wired
TRANSCRIPT
WASTE IDENTIFICATION ANDREDUCTION
[WIRed]
PROJECT SUBMITTED BY :-
1. V.R. ANANTHA KRISHNA KARANTH
2. SRINAG K.A
3. ROHAN SHENOY K.P
4. KARTHIK KIRAN R.M
5. VARUN K.B
6. J. PRASANNA VENKATESH
STATION & FEEDER WASTES CLASSIFIED
UNDER
QUANTITY IