On

ANALYSIS OF ENERGY COST

BY :-> MOHD AZAM SIDDIQUE
(B. Tech Mechanical Engineering)

BHABHA INSTITUTE OF SCIENCE AND

TECHNOLOGY
(Affiliated to UPTU, Lucknow)

ACKNOWLEDGEMENT

The successful completion of this project report would not have been possible with
out the help and guidance of many SPRL personnel.
I avail this opportunity to convey my gratitude to them while presenting this report.
I am thankful to all SPRL employees who came in my contact during the
vocational training for their coordinal, cooperative and supportive attitude toward
me.

MOHD AZAM SIDDIQUE

INDEX
1.Acknowledgement
2.Introduction
3.Company profile
4.Plant profile
5.Process operation sequence
6.Sand preparation
7.Melting
8.Furnace
9.Barreling
10. Hydraulic system
11. Pneumatics
12. Machine specification
13. Machine parts accessories
14. Time study of the machine

INTRODUCTION
Shriram Piston & Rings Limited (SPR) is part of Shriram Group, one of the largest
and most reputed industrial houses in India,. It was established In 1972. It is
located at Ghaziabad 28 Km. from Delhi. The organization has evolved in to a
centre of excellence , employing over 2500 employees and achieving an annual
turnover of approximately Rs. 3855.78 million as on 31st march 2006.
Today, Shriram Pistons and Rings Limited (SPR) has emerged as one of the
countrys largest integrated manifacturers of Pistons. Piston Rings and Engine
Valves. The companys products are ,arketed under the brand names USHA and
SPR, names that are syonymous with quality and reliability.

COMPANY PROFILE
Shriram Pistons and Rings Ltd. Is spreaded in the area of 27 acre. The
organozation has total turn over 40 Cr. The company manufactures four autumative
component, they are Pistons, Pins, Rings, and Engine valves.

COLABORATORS:
\

PISTONS

KOLBENSCHMIDT

RINGS

RIKEN CORPARATION-

ENGINE VALVE -

FUJIOOZX

GERMANY
JAPAN
JAPAN

CLASSIFICATION OF THE PREMISES:

The company premises is classified in to three parts:

P.T.E.

C.A.A.
R&D

PRODUCTION TECHNOLOGY & ENGINEERING

-COMMERCIAL ADMINISTRATION & ACCOUNTS

RESEARCH & DEVELOPMENT

SPR is the Largest Exporter of Pistons of India and has been recognized as an
EXPORT HOUSE by the Government of India.

COMPANY POLICIES:

The policies which are followed by the SPR are given follow:
SPR 5 S POLICIES
In this policies there are five words starting from latter S on which company pay
more attention
S

SHIT-SUKE

DISCIPLINE

SEIKETSU

CLEANLINESS

SEISO

CLEANING

SEITEN

ARRANGEMENT

SEIRE

PROPER SELECTION

SPR TDM POLICY

Zero Failure, Zero Defects & Zero Accident
Through Introduction Of TDM, With
Participation Of All Employment

Maximum Profit Through Improvement OF

Overall Equipment Efficiency, Reduction
6

In Cost & Increase In Customer

Satisfaction

SPR QUALITY POLICY

TOTAL CUSTOMER SATISFACTION

THROUGH QUALITY MANAGEMENT AND
CONTINOUS IMPROVEMENT

SPR ENVIRONMENT POLICY

Contionual Improvement In Environment Performance

Through Prevention, Monitoring & Control of Pollution & Improving

Environmental Bench Marks for Sustainable Growth of

Company Operation.

COMPANY COLLABORATORS:

KOBENSCHMIDT AG COMPANY PROFILE

 This company was founded in 1910.

The company is world 2nd number Pistons manufacturer.
It has 6600 employees in 7 German Plants.
The company exports is products to 120 countries.
The diameter range of Pistons in 20mm-66mm

RIKEN CORPORATION COMPANY PROFIE

This company was established in 1972.
This is the undisputed would ladder in Piston & Rings.
Riken holds more then 86%.
Its Piston Rings range to 200mm to 640mm square daimeter.
Beside Pistions Rings, they also in manufacturere.
Precision cast Riken.
Other Engineer Section PISTONS INSERTS, PRE- COMBUSTION
CHAMBER, ROCKERARM TAPPET etc.

