24 WEEK PROJECT REPORT

ON

WELDING AND TIME STUDY DONE AT JAY BHARAT MARUTI

Submitted by AASHISH KUMAR PANWAR Under the Guidance of MR. CHANDRASHEKHAR ASSIT. PROFESSOR(MECHANICAL) in partial fulfillment for the award of the degree of

BACHELOR OF TECHNOLOGY
IN

MECHANICAL ENGINEERING

Faculty of Engineering & Technology

Manav Rachna International University, Faridabad

JANUARY, 2014

Acknowledgement
I would like to express my sincere gratitude to my project guide Mr. NIKHIL VERMA for giving me the opportunity to work on this topic. It would never be possible for me to take this project to this level without his innovative ideas and his relentless support and encouragement.

Aashish Kumar Panwar, 10/FET/M(F)/1116

Declaration
I hereby declare that this project report entitled WELDING AND TIME STUDY by, AASHISH KUMAR PANWAR, 10/FET/M(F)/1116 being submitted in partial fulfillment of the requirements for the degree of Bachelor of Technology in MECHANICAL ENGINEERING under Faculty of Engineering & Technology of Manav Rachna International University Faridabad, during the academic year 2013-2014, is a bonafide record of my original work carried out under guidance and supervision of Mr. NIKHIL VERMA, EXECUTIVE ENGINEER and has not been presented elsewhere.

Aashish Kumar Panwar, 10/FET/M(F)/1116

Manav Rachna International University, Faridabad Faculty of Engineering & Technology Department of Mechanical

Certificate
This is to certify that this project report entitled WELDING AND TIME STUDY by AASHISH KUMAR PANWAR, 10/FET/M (F)/1116, submitted in partial fulfillment of the requirements for the degree of Bachelor of Technology in MECHANICAL under Faculty of Engineering & Technology of Manav Rachna International University Faridabad, during the academic year 2010-2014, is a bonafide record of work carried out under my guidance and supervision.

Mr. Chandrashekhar Assistant Professor, Department. Of Mechanical Faculty of Engineering & Technology Manav Rachna International University, Faridabad

Mr. Ranvijay Singh

TABLE OF CONTENTS
Acknowledgement Declaration Certificate Table of Contents List of Figures List of Tables Abstract Chapter No

i ii iii iv v vi vii Page

INTRODUCTION OF JBM Introduction and History of the company Groups of the company Guiding principles at JBML Milestones of the company Departments in JBM

KAIZEN AND POKA YOKE Types of Kaizen and Poka Yoke

14

WELDING Types of welding Defects of welding

17

EXHAUST SYSTEM Overview and Functions of Exhaust System Stepwise Making Procedure of Exhaust System
5

22

Exhaust system layout Parameter Study in Alto and Omni lines Time Study of Omni, Alto and M800 lines 39

MEMBER SET FLOOR Member Set Floor Layout of Member Set Floor Parameter and Time Study

YR-9 (WAGON R) Parameter Study Time Study Improvement Suggested in Layout

47

YE-3 ( ALTO) To find out number of spots made between two consecutive Tip Dressings

55

YL-8 ( ERTIGA) Time study of YL-8 Line

57

CONCLUSION

59

References/Bibliography

viii

LIST OF TABLES
Table
Table 1.1 Table 2.1 Table 2.2 Table 2.3 Table 2.4 Table 2.5 Table 2.6 Table 3.1 Table 3.2 Table 3.3 Table 3.4 Table 3.5 Table 4.1 Table 4.2 Table 4.3 Table 4.4 Table 5.1 Table 6.1 Table 6.2 Exhaust system machines classifications Alto exhaust line machine specifications Omni exhaust line machine specifications Alto exhaust line time study Alto exhaust line time study M 800 exhaust line time study Omni exhaust line time study Member Set Floor machines specifications Member Set Floor machines specifications Member Set Floor time study Member Set Floor machines specifications Member Set Floor time study Parameter study YR-9 Parameter study YR-9 Parameter study YR-9 Time study YR-9 Tip dressing schedule Time study YL-8 Time study YL-8

Page No
25 30 31 35 36 37 38 40 43 44 45 46 48 51 52 53 56 57 58

LIST OF FIGURES
Figure Page No.

Figure 1.1 Figure 1.2 Figure 1.3 Figure 2.1 Figure 2.2-2.7 Figure 2.8-2.11 Figure 2.12 Figure 3.1 Figure 3.2 Figure 3.3 Figure 4.1 Figure 4.2 Figure 5.1-5.3

JBM Plant No.1 Resistance Welding Sequence of Resistance Welding Exhaust system line layout Exhaust system making in JBM Exhaust system making in JBM Alto Exhaust system Member set floor Member set floor Member set floor Member set floor line Member set floor Member set floor line Current Layout YR-9 Improved Layout Suggested YR-9 YE-3 Tip dresser and Robot

9 18 19 26 27 28 29 39 42 42 54 54 55

INTRODUCTION OF THE COMPANY

JBM is a multi unit, multi product group with extensive and diversified interests in engineering and precision tooling, dies and chemicals and textiles and facilities spread over different parts of the country. JBM group began its engineering activity in 1983 with the establishment of Gurera gas cylinder limited and entered the auto component industries in 1985 with the inception of SUZUKI AUTO INDIA. The JBML engineering groups deals in broad range of sheet metal assemblies, die casting components and forging for the domestic and export markets. The working environment at JBML is based on Japanese systems of manufacturing. 300 trained and highly motivated personnel are the companys greatest asset. The core group works closely with its staff and workers to provide solution and create new goals for JBML. Owing to companys policy of continual improvement, use of latest manufacturing technologies, establishing effective quality management system, continually improving employee skills, JBML has constantly been upgrading and improving companys resources.

