Objective

The task assigned to me was to improve the making of the top frames of Deep
Freezers.

Process
The top frames are made by thermalfoaming the abs plastic sheet and then cut into
its precise dimensions.
1) The sheet is thermofoamed
2) The sheet sides are punched.
3) The sheets are scratched.
3) The sheet outer edges are trimmed to 15mm
4) The inner part is cut and separated from the top frame
The part which are cut are recycled by crushing and then feed it into the extruder ,
converting it into sheet again.

Problems faced
1) Dimensional accuracy
2) Human error (wastage of piece)
3) Safety (cutting incidents)
4) Cutting tool adjustment problem.

Available options
Manual operation improvements
1) To use flexible ball bearing that would not cause the wear of wooden frame and
thus affecting the cutting of outer edges.
2) Cut resistant gloves should be used by workers to minimize safety hazards.
Pros
Cheap

Increase in dimensional accuracy

Incremental improve in safety
Cons
No increase in production capacity
Safety is still at risk.
Cost
2pair of gloves
Flexible bearing

PKR 2000
PKR 300

Total cost

PKR 2300

Automated Process
In past 20 years automation has allowed for companies to mass produce products at
outstanding speeds and with great repeatability and quality. Automation has
become a determining factor in whether or not a company will remain competitive
within the manufacturing industry.
Automation Advantages

Reduction in production time having a machine that is automated definitely

speeds up the production time since no thinking is needed by the machine,
there is better repeatability, and less human error.

Increase in accuracy and repeatability when an automated machine is

programmed to perform a task over and over again, the accuracy and
repeatability compared to an employee is far greater.

Less human error no one is perfect, and we are all prone to making
mistakes. Which is why a machine that performs repeated tasks is less likely
to make mistakes than an employee.

Less employee costs by adding automated machines to an operation,

means less employees are needed to get the job done. It also indicates less
safety issues, which leads to financial savings. With having less employees,
there are numerous costs that are diminished or reduced such as payroll,
benefits, sick days, etcetera.

Increased safety having automated machines means having less employees

who perform tasks that can be dangerous and prone to injury, which can
make the work environment safer.

Higher volume production investing in automated equipment creates a

valuable resource for large production volumes, which in turn, will increase
profitability.

Automation Disadvantages

Less versatility by having a machine that can perform a certain task limits
to the flexibility and variety of tasks that an employee could do.

More pollution different types of machines operate using motor which may
require gases or chemicals in order to operate. This can cause an increase in
pollution in the workplace.

Large initial investment automated machines can be one of the most costly
operating costs for a company. With automated machines running anywhere
between thousands and millions of dollars depending on the type and degree
of automation.

Increase in unemployment by increasing the amount of automation, there

are less employees required causing high unemployment rates.

Unpredictable costs there can be several unpredictable costs that may

exceed the actual cost saved by the automation itself. Some of these costs
could include research and development costs of automating a process,
preventative maintenance costs, and the cost of training employees to
operate automated machines.

Factors to be selected before selecting an automated machine

Depending on the operations, automation may or may not be a good fit. If it is a
small operation with low production quantities, the initial investment of purchasing
an automated machine would not be economical. On the other hand, if the
operation has a larger facility with many employees on the shop floor two fabricate
medium to large runs, automated machines would be better suited.
Automated machines options

Injection Molding Machine

Injection moulding is one of the most widely used manufacturing processes in the world.

Advantages
1) Fast production
2) Low waste
3) Low labour cost

Disadvantages
1) High Initial cost
2) Part Design restrictions
Total cost

PKR 7,000,000-9,000,000

Laser cutting
Laser cutting uses an energy emission device to focus a highly-concentrated stream
of photons onto a small area of a workpiece and cut precise designs out of the
material. Lasers are computer-controlled and can make highly accurate cuts with a
quality finish.
Pros
1) Excellent accuracy
2) Fast production
Cons
1) High initial cost
2) Difficult to maintain
3) Melting of ABS plastic may occur
Total cost

PKR 3,000,000 4,000,000

Water jet cutting