EMD BLADE ROD

AMTEK TRANSPORTATION SYSTEMS LTD. GURGAON Date 23.07.19

Prod. In Prod. In
Load,unload,deburi Tool change, Prod. In Prod. In
Cycle 15.5 hrs. on 22 hrs.
S.N Machining ng before loading inspection on Prod. / 15.5 hrs. 22 hrs. on
M/C NAME OPN. NO. OPERATION DESCRIPTION time 2 shift on 3 shift Shift Reqd. Remarks
O. Time(Min.) to work station,part m/c &tool hr. on 2 shift 3 shift
(Min.) basis@80% basis@8
clean & dialing cleaning basis basis
eff. 0% eff.

Raw Material
1 5 Raw Material Inspection 0 0 21 21 2.9 44.3 35.4 62.9 50.3 20.9
Inspection
Reference face finish milling & other side
2 VMC 10&20 50 2 1 53 1.1 17.5 14.0 24.9 19.9 52.7
( upto half width )
Both end rough boring,one side shoulder
3 HMC 30 dia machining, angular milling & pin end 25 1 1 27 2.2 34.4 27.6 48.9 39.1 26.8
face milling
All side finish milling & back counter hole
4 HMC 40 17 1 1 19 3.2 48.9 39.2 69.5 55.6 18.9
machining

5 MANUAL 50 Marking for part Identification 3 2 0 5 12.0 186.0 148.8 264.0 211.2 5.0

INDUCTION
6 60 Hardening on slipper face 10 2 1 13 4.6 71.5 57.2 101.5 81.2 12.9
HARDENUNG

7 SHOT PEENING 65 Shot peening on I - section area 5 10 0 15 4.0 62.0 49.6 88.0 70.4 14.9

SURFACE Both side Surface grinding after induction

8 70A&B 30 2 2 34 1.8 27.4 21.9 38.8 31.1 33.8
GRINDER hardening

9 HMC 75 Big end bore hard machining 18 2 0 20 3.0 46.5 37.2 66.0 52.8 19.9

INTERNAL Crank end bore & one side shoulder dia

10 80 24 3 3 30 2.0 31.0 24.8 44.0 35.2 29.8
GRINDER grinding

11 Manual 85 Chamfer Polishing of both ends 25 4 2 31 1.9 30.0 24.0 42.6 34.1 30.8

INTERNAL
12 90 Second side shoulder dia grinding 7 4 2 13 4.6 71.5 57.2 101.5 81.2 12.9
GRINDER
INTERNAL
13 100 Pin end bore grinding 15 6 2 23 2.6 40.4 32.3 57.4 45.9 22.9
GRINDER
Magnetic particle inspection and
14 MPI 120 3 2 2 7 8.6 132.9 106.3 188.6 150.9 7.0
demegnetisation.

15 Washing …. Washing 4 3 2.5 9.5 6.3 97.9 78.3 138.9 111.2 9.4

Buffing on crank end bore & entry

16 BUFFING 110 17 2 3 22 2.7 42.3 33.8 60.0 48.0 21.9
chamfer

17 MANUAL Part Cooling at Room Temperature 35 0 0 35 1.7 26.6 21.3 37.7 30.2 34.8

18 MANUAL …. 100% Ra Inspection in STD Room 6 2 1 9 6.7 103.3 82.7 146.7 117.3 8.9
19 MANUAL …….. Final deburing offer to Qa 0 20 0 20 3.0 46.5 37.2 66.0 52.8 19.9