HONDA FOUNDRY COMPANY PROFILE

The company was founded in December 1963.
It is affiliated to Honda Motor Company.
The monthly production of company is 7,20,000 Nos, Poistons.
It is fully automatic Piston casting.
It is fully automatic Piston machining.
The main customers of company are
HONDA
8

 MITSUBISHI
NIPPON DENSO
SANDAN CORPORATION

Other products of company are

Intake Manifolds
Cylinder head

FUJI OOZX COMPANY PROFILE

It is the largest engine valve manufacturer in Japan.
The production of company is over 75 lakhs (7.5 million/valve/month)
Fuji Oozx have six plants in Fujisawa one fully automatic State-Of -The
Art plant at shizuka.
It has joint ve3ntures located in USA, Thailand, south Korea and Taiwan
besides technical collaboration with SPR India.
OE of the company are all Japanese vehicles/Engine manufacturers
including Toyota, Mitsubishi, Nissan, Honda, Isuzu, Suzuki, Hino etc.

SPR ACHIEVEMENTS:
Largest Exporter of Pistons & Rings.
First to Introduce low weight, thin, walled pistons for gasoline
engines.
Largest manufacturer of steel Rings for gasoline engines.
Exclusive supplier status to TATA Cummins for Piston & Pins.
First to introduce OD/ID chrome plated spring loaded oil control ring.
9

 First to introduce steel DBM oil control ring for diesel engines.

SOME MILESTONE:
SPR is the first and only pistons, rings & engine valves manufacturer in
India to win the TPM Excellence award from JIPM, Japan.
Honda Motorcycle and Scooter India Limited felicitated Shriram Pistons and
Rings Limited (SPR) with Grand award for QCDDM 2003-04.
Tata Cummins recognized Shriram Pistons and Rings Ltd. (SPR) as Best
Supplier Category A for the year 2002-03.
For 4th year in a row, Shriram Pistons and Rings Ltd. (SPR) was awarded
with Trophy of Excellence from Maruti Udyog Limited for Outstanding
Overall Performance during 2002-93.
Shriram Pistons and Rings Ltd. (SPR) won Maruti vendor Performance
Award 2000-01 for Excellent Overall Performance for the third consecutive
year.
Shriram Pistons and Rings Ltd. (SPR) won the ACMA Certificate of Merit
for Excellence in Exports in 2000-01 and (Automotive Component
Manufacturers Association of India) Quality Award in 1998-1999.
Shriram Pistons and Rings Ltd. (SPR) bagged the Supplier Award for
Quality from Honda Motorcycle and Scooter India Limited.
Shriram Pistons and Rings Ltd. (SPR) was received the Best Overall
Performance Award in 1998-1999 and 1999-2000 from Tata Cummins Ltd.
Shriram Pistons and Rings Ltd. (SPR) was awarded with ISO 9001 and QS9000 certification by RWTUV of Germany in 1999. This is a certification
for its High Quality Standards
Shriram Pistons and Rings Ltd. (SPR) was awarded with 2 Star Export
House Status by the Government of India.
10

SPR TODAY:
Access to World class technology small and management systems through
close working relationship with collaborations.
Quality control is done through On-Line process.
Approx 30% of internal accruals being invested towards modernization &
quality up gradation every year.
Continuous training and multi skilling of workers to achieve zero
supervision.
Investment is done in R & D for faster new model development.
Continuous up gradation is done through bench marking.
Productivity improvement to collaborators standards.

WORLD CALSS FACILITIES AT SPR PISTONS:

STATE OF THE PISTON LINES

On line computerized SPC
Quality automate
Coolant chilling plant
Single tool grooving
Pin bore bombing
11

 Ultrasonic cleaning of pistons

12

PLANT PROFILE
CAST IRON FOUNDRY
INTRODUCTION:
Cast iron foundry is an important pat of Shriram Pistons and
Rings Ltd. (SPR) here Rings are manufactured from the cast iron by the process of
casting. The officers and workers working in this department are best in there field
and they have very cooperative nature and supporting attitude. It is divided into
two parts.
CAST IRON Foundry
New CAST IRON Foundry
C.I. Foundry manufacture six types of Rings.
RIK 40 B
RIK 40 S
RIK 10
RIK 20 A
RCP
SPR 0r
TYPES OF MOLDING MACHINE IN CI FOUNDRY:
SIM molding machine
RIK 66 molding machine
RIK 87 molding machine
SM 50 v molding machine

13

SIM MOLDING MACHINE:

It is operated manually.
Its quality is 1.

RIK 66 MOLDING MACHINE:

It is a semi automatic machine.
Its quality is 4.
It is purchased from Japan.
It is mot suitable for large diameter rings.

RIK 87 MOLDING MACHINE:

It is fully automatic machine except loading of Flask.
It is suitable for all rings specially for large diameters ring.
Its quality is 1.

SM 50 V MOLDING MACHINE:
It manufacture small sleeve which is in form of pipe from which rings are
cut.
It is purchased from Japan.

14

PROCESS OPERATION SEQUENCE

Mould Preparation
Preparation

Metal

Sand Preparation

Melting

Mould Making

Tapping

Pouring

Shake Out

Surface Cleaning

Deburring

Visual Inspection

Heat Treatment

15

SAND PREPARATION
For the preparation of sand the following additives are mixed together in the sand
muller.

ADDITIVES
MULLER

SAND
RANGE

Total Batch Weight

950Kg

ACTUAL

900Kg

New Sand

Nil-50Kg

20Kg

Bentonite

Nil-7Kg

3Kg

Dextrin

Nil-0.50Kg

0.20Kg

Bentokol

Nil-0.05Kg

Do

System Sand

Balance

Moisture

2.80-3.20%

Do
Do

NOTE:- Actual weight of additives are approximately variation may be 10% of

addition except total batch weight.

For preparation of molding sand 1Kg/ batch should be added additionally and
moisture riser should not exceed 3%.
16

Seeing the situation in the sand (G.C.S.) and sand stone Bentonite may be
increased/ decreased.

ADDITVES

PROPERTY

Bentonite

As binder

Bentokol

For shake out & finishing

Dextrin

...
stability

For compactness &

to Mould.

SAND PREPARATION:
OPERATION SEQUENCE: Movement of return sand to cooler through belts.
Storing of sand into return sand bunker.
Charging of return sand, bentonite, dextrin, and bentokol in batch hopper.
Addition of water.
Mulling of sand for 4-5 minutes.
Discharge of prepared sand to surge hopper.
Transfer it through online Aerator & Vertical Aerator.
Transfer sand to moulding machine hopper.
Testing of moulding sand at moulding machine.

17

SAND TESTING
FIVE ESSENTIAL TESTS FOR SAND QUALITY :
1. Green compression strength .1000-1380 gm/cm2
2. Compatibility.30-35%
3. Permeability...50AFS
4. Flow ability...60AFS
5. Moisture2.8-3.2%
The sample size used for Green Compression strength (GCS) is 50x50mm and
after compression
it should be 2X2 inch.

OTHER THINGS TO BE DETERMINED IN SAND TESTING:

6.Density
7.Active clay
8.Flow off, Total clay
9.AFS Number after washing
10.Total carbon
There properties are checked to have on the sand quality.These properties
should never be out of the standard specification.

MOULDING
The procedure described below is applicable for Rik40B, Rik40S and Rik10 &Rik20A.
18

The opration consists of activities for preparation of sand mould on five nos. of
pneumatically operated moulding machine.

OPERATION SEQUENCE:
1. Receipt of moulding sand in hopper ,preparatory work for each stack
2. Positioning of Trolley/cleaning.
3. Position of stack alignment rods.
4. Pattern palate cleaning by air.
5. Placement of frame on Pattern palate.
6. Placement of Aux. frame (only for SIM moulding m/c).
7. Taking sand from hopper.
8. Scrapping of excess sand.
9. Removal of Aux.frame (for SIM moulding m/c).
10. Squeezing.
11. Vibrating.
12. Ejection of mould.
13. Cleaning of spur by air.
14. Inspection of mould.
15. Stacking of mould, using bottom most mould as dummy after spur plugging.
16. Blowing of air on each mould,post moulding operation.
17. Covering top mould by spur cover.
18. Removal of Stack alignment rods.
19. Forward pushing of trolley.

NOTE:Operation no.7 &11 are performed automatically on Rik-66 m/c and manually on
SIM moulding m/c.
19

MELTING
This Operation consists of preparation of molten metal for pouring into the mould
for rings castings of RIK40B/40S, RIK10, and RIK20A alloy and for RCP inserts.

The control of melt composition is done by change calculations which in turn are
based on chemical composition of input materials.
The change calculation targets of chemical composition are kept within shop floor
specification.
Both sample analysis is done to validate the charge calculation only. Both samples
may not be done for all the heats.
However all the heats checked on 100% for chemical composition before dispatch
to store.
If the material in the furnace is beyond correction level for chemical composition,
the material is rejected by pigging it in the ingots.

FURANCE TYPE: Medium frequency induction furnace.

TEMPRATURE RANGE: 155010C

CAPACITY: Two furnaces are of 1000Kg capacity.
And other two are of 500Kg capacity.

Molten metal can be obtained from each furnace after 45 min.

20

FURANCE
PRICIPLE:
The furnace used is of PILLER make. It is a medium frequency
coreless induction furnace. The furnace is 500 cycle/sec (usually).

The furnace consists of a variable voltage. Variable frequency A.C. source

connected to an induction heating or melting both by means of coupling capacitors.

The coupling capacitors provide self-starting capacity and acts as a voltage

multiplier to impedance matches a wide range induction heating/melting load.

The induction heating/melting coil a long with the load capacitors from a resonant
L.C.ckt. a L.C.ckt. has a varying ability to accept power dependent upon what
frequency the power source is operating.

POURING/CASTING
The ladle used for pouring is of bucket type and the molten metal from the furnace
taken at a time in the ladle is 250Kg. After molding pouring/casting should be done
within 48 hrs. , otherwise sand will lose many of its properties.
The pouring system is handled by automatic lift and slide system for pouring
following operations are done in the plant.
- Lining of pouring ladle.
21

- Ladle drying.
- Preheating of ladle.

- Take metal from the furnace.

- Put ladle cover on ladle after removing slag.
- Pour metal in stacks.
- Pig leftover metal from ladle into ingot & insert alloy wise pouring cup into
except Rik 40B.
- Withdrawal of sample for final product inspection.

SHAKE OUT
This operation is done at the five shake out m/c.
Some specification and part of shake out m/c are as follows:

MACHINE
MOTOR

SPECIFICATION OF

Vibrator

H.P 200

Blower

C.F 2800Kgf

Electromagnetic motor-2

R.P.M 1440

Base sieves

volts 415

Compressor

AMPS - 3.00, 50hz

In the shake out operation rings are separated from the moulds. This operation
consists of ring casting, return scup and sand by knocking out the stacks.

SHAKE OUT OPERATIONS ARE AS FOLLOWS:

Placing the poured stack on station.
22

 Knock out ring casting with the help of pneumatic vibrator.

Transfer empty moulding frames to moulding m/c.
Collect ring casting to carrier boxes.
Send the ring casting to barreling section for cleaning.

