HITEC University Taxila

Department of Electrical Engineering

PERFORMANCE MEASUREMENT OF FITMENT OF SUSPENSION SYSTEM

APC Factory HIT Taxila Cantt. August 20, 2008

Completed By:

Nisar Ahmed Rana

nisarahmedrana@yahoo.com

Supervised By:

Col. Syed Irshad Ali

Introduction and Background

This case study was performed in ORGANIZATION-V in the year 2008. It is one of the

most important organizations of country. It was established in 1989. This organization

provides APCs to defense agencies. Some APCs are also exported to allies. The

organization have 150 employees and had a turnover around 90 million rupees per year.

The case study was conducted at fitment of suspension system. The purpose of this

study was the performance measurement of the "Fitment of Suspension System".

During study some interviews of employees was also carried out. Some internal

documents were also studied. Direct observation of manufacturing plant was also

carried out in a visit of two days.

Objectives and Methods

The basic purpose of this case study was to explore the performance measurement

techniques and method to improve work that was conducted at the suspension system.

We have to identify and suggest new method and technique for product improvement.

We have used balanced scorecard as well as overall equipment effectiveness. Balanced

scorecard deals with external as well as internal business process. OEE is used as key

performance indicator. Organization has some objectives to be achieved in following

year.

Performance: Increase the speed of work.

Efficiency Increase the effectiveness of the product.

Quality: Deliver product to the right quality and high degree of excellence.

During study some interviews of employees was also carried out. Some internal

documents were also studied. Direct observation of manufacturing plant was also

carried out in a visit of two days.

Balanced Score Card

The Balanced Scorecard (BSC) began as a concept for measuring whether the smaller-

scale operational activities of a company are aligned with its larger-scale objectives in

terms of vision and strategy. The balanced scorecard has evolved from its early use as a

simple performance measurement framework to a full strategic planning and

management system.

The balanced scorecard suggests that we view the organization from four perspectives,

collect data and analyze it relative to each of these perspectives. These four

perspectives are given below:-

a) Learning and Growth Perspective

b) Customer Perspective

c) Financial Perspective

d) Internal Business Process Perspective

1. The Learning and Growth Perspectives

Learning and growth perspective include employee training. In a technical organization

such as factory of armored personnel carrier peoples are the only source of knowledge.

In current climate of rapid learning and growth, there is a strong need of continues

training and learning process. In government organization it is difficult to hire new

technical workers. At the same time there is declined training of existing workers. This

whole process will be reversed. In any case, learning and growth constitute the essential

foundation for success of any knowledge worker organization.

The learning and growth process in ORGANIZATION-V is very slow. There is no proper

training for existing employee. Proper training of existing employee and workers should

be maintained. Also cross training of workers of different shops should be held. Without

learning and growth process organization will go to decline.

Suspension system of the vehicle is improved. Six shock absorbers are used in the APC

to reduce shock. Also torsion bar is used to reduce the effect of shock. These dual shock

absorbers are used to reasonably reduce the shock.

2. The Customer Perspective

There is a need of customer satisfaction and customer focus in every business. If a

customer is not satisfied he will eventually find other supplier that will meet his needs.

Poor performance from this perspective is thus a leading indicator of future decline.

The main customers of APCs are defense agencies. They demanded APCs. The main

consideration while it's manufacturing is that it should be user friendly. At each

feedback from user series of modifications are made in APC since its first manufacturing.

3. The Financial Perspective

Firstly these vehicles were imported but now they are manufactured and fitted inside

the country. When imported it cost three times as compared to the present cost of the

fitting in APC factory. By this we are saving a huge foreign exchange.

4. The Business Process Perspective

This perspective refers to internal business process. This perspective allow the managers

to know how well their business is running, and whether its products and services

conform to customer requirements. These processes have to be carefully monitored.

Manufacturing Process

The system which is responsible for the movement of the APC is called suspension

system. This system includes wheels, sprocket, idler assembly, shock absorbers and

track.

This process starts from the pasting of inserts in the drilled holes. These inserts made

from steel and used to strength the screw. This process of pasting of inserts takes 1

hour. After this supporting arms and torsion bars are fitted. Torsion bars are used to

render the shock. They also fix the arm at proper angle. Torsion is a long steel rod. This

torsion bar fit in the anchor which is situated inside the hull of APC.

One arm is made from three major parts which are hub, arm and housing. Wheel is

fitted on the hub, arm is for support and housing is fitted inside the body of vehicle.

