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Training Semester
Scooters India Limited

Shubhankar Shukla
101108102
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Projects
Analyze and Provide Solution for Reducing
rejections at different operations on Clutch
Housing.
Optimize The post-procurement process.
Study manufacturing of the drive shaft and
reduce rejections.
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 2
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Department
S
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I
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L
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R & D
Production
Engine
Assembly
Casting
Paint
Weld
Machine
Sales and Supply
Chain
Store
BOF
BOSF
Tool
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 3
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Project 1
Analyze and Provide Solution for Reducing
rejections at different operations on Clutch
Housing.

Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 4
Clutch/gear
Box housing
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Sub Projects
Study Of Die casting process involved in
manufacturing of Clutch/gear Box Housing and
study rejections for a month and suggest
improvements.
Study various machining process performed on
Clutch/gear box housing and identify defects and
suggest ways to eliminate them.
Study and Validate the complete clutch/gear box
assembly and perform Assembly Line balancing in
order to improve productivity.
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 5
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Die Casting
Process Factors
Die Spray
Flow Control
Thermal Management
Monday, September 08,
2014
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Rejection Report (Initial)
S
no.
Total production Rejection
1 75 2
2 76 2
3 76 3
4 72 2
5 77 4
6 68 2
7 76 1
8 74 4
9 76 0
10 74 2
11 81 6
12 76 2
13 75 1
14 75 3
15 74 0
16 76 1
17 76 6
18 71 5
19 75 2
20 76 2
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 7
Rejection Rate 3.7%
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Defects
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 8
Thermal cracks- coolant failure, holding furnace.
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Die Wear
Monday, September 08,
2014
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Countermeasures
Make a 3mm Radius
Installation of Temperature Controller
training of operators
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 10
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Rejections (improved)
S no. Total no. of produce Rejections
1 78 1
2 76 0
3 78 2
4 73 0
5 51 4(die wear)
6 72 0
7 82 1
8 78 1
9 75 0
10 76 0
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 11
0
10
20
30
40
50
60
70
80
90
1 2 3 4 5 6 7 8 9 10
total rejections Series 3
Improved Rejection
Rate = 1.21%
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Machine Shop (Ln No. 2)
Operation No. Machine no. Details
-- -- Face milling with a HSS tool with a
Carbide tip to rectify the height of
Clutch box housing.
Operation 20 2602 Drilling and daweling
Operation 25 4047 Side milling(undercut for diesel
engines as they have large first gear)
Operation 50 3195 Drilling, counter, chamfering
Operation 100+90 -- Dawel Pin
Operation 60 2595 Boring, chamfering
Operation 20 -- Side stab
Operation 70 3567 Milling for gear pin
Operation 75 2155 Step drilling
Operation 80 2603 Tapping of all drills
Operation 120 145 Tapping of drills in operation 50
Operation 40 3202 Step boring off GB flange
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 12
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Problems
Unavailable tools
Machine vibrations
Machine breakdown
Weak Inspection schemes
Less compression pressure
Voltage fluctuations (rare)

Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 13
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Process Capability
Process capability is the ability of the process
to meet the design specifications for a service
or product.
Cp = Allowable Process Spread / Actual Process Spread
Cpk= Process capability index that indicates process actual
performance by accounting for shift in the mean of the
process within the upper and lower specification limit.

Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 14
Equivalent, Cp value

Capability to produce nonconformance
product, %
0.50 86.64
0.62 93.50
0.68 96.00
0.81 98.50
0.86 99.00
1.00 99.73
1.33 99.994
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Boring Process Capability
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 15
52mm and 16mm
4 readings for 15 days(initial)
4 readings for 19
days(improved)
Analysis on minitab 17
Improvements

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52mm (Initial)
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 16
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16mm (intial)
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 17
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16mm (initial)
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 18
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Problems
Old machinery
High vibrations
Jammed Oiling Ducts
Poor maintainance
Noise
Monday, September 08,
2014
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Improvements
Tool Holder changed
Shock Absorbers installed
Internal Oiling
Oiling pipes and filters changed
Worker Training
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 20
Shock
absorbers
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52mm (improved)
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 21
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52mm (improved)
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 22
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16mm (improved)
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 23
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16mm (improved)
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 24
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Gear Box Assembly
Gear box assembly (sequential 4 gear system)
Clutch assembly
Reverse gear assembly

Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 25
Clutch/Gear box
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Line Balancing
Task Time Description Preceed
A 43 Gear box house loading
B 76 Inner lever + gc shaft A
C 75 Lay shaft, davel pin, lay shaft spacer B
D 88 Cluster gear C
E 97 Gb flange, sheam clearance D
F 38 Pt wheel E
G 69 Clutch well, torque nut F
H 76 Clutch assembly, lock nut G
I 61 Reverse gear 0093, lock nut, needle bearing E
J 48 Push rod, sector A
K 36 TOP shaft I, J
L 88 Spindle rod, reverse gear set K
M 87 Gasket, top cover, o ring, speed pinion L
N 93 Companion flange, reverse gear selector M
O 92 Engine mountings, unloading of clutch box
housing
N, H
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 26
A
B C D E
F G H
O
I K L M N
J
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Line Balancing
Calculate the theoretical minimum number
of workstations.

NUMBER OF WORK STATIONS = ( SUM OF TOTAL
TASK TIMES) / (CYCLE TIME)
= 1109 secs / 180 secs = 6.31 = 7(rounded)


Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 27
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Line Balancing
STATION TASK TIME FOLLOWING TIME REMAINING
1 A
B
J
43
76
48+10
14
12
6
137
61
3
2 C
D
75+10
88
11
10
94
5
3 E
I
97
61+10
9
5
83
12
4 F
G
K
38+10
69
36+10
2
1
4
132
63
17
5 L
M
88
87
3
2
92
5
6 N
H
93
76+10
1
1
87
1
7 O 92 0
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 28
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Line Balancing
Benefits
1. Equal Work Load distribution
2. No idle time
3. High efficiency
4. Less Human resource required
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 29
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Post Procurement
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 30
Main gate Security Check Store manager
Quality
control
department
store manager
store
assembly line/
manufacturing
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BOF store
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 31
Finished Items
Glass Store, Tyre store, leaf spring suspension store etc.
Online database
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Current scenario
Monday, September 08,
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THAPAR UNIVERSITY, PATIALA 32
Area destroyed in fire
18.6*60 m
2
Used for various BOF stores
located at the entrance eg.
Glass store, Silencer store,
tyre store etc

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Layout Initial
Monday, September 08,
2014
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Proposed Layout
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 34
Bins Added
Min path width 3m
Major BOF stores shifted to
fire destroyed area
No ground storage
Extra storage for extra
inventory
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Detailed Look
Monday, September 08,
2014
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BOSF store
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 36
BOSF- Bought of semi finished
Unplanned
High Ground Storage
No FIFO
Degradation
Slow material flow
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Initial Layout
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 37
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Proposed Layout
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 38
Min 3.5 mm pathway
U shaped for quick material flow
Bins added
Special area for packaging
material
Ground storage for extra
inventory
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Detailed Look
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 39
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5s implimentation
Good layout not enough
At present no principles to follow for store
management.
New products would put more pressure
5s for sustainable organization maintainence
suggested
Special set of instructions


Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 40
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Principles
Sort:
No useless wrappers, cartons or boxes should be present in the store premises.
Keeping material on ground not allowed.
Degraded items should be reported and removed.

Straighten
Bins should be arranged properly with no bins blocking others.
Strict use of FIFO methodology, so as to minimize wastage due to degradation of
material.
Use big bin numbers which are clearly visible. And numbering to be done in such a
way so that finding a bin becomes easier.
A manual trolley specifically for store so that in store movement is smooth and fast
as well.
Shine
Packaging of materials to be moved out of the storage thrice every day.
Maintain safety is case of dealing with heavier material.


Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 41
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Standardize
Store Manager is to be held accountable for all problems in storage.
Handle all materials following the instructions especially with handle
with care items.
Divide areas for specific materials eg. Shelves for smaller items and
bings for bigger ones.
Sustain
To keeps check on store workers so the instructions are followed
Keep the workers updated with rules and regulations.

Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 42
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Drive Shaft
Cutting
Lathe turning
Hobbing
Heat Treatment
Grinding
Visual Inspection

Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 43
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Month Rejections
Feb 17
March 19
April 22
May 21
June 15
July 12
Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 44
The number of rejections for feb july are recorded and are as follows:

0
5
10
15
20
25
feb april june
Rejection
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Defects (rod)
Dents
Material Defect
Grinding Fault- unbalanced, vibrations
Rust

Monday, September 08,
2014
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Improvements
The unbalanced wheel of the grinding wheel
fixed.
Inspection schedule made.
Training to workers as visual inspection is
done
Coolant temperature varied so as the
abrasives do not get attached to the work
piece. Filters changed.
Feed maintained

Monday, September 08,
2014
THAPAR UNIVERSITY, PATIALA 46