BARRELING
Barreling is the sand removal operation after shake out.
In this procedure sand removal is done in Tumbling barrel & Shot blasting
machine.
This operation is as follows:

OPERATION
Tumbling of rings casting
surface

ACCEPTANCE CRITERIA
:

No sand adored to ring casting on

(Visual inspection)
Tumbling of return scrap :

No sand adored

Shot blasting of pig iron :

No sand / dirt / rust on the surface

Tumbling barrel is a hollow cylindrical pipe of very large dia. In which there is a
connection of compressor which is attached to the blower for sand removal.
While shot blasting is done only for Pig iron which removes rust from its
outer surface in the form of very small (dia. 3mm) shots.

DEBURRING
Deburring is the operation of removal of burrs from the surface and faces of the
ring.
23

This operation is carried out on the grinding machines.

Burrs removal operation is especially done at the inner dia and outer of the ring.
The operation of burrs removal is as follows: Arrange the rings in stacks and transfer the stacks to deburring m/c.
Deburr I.D. of the rings.
Deburr of O.D. of the rings.
Give the rings inspection.
After deburring the are sent for visual inspection to check the burrs at I.D. & O.D.
of rings.

RIK 87 MOULDING MACHINE

INTRODUCTION:
RIK 87 is an automatic moulding machine. In this machine all operation are done
by itself except only the feeding of empty flask. This operation is done by the
operator.
RIK 66 machines are not suitable for larger diameter rings. So new machines (RIK
87) was purchased from Japan, RIKEN COOPERATION. This machine is suitable
for all rings especially for large diameter rings.

PURPOSE OF THE MACHINE :

This moulding & handling system set is a dedicated unit capable of moulding
casting moulds using casting sand for RIK 40 materials forsingle-cavity moulding
of piston rings, RIK 20 materials & two-cavity moulding materials & staking them
continuously, by way of supplying empty moulds flask, sand filling & moulding,
taking out casting moulds & stacking them.
24

This equipment consists of the moulding machine handling system, mould pusher
(Transversing Tolly) , sand supplying feeder, etc. With the hydraulic unit & control
panel installed separately and its operations is all automatic except for feed to
empty flasks.
This machine is has two system:

Hydraulic System
Pneumatics System

HYDRAULICS SYSTEM:
What is hydraulics?
The purpose of transmission of force or movement with the help of pressurized
fluid.

Working Sequence:
EMOTOR
E.MOTOR

FLOW
CONTROL
VALVE

PUMP

DIRECTION
CONTROL
VALVE

25

PRESSURIS
ED
CONTROL
VALVE

CYLINDE
R

Advantages of Hyraulics system:

MOVING
PARTS

High force is possible.

Self lubrication of moving parts.
Equal force from starting to end.
Smooth transmission without jerks.

Disadvantage of Hydraulic System:

High pressure can create bursting inline.
Oil leakage reduces force.
Hydraulic system is like a human body, where pump works as hard ,oil works as
blood,cylinder as hand and pipes as nerves.

Physical properties of Hydraulic OIL:

Viscosity index.
Compressibility.
Anti rust property.
Anyi wear property.
Resistance to foaming.
These properties should be maintained as per specification.

Oil Quality check points:

Oil filter should be cleaned at intervals.
Oil temperature should not exceed above 50 degree C.
Bleed the system to take out locked air.
Maintain proper oil level in tank.
26

 Leakage should be corrected immediately.

Do not use leakage back in tank.
Impurities should not enter into reservoir.

RESERVOIR SPECIFICATION:
Capacity

400 litre

Grade of oil

ISO VG-32

Oil Pressure

35kg/cm^2(3.5Mpa)

Pump Discharge rate -

65 litre/min

Hydraulic Accumulator:
Installation:
This is a plated bladder type accumulator and to be operated rightly and
safely.
The accumulator is merely used for appropriate accumulator application.
Any other combination or improper uses which are against the rules or
beyond the allowed range may result in an accumulator accident which
will cause injuries and damage to the equipment.
Terms:
Maximum allowable working pressure : The maximum
pressure,which is
permitted to load accumulator.
Maximum operating pressure
which will be

:The highest pressure

27

applied on accumulator while

operating.
Maximum operating pressure
will be

:The lowest pressure which

applied on the accumulator
while operating.

