Presented By - Rohit.R.

Ranpise

Company Name - Kirloskar Oil Engines

 Renovation of the existing assembly lines

 To design an efficient Layout

 To create conducive work Environment

 To calculate the time required for various steps

which leads to the complete manufacturing of the

engine on the assembly line

 The time calculated by using this process will
be used to study and implement various
methods to optimize and increase productivity
and conversion costs respectively
Product Information
Engine Model
HA R-1080 SL90

No. Of
2,3,4,6 2,3,4,6 6
Cylender
 WORK
WORKCONTENT
CONTENTEVALUATION
EVALUATION&&LINE
LINEBALANCING
BALANCING

WORK
WORKCONTENT
CONTENT EVALUATION
EVALUATION LINE
LINE BALANCING
BALANCING

Enlist
Enlistall
allthe
the activities
activitiescarried
carried Everyone
Everyoneisisdoing
doingthe
thesame
same
out
outon
onthe
theAssembly
Assembly amount
amountof
ofwork
work
Line
Line 
Variation
Variationisis‘smoothed’
‘smoothed’
Identify
Identify the
thewaste
wasteactivity
activity 
No
Noone
oneoverburdened
overburdened

Eliminate
Eliminatethe
thewaste
wasteactivity
activity 
No
Noone
onewaiting
waiting

Reduction
Reductionininwork
workcontent
content
 Number of activities are carried out

CLYLINDER HEAD FITMENT PIPE FITMENT

ALTERNATOR FITMENT
 Introduction:
Initially in the first week I was shown around
the assembly lines, store, testing, packing
areas.
 Video shooting:

Started with the Video Shooting of Assembly

lines of SL-90, 4R-1080, 6R-1080, HA-6 and
Later RA.
After Shooting the videos were loaded on the
Desktop.
  Stage wise break up of videos
The videos were stage wise broken up and labeled accordingly.
 Video Analysis
The video analysis of the videos taken were done. Detail Break up
of each Activity was done. The time required for each activity
involved were listed according to the videos. The start and end
time for each step of a particular activity, the manpower involved
in it
ORIENTATIO
STATION SERIAL ACTIVITY MANPOWER OPERATION ON
TIME N TOOL USED
NUMBER NUMBER (PER STATION) FACE
( SIDE UP )

START END
 Identifying & Eliminating Non-Valuable
Activity
 Briefing of each activity
This Analysis was then briefed into the time taken for each
activity neglecting the non valuable activity.

 Targeted data
Data for the number of stations planned and number of engines
targeted was taken.
 Existing Assembly Line Layout
Total Time = 144 min

Station Station Station Station Station Station Station Station Station Station Station
No. 6 No. 7 No. 8 No . 9 No. 10 No.11 No.12 No.13 No.14 No.15 No.16

Station
No. 5
Station Operations Work Force Cycle Time(sec)
Number
Station
Number 1 Crankcase plugging 1 0:07:13
No.4
5 2 Crankshaft fitment 2 0:15:44
3 Crankcase loading 1 0:04:31
Station
Nu 4 Header, Lubrication Oil Pump assembly 2 0:06:39
No.3 5 Connecting Rod assembly 2 0:06:56
6 Bell housing & Flywheel assembly 2 0:09:54
Station 7 Gear casing assembly 1 0:15:57
No.2 8 Lube. Oil Sump assembly 2 0:07:12
9 Fuel timing and alternator mounting 2 0:21:21
10 Engine unloading 1 0:06:14
Station 11 Cylinder head fitment 2 0:09:52
No.1 12 Tappet and pipes fitment 2 0:15:04
13 Turbo accessories fitment 2 0:15:55
14 Leak testing - 0:01:31
15 Turbo completion - 0:07:13
16 Special engine completion 1 0:15:44
Total 23 144 min
 Everyone is doing the same amount of work
 Doing the same amount of work to customer
requirement
 No one overburdened
 No one waiting
 Everyone working together in a BALANCED
fashion
 Variation is ‘smoothed’
 Unbalanced
Unbalanced
Assembly
AssemblyLine
Line

Balanced
BalancedAssembly
Assembly
Line
Line
 The line balancing was done for each Assembly lines

( 6R, SL-90, HA-6 ) according to the data given.

 Change of Stations when orientation change, clubbing
of activities which can be carried on the same side and
which doesn’t depend on other activities were done
 For HA 6 Engine
 Targeted Engines per shift = 10
 Working hours per shift = 460 minutes
 Efficiency = 90%
 Effective Working Hours = 414 minutes
 TAC time = 41 minutes 24 seconds
 Time taken for the entire engine to be assembled = 2 hours 17 minutes 46
seconds.
 After balancing of the line, the time required for one engine to be
completed is 1 hour 56 minutes 18 seconds.
 For 6R 1080 Engine
 Targeted Engines per shift = 20
 Working hours per shift = 460 minutes
 Efficiency = 90%
 Effective Working Hours = 414 minutes
 TAC time = 21 minutes 10 seconds
 Time taken for the entire engine to be assembled = 2 hours 24 minutes
03 seconds.
 After balancing of the line, the time required for one engine to be
completed is 1 hour 38 minutes 3 seconds.
 For SL90 Engines
 Targeted Engines per shift = 10
 Working hours per shift = 460 minutes
 Efficiency = 90%
 Effective Working Hours = 414 minutes
 TAC time = 41 minutes 24 seconds
 Time taken for the entire engine to be assembled = 2 hours 44
minutes 10 seconds.
 After balancing of the line, the time required for one engine to be
completed is 2 hour 09 minutes 29 seconds.
 Proposed Assembly Line Layout

Total Time = 98 min

Station No .1 Station No. 2 Station No. 3 Station No. 4 Station No. 5 Station No.6

FLOW

Station Operations Work Force Cycle Time(sec)

Number
1 Core Plugging & Camshaft assembly 1 0:21:00
2 Loading, Deflector, LOP, Bell Hsg,
2 0:20:32
Flywheel ass. Con rod ,Header
3 Cam bush, Gear Casing, Tappet, Gear
2 0:18:53
fitment, Cam shaft ,Crank pulley ,
4 Fuel Timing ,Alternator, Belt, Fuel Filter 2 0:11:04
5 Engine Unloading, Starter, Pipe fitment,
2 0:16:23
Push Rods, Rocker lever, Tappet Setting.
6 Rocker cover, Pulley and Belt fitment,
Turbo pipes fitment, Turbo accessories 2 0:11:00
fitment.
Total 11 98 min
 Reduction in the Work Force

RA HA SL90
Engine Model
Engines Engines Engines
       
Present Work Force 23 15 11

Proposed Work Force 11 12 7

Reduction In Work
12 3 4
Force

Percentage Reduction
52.2% 20.0% 36.4%
In Work Force

Total Work Force

Reduction
19
 Initially some of the stations were overloaded
 High WIP
 Excess workforce were allocated than required
 Lot of engines were accumulated after station 2
 Sharing of equipment increased the assembly
time
 Work content was reduced
 Assembly time was reduced
 Line Imbalance was reduced
 Optimum work force was calculated
 Productivity will increase
THANK YOU