Sample design

Thermoforming design:

Grip LH
Location as reference
to part surface

TVSM / PED / MSE / MHSE Slide 101

 Sample design

Thermoforming design:

Secondary injection valve

TVSM / PED / MSE / MHSE Slide 102

 Sample design

Thermoforming design:

Horn assembly

TVSM / PED / MSE / MHSE Slide 103

 Sample trays

Thermoforming design:

Drums sprocket Tray design Sample tray

Brake panel assembly Tray design Sample tray

TVSM / PED / MSE / MHSE Slide 104

 Sample Parts for Design

TVSM / PED / MSE / MHSE Slide 105

 Part details

1. Connecting rod

15
Part name : Connecting rod

Part number : N8020169

50
Part type : Metal part

Material : Casting

Part profile : Odd 125

Classification : ‘B’ Class

Part weight : 0.13 kg

Category : MIW

Part dimension : 125 x 50 x 15 mm

Nature : Machined part (More sensitive)

TVSM / PED / MSE / MHSE Slide 106

 Part details

2. Crank shaft RH

Part name : Crank shaft RH

Part number : N8020189

Part type : Metal part

Material : Casting

Part profile : Odd

Classification : ‘B’ Class

100
Part weight : 0.94 kg

Category : MIW

Part dimension : Dia.105 x 100 mm

Dia. 105

Nature : Machined part (More sensitive)

TVSM / PED / MSE / MHSE Slide 107

 Part details

3. Gear primary driven

Part name : Gear primary driven

30
Part number : G3080250

Part type : Metal part

Material : Casting

Part profile : Odd

Classification : ‘B’ Class

Part weight : 0.85 kg

Category : MIW
Dia. 145
Part dimension : Dia.145 x 30 mm

Nature : Machined part (More sensitive)

TVSM / PED / MSE / MHSE Slide 108

 Part details

4. Tail lamp assembly

Part name : Tail lamp

80
Part number : N5220810

Part type : Fragile part

Material : Glass

Part profile : Odd

Classification : ‘B’ Class

220
Part weight : 0.43 kg

Category : MIW

Part dimension : 220 x 190 x 80 mm 190

Nature : More sensitive

TVSM / PED / MSE / MHSE Slide 109

 Design of Storage Racks
for Crates

TVSM / PED / MSE / MHSE Slide 110

 Design of Storage facility

Design of storage facility

Storage racks (FIFO Stand)

Storage rack - Fabricated Storage rack - Modular

TVSM / PED / MSE / MHSE Slide 111

 Factors of Storage facility Design

 Criteria for designing of kitting crates:

1. Quality:
• Parts / Crates should not project outside the rack
• No sharp corners
2. Safety & Ergonomics:
• Rack should with stand the material weight.
3. Ease of operation:
• Easy to load / unload parts/crates.
4. Ease of Maintenance:
• Easy to clean
• Easy to assemble and dismantle.
5. Flexibility:
• Design must be common for each part per model
• Shelf height should be adjustable for any other part
6. Cost:
• Utilize maximum volume of space within the crate and reduce cost of storage per part
TVSM / PED / MSE / MHSE Slide 112
 Elements of Storage facility Design

 Storage rack design:

The different levels of designing a storage racks are explained in detail below,
1. Material:
• M.S Material with the specification Of IS 513 Grade “0” (Cold rolled low
carbon steel) Square tube, Rectangle tube, Plates, Flats, Tubes, Rods,
Angles, Sheets,
• ID range from 6mm dia to 38 mm dia with 2.2 to 3.0 mm thk as in the table
below

Wall Working Bursting

ID
Thickness Pressure Pressure Mtrs.
mm. mm. Kg/cm2 Kg/cm2
6 2.2 4 13 30
8 2.5 4 13 30
10 2.5 4 13 30
12.5 2 2.5 8.5 30
20 2 2.5 8.5 30
25 2.5 2 8 30
32 2.5 1.5 6 30
38 3 1.5 6 30
o
Recommended Max Working Temp: 60 / 70 C

TVSM / PED / MSE / MHSE Slide 113

 Storage racks

Storage racks

3R Card

Roller chute

3Tier Rack 2Tier Rack

TVSM / PED / MSE / MHSE Slide 114

 Drawing Standardization

Storage rack detail design

BOM

Drawing
Standardization

Drawing revision Remarks

TVSM / PED / MSE / MHSE Slide 115

 Design of HDR System

Pallets

HDR System
TVSM / PED / MSE / MHSE Slide 116
 Interplant Movement Facility

Material handling facility for interplant movement,

 Parts are moved from one plant which is the Point of Manufacturing to other plant which is the Point
of Consumption.
 To utilize the process plant capacity and resolve the process constrain between the plant, materials
are moved between one plant to another plant.