Fig 1.1
9

HISTORY OF THE COMPANY

Jay Bharat Maruti Limited was set up in 1987. It is one of the largest joint ventures of Maruti Udyog Limited. This is a unique combination of modern Press Shop and Weld Shop capable of supplying components with successfully meeting customers quality and quantity requirements. Manufacturing facilities at JBML also include die maintenance, dedicated facilities for manufacturing exhaust systems and in house modern tool room. JBML is rising to meet new challenges with modern equipment and higher goals of manufacturing and quality control.

GROUPS OF THE COMPANY

The JBM group has following established plants:1. Jay Bharat Maruti Limited 2. JBM Auto Components Limited 3. JBM Industries Limited

GUIDING PRINCIPLES AT JBML

MISSION
To make JBML a synonym for world class organization excelling in sheet metal technologies.

VISION
Expanding leadership in our business through people keeping pace with market trends and technology.

10

 HR POLICY
JBML will always keep on striving for the deployment of competent and efficient employees at all levels to create inculcate and foster excellent working and learning environment, because it believes in nurturing strength of individuals for developing mutual trust, support and positive attitude for achieving organization goals to create a world class manufacturing organization and to remain the market leader in sheet metal components not only today but for all the tomorrows to come.

QUALITY POLICY
The policy of JBML is to achieve total customer satisfaction by delivering products and providing services that meet or exceed their exacting requirements and expectations and to do so on time and at most competitive prices in domestic and export market for our entire product range.

ENVIRONMENT, HEALTH AND SAFETY POLICY

Jay Bharat Maruti Limited, as a responsible manufacturer of sheet metal components, welded sub assemblies and exhaust systems for automotive applications, re-affirms its commitment to minimize the adverse impacts of its operations, products and services on the environment, health and safety. To this end, the company endeavor to develop and maintain an Environment, Health and Safety Management System and continually monitor, set and review the environmental, health and safety objectives and targets.

11

MILESTONES OF THE COMPANY

1. 1987 2. 1989 3. 1995 4. 1996 5. 1997 6. 1999 7. 1999 8. 2000 9. 2001 10. 2003 11. 2003 12. 2005 13. 2005 14. 2006 15. 2007 16. 2008 17. 2009 18. 2010 19. 2011 20. 2012 21. 2013

: : : : : : : : : : : : : : : : : : : : :

Company Incorporated Commercial Production Plant-2 commissioned Exhaust System M-800 & Omni Fenders Baan IV Software System Exhaust system Alto & WagonR M-800 Car Under Bodies Versa line Fuel Neck Filler & Electroplating Axle Line 800CC & ALTO SWIFT-Line Axle line Swift & CED Painting Plant-3 Commission SX-4 Axle Line Commissioned RITZ Axle Line Commissioned YR-9 Axle Line Commissioned EECO Line Commissioned ALTO K-10 Line Commissioned YL-8 Axle and BIW Line YE-3 Line Commissioned

12

DEPARTMENTS IN JBM

1. BODY IN WHITE 2. HUMAN RESOURCE DEVELOPMENT 3. QUALITY ASSURANCE 4. QUALITY SERVICE 5. ENGINEERING 6. AXLE 7. MATERIAL EXCHANGE 8. PLANT MAINTENANCE 9. EXHAUST 10. PURCHASE 11. RAW MATERIAL 12. FINANCE 13. PERSONAL AND ADMINISTRATION

13

KAIZEN

Kaizen is the small improvements in production as a result of continuous efforts covering all areas and all employees. The difference between Kaizen and Innovation is that Innovation involves a drastic improvement as a result of large investment in new equipment or new technology but does not require large investment.

TYPES OF KAIZEN

SPACE SAVING
Any equipment, accessories projecting out are shifted to suitable locations like top of some other items thus saving space. Any vacant space below working table, roller conveyor etc can be utilized effectively.

OPERATION IMPROVEMENT
Operations where operator is working in uncomfortable posture should be rectified by providing proper working posture. Distance between 2 workstations should be reduced so that wasteful man movements in various processes can be eliminated. Location of material storage or material flow should be proper.

ENERGY SAVING
Illuminance is inversely proportional to the square of distance, so lamp should be placed closer to the operator. Lamp position should be adjusted so that shadow of operator does not affect his work.

14

Whenever possible, individual lighting should be used for each work area as compared to general lighting. Use of motorized conveyors should be eliminated wherever flow material using gravity force is possible. of

MATERIAL FLOW IMPROVEMENT

Try to introduce direct supply of material to line and eliminate intermediate storage. Capacity of bins and trolleys should be improved so that higher number of components can be carried at one time to reduce number of trips. If possible, change from one layer storage to double layer storage.