Fitment of Suspension

System

Pasting inserts in drilled holes

Fitment of supporting arms

Fitment and Adjustment of

Torsion Bar

Fitment of Shock Absorbers

Fitment of Wheels

Track is fitted on Wheels

Fitment of Idler

Fitment of Sprocket

5 supporting arms are fitted on one side of APC. 10 supporting arms are fitted the both

sides of vehicle. Since APC is a heavy duty vehicle that’s why only torsion or shock

absorbers are not enough to render shocks. Three shock absorbers are used on one side

of APC. Two shock absorbers are on front side and one is at rare because engine weight

is on front side. Total of six shock absorbers are used on both sides of the APC for this

purpose.

After this 10 wheels are fitted on one sides of the vehicle. An APC have 10 combinations

of 20 wheels on both side. Two wheels are fitted on single axis with little separation to

adjust track in it. After this Idler assembly is fitted on the vehicle. This idler assembly is

responsible to adjust the track. Track can be loosened or tightened by this idler

assembly.

Then sprocket is fitted in vehicle. Sprocket is one of the most important parts of

suspension system. It has six edges like small rods. It receives the actual power from the

engine and drives the whole suspension system.

In the end track is fitted on all the wheels. This track is made by combining the track

pads through track pins. 63 pads are used to make the left side track and 64 for right

side track. This is because whole weight of engine is on right side.

Overall Equipment Effectiveness

Item Data

Shift Length 8 hours = 480 min.

Short Breaks 0 @ 0 min. = 0 min.

Meal Break 1 @ 30 min. = 30 min.

Down Time * 45 minutes

Ideal Run Rate ** 0.0037 pieces per minute

One piece should be produced in 4.5 hour. 0.0037% piece should be

produced in one shift.

One suspension system is fitted in 5 hours.

Total Pieces 1.227pieces

Reject Pieces 0.11493 pieces

* Delay due to any mal function.

** %age of Vehicles produced per minutes

Planed Production Time

= [Shift Length – Breaks]

= [480 minutes – 30 minutes]

= 450 minutes

Operating Time

= [Planed Production Time – Down Time]

= [450 minutes – 45 minutes]

= 405 minutes

Good Pieces

= [Total Pieces – Rejected Pieces]

= [1.227 – 0.11493]

= 1.11207 pieces

Availability = Total Time / Operating Time

= Operating Time / Planed Production Time

= 405 minutes / 450 minutes

= 0.9000 (90.00 %)

Performance = (Total Pieces / Operating Time) / Ideal Run Rate

= (1.227 / 405) / 0.0037

= 0.8180 (81.80%)

Quality = Good Pieces / Total Pieces

= 1.11207 / 1.227

= 0.9063 (90.63%)

OEE = Availability x Performance x Quality

= 0.9000 x 0.8180 x 0.9063

= 0.6672 (66.72%)

A comparison between world class OEE and its other factors are given below in the

table. We can monitor our performance and quality by relating it to world class OEE.

OEE Factors World Class OEE OEE of PRODUCT-II

Availability 90.00% 90.00%

Performance 95.00% 81.80%

Quality 99.90% 90.63%

OEE 85.00% 66.72%

Process Improvement

Some process improvements are made in manufacturing process. Firstly supporting arm

and track of the suspension system was completed and fitted in this shop. Now

supporting arm is supplied by vendors. In assembly shop it is fitted on the vehicles. No

need to manufacture supporting arm in the shop. Also completion of track also takes a

long time to make. It came from Heavy Rebuild Factory. The job of the assembly shop is

to fit the track on the tires to complete the suspension system.

Results

From the above data and OEE calculation it is clear that quality and performance are

factors which reduce OEE. Quality can be improved by introducing skillful workers.

Quality is the main factor which needs most attention. All other factors depend on

quality in one way or other. Also the workers should be assigned right job.

Following factors were identified during the study to have major drawbacks on

performance issues.

Material Shortage and Disturbed Flow: Raw material or parts coming from other

factories doesn't arrive at time. Workers have to wait for long time. They do some other

works but performance is affected by it. Also flow of the process is disturbed by it. It

takes long time do some work a wait for material.

Low Labor Productivity: One most severe cause of low performance is low labor

productivity. The value adding time of the operators in the assembly was at an

unacceptable level compared to total time. The main reason behind it is the worker

didn't work honestly except some. They work only 6 hour and the remaining time is

wasted in down time losses and speed losses.