20 MANUAL 130 Final Inspection 0 12 0 12 5.0 77.5 62.0 110.0 88.0 11.9

21 Buffing …. Sliper face touching 17 2 3 22 2.7 42.3 33.8 60.0 48.0 21.9

22 WASHING 140 Washing 4 3 2.5 9.5 6.3 97.9 78.3 138.9 111.2 9.4

Total machining time / Blade(Min.) 315 85 50 450

 CAPACITY ESTIMATION M/S AMTEK TRANSPORTATION
SYSTEMS LTD

Production Target FORK BLADE CAP

DATE-23.07.22
FORK ROD ASSLY.
Shift Time(Hrs) Efficiency Start Date 25.07.22

AMTEK TRANSPORTATION SYSTEMS LTD. GURGAON

Load,unload,de Tool Prod. In 15.5

buring before change, Cycle Prod. In 15.5 hrs. on 2 Prod. In 22 Prod. In 22 hrs.
Sr OPN. Machining Shift
M/C NAME OPERATION DESCRIPTION loading to work inspection time Prod. /hr. hrs. on 2 shift hrs. on 3 on 3 shift Remarks
No. NO. Time(Min.)
station,part on m/c &tool (Min.) shift basis basis@80% shift basis basis@80% eff.
Reqd.
clean & dialing cleaning eff.

EMD FORK ROD

1 Receipt Inspection 5 Raw Material Inspection 0 2 20 22 2.7 42.3 33.8 60.0 48.0 21.9

2 Manual Grinding … Emd Grinding with Hand Grinding 6 2 1 9 6.7 103.3 82.7 146.7 117.3 8.9

3 VERTICAL MILLING 10&20 Facing both side (Top + Bottom) 27 2 0 29 2.1 32.1 25.7 45.5 36.4 28.8

4 VERTICAL MILLING 30&40 Side milling both side (Left+Right) 27 2 0 29 2.1 32.1 25.7 45.5 36.4 28.8
Reference face finish milling & other side
5 VMC-01 50&60
( upto half width ) 58 2 1 61 1.0 15.2 12.2 21.6 17.3 60.7

6 HMC 65 Rough U slot milling &R127.0 machining 35 3 2 40 1.5 23.3 18.6 33.0 26.4 39.8
Boring Crank end & Pin end , U- slot
7 HMC 70
machining,R5 milling end face milling
48 0 1 49 1.2 19.0 15.2 26.9 21.6 48.7

8 SURFACE GRINDER 80 Dimn 22.22 & 142.87 mm 10 3 3 16 3.8 58.1 46.5 82.5 66.0 15.9

9 HMC 90 Slab milling , drilling ,tapping & reaming 19 0 2 21 2.9 44.3 35.4 62.9 50.3 20.9

10 SHOT BLASTING 100 Shot Peening in U- slot area & R5. radius area. 5 10 0 15 4.0 62.0 49.6 88.0 70.4 14.9

11 Marking m/c Serial Number Marking 5 1 0 6 10.0 155.0 124.0 220.0 176.0 6.0

Total machining time / fork 240 27 30 297 295.3

EMD. CAP

1 Incoming Inspection 5 Raw Material Incoming Inspection 0 2 10 12 5.0 77.5 62.0 110.0 88.0 11.9

2 VERTICAL MILLING 10 Rough U slot milling 10 10 2 22 2.7 42.3 33.8 60.0 48.0 21.9
Top face ,bottom face,Drilling,Reaming ,
2 VMC 20,30&40
counter boring & pocket milling
73 4 3 80 0.8 11.6 9.3 16.5 13.2 79.5

3 HMC 50 Finish side milling & rough boring 24 2 2 28 2.1 33.2 26.6 47.1 37.7 27.8
100% Inspection before Grinding Dim24.38 &
4 Manual Inspection ….
73.95 0 1 6 7 8.6 132.9 106.3 188.6 150.9 7.0

5 Surface Grinder 55 Dimn 73.55 Face grinding 3 4 0 7 8.6 132.9 106.3 188.6 150.9 7.0
100% Inspection After Grinding Dim24.38 &
6 Manual Inspection ……
73.95 0 1 6 7 8.6 132.9 106.3 188.6 150.9 7.0
Pair Making Dowel & Without Dowel Cap with
7 Manual ……
Ref. Dim 0 1 4 5 12.0 186.0 148.8 264.0 211.2 5.0
Serial Number Punching Dowel & Without
6 Marking m/c
Dowel Cap
8 1 0 9 6.7 103.3 82.7 146.7 117.3 8.9

Total machining time / fork 118 13 15 136 176.0

 EMD. ASSLY.