QUALITY IMPROVEMENT
Ensure that no coolant or oil spillage is taking place. Operators should not wear any loose and hard object which can create scratches during working. Lighting should be proper in inspection area to avoid defects being passed on to next stage.

15

POKA-YOKE

Poka-Yoke is a Japanese term that means fool proofing or mistake proofing. A Poka -yoke is a mechanism in a lean manufacturing process that helps an equipment operator avoids mistakes. Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.

TYPES OF POKA-YOKE
On the basis of signal of detection On the basis of types of sensor used in detection On the basis of physical contact

Whenever a defect is predicted or an error is detected: The process is shut down or A control prevents going ahead or A warning is sent

16

WELDING

Welding is the process of permanently joining two or more metal parts, by melting both materials. The molten materials quickly cool, and the two metals are permanently bonded.

TYPES OF WELDING DONE AT JBM

1. RESISTANCE WELDING ( SPOT WELDING) 2. MIG WELDING 3. MAG WELDING

RESISTANCE WELDING (SPOT WELDING)

Spot welding is done with the help of electrodes. Firstly, we approach the parts which is being spot welded. With the help of high current, the parts are heated up to plastic flow of materials takes place and then immediately pressing them by electrodes with high pressure. Spot welding is primarily used for joining parts normally up to 3 mm (0.125 inch) thickness. Spot-weld diameters range from 3 mm to 12.5 mm (0.125 to 0.5 inch).Low carbon steel is most suitable for spot welding.

17

PRINCIPLE OF RESISTANCE WELDING

Fig 1.2 R1 & R5 - Resistance between tip and sheet R2 & R4 - Sheet individual resistance R3 - Surface contact resistance

H=I2xRxT H = Heat I = Current in amperes, R = Resistance of the work in ohms, T = Time the current flow in cycles (50 CYCLES = ONE SECOND)

In welding it is desirable to have R1,R2,R4,R5 low R3 high

18

Sequence of Resistance Welding

Fig 1.3

a). SQUEEZE TIME - Time required for the electrode to close on metal and apply proper
pressure. It varies with the gap between the electrodes.

b). UP SLOPE TIME - Time taken for the current to reach from zero the set value.

c). WELD TIME - Time for current flow in object.

d). DOWN SLOPE TIME - Time taken for the current to come down from set current to
zero.

e). HOLD TIME - Time taken by the electrodes to hold the sheets together after the current
flow stops. Pressure still applied to allow the molten metal to solidify.

f). OFF TIME - It is the time between the end of one spot sequence to start of next spot
sequence.
19

MIG AND MAG WELDING

Gas metal arc welding(GMAW), referred to by its subtypes Metal Inert Gas(MIG) or Metal Active Gas(MAG) welding, is a welding process in which an electric arcs forms between a consumable wire electrode and the work piece metal, causing them to meet and join. Along with the wire electrode, a shielding gas feeds through the welding gun, which shields the process from contaminants in the air.

Difference between MIG and MAG Welding

MIG stands for Metal Inert Gas. Inert meaning the gas has no affect on the weld except to shield it from oxidation from the atmosphere. E.g-Argon,CO2,etc. MAG stands for Metal Active Gas. This would be a gas like oxygen that is reactive to the arc and affects the temperature and other characteristics of weld and performs a function besides just shielding. E.g.- Oxygen,Helium,etc.

20

WELDING DEFECTS

Excess Penetration - Burning through is more of a problem with thin sheet as a

higher level of skill is needed to balance heat input and torch traverse when welding thin material.

Porosity - This occurs when gases are trapped in the solidifying weld metal. These may
arise from damp metal or from dirt.

Inclusions - These can occur when several runs are made along a V-join when joining
thick plate using flux cored and the slag covering a run is not totally removed after every run before the following run.

Cracking - This can occur due just to thermal shrinkage or due to combination of strain
accompanying phase change and thermal shrinkage. A combination of poor design and inappropriate may result in cracking.

Lack of Fusion - This is one of the most serious weld defect. It produces the notch
effect. In welds, incompletely fused spots are called lack of fusion.

21

EXHAUST SYSTEM IN JBM OVERVIEW

Maruti 800,Alto and Omni are the 3 car models whose exhaust systems are made in the plant and only for omni cars exhaust system contains catalyser. Between catalyser and muffler there is a hole in pipe for sensor which determines the amount of pollutants coming out of the exhaust pipe.

FUNCTIONS OF EXHAUST SYSTEM IN A CAR

1. To reduce the velocity of exhaust gases coming out from engine using pipes. 2. To reduce noise . 3. To reduce exhaust gases temperature . 4. To reduce the harmful pollutants from escaping into atmosphere using catalyser.

22

EXHAUST SYSTEM MAKING IN JBM CONSISTS OF FOLLOWING STEPS:1. 2. Rolling and spot welding of metal sheets on DC1 (double coiling) machine. Flanging operation on flanging machine (FFC1) in which both corners of cylindrical shape are bent at right angle outward. 3. Fitting baffle after flanging on baffle fitting machine (BPC-1)by applying pressure from upper side. 4. 5. Covers on both the sides are attached by spot welding on (SMC-2) machine. (CSC-1) machine is used for curling and seaming. for this two rollers are used a. b. 6. Right side roller is used for curling Left side roller is used for seaming

(AWC-1) machine is used to attach engine side rod to the muffler, using MIG welding.