Gas charging pressure

: The charged nitrogen gas pressure in

accumulstor when the

hydraulic
Circuit is turnd off
Allowable discharge

: The limited oil flow out speed from

accunulator , which does not lead to
the malfunction of the accumulator.

Safety :
Use the accumulator bellow the working pressure.
Do not weld or cut or grind any parts of the accumulator.
Use name thread size connecting part. (if the unmatched
(specification, diameter & pitch) thread size for connected, there is
a possibility that the thread parts are damaged while the pressure is
rising up)
Fasten the accumulator using a clamp.
Do nt use accumulator in the corrosive environment.
28

 Before disassembling, release the gas & fluid pressure down to

atmosphere pressure .
Do not heat the accumulator.
Use special hanging tool to hang the accumulator.
At the time when user discharge the nitrogen gas, keep the
discharge port of the gas away from the face, and let some fresh air
in the work area.
Ypon discarding the accumulator, completely disassemble the part
and destroy them so that may not be reassemble.

PNEUMATICS:
It is a fluid power system that transmits & control energy through the use of
pressurized(compressed) AIR.
Compressed air is mainly used to work by acting on a piston and cleaning.

Contents:
Pneumatics and components of pneumatic system.
Pneumatic production system.
Pneumatics construction system.

Production system
System

Consumption

Compressor

Air Tank off

Electric motor

Auto drain

Check Valve
unit

Air service

29

 Pressure switch

Direction valve

Tank

Actuator

Pressure gauge

Speed controllers

Auto drain
Safety valve
Air dryer
Line filter

Air Production system:

Compressor:
Air taken in at atmospheric pressure is compressed and
delivered at a
higher pressure to the pneumatic energy.
It transforms mechanical energy to pneumatic energy.

Electric Motor:
It supplies the mechanical power to the compressor.
It transforms electric energy to mechanical.

Pressure Switch:
It controls the electrical motor by sensing the pressure in the tank.
It is set to a maximum pressure at which it stops the motor, and a minimum
pressure at which it restarts it.

Check Valves:
30

It allows entering compressed air from the compressor into the

tank and preventing it leaking back when the compressor is stopped.

Tank:
It stores the compressed air. Its size is defined by the capacity of the compressor.

Pressure Gauge:
It indicates the tank pressure.

Auto Drain:
It drains all the water condensing in the tank without supervision.

Safety Vslve:
It blows compressed air of if the pressure in the tank above the allowed Pressure.

Line Filter:
It helps to keep the line free from dust water and oil.

Air Consuming System:

Air Take Off:
Air is taken from the top of the main to allow occasional condensate to stay in the
main pipe, when it reaches a low point, water take off from beneath the pipe will
flow into an automatic drain and condensate will remove.

Auto Drain:
Every descending tube should have a drain at its lowest point. This drain should be
in auto.

Air Service Unit:

31

Conditions the compressed air to provide clean air at optimal Pressure and
occasionally adds lubricant to extend the life of house pneumatic system
components which needs lubricant.

Directional Valve:
Alternately pressurizes and exhaust the cylinder Connection to control the
direction of movement.

Actuator:
It transforms the potential energy of the compressed air into mechanical Work.

Speed Controllers:
It allows an easy and step less speed adjustment of the actuator Movement.

MACHINE SPECIFICATION:
Work
Ring Size

40mm ~300 mm

Pattern Height

3.3 to 10 mm

430 mm

Mould Frame:
Frame Size
Frame Height

35mm

Effective number of stack

frame

15 to 20 No. of

Moulding Machine:
32

 No of station out

3(Frame mount, moulding &

Taking)

Sand feed
conveyer)

O.H.B.C (over head belt

Set hydraulic pressure

3.5 Mpa

Set air supply pressure

0.5 Mpa

Sequeeze thrust

~ 10,000 Kgf

Hopper vibrating Motor -

415 V/50 Hz, 50 W, 2P

Vibrating feeder

200 V/50 Hz, 100 0VA

2 (Taking out & Stacking)

Transfer Equipment:
No. of stations
Arm driven System
hydraulic cylinder
Moulding cycle time