Production unit 1 Production unit 2

Plastic Metal Metal

painting painting painting
Parts moved for plastic painting

After plastic painting moved to unit 2

TVSM / PED / MSE / MHSE Slide 117

 Interplant Movement Facility

Material handling facility for interplant movement,

 Mode of transfer should be,

- Operate as unit load to avoid no. of trips and reduce movement time
- Mechanized transfer method (using prime mover)

Primary container

Trailer

Prime mover

TVSM / PED / MSE / MHSE Slide 118

 Estimation of Material
Handling Facility

TVSM / PED / MSE / MHSE Slide 119

 Estimation of MHF

Estimation
- Calculate the No. of facilities required to carryout the process
- Effective utilization of available facilities

Factors to be considered,

• Production volume
• Facility type
• Quantity per container
• No. of shifts (working hours) – Feeder shop & Receiver shop
• Inventory (hours) at Feeder shop & Receiver shop.

TVSM / PED / MSE / MHSE Slide 120

 Estimation of MHF

Calculation method:
Say,
Production volume (V) – 1200 Nos
Facility type – Trolley
Quantity/container (q) – 14 Nos
Feeder shop: Shift working hours (FS) – 22.5 hr
Inventory hours (FI) – 2 hr
Receiver shop: Shift working hours (RS) – 22.5 hr
Inventory hours (RI) – 3.5 hr

No. of containers required for feeder shop,

= (((V*FI)/FS)/q) Nos

= (((1200*2)/22.5)/14) = 7.61

~ 8 No. of trolleys are required at feeder shop.

TVSM / PED / MSE / MHSE Slide 121

 Estimation of MHF

No. of containers required for feeder shop,

= (((V*RI)/RS)/q) Nos

= (((1200*3.5)/22.5)/14) = 13.33

~ 14 No. of trolleys are required at receiver shop.

Total no. of facilities required for the part,

= No. of containers required for feeder shop +

No. of containers required for feeder shop

= 8 + 14

= 22 No. of trolleys are required for the part.

TVSM / PED / MSE / MHSE Slide 122

 Inventory Guidelines

Inventory guidelines for Feeder & Receiver shop

Feeder Receiver Feeder Receiver

No WIP Norms Cell category
Shift Shift Stock Hrs Stock Hrs
1 1 2 2 hours of feeder + 8 hours of receiver For non process plants 2.00 8.00
2 1 3 2 hours of feeder + 16 hours of receiver For non process plants 2.00 16.00
3 2 1 8 hours of feeder + 2 hours of receiver For non process plants 8.00 2.00
4 2 3 2 hours of feeder + 8 hours of receiver For non process plants 2.00 8.00
5 3 1 16 hours of feeder + 2 hours of receiver For non process plants 16.00 2.00
6 3 2 8 hours of feeder + 2 hours of receiver For non process plants 8.00 2.00
7 3 3 2 hours of feeder + 2 hours of receiver For non process plants 2.00 2.00
8 1 1 20 hours of feeder + 20 hours of receiver Hosur to Mysore 20.00 20.00
9 1 1 8 hours of feeder + 8 hours of receiver Hosur to Vendor 8.00 8.00
10 2 2 8 hours of feeder + 8 hours of receiver One plant to another plant 8.00 8.00

TVSM / PED / MSE / MHSE Slide 123

 Inventory Guidelines

Inventory guidelines for Feeder & Receiver shop

Feeder Receiver Feeder Receiver

No WIP Norms Cell category
Shift Shift Stock Hrs Stock Hrs

11 1 1 4 hours of feeder + 2 hours of receiver For process plants 4.00 2.00

12 1 2 4 hours of feeder + 8 hours of receiver For process plants 4.00 8.00

13 1 3 4 hours of feeder + 16 hours of receiver For process plants 4.00 16.00

14 2 1 8 hours of feeder + 4 hours of receiver For process plants 8.00 4.00

15 2 3 4 hours of feeder + 8 hours of receiver For process plants 4.00 8.00

16 3 1 16 hours of feeder + 4 hours of receiver For process plants 16.00 4.00

17 3 2 8 hours of feeder + 4 hours of receiver For process plants 8.00 4.00

TVSM / PED / MSE / MHSE Slide 124

 Estimation of MHF

Examples:

Feeder Inventory No. of Inventory No. of

Qty/ Stock - Receiver Stock - Total
Production shop hours - Container hours - Container-
# Part Description Contain Feeder shop feeder Receiver shop shop receiver container
Volume/day working feeder - feeder receiver Receiver
er shop shift shop reqd
hours shop shop shop shop

13 Housing head lamp 20 Painting-2 1200 22.5 6.50 347 18 Vehicle assy-1 16 2 150 8 26
Housing head lamp 20 Transit up 1200 22.5 1.00 54 3 Transit dwn 22.5 1 54 3 6
Housing head lamp Total 32
P la s tic p a in tin g

14 Cover front 30 Painting-2 1200 22.5 6.50 347 12 Vehicle assy-1 16 2 150 5 17
Cover front 30 Transit up 1200 22.5 1.50 80 3 Transit dwn 22.5 1.5 80 3 6
Cover front Total 23
15 Cover bottom tail center 25 Painting-2 1200 22.5 6.50 347 14 Vehicle assy-1 16 2 150 6 20
Cover bottom tail center 25 Transit up 1200 22.5 1.00 54 3 Transit dwn 22.5 1 54 3 6
Cover bottom tail center Total 26

TVSM / PED / MSE / MHSE Slide 125