7. 8.

(AWC-2) machine is used to attach other side rod to the muffler, using MIG welding. Pressure check is done by sealing it from both sides and then dipping into water, if bubbles do not come the piece is ok.

9.

After welding the rods the leakage testing is done using (LTC-1), for which a gas is filled into the exhaust system and pressure is checked for next 15 seconds ,if pressure is constant throughout the piece is ok.

23

MUFFLER
Mufflers are installed within the exhaust system of most internal combustion engines, although the muffler is not designed to serve any primary exhaust function. The muffler is engineered as an acoustic soundproofing device designed to reduce the loudness of the sound pressure created by the engine by way of Acoustic quieting. The majority of the sound pressure produced by the engine is emanated out of the vehicle using the same piping used by the silent exhaust gases absorbed by a series of passages and chambers lined with roving fiberglass insulation and/or resonating chambers harmonically tuned to cause destructive interference wherein opposite sound waves cancel each other out. An unavoidable side effect of muffler use is an increase of back pressure which decreases engine efficiency. This is because the engine exhaust must share the same complex exit pathway built inside the muffler as the sound pressure that the muffler is designed to mitigate. An exhaust pipe must be carefully designed to carry toxic and/or noxious gases away from the users of the machine. Indoor generators and furnaces can quickly fill an enclosed space with carbon monoxide or other poisonous exhaust gases if they are not properly vented to the outdoors. Also, the gases from most types of machine are very hot; the pipe must be heatresistant, and it must not pass through or near anything that can burn or can be damaged by heat. A chimney serves as an exhaust pipe in a stationary structure. For the internal combustion engine it is important to have the exhaust system "tuned" (refer to tuned pipe) for optimal efficiency. Also this should meet the regulation norms maintained in each country.

24

EXHAUST SYSTEM LINES AT JBM

MARUTI-800 (C) 1. 2. 3. 4. 5. DC-1 FFC-1 BPC SMC-2 CSC-1

OMNI

(V)

ALTO (Y) 1. AWY-1 2. AWY-3 3. MWY-1 4. MWY-2 5. LTY-1 6. GY-1 7. AWY-5 8. AWY-6 9. MWY-3 10. MWY-4 11. LTY-2 12. GY-2

1. DC-2 2. BPV-3 3. CSV-1 4. AMV-3 5. AMV-4 6. AMV-5 7. LTV-1 8. AWV-1 9. MMY-2 10. LTV-2 11. BTV-1 12. FOR BAFFLE MAKING 1. BPV-1 2. BPV-2 3. MMV-1
Table 1.1

25

EXHAUST SYSTEM LINES LAYOUT

Fig 2.1

26

WELDING PICTURES IN EXHAUST LINE

Fig 2.2

Fig 2.3

Fig 2.4

Fig 2.5

Fig 2.6 27

Fig 2.7

Fig 2.8 - 2.11

28

ALTO EXHAUST SYSTEM

ALTO EXHAUST SYSTEM CONSISTS OF FOLLOWING PARTS:1) 2) 3) 4) 5) Muffler Box Baffles Pipes Flanges Hangers

All these parts are joined together by : (MIG/MAG) welding process, Spot Welding and Pressing.

Fig 2.12

There are nine processes used in Alto Exhaust Line

1. 2. 3. 4. 5. 6. 7. 8. 9. Rolling And Spot Welding Flanging Baffle Fitting Cover Attach Curling And Seaming Engine Side Rod Welding Other Side Rod Welding Pressure Check Leakage Testing

29

SPECIFICATIONS OF MACHINES FOR ALTO EXHAUST SYSTEM:-

SNO.

MACHINE NAME

MACHINE TYPE SPM

WIRE DIAMETER USED 0.8

WIRE MATERIAL USED MS

WELD CURRENT(A) 120-160

VOLTAGE

GAS FLOW(LI T/MIN) 10-15

AWY-5

18-22

AWY-6

SPM

SS

120-140

18-22

10-15

MWY-3

WELD FIXTURE WELD FIXTURE

SS

120-160

18-24

10-15

MWY-4

SS

120-160

18-24

10-15

LTY-2 permissible leakage:-(750 cubic cm at 0.3 kg/square cm) for minimum 15 seconds.

AWY-1

SPM

SS

120-160

22-26

10-15

AWY-3

SPM

SS

160-200

22-26

10-15

MWY-1

WELD FIXTURE WELD FIXTURE

0.8

MS

140-180

22-26

10-15

MWY-2

0.8

MS

140-180

22-26

10-15

10

LTY-1

AIR PRESSURE:-no leakage at 0.3 kg/square cm for 13 seconds. LEAKAGE TO BE MAXIMUM UPTO:- 87 cubic cm ,is OK. Table 2.1

30

OMNI EXHAUST SYSTEM

DETAILS OF THE MACHINES USED FOR MAKING EXHAUST SYSTEM OF OMNI

BPV-1 and BPV-2 : These machines are used to prepare baffles by fitting pipes into circular mild steel plates by applying pressure. Machine nameCylinder force in eachPress Fitting Machine. (50-200)kgf.

