PED / MSE / MHSE Slide 85

 Selection of Material

Selection of Material - Plastics

TVSM / PED / MSE / MHSE Slide 86

 Selection of Material

Selection of Material - Plastics

TVSM / PED / MSE / MHSE Slide 87

 Selection of Material

Selection of Material - Plastics

TVSM / PED / MSE / MHSE Slide 88

 Selection of Material

Selection of Material - Plastics

TVSM / PED / MSE / MHSE Slide 89

 Drawing Standardization

Kitting crate detail design

BOM

Drawing
Standardization

Name board details

TVSM / PED / MSE / MHSE Slide 90

 Sample crates

Sample crates

Crank case Magneto rotor

Piston

TVSM / PED / MSE / MHSE Slide 91

 Improvements

Details of improvement : Cell : Engine assy-& machining units -1,2

Weld breakage in Partition Crates
Current Proposed

Frequent breakage in weld joints

Insert type introduced for rigidity.
(plastic crates)

Major improvements:- Benefit:-

Insert type introduced for rigidity.
Crate life increased from 3 months to 2 years.

No breakage in weld joints.

Rework of crates eliminated.

TVSM / PED / MSE / MHSE Slide 92

 Thermoforming tray

Thermoforming trays
• Thermoforming is a process in which a flat thermoplastic sheet is heated and
deformed into the desired shape.
• The process is widely used in packaging of consumer products and to fabricate
large items such as bathtubs, contoured skylights, and internal door liners for
refrigerators.

Kitting crate with forming trays Thermoforming process

TVSM / PED / MSE / MHSE Slide 93

 Methods of Forming

Different varieties of forming are,

injection molding,
blow molding,
rotational molding,
and other forms of processing plastics.

Injection molding Blow molding

Rotational molding

TVSM / PED / MSE / MHSE Slide 94

 Thermoforming process

There are two general thermoforming process categories.

• Sheet thickness less than 1.5 mm (0.060 inches) is usually delivered to the
thermoforming machine from rolls or from a sheet extruder.
• Thin-gauge roll-fed or inline extruded thermoforming applications are dominated by
rigid or semi-rigid disposable packaging.

TVSM / PED / MSE / MHSE Slide 95

 Thermoforming process

• Sheet thicknesses greater than 3 mm (0.120 inches) is usually delivered to the

forming machine by hand or an auto-feed method already cut to final dimensions.
• Heavy, or thick-gauge, cut sheet thermoforming applications are primarily used as
permanent structural components

TVSM / PED / MSE / MHSE Slide 96

 Thermoforming – Selection of Materials

Selection of Material

Sl.
Material Key properties Typical Applications
No.
Instrument enclosures,
1 ABS (1,2,3,4,5,6) Stiff, Tough, General purpose
Functioning parts
2 Acrylic Very clear, Excellent weatherability, brittle Skylights, windows
Food containers, point of
3 Styrene (3,5) Stiff, Low impact, inexpensive
purchase displays
Somewhat flexible, chemical resistance, tough
4 Polyethylene (2,5,7) Bottles, Truck bed liners
enough at low temperatures, inexpensive
Very tough, good heat resistance, good Bullet-proof windows, water
5 Polycarbonate (1)
weatherability battles
Very tough, very flexible, chemical resistance, low
6 Polypropylene (7) Living hinge
heat distortion
7 PETG (5) Clear, tough, notch sensitive Chemical trays
TPO (thermo-plastic- Very tough, excellent cold resistance, low thermal Automotive skirts and
8
olefin) expansion, excellent UV resistance fenders
TPU (thermo-plastic
9 Extremely tough, flexible, outstanding cold impact Ski boots shells
urethane)
Flame resistance, good chemical resistant, good
10 Noryl Electrical enclosures
electrical properties
11 PVC Flexible, chemical resistant, flame resistant Medical packaging

TVSM / PED / MSE / MHSE Slide 97

 Structure design

Thermoforming kitting design:

Kitting crate design

TVSM / PED / MSE / MHSE Slide 98

 Structure design

Thermoforming kitting design:

Kitting crate design

TVSM / PED / MSE / MHSE Slide 99

 Sample tray

Thermoforming kitting design:

Sample tray Sample tray loaded

TVSM / PED / MSE / MHSE Slide 100