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  • By, Deepak Chandran A20336465 Kaivalya Chaturvedi A20335367 Praveen S R A20325931 Prasanna Venkatesh Ramkumar A20338828 Rahul Garg A20334391 Saurabh Dhuri A20325517

    CONSULTING PROJECT REPORT

    MMAE 557: Computer Integrated Manufacturing- Systems

    Course Instructor: Prof. John C. Cesarone

  • I

    Table of Contents 1) Client Description ............................................................................................................................ 1

    1.1) About the factory/operations .................................................................................................. 1 2) Analyze the client ............................................................................................................................ 3 3) Optimization of System ................................................................................................................... 4

    3.1) Optimum number of workstations ........................................................................................... 4 3.2) Motion Study Analyses .............................................................................................................. 6 3.3) Analyzing after implementation of new system ....................................................................... 8

    3.4) Machine Cluster Analyses ......................................................................................................... 9

    3.5) Cost Analyses with Machine Cluster ....................................................................................... 10

    4) Automation of System ................................................................................................................... 11

    5) Quality Assurance and Inspection ................................................................................................. 13

    5.1) Statistical Process and Quality Analyses ................................................................................. 13

    5.2) Inspection Analyses ................................................................................................................. 18

  • Page 2

    CHAPTER 1 CLIENT DESCRIPTION:

    Our client is KCP technologies Private Ltd, Goa, India. A firm that makes screw pumps rotors for South Asian pump manufacturers like ROTO, Flowserve, Netzsch etc. Their products cater pumping solutions for handling complex fluids in food, chemical, oil and gas, waste water, renewable energy and further more industries. In the recent times, they are looking forward to adapt the latest manufacturing methods or production management tools which would improve their current profit margin without investing much on technological changes. As a result, we have been appointed as a CIM consultant to audit, analyze and optimize their present system. This report will serve as a basis for future expansion and construction of new optimized plants across the country. 1.1 About the factory/operations:

    The factory consists of 3 CNC workstations, 4 full time workers and 1 utility worker. There is a loading and unloading bay where raw materials are transported into and out of the workshop through crates in forklifts. Each workstation has a tool table, job table where they next part to be loaded is stacked and finished product stock where the finished part is kept. Upon completion of the manufacturing process, the utility workers transport the parts to the inspection table where a worker inspects the finished products with their corresponding part drawings. A basic layout of the factory is sketched for further understanding.

    They significantly make 2 models of screw pump rotors in a batch production process. The batch size is normally decided to meet the current demands of their client. The list of activities within the CNC are facing, turning, taper turning, knurling, grooving, drilling and whirling.

    According to the classifications of various manufacturing systems, this factory belongs to Type I M B. Type I M states that it works on single station manned cell and B indicates that the cell produces rotors in batch production system.

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    PLANT LAYOUT

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    CHAPTER 2 ANALYZE YOUR CLIENT: Our client manufacturers 5050 screw pump rotors (on average) for every financial year in 2 batches. Among this, 3200 units are rotor A and 1850 units are Rotor B. By constant observations of the machining activities of the workers in the CNC lathe, we have recorded machining time for 5 samples of Rotor A and 5 samples of Rotor B using stop watches in order to deduce the average cycle time and thereby calculate the average production rate of each product.

    Machining Activity

    Rotor A Rotor B 1 2 3 4 5 Avg. 1 2 3 4 5 Avg.

    Unload & Load next part 2.70 2.30 2.00 3.00 2.50 2.5 3.00 3.00 3.00 3.50 2.50 3 Unload & Load next tool 7.50 7.50 7.60 7.70 7.20 7.5 8.00 8.00 7.50 7.80 8.70 8 Part program checking 1.00 1.00 1.00 1.00 1.00 1 1.00 1.00 1.00 1.00 1.00 1 Facing 2.95 3.05 3.00 2.90 3.10 3 4.95 5.05 5.10 5.15 4.75 5 Turning 6.50 6.50 6.25 6.45 6.80 6.5 8.55 8.50 8.45 8.40 8.60 8.5 Taper turning 3.90 4.00 4.00 3.95 4.15 4 6.00 6.00 6.15 5.90 5.95 6 Grooving 3.50 3.55 3.40 3.40 3.65 3.5 4.50 4.55 4.45 4.40 4.60 4.5 Knurling 4.00 3.90 4.10 3.95 4.05 4 3.50 3.50 3.55 3.55 3.40 3.5 Drilling 5.50 5.35 5.40 5.65 5.60 5.5 6.90 6.85 7.15 7.05 7.05 7 Whirling 10.40 10.70 10.25 10.50 10.65 10.5 16.50 16.45 16.55 16.60 16.40 16.5 Average Cycle

    time (min/part)

    48 63

    Production rate (Rp) = 60 / Tc Average Cycle time for rotor A (Tc) = 48 min Average Cycle time for rotor B (Tc) = 63 min This implies,

    Production rate (A) [parts/hr] = 1.25. Production rate (B) [parts/hr] = 0.95.

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    CHAPTER 3 OPTIMIZATION OF SYSTEM: After a thorough study and analysis of the present system, we have worked on the following parameters for optimization of the current process of the manufacturer:

    1. Evaluating the optimum number of workstations for the present work scenario. 2. Application of motion-study and thereby reducing the repositioning time of the

    active workers. 3. Formulating the possibilities for combining to a machine cluster.

    3.1- Optimum number of workstations: For evaluating optimum number of workstations, we have assumed the following data from the various sources: Parameter Unit Quantity Source of data Units produced Parts/hr Q(A) - 3200 Average values taken from the financial report of company for the past 5 years. Q(B) - 1850 Cycle time min Tc(A) 48 Average value taken form the series of sample machining time. Tc(B) 63 Scrap rate % (A) 3 Average scrap produced by client for each rotor. (obtained from clients end) (B) - 7 Worker efficiency during operation % 92

    Values measured/ assumed from clients end based on their current manufacturing scheme.

    Reliability during running % 90 Reliability during setup % 95 Setup time min T(sp) - 45

    Average Batch size parts N - 20

    On reviewing the annual sales reports for the past 5 years, it said that there is an average changeover from Rotor A to B for every 20 rotors produced. Therefore, we may assume 20 as our batch size as instructed by our client.

    Factory Operating hours: Hours/day (h/d) = 8. Days/week (d/wk) = 5. Weeks/year ( wk/yr) = 50.

  • Page 6

    Workload (A) = WL(A) = Q(A) * Tc (A) = 3200 * (48/60) (1- (A) ) (1 - 0.03 ) = 2639.17 hours/yr Workload (B) = WL (B) = Q(B) * Tc (B) = 1850 * (63/60) (1- (B)) (1 - 0.07 ) = 2088.71 hours/yr Available time (AT) = 8 * 50 * 5 = 2000 hours/yr No. of setup changes = Q (A) + Q (B) = 3200 + 1850 N 20 = 252.5 Workload (setup) = WL (sp) = No. of setup changes * T(sp) = 252.5 * (45/60) = 189.375 hours/ year Optimum number of workstations = WL (A) + WL (B) + WL (sp) AT * * AT * = 2639.17 + 2088.71 + 189.38 2000 * 0.9 * 0.92 2000 * 0.95 = 2.88 + 0.09 = 2.97 Since there are currently 3 workstations, the system already has the optimum number of wo