MMV-1: Preparation of baffles through welding the baffle pipes to mild steel plates to fix them. Diameter of wire usedMaterial of wire usedCurrent usedVoltage usedGasflow(litre/minute)1mm. SS. 120-160 Amperes. 20-24 volts. (10-15) litre/min.

DC-2 : Mild steel Sheets are rolled and then spot welded on 10 spots on double coiling machine. It also consists of a sheet lifter which automatically lift and move it to roller where it is rolled. Pressure in mpa when m/c not lifting the sheets -0.3 Pressure in mpa when m/c is lifting the sheets -0.6

BPV-3:

31

Baffles are fitted into covers (mufflers) using pressure. Machine name Cylinder forcePress Fitting Machine. (50-200) Kgf.

CSV_1: Machine name - Curling And Seaming Machine. Curling and seaming of both ends of muffler is done after putting lids on them. Curling width ( 9.1 - 0.5)mm

Length of pipe from end plate- ( 0.5~1.5) mm

AWV-3: Flange is welded on pipe which is fitted to catalyser on AWV-4 Machine nameDiameter of wire usedMaterial of wire usedCurrent usedVoltage usedGasflow(litre/minute)SPM 1mm SS 120-160amperes 20-24 volts 10-15litre/min

AWV-4: Pipe is fitted on 1 side of catalyser. Machine name/type Diameter of wire usedMaterial of wire usedCurrent usedVoltage usedGasflow(litre/minute)SPM 1mm SS 120-160amperes 20-24 volts 10-15litre/min

AWV-5: pipe is fitted on another side of catalyser.

32

Machine name/type Diameter of wire usedMaterial of wire usedCurrent usedVoltage usedGasflow(litre/minute)-

SPM 1mm SS 120-160amperes 20-24 volts 10-15litre/min

LTV-1: Leakage test of product prepared on AWV-5 is done.

10 AWV-1: catalyser and box are joined together using welding process. Diameter of wire usedMaterial of wire usedCurrent usedVoltage usedGasflow(litre/minute)1mm SS 120-160amperes 18-24 volts 10-15litre/min

11

AWV-2: Pipe is joined on 1 side of the workpiece prepared on AWV-1. Diameter of wire usedMaterial of wire usedCurrent usedVoltage usedGasflow(litre/minute)1mm SS 120-160amperes 18-20 volts 10-15litre/min

12 MMV-2:
33

Machine name Welding Fixture. Diameter of wire used- 0.8mm Material of wire used- MS Current used-120-160amperes Voltage used-24-30 volts Gasflow(litre/minute)-10-15litre/min Supports are added on both sides of muffler using welding process.

13

LTV-2: Leakage test of complete system is done

14

BTV-1: Cover is added on catalyser using bolts using drill to avoid heat dissipation .

Table 2.2

34

TIME STUDY OF EXHAUST LINE ALTO

NAME OF MACHINE AWY-1

EXHAUST

SYSTEM
TIME PER PIECE(sec.) 40.75 43.25 48 40.5 38 36.5 27.5 38 26.5 27.75 18.5 18

NUMBER OF PIECES 4 4

CYCLE TIME(sec.) 163 173 192 162 152 146 110 152 106 111 74 72

AWY-3

4 4

MWY-1

4 4

MWY-2

4 4

LTY-1

4 4

GY-1

4 4

Table 2.3

35

TIME STUDY OF EXHAUST LINE ALTO EXHAUST SYSTEM

MACHINE NAME AWY-5

NUMBER OF PIECES 4 4

CYCLE TIME (IN SECONDS) 217 221 172 164 154 204 256 217 320 306 102 106

TIME PER PIECE ( IN SECONDS) 54.25 55.25 43 41 38.5 51 64 54.25 80 76.5 25.5 26.5

AWY-6

4 4

MWY-1

4 4

MWY-4

4 4

LTY-2

4 4

GY-2

4 4

Table 2.4

36

TIME STUDY OF EXHAUST LINE MARUTI 800 EXHAUST SYSTEM

MACHINE NAME

NUMBER OF PIECES 4

TIME TAKEN(sec.)

TIME PER PIECE(sec.) 30

DC-1

120

FFC-1

47

11.75

BPC

62

15.5

SMC-2

36

CSC-1

255

63.75

Table 2.5

37

TIME STUDY OF OMNI EXHAUST SYSTEM

MACHINE NAME

NUMBER OF PIECES

TIME TAKEN(sec.)

TIME PER PIECE(sec.)

MMV-1 DC-2 BPV-3 CSV-1 AWV-4 AWV-1 AWV-2 MMV-2 LTV-2 BTV-1 DC-2 BPV-3

4 4 4 4 4 4 4 4 4 4 4 4

112 218 185 221 152 230 207 282 276 148 218 185

28 54.5 46.25 55.25 38 57.5 51.75 70.5 69 37 54.5 46.25

Table 2.6

38

WELDING MEMBER SET FLOOR (ALTO)

MEMBER SET FLOOR:

Member set floor is steel welded rigid assembly which acts as a base of a car and act as rear wheel housing and thus helps the car body parts to be in their respective positions under different circumstances. It holds and also supports the rear seating arrangement.

