Improvement Project

Machine shop
SELECTION OF PROJECT

 Scrap Bin Replacement System for KOLB

DEEP HOLE DRILLING MACHINE

 LOCATION: Machine Shop

A8-A9

15/12/2008
Why KOLB Deep Hole Drilling
Machine?
 KOLB is very critical
machine in machine
shop
 There is need to
reduce the cycle time
of job on KOLB over
and over

15/12/2008
DATA COLLECTION
 KOLB produces chips
at very high rate
 Feed rate is needed to
be reduced to ensure
that desirable hole
finish is obtained
 At different feed rates
size of the chips
varies, size of the
chip increases with
reduced feed rate

15/12/2008
DATA COLLECTION
 With reduced feed
rate chip size
increases drastically
 It results into filling of
the bin within short
time
 Hence, void space in
bin increases as
volume consumed by
chips increases

15/12/2008
 DATE PROJECT DETAILS
No. of Holes Drilled Bin Changed Resource Used
Machine Idle Time Minut

    I II III I II III    

28/10/2008 20 U/M U/M          

29/10/2008 U/M U/M 43          

30/10/2008 U/M U/M 44    √ Crane  43

 

31/10/2008 66 62 41          

1/11/2008 65 60 50 √     Forklift 51
Material: 13CrMo4-5+Wo, Thickness: 488 mm, Hole Diameter: 25.3 mm, No. of Holes: 1640
2/11/2008 U/M 55 41          

3/12/2008 65 66 42 √     Crane 37

4/11/2008 65 63 47   √   Crane 55

5/11/2008 67 61 41          

6/11/2008 67 66 43 √     Forklift 38

7/11/2008 6 U/M U/M          

15/12/2008
 DATE PROJECT DETAILS
No. of Holes Drilled Bin Changed Resource Used
Machine Idle Time Minutes

     I II   III    I II  III   

8/11/2008 20 76 58          

9/11/2008 58 24 60   √   Crane 26

10/11/2008 U/M 88 79          

11/11/2008 U/M U/M 65          

12/11/2008 42 U/M U/M          
13/11/2008 27 72 27          

14/11/2008 53 70 63     √ Crane 31
Material: SA336 Gr F11 Cl2, Thickness: 485 mm, Hole Diameter: 19.25 mm, No. of Holes: 7240
15/11/2008 63 88 71          

16/11/2008 86 88 71   √   Crane 48

17/11/2008 91 89 71   √   Crane 43

18/11/2008 92 91 70          
19/11/2008 U/M U/M U/M          
20/11/2008 U/M U/M U/M          
 
21/11/2008 U/M U/M U/M          

15/12/2008
ANALYSIS
Resource Consumption

Forklift
22%

Forklift
Crane

Crane
78%

15/12/2008
IDLE TIME OF MACHINE (minutes)
60
50
40
30

20
10
0
30/ 10/ 2008 3/ 11/ 2008 6/ 11/ 2008 14/ 11/ 2008 17/ 11/ 2008

IDLE TIME

15/12/2008
FINDINGS

 Bin gets filled in approximately 21-27 Hours

 With low feed rate bin gets filled quickly
 Idle Time of the Machine while bin is getting
replaced is quite negotiable
 Resource’s time consumed in replacement
affects other projects as well
 Cycle time of Job on KOLB increases
cumulatively

15/12/2008
 No. of Holes for PROJECT: 130568

12
10
8
6
4
2
0
30/10/2008 3/11/2008 7/11/2008

No. of Holes

15/12/2008
 No. of Holes for PROJECT:130561

15
14
15
10
10 8

0
9/11/2008 14/11/2008 16/11/2008 17/11/2008

No. of Holes

15/12/2008
CONCLUSION

 Time consumed in replacement of bin can be

dropped
 Consequently, Idle time of the machine can
be reduced
 Hampering schedule of other jobs as well can
be minimized

15/12/2008
SUGGESTION
 Rotating Chuck Type
arrangement to replace
the bins
 SIMULATION

15/12/2008
BILL OF MATERIAL

5 Plate SA 36 01 800x400x10

4 Roller Contact Bearing      STANDARD

3 Thrust Bearing     STANDARD 

2 Shaft C 45 Mn 75 01 Dia. 100x1500

1 Chuck (plate) C 55 01  

SR NO. PART NAME MATERIAL QTY Size

15/12/2008
DEFORMATION

15/12/2008
SHEAR STRESS

15/12/2008
EQUIVALENT STRESS

15/12/2008
THANKING YOU!

15/12/2008