DESIGN OF LOADER BACKHOE ASSEMBLY SHOP AND INSPECTION OF ASSEMBLY COMPONENTS

REPORT OF STUDY CARRIED OUT DURING VOCATIONAL TRAINING IN CASE NEW HOLLAND CONSTRUCTION EQUIPMENT INDIA PVT LTD, PITHAMPUR IN MONTH OF JULY 2011

Patel College of Science and Technology, Indore Department Of Mechanical Engineering 2011

SUBMITTED BY Arpit Verma

SUBMITTED TO Mr. Tarun Jana Manager,Quality Assurance Case New Holland Construction Equipment (India) Private Limited Pithampur M.P.

DESIGN OF LOADER BACKHOE ASSEMBLY SHOP AND INSPECTION OF ASSEMBLY COMPONENTS

APPROVED BY : Mr. Ashish Lekhwani Senior Engineer,Quality Assurance Case New Holland Construction Equipment (India) Private Limited

ABSTRACT The objective of this project report is to bridge the gap between theory and practical. It is the study of Loader Backhoe assembly shop in an esteemed organization, CASE NEW HOLLAND CONSTRUCTION EQUIPMENT INDIA PVT LTD. It is the study of various assembly line equipments, assembly shop design to reduce various wastes like transportation, over production, waiting and techniques to make the manufacturing leaner.

Study carried out through this report explains the line manufacturing process with the implementation of single piece flow concept, five S methodology and elimination of seven waste forms; Use of PLC control for conveyor automation, Inspection techniques for various components and various instruments used for inspection.

Acknowledgement
We have tried our best to learn the industry practices by means of this project. However, it would not have been possible without the kind support and help of many individuals and organization. We would like to extend my sincere thanks to all of them.

We are highly indebted to Mr. Ashish Lekhwani and Mr. Subhash Majumdar for their guidance and constant supervision as well as for providing necessary information regarding the project and also for their support in completing the project.

We would like to express our gratitude towards our parents & the members of CASE NEW HOLLAND CONSTRUCTION EQUIPMENT INDIA PVT LTD for their kind co-operation and encouragement which helped us in the completion of this project.

We would like to express our special gratitude and thanks to Mr. Abhishek Deshmukh and Mr. Nirshi Rajawat for giving us their attention and time.

Our thanks and appreciation also goes to our team work and people who have willingly helped us out with their abilities.

This is to certify that Arpit Verma student of 6th semester of Mechanical Engineering from Patel College of Science & Technology, Indore (M.P.) has undergone industrial training in our organization from 01/07/2011 to 30/07/2011.

During the training their conduct was good.

We wish them all the best in their future Endeavour.

LIST OF ABBREVIATIONS
JIT - JUST IN TIME CNH - CASE NEW HOLLAND LCV - LIGHT COMMERTIAL VEHICAL PLC - PROGRAMMABLE LOGIC CONTROLLER LB - LOADER BACKHOE WIP - WORK IN PROGRESS TRG - THREAD RING GAUGE PCD - PITCH CIRCLE DIAMETER VC - Vernier Caliper HG - Height Gauge BDG - Bore Dial Guage

LIST OF FIGURES Figure - 1 ,CNH 770 Figure - 2 ,CNH 851 Figure - 3, CNH 1107 Figure - 4, CNH 752 Figure - 5, CNH 450 Figure - 6, Assembly line of model T (1908) Figure - 7, Assembly line layout Figure - 8, Analogue Vernier Caliper Figure - 9, Digital Caliper Figure - 10, Micrometer Figure - 11, Simple dial Indicator Figure - 13, Digital dial indicator Figure - 14, Thread plug Gauge Figure - 15, Thread Ring Gauge Figure - 16, Connector Figure - 17, Connector fitted to tube with nut Figure - 18, Front view of connector A Figure - 19, Front view of connector A Figure - 20, Single piece wheel Rim

LIST OF TABLES Table - 1 ,Conveyor Specifications Table - 2,Conveyor Capacity Matrix Table - 3,Inspection report of connector (1-5) A Table - 4, Inspection report of connector (6-10) A Table - 5, Inspection report of connector (1-5) B Table - 6, Inspection report of connector (6-10) B Table - 7, Inspection report of Wheel Rim samples for Vendor A Table - 8, Inspection report of Wheel Rim samples for Vendor B

Department of Mechanical Engineering

TABLE OF CONTENT 1. 1.1 1.2 1.3 1.4 1.5 INTRODUCTION BACKGROUND THE COMPANY CASE NEW HOLLAND INDIA PVT LTD FACTORY LAYOUT PRODUCTS CONSTRUCTION EQUIPMENTS COMPETITORS 10-11 3-10

2. THEORETICAL FRAME AND REFERENSES 2.1 2.2 2.3 2.4 ASSEMBLY LINE CONCEPT DEFINING QUALITY QUALITY ASSURANCE INSPECTION

3. DESIGN OF ASSEMBLY SHOP FOR BACKHOE LOADER 3.1 LB (LOADER BACKHOE) ASSEMBLY SHOP DESIGN ASSEMBLY LINE LAYOUT 3.2 SEVEN WASTE PRINCIPLE OVERPRODUCTION WAITING TRANSPORTING INAPPROPRIATE PROCESSING UNNECESSARY INVENTORY UNNECESSARY MOTION DEFECTS 3.3 FIVE S METHODOLOGY SORTING SETTING IN ORDER SWEEPING STANDARDIZATION SELF-DESCIPLINE 3.4 SINGLE PIECE FLOW CONCEPT 3.5 KANBAN SYSTEM 3.6 TAKT TIME 3.7 PLC CONTROL
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Department of Mechanical Engineering

3.8 ASSEMBLY SHOP EQUIPMENTS ASSEMBLY CONVEYOR UNDER SLUNG CRANES WORK CENTRE CRANES TORQUE CONTROLLED TOOLS BULK OIL STORAGE SYSTEM DIESEL DISPENSING SYSTEM TROLLYS RACKS TYRE MOUNTING ZERO BALANCE HEATING VENTILATION AND AIR CONDITIONING 4. INSPECTION OF LB COMPONENTS 24-44

4.1 METROLOGY 4.2 INSTRUMENTS 4.3 DETAILED EXAMPLES OF INSPECTION INSPECTION OF CONNECTORS INSPECTION OF WHEEL RIMS 5. CONCLUSION 6. REFERENCES 45 46

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