MEMBER SET FLOOR CONSISTS OF FOUR MEMBERS:-

Figure 3.1 NO. OF SSW MACHINES USED NO.OF C-GUNS USED NO.OF X-GUNS USED NO. OF LABOUR USED 9 4 4 12

39

MACHINES USED
1.SWL-16 :In this operation M8 nut is welded to Runf .RR FLFR XMBR CTR. Parts to be welded:1.) Runf .RR FLFR XMBR CTR. 2.) M8-SQ nut Filing of electrode is done after 100 components. 2.SWL-23 :- components to be welded:1.) Cross member RR Floor Front 2.)M6 BOLT PROCEDURE:- 1.)place the component(opn.10) on electrode guide pin. 2.) On SSW machine weld 1 M6 stud (62612) on the component. Filing of electrode is done after 100 components. 3. WIP-25 :-on this machine 5 ,M5 studs are welded to the component after operation no. (20/50). Filing of electrode is done after 100 components 4. WIP-20:- In this process IT gun (C-type) is used . Parts to be welded:1.) Components from opn. 30/50. 2.) Hanger comp MUF FR. Procedure :1.) All clamps should be in open position . 2.) Place 62620 , component from opn. 30/50 , 62612 in JIG in its place . 3.) Weld and count 5 spot 5. SWL-16:- In this operation 9 spots are welded on component from opn.40/50 and electrode is filed after every 25 components. Components required:- component from operation no.40/50. Procedure:- make 9 spots on SSW, count 9 spots on SSW.

Table 3.1

40

MEMBER SET FLOOR LAYOUT

SWL-23 20/50 WIP-25 30/50 WIP-20 40/50 SWL-11 50/50 SWL16 10/50 (M-6 BOLT) (5-STUDS) (HANGER,JOINING) (9-SPOTS) M8 SQNUTS

10/30 C-GUN ,12-SPOTS .X-GUN,32-SPOTS

20/30 C-GUN ,1-4 SPOTS .X-GUN,1-8 SPOTS

10/30 C-GUN ,12-SPOTS .X-GUN,32-SPOTS

C-GUN

X-GUN

C-GUN

X-GUN

C-GUN

X-GUN

30/30 C GUN ,1-8 SPOTS .X-GUN,1-4 SPOTS

C-GUN

X-GUN

41 TROLLEY

MEMBER SET FLOOR

Fig 3.2

Fig 3.3

42

MACHINE SPECIFICATIONS

MACHINE NAME

WELD TIME

HOLD TIME

WELD CURRENT (on load)

ELECTRODE FORCE (KGF)

ELECTRODE NUMBER

SWL-16

6-7

06

11-12

240-280

T-53, T-28C, T-36

.SWL-23

10-11

06

8-9

240-280

T-30, T-27B, T-36

WIP-20

12-13

06

8-9

180-220

T-86/60, T-13D, T-4

SWL-11

12-13

06

8-9

200-240

T-86/60, T-13D, T-62/60

Table 3.2

43

TIME STUDY OF MEMBER SET FLOOR

SNO.

OPERATION NO.

MACHINE NAME

NO.OF PIECES

TIME IN SECONDS

10/50

SWL-16

147

TIME PER PIECE (IN SECONDS) 36.75

20/50

SWL-23

109

27.25

30/50

WIP-25PC

34

8.5

40/50

WIP-20PC

78

19.5

50/50

SWL-11

41

10.25

Table 3.3

44

MACHINE SPECIFICATIONS

SNO. OPERATION MACHINE WELD HOLD CURRENT ELECTRODE ELECTRODE NO. USED TIME TIME FORCE NO.

10/30

X-23 KVA C-23 KVA

12-13

06

9-10

180-220

T-52 T-86-40 T-13D T-4

20/30

X-23 KVA C-23 KVA

12-13

06

9-10

180-220

T-52 T-86-40 T-13D T-4

30/30

X-23 KVA C

12-13

06

9-10

180-220

T-52 T-86-40 T-13D T-4

Table 3.4

45

TIME STUDY OF MEMBER SET FLOOR

SNO.

OPERATION MACHINE NO.OF NO. USED PIECES

10/30

X-23 KVA C-23 KVA

TIME IN TIME PER SECONDS PIECE (IN SECONDS) 304 76

No. of spots by X-GUN 32

No.of spots by C-GUN 12

20/30

X-23 KVA C-23 KVA

188

47

1-8

1-4

30/30

X-23 KVA C

187

46.75

1-4

1-8

Table 3.5

46

YR-9 ROBOTICS (WAGON-R)

In YR-9 line Dash Panel Component of front side of Wagon-R is prepared using MIG, Projection and Spot Welding.

TO STUDY THE FOLLOWING:1. PARAMETER STUDY 2. TIME STUDY 3. NEW POSSIBLE INNOVATIONS

47

PARAMETER STUDY

SNO.

OPERATION NO.