1 Creep feed grinder 110&60 Fork & Cap Assembly. 46 12 0 58 1.0 16.0 12.8 22.8 18.2 57.7

2 MANUAL 20 Fork & Cap Assembly. 17 13 0 30 2.0 31.0 24.8 44.0 35.2 29.8

3 HMC 30 Crank end finish boring 34 0 8 42 1.4 22.1 17.7 31.4 25.1 41.8

4 MANUAL 40 Disassembly 0 8 0 8 7.5 116.3 93.0 165.0 132.0 8.0

5 MANUAL ….. Emd Cap Deburing &U-slot R6 Radius grinding 0 24 1 25 2.4 37.2 29.8 52.8 42.2 24.9

6 MANUAL ….. Fork Rod Deburing 0 12 1 13 4.6 71.5 57.2 101.5 81.2 12.9

7 INTERNAL GRINDER 50 Pin end grinding- Fork rod 15 6 2 23 2.6 40.4 32.3 57.4 45.9 22.9

8 HMC 60 Both dowel hole machining 7 2 2 11 5.5 84.5 67.6 120.0 96.0 10.9

9 MANUAL FIXTURE 70 Both dowel fitment 0 12 3 15 4.0 62.0 49.6 88.0 70.4 14.9

10 MPI 80 M.C.D 7 4 5 16 3.8 58.1 46.5 82.5 66.0 15.9

MANUAL …….. Final deburing offer to Qa 0 50 0 50 1.2 18.6 14.9 26.4 21.1 49.7

11 Manual 90 Final inspection 15 0 0 15 4.0 62.0 49.6 88.0 70.4 14.9

12 WASHING 100 Washing & packing 6 6 5 17 3.5 54.7 43.8 77.6 62.1 16.9

Total machining time / fork rod assly. 147 149 27 323 321.2
 CAPACITY ESTIMATION
Alco rod assly.-100 nos/month Date 10.10.14
03.01.14 AMTEK TRANSPORTATION SYSTEMS LTD. GURGAON

Tool Prod. In
Load,unload,debur Prod. In
change, Prod. In Prod. In 22 hrs.
ing before loading Cycle 15.5 hrs.
S.N OPN. Machining inspection Prod. 15.5 hrs. 22 hrs. on on 3
M/C NAME OPERATION DESCRIPTION to work time on 2 shift Shift Reqd. Remarks
O. NO. Time(Min.) on m/c /hr. on 2 shift 3 shift shift
station,part clean (Min.) basis@80
&tool basis basis basis@
& dialing %eff.
cleaning 80% eff.

A . ALCO ROD

Tempoary number punching for opn wise

1 MANUAL 3 2 0 5 12.0 186.0 148.8 264.0 211.2 5.0
treacibility

1 VMC 10 Clean Cut 7 2 0 9 6.7 103.3 82.7 146.7 117.3 8.9

VERTICAL Facing First side & Maintain Dimn. 26.5 +/-

2 15 23 3 4 30 2.0 31.0 24.8 44.0 35.2 29.8
MILLING 0.50 mm
Facing second side , Small end rough
3 VMC 20 22 4 2 28 2.1 33.2 26.6 47.1 37.7 27.8
boring & Ref. side milling
VERTICAL
4 25 Semi finish thickness 7 2 0 9 6.7 103.3 82.7 146.7 117.3 8.9
MILLING
SURFACE
5 30 Face Grinding Both side 38 3 1 42 1.4 22.1 17.7 31.4 25.1 41.8
GRINDER

