Improvement Project

Machine shop

SELECTION OF PROJECT

Scrap Bin Replacement System for KOLB DEEP HOLE DRILLING MACHINE LOCATION: Machine Shop A8-A9

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Why KOLB Deep Hole Drilling Machine?

KOLB is very critical machine in machine shop There is need to reduce the cycle time of job on KOLB over and over

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DATA COLLECTION

KOLB produces chips at very high rate Feed rate is needed to be reduced to ensure that desirable hole finish is obtained At different feed rates size of the chips varies, size of the chip increases with reduced feed rate

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DATA COLLECTION

With reduced feed rate chip size increases drastically It results into filling of the bin within short time Hence, void space in bin increases as volume consumed by chips increases

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DATE PROJECT DETAILS of Holes Drilled Bin Changed No.
I 28/10/2008 29/10/2008 30/10/2008 31/10/2008 1/11/2008 Material: 13CrMo4-5+Wo, 2/11/2008 3/12/2008 4/11/2008 5/11/2008 6/11/2008 7/11/2008 20 U/M U/M 66 65 II U/M U/M U/M 62 60 III U/M 43 44 41 50 Hole 41 42 47 41 43 U/M I II III

Resource Used Machine Idle Time Minut

 

Crane

43


Diameter: 25.3 mm,

Forklift No. of Holes: 1640 Crane

51

Thickness: 488 mm, U/M 55 65 65 67 67 6 66 63 61 66 U/M

√ √ √

37 55

Crane

Forklift

38

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DATE PROJECT DETAILS of Holes Drilled Bin Changed Resource Used No. Machine Idle Time Minutes
I 8/11/2008 9/11/2008 10/11/2008 11/11/2008 12/11/2008 13/11/2008 20 58 U/M U/M 42 27 II 76 24 88 U/M U/M 72 70 III 58 60 79 65 U/M 27 Crane √ No. of Holes: 7240 Crane Crane 31 I II III

Crane

26

14/11/2008 53 Material: SA336 Gr F11 Cl2, Thickness: 485 mm, 15/11/2008 63 16/11/2008 17/11/2008 18/11/2008 19/11/2008 20/11/2008 21/11/2008 86 91 92 U/M U/M U/M

63 Hole Diameter: 19.25 mm, 88 71 88 89 91 U/M U/M U/M 71 71 70 U/M U/M U/M

√ √

48 43

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ANALYSIS
Re source Consumption

Forklift 22% Forklift C rane Crane 78%

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IDLE TIME OF MACHINE (minutes)
6 0 5 0 4 0 3 0 2 0 1 0 0 3 / 1 / 2 0 3 1/ 2 0 6 1/ 2 0 1 / 1/ 2 0 1 / 1/ 2 0 0 0 08 / 1 08 / 1 08 4 1 08 7 1 08 IDLE TIME

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FINDINGS
  

Bin gets filled in approximately 21-27 Hours With low feed rate bin gets filled quickly Idle Time of the Machine while bin is getting replaced is quite negotiable Resource’s time consumed in replacement affects other projects as well Cycle time of Job on KOLB increases cumulatively

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N o . o f H o le s fo r P R O JE C T : 130568
12 10 8 6 4 2 0 3 0 /1 0 /2 0 0 8 3 /1 1 /2 0 0 8 N o . o f H o le s 7 /1 1 /2 0 0 8

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No. of Hole s for PRO JECT :130561
15 15 10 10 5 0 9/11/2008 14/11/2008 16/11/2008 17/11/20 08 N o. of H oles 8 14

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CONCLUSION

Time consumed in replacement of bin can be dropped Consequently, Idle time of the machine can be reduced Hampering schedule of other jobs as well can be minimized

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SUGGESTION

Rotating Chuck Type arrangement to replace the bins SIMULATION

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BILL OF MATERIAL
5 Plate SA 36 01 800x400x10

4 3 2 1 SR NO.

Roller Contact Bearing Thrust Bearing Shaft Chuck (plate) PART NAME C 45 Mn 75 C 55 MATERIAL 01 01 QTY

STANDARD STANDARD Dia. 100x1500

Size

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DEFORMATION

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SHEAR STRESS

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EQUIVALENT STRESS

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THANKING YOU!

15/12/2008

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