Rack & Pinion with

12.6 Sec.

Dimensions of machine:
Dimensions of machine -

3500 X 1400 X 2500

Hydraulic unit

1700 X 1100 X 1700

Control pannel

1800 X 800 X 2000

Air condition

400 X 230 1000

Weight of the machine:

Moulding machine & Transfer equipment

Control panel & hydraulic unit

1.5 tons

33

4.5 tons

 Vibration feeder

0.2 tones

Cast mould delivery & transverse trolly

Total weight

6.7 tones

34

0.5 tones

MACHINE PARTS & ACCESSORIES

The machine is comprised of following equipments
High pressure sequeeze Moulding machine.
Three stations frame handling unit.
Twin arm robotic system for moulds stacking.
Vertically mounted stacking cylinder.

35

36

37

38

39

40

41

RESULT :
Process Description

Standard
Time
Given by
manufacturer
12.5 sec .

Time taken in preparation of

one
Mould .
Time taken to complete one
11.1 sec .
cycle
Time taken to make one stack 4.1 min .
(20 moulds)
Number of moulds perpared in 270 moulds
one
hour

Actual time of
the
Machine
9.7 sec .
8.3 sec .
3.25 min .
370 moulds

*When the machine is working continuously , it make 100 moulds more then
standard no . of moulds in a hour .

42

SUGGESTION :
Mould production can be improved by taking the following
steps..
By decreasing time gap between removal of a pallet by the pusher
and motion of the transverse trolley .
By providing the hydraulic lifting under the loading pallet .So that
operator needs not to bend again . This make the operator refresh for
the long time and increase his working efficiency .
By providing the hydraulic pusher at the loading section .
Operator should check the hardness of mould after certain interval of
time . If the hardness of mould is less , then it will break during
turning operation that may cause damage to moving arm of the
machine .

43

TIME STUDY OF THE MACHINE :

OBSERVATION TIME

Element
description

Obeserved Time

1.
Loading

2.16

3.88

3.91

4.46

4.6

4.53

2.65

2.27

4.7

1.76

2.61

1.87

4.3

4.31

4.
19

2.
Rotating

1.3

1.1

1.1

1.3

.90

1.2

1.1

1.2

1.3

1.1

1.4

1.3

1.
4

3.
Squeezing

2.35

2.1

2.17

2.1

2.56

2.16

1.84

1.49

2.19

1.88

1.68

2.04

1.57

1.52

1.
85

1.06

0.92

1.03

1.06

1.05

1.08

1.05

1.08

1.07

1.08

1.05

1.06

0.92

1.01

1.
02

4.

44

Unloading
5. Turning

2.17

2.11

2.19

2.15

2.03

1.94

1.92

2.18

1.96

2.11

2.14

2.13

2.17

2.19

2.
17

6.Stacking

0.98

0.50

0.84

0.65

0.75

0.48

0.79

0.49

0.70

0.94

0.55

0.49

0.52

0.49

.
51

7.Gap b/w

3.48

3.60

3.51

3.72

3.50

3.54

3.62

3.60

3.34

3.50

3.68

3.45

3.60

3.55

3.
75

1.02

0.98

0.70

0.96

0.74

0.92

0.87

0.92

0.73

0.69

1.02

0.99

0.92

1.01

0.
99

2.63

2.5

2.53

2.60

2.93

2.60

2.57

2.60

2.60

2.63

2.60

2.93

2.53

2.60

2.
50

Unloading
& Turning
8. Gap
b/w
Turning &
Stacking
9. Gap
b/w
Stacking
&
Motion
of
Transverse
Trolley

45

Cycle
Time

8.96 8.87 8.60 8.45 8.46 8.78 8.81 9.28 9.19 8.83 8.63 8.23 8.68 8.80 8.79 8.3
sec

Time taken
in Stack

3.15 3.33 3.14 3.20 3.30 3.27 3.14 3.28 3.24 3.28 3.24 3.25 3.28 3.25 3.2

Formatation

46