Comparative Analysis of

Undercarriage Components
Rajesh Shah
Pramod Kokane
August 2015

Table of Contents
Abstract:................................................................................................................................... 3
1.

Introduction ................................................................................................................. 3

2.

Methodology Adopted ................................................................................................ 4

3.

Tools Used .................................................................................................................... 4

3.1

Dimensional Measurement ......................................................................................... 4

3.2

Material Characterization ........................................................................................... 4

3.3

Hardness Characterization .......................................................................................... 4

3.4

Sample Preparation ..................................................................................................... 5

4.

Project Activities .......................................................................................................... 5

4.1

Dismantling of Assembly ............................................................................................. 5

4.2

Visual Observation & Pictures..................................................................................... 6

4.3

Dimensional Measurement ......................................................................................... 6

4.4

Sample Preparation ..................................................................................................... 6

4.5

Metallurgical Testing ................................................................................................... 6

4.6

Manufacturing Process Evaluation ............................................................................. 7

4.7

Should Costing ............................................................................................................. 7

5.

Final Report Generation .............................................................................................. 7

6.

Conclusion .................................................................................................................... 8

7.

References ................................................................................................................... 9

About L&T Technology Services ............................................................................................. 10

Abstract:
In recent years, the undercarriage components market has grown competitive.
Suppliers are facing huge competition to manufacture parts at lower cost by using
advanced techniques to meet the prevailing market demand and specification.
Comparative analysis of undercarriage components provide a good insight into the
properties of your own product/components vis--vis competitor and helps the
undercarriage manufacturers to optimise their own product. This paper highlights
the process followed in comparative analysis and various tests conducted to
achieve the desired output with findings and conclusions for product cost
performance optimization.
Keywords - Comparative analysis, Benchmarking, Metrology, Value Engineering,
Undercarriage Assembly, Construction Equipment

1.

Introduction

The Original Equipment (OE) undercarriage component markets have grown

competitive day-by-day and OE spare parts prices are declining by 1 to 2% each
year.

This pressure of keeping prices low has also forced the industry to

consolidate, because bigger suppliers can realize economies of scale and offer
products at lower prices. The suppliers have responded by redesigning products to
be less expensive without losing functionality or quality, and by maximizing
manufacturing efficiencies. On the other hand, technological advances have
opened various avenues to market leaders to adopt state of the art technologies
resulting in significant growth in market share.
In this scenario, it is important to know the trends of competition with respect to
technology, cost, performance prediction and product range. Hence, comparative
analysis of companies product vis--vis competition product becomes a very
important activity to understand these trends and these can be best achieved by
detailed competitive benchmarking. Through the exercise of benchmarking,
undercarriage manufacturers understand how the competitors are better from a
design, manufacturing and performance standpoint, leveraging cost reduction
opportunities and exceeding customer expectations. In addition, the intention of
management is to look beyond engineering and market place and cater most
market needs.

2.

Methodology Adopted

The methodology used for Competitive Benchmarking of components is shown

below:

Fig.: Methodology Adopted

3.

Tools Used

Below are the major tools used for comparative analysis under various processes.

3.1
i.
ii.
iii.
iv.

3.2
i.
ii.

3.3
i.
ii.
iii.
4

Dimensional Measurement
Micrometre
Coordinate Measuring Machine
Vernier Callipers
Radius & Thread Gauges

Material Characterization
Optical Emission Spectrometers
Optical Microscope

Hardness Characterization
Surface Roughness Tester
Surface Comparators
Hardness Tester

3.4
i.
ii.

Sample Preparation
Wire Cut
Water Jet Cutting

Based on the above tools and methodologies, the intention of this project is to
unfold the following information:
a)
Dimensional comparison of components
b)

Metallurgical Composition with information of alloying elements

c)

Hardness profile and case depth

d)

Various methods of heat treatment to elucidate process characteristics

e)

Microstructure examination to elucidate quality of heat treatment during

processing

f)

Elucidation of manufacturing processes of competitors products

g)

Should-costing of competitors products

4.

Project Activities

A team of engineers with experience in various domains along with industry

experts worked to complete the project including:
i.

Pre-planning before the arrival of shipment

ii.

Coordination with freight forwarder from the pick-up to the arrival in India

iii.

Visual observation & Dimensional measurement

iv.

Sample preparation

v.

Metallurgical testing

vi.