OPERATION DESCRIPTION

10/10

TYPE OF WELDING:ASSEMBLY NAME:COMPONENT NAME:-

MIG WELDING. PANEL COMP,DASH LWR SIDE,R 1).PANEL DASH LWR SIDE 2).STAY BODY MTG

20/150

TYPE OF WELDING:ASSEMBLY NAME:COMPONENT NAME:-

PROJECTION WELDING.,M-14 NUT MEMBER COMP FRONT SIDER 1).BRKT SSPN FRM RRMTG,R 2).NUT SNPSN FRAME,RR 3). MTG(M14 NUT)

30/150

TYPE OF WELDING:ASSEMBLY NAME:COMPONENT NAME:-

MIG WELDING. MEMBER COMP FRONT SIDER,L 1). BRKT SSPN FROM RRMTG,L

40/150

TYPE OF WELDING:ASSEMBLY NAME:COMPONENT NAME:-

PROJECTION WELDING. MEMBER COMP DASH SIDE R AND L 1). MEMBER COMP DASH SIDE R AND L 2). NUT SNPSN FRAME,FRT MTG (M14

NUT) 5 50/150 TYPE OF WELDING:ASSEMBLY NAME:COMPONENT NAME:MIG WELDING. MEMBER COMP DASH SIDE L 1). COMP. FROM OPERATION 40/150

48

60/150

TYPE OF WELDING:COMPONENT NAME:-

SPOT WELDING.

,5 SPOTS

1). BRKT SSPN FRM RRMTG,L 2).EXT DASH LOWER SIDE L

FILE THE TIP AFTER 40 COMPONENTS 7 70/150 TYPE OF WELDING:ASSEMBLY NAME:COMPONENT NAME:SPOT WELDING. MEMBER COMP FRONT SIDER,L 1). COMP. FROM OPERATION 10 2).MEMBER DASH SIDE ,L 8 80/150 TYPE OF WELDING:ASSEMBLY NAME:COMPONENT NAME:9 120/150 TYPE OF WELDING:ROBOTS -2 10 SPOTS ON EACH COMPONENTS ASSEMBLY NAME:MEMBER COMP FRONT SIDE,L SPOT WELDING.(FIXED TYPE ) MEMBER COMP FRONT SIDER,R 1). COMP. FROM OPERATION 70 SPOT WELDING (ROBOTICS) NO.OF

COMPONENT NAME:- 1). COMP. FROM OPERATION 70 2). COMP. FROM OPERATION 90 3).REINF ,DASH SIDE MBR-L TIP DRESSING IS DONE ON TIP DRESSING ALARM. 10 130/150 TYPE OF WELDING:ASSEMBLY NAME:COMPONENT NAME:SPOT WELDING ,37 SPOTS MEMBER COMP FRONT SIDER R AND L 1). COMP. FROM OPERATION 120 2). REINF ,DASH SIDE MBR-L ELECTRODE FILING IS DONE AFTER 5 COMPONENTS 11 140/150 TYPE OF WELDING:ASSEMBLY NAME:COMPONENT NAME:SPOT WELDING , 23 SPOTS MEMBER COMP FRONT SIDE,L 1). COMP. FROM OPERATION 130 2). COMP. FROM OPERATION 110 1-12 SPOTS :13-23 SPOTS:IST ROBOT ,A 2ND ROBOT ,B

TIP CHANGING IS DONE ON CHANGING TIP ALARM.

49

12

150/150

TYPE OF WELDING:ASSEMBLY NAME:OPERATIONS:-

SPOT AND MIG WELDING MEMBER COMP FRONT SIDER R AND L

1).19 SPOTS ON EACH COMPONENT 2).PLUG WELDING ON 4 PLACES 3).10mm MIG WELDING ON 1 SPOT. COMPONENT NAME:- 1). COMP. FROM OPERATION 140 FILING IS DONE AFTER 15 COMPONENTS

Table 4.1

50

PARAMETER STUDY OF YR-9

SNO.

OPERATION NO.

WELD TIME (CYCLES) 18-20

HOLD TIME (SECONDS)

WELD CURRENT (KA) 16.5-17.5

ELECTRODE FORCE (KGF)

SLOPE TIME

ELECTRODE NO.

20/150

25

530-570

2-3

T 332 T 333

40/150

18-20

25

16.5-17.5

530-570

2-3

T 332 T 333

60/150

13-14

10

10.5-11.5

180-220

2-3

T 331 T62/50 T95 ,T23 T 331 T62/60 T95 ,T23 T 13-D T -95

70/150

13-14

10

10.5-11.5

240-300

2-3

80/150

18-20

25

10.5-11.5

240-300

2-3

120/150

14-15

10.5-11.5

3000-3500

2-3

T 325 T334 , T16D

130/150

13-14

10

10.5-11.5

240-300

2-3

T 331, T62/50, T 95 T 325 T334 , T16D T 331, T62/50, T 95

140/150

14-15

10.5-11.5

3000-3500

2-3

150/150

13-14

10

10.5-11.5

240-300

2-3

Table 4.2 51

PARAMETER STUDY OF YR-9

SNO.