6 HMC 40 Big end rough boring , facing & centering 14 2 0 16 3.8 58.1 46.5 82.5 66.0 15.9

7 CNC TURNING 50 OD. Turning 24 3 2 29 2.1 32.1 25.7 45.5 36.4 28.8

8 HMC-KH80G 60 Through drill dai 12.7 mm 15 3 0 18 3.3 51.7 41.3 73.3 58.7 17.9

9 GUN DRILLING 70 Bolt Hole 19 2 1 22 2.7 42.3 33.8 60.0 48.0 21.9

Total machining time / Alco Rod 172 26 10 208

B. ALCO CAP

Tempoary number punching for opn wise

1 MANUAL ….. 3 2 0 5 12.0 186.0 148.8 264.0 211.2 5.0
treacibility
VERTICAL
1 …. Clean Cut 7 2 0 9 6.7 103.3 82.7 146.7 117.3 8.9
MILLING
VERTICAL Facing First Side & maintain Dimn. 8.35 +/-
2 10A 25 2 2 29 2.1 32.1 25.7 45.5 36.4 28.8
MILLING 0.50 mm
VERTICAL Facing second side & maintain Dimn.
3 10B 25 2 2 29 2.1 32.1 25.7 45.5 36.4 28.8
MILLING 77.1+/- 0.10 mm
SURFACE
4 20A&B Face Grinding Both side 22 2 0 24 2.5 38.8 31.0 55.0 44.0 23.9
GRINDER

5 CNC TURNING 30 Shoulder Facing & O.D. Turning 22 2 0 24 2.5 38.8 31.0 55.0 44.0 23.9

6 CNC TURNING 40A ID semi finish Turning ( Second set up ) 22 2 0 24 2.5 38.8 31.0 55.0 44.0 23.9

7 CNC TURNING 40B ID Finish Turning 10 2 1 13 4.6 71.5 57.2 101.5 81.2 12.9

8 HMC 50 Bolt Hole 27 3 0 30 2.0 31.0 24.8 44.0 35.2 29.8

Total machining time / Alco Cap 163 19 5 187

 C. ALCO ASSEMBLY

1 MANUAL 80 Alco rod &Cap Assembly 30 0 5 35 1.7 26.6 21.3 37.7 30.2 34.8

Rough boring Diameter 160.5 mm with

2 HMC 90 19 2 2 23 2.6 40.4 32.3 57.4 45.9 22.9
Cap

VMC 95 Weight Reduction 40 2 0 42 1.4 22.1 17.7 31.4 25.1 41.8

100
3 MANUAL Deburing no. punching &Diss-assly. 25 0 0 25 2.4 37.2 29.8 52.8 42.2 24.9
&105
110
5 HMC Notch Milling 25 3 2 30 2.0 31.0 24.8 44.0 35.2 29.8
A&B

6 MANUAL 120 Alco rod &Cap Re-Assembly 25 0 5 30 2.0 31.0 24.8 44.0 35.2 29.8

7 HMC 130 Finish Boring &Oil Grooving 35 4 5 44 1.4 21.1 16.9 30.0 24.0 43.8

8 HMC 140 Side Drilling & Boss machining 15 3 2 20 3.0 46.5 37.2 66.0 52.8 19.9

9 VMC/MILLING 150 Weight reduction by hand grinder 50 2 2 54 1.1 17.2 13.8 24.4 19.6 53.7

Ch. On gun drill, O & E22 Punch,dowel

160 &
11 MANUAL fitment,final deburingon oil groove ,Bore 30 0 0 30 2.0 31.0 24.8 44.0 35.2 29.8
170
inspection & Rework

12 MANUAL 180 Mpi 20 2 2 24 2.5 38.8 31.0 55.0 44.0 23.9

MANUAL 190 Final inspection 20 0 0 20 3.0 46.5 37.2 66.0 52.8 19.9

13 MANUAL 200 Packing 20 2 0 22 2.7 42.3 33.8 60.0 48.0 21.9

Total machining time / Alco assly. 354 20 25 399