Should-costing

vii.

Report preparation

4.1 Dismantling of Assembly

A typical dismantling activity includes:

i.

Transportation of assembly (~500 Kgs) to service station for dismantling

ii.

Prepare necessary fixture and tooling for dismantling

iii.

Dismantling using double acting 300T hydraulic press

iv.

Collection of lubrication oil during dismantling

v.

Transportation of dismantled part to storage area with proper identification

vi.

Arrangement of parts as per layout

4.2 Visual Observation & Pictures

This activity comprises:
i.

Recording pictures of all the components capturing distinct features or

specific identification

ii.

4.3
i.

Visual comparison of components comparing design features

Dimensional Measurement
Measurement of major dimensions using conventional tools like vernier
caliper and micrometre

ii.

Use of specialized equipments like CMM for critical dimensions

iii.

Creation of assembly drawings for all the components

4.4

Sample Preparation

Under this process test pieces are prepared for its microstructure analysis and
heat transition zone. This can be done by:
i.

Conventional methods for sample preparation e.g. Hack-saw cutting

ii.

Parts with high hardness and large size use the following methods:
Wire Cutting
Water Jet Cutting

4.5

Metallurgical Testing

Following major tests were conducted on components:

i.

Chemical Composition & likely Material

ii.

Surface Roughness

iii.

Surface & Core Hardness

iv.

Case Depth Measurement

v.

Microstructure Examination

vi.

Macrostructure Examination

vii.

Micro Hardness

viii.

Lubrication Oil Testing

ix.

Hardware Testing

x.

Bimetal Thickness

4.6

Manufacturing Process Evaluation

i.

Evaluation of manufacturing process such as casting and forging

ii.

Evaluation of Hardening process e.g. Induction Hardening, Direct hardening

iii.

Evaluation of welding process

iv.

Detail analysis of steps used in manufacturing of components

v.

Details of machine/tools used for manufacturing

4.7

Should-Costing

i.

Estimated Material cost as per Indian market

ii.

Detail cost for each manufacturing process performed considering the batch
size & setup cost of special machines

iii.

Final cost considering overheads and profit

5.

Final Report Generation

During this project, the team has generated test reports for all the components.
Below is a glimpse of the activities performed:
i.

Pre-planning before arrival of Shipment

ii.

Identification of space for Storage

iii.

Layout design for efficient utilization of space and easy accessibility to parts

iv.

Efficient material flow between storage and metallurgical lab

v.

Contingency planning in case of schedule slippage

vi.

Project plan with details at micro level for each activity with responsibility
matrix

vii.

Assembly Identification, tagging & measurement

viii.

Placing assembly according to layout

ix.

Tagging of assembly as per its part number

x.

Weight measurement of assembly

xi.

Visual Observation of assembly (engravings, sticker etc.)

xii.

Assembly dimensional measurement

6.

Conclusion

The detailed process followed for benchmarking results in a good amount of data
for analysis of undercarriage components. The type of data gathered and its
interpretation is captured in the table below:

Data
Dimensional

Interpretation
Machining operations, Fits

Depicts
Design

Intent,

Cost

of

machining
Material

Raw material type and the Initial cost

grade of material

Heat Treatment

Type

of

heat

treatment

process followed for the

specific duty requirements

Process

Visual Observation

functionality

and

associated cost for the service

life of the product

Good
Any special feature and its

reliability

comparison

competitors

parts

with
and

the

value add of the product in

total

life

maintenance

including
cost

of

the

assembly

Such interpretation provides a platform for engineering and product design teams
to re-visit various in-house manufacturing processes and product designs to
consider cost reduction opportunities in order to exceed customer expectations.

7.

References

i.

Mechanical Engineering Handbook, Frank Kreith, 1999

ii.

Metrology and Heat Treatment, SMDC27, 1996

iii.

Indian Standard, Methods for measurements of case depth of steel,

IS6416:1988

iv.

Specification for superstrength alloy steel forging, ASTM A579-1, 2000

v.

Basic components and elements of surface topography, Dec 2012

vi.

Cooper R., Slagmulder R., 1997. Target Costing and Value Engineering,
Productivity Press, Oregon.

vii.

Ugo I., Paulo C. K., 2006. Product development process with a focus on
value engineering and target costing: A case study in an automotive
company. International Journal of Production Economics 105(2007) 459474.

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