MACHINE NAME MIG WELDING MACHINE MIG WELDING MACHINE MIG WELDING MACHINE MIG WELDING MACHINE

OPERATION NO. 10/10

WIRE DIAMETER 0.8

WELD CURRENT 130-180

VOLTAGE

GAS FLOW 15-25

WIRE MATERIAL MS

20-35

30/150

0.8

100-130

25-30

20-25

MS

50/150

0.8

100-130

25-30

20-25

MS

150/150

0.8

100-130

25-30

20-25

MS

Table 4.3

52

TIME STUDY OF YR-9

SNO.

OPERATION NO.

MACHINE NAME

1 2 3 4 5 6 7 8 9 10 11 12

10/10 20/150 30/150 40/150 50/150 60/150 70/150 80/150 120/150 130/150 140/150 150/150

MIG WELDING MACHINE SSW MIG WELDING MACHINE SSW MIG WELDING MACHINE IT GUN C TYPE IT GUN C TYPE IT GUN126 IT GUN X TYPE IT GUN C TYPE SPOT WELDING MIG WELDING MACHINE

TIME FOR 5 PIECES IN SECONDS 180 48 61

TIME FOR 1 COMPONENT IN SECONDS 36 9.6 12.2

360 128 395 308 163 365 193 368

72 25.6 79 61.6 32.6 73 38.6 73.6

Table 4.4

53

IMPROVEMENT SUGGESTED
LINE NAME YR9 (WAGON R)

Operation number-150/150
Current situation- worker has to move a longer distance so fatigue is more.

CURRENT SITUATION Fixture 1 Fixture 2

Figure 4.1 Improved Situation:- Workers moving distance is reduced so he will have lesser fatigue. Fig 4.2

IMPROVED SITUATION

FIXTURE 1

FIXTURE 2

54

LINE NAME :-

YE-3 LINE

TIP DRESSING OF ROBOTS ON WELDING LINE

On Robotics Line Tip Dressing Is Done Automatically By The Robots After Making Certain Number Of Spots. Each Robot Has Been Programmed Such That It Do Dressing After Different Number Of Spots According To The Requirements.

(Fig 5.1 -5.3)

55

THIS TABLE SHOWS AFTER HOW MANY SPOTS EACH ROBOT DO ITS TIP DRESSING
SNO. NAME OF ROBOT NUMBER OF SPOTS AFTER WHICH DRESSING OF TIP IS DONE 1 RYE-1 266

RYE-2

174

RYE-3

204

RYE-4

221

RYE-5

206

RYE-6

194

RYE-7

205

RYE-8

202

RYE-9

154

10

RYE-10

204

11

RYE-11

133

Table 5.1
56

YL-8(ERTIGA) TIME STUDY ROBOT NAME WHL

COMPONENT NAME-PANEL COMPONENT WHEEL HOUSE INNER LEFT SNO. OPERATION NUMBER 40/80 27 28 28 29 28 29 29 28 28 29 2.27 OPERATION NUMBER 50/80 25 25 25 25 25 26 24 25 26 26 25.25 OPERATION NUMBER 60/80 59 54 55 54 55 78 54 54 54 54 57.1 OPERATION NUMBER 70/80 48 48 48 46 48 55 48 49 48 48 48.6

1 2 3 4 5 6 7 8 9 10 AVERAGE TIMINGS (Sec.)

Table 6.1
57

YL-8(ERTIGA) TIME STUDY ROBOT NAME WHR

COMPONENT NAME-PANEL COMPONENT WHEEL HOUSE INNER RIGHT SNO. OPERATION NUMBER 40/80 1 2 3 4 5 6 7 8 9 10 AVERAGE TIMINGS (Sec.) 36 38 36 35 35 36 36 36 36 37 35.8 OPERATION NUMBER 50/80 26 27 26 27 26 27 26 26 27 32 27 OPERATION NUMBER 60/80 53 53 52 53 53 58 54 54 53 56 53.9 OPERATION NUMBER 70/80 65 57 56 56 56 56 56 55 64 56 56.8

Table 6.2

58

CONCLUSION
JAY BHARAT MARUTI LTD is a world class company in sheet metal technology. Training here has been very useful in understanding the working environment of the company, relation between officers and their subordinates, shop floor, organizational value of the industry and many other things like how people work together and achieve mass production in any industry in prescribed time with quality. I came to know about various processes and activities done to develop and produce the components effectively and accurately. I saw and learn, how the latest machineries like CNC, WELDING ROBOTS etc. save the time and improve the accuracy and increases the production. The industrial training is very beneficial to me. During the training, I got the practical knowledge about machines and machine processes & also know how these machines are used for making different kind of equipment, machines and products. During training I tried to improve productivity in several lines in shop floor through time study. I finally thanks to Mr. NIKHIL VERMA, Mr. ROHAN and Mr. TARUN BHATIA for guiding me throughout the training and encouraging me to learn about the industrial environment.

59

REFERENCES

a. Mr. Ranvijay Singh Head Of Department (Mechanical), Manav Rachna International University. E-mail- rvsingh.fet@mriu.in

b. Nikhil Verma Executive Engineer, Manufacturing Department (Welding), Jay Bharat Maruti Ltd. Contact No. - +91- 9953864924

60