INDUSTRIAL TRAINING

REPORT

SUBMITTED
BY:SANDEEP
KUMAR
HARMEET

PROJECTS UNDERTAKEN
PROJECT-1:
STUDY OF EXCESSIVE NON VALUE ADDING
WORK DONE BY WORKERS IN AXLE ASSEMBLY
STATION.
PROJECT-2:
STUDY OF ENGINE TESTING FACILITY

ANUAL ASSEMBLY LINES

A production line that consists of a sequence of

workstations where assembly tasks are
performed by human workers.
Products are assembled as they move along the
line.
At each station a portion of the total work
content is performed on
each unit.

Work Transport Systems-Manual

Methods:
Manual methods:
Work units are moved between stations by the
workers (by hand) without powered conveyor.
Problems:
Starving of stations:
The assembly operator has completed the assigned
task on the current work unit, but the next unit has
not yet arrived at the station
Blocking of stations
The operator has completed the assigned task on the
current work unit but cannot pass the unit to the
downstream station because that worker is not yet

ASSEMBLY LINE

REAR AXLE

FRONT AXLE

YPES OF WASTES:
Following are some of the non-value-adding
processes during assembly:
1)Transportation
2)Inventory
3)Motion
4)Waiting
5)Over-processing
6)Over-production
7)Defects
*WASTES= Activities that dont add any value
to the final product

XLE ASSEMBLY STATION:

The present axle assembly stations layout brought
many inefficiencies in the production process like :
LESS FLEXIBILITY
NON VALUE ADDING WORK
HIGH PRODUCTION TIME
NOT PROPER CAPACITY UTILISATION
Our study was aimed at reducing these
inefficiencies by making suitable improvements in
the present layout of workstation.

PRESENT LAYOUT

Rear Axle

SUGGESTED LAYOUT

BENEFITS OF NEW LAYOUT

FLEXIBILITY .
REDUCTION IN NON VALUE ADDING WORK.
REDUTION IN TIME.
CAPACITY UTILISATION.

ENGINE TESTING SETUP

ENGINE TESTING
PARAMETERS
WATER INLET AND OUTLET TEMPRATURE.
AIR INLET AND EXHAUST.
INTERCOOLER INLET AND OUTLET

TEMPRATURE AND PRESSURE.

LUBRICATING OIL TEMPRATURE AND
PRESSURE.
RPM

RESULTS
S NO

Parameters of engine testing

Output
1

Output
2

Output
3

RPM

1218

2000

2792

Water outlet temp

29C

30C

30C

Exhaust temp

50C

55C

62C

Engine air inlet temp

45C

46C

46C

Air temp(before intercooler)

62C

89C

136C

Air temp(after intercooler)

40C

40C

40C

Intake water temp

40C

42C

45C

Lubricant oil temp

113C

124C

138C

Lubricant oil pressure

1 bar

1bar

1bar

10

Boost pressure(before intercooler)

0.084

0.305

0.666

11

Boost pressure(after intercooler)

0.067

0.261

0.561

12

Engine air intake pressure

-29kg/cm

-50 kg/cm

-75 kg/cm

13

Intercooler temp

46.2C

46.9C

49.6C

14

Idle oil pessure

1.7 kg/cm

4.5 kg/cm

4.9 kg/cm

CAUSES OF ENGINE REJECTION

1)Noise from the turbocharger

2) Engine fails to start
3) Noise from the bearings of engine
4) Leakage from oil filter
5) Engine head noise
6) Water leakage from engine
7) Less power output than required
8) Leakage from cylinder head

ANALYSIS: FITMENT
Problem

Why?

Why?

Turbocharger
making noise
during the
testing stage

Wrong bolts
used during
engine testing
for fitment of
turbocharger
duct to the inlet
of turbocharger.

Mix-up of bolts
at engine testing
for fitment of
turbocharger
duct to
turbocharger.

ROOT CAUSE IDENTIFIED:

Wrong fitment of bolts during assembly of duct
to turbocharger.
Wrong bolts were used because two different
kinds of bolts used for testing setup didnt have
any identification marks.
The different bolts were not segregated in
different boxes.

SUGGESTED SOLUTIONS:
Use same standardized bolts
Use standardized tool
Use color code for bolts
Put the different bolts in different boxes
Inspection of all testing arrangements

IMPACT OF SOLUTIONS:
Time impact: Less wastage on the rework of
defected engines.
Customer satisfaction impact: Higher production
rates and in-time delivery of the finished product.
Cost impact: Cost of poor quality would be
reduced as less amount of rework would be
needed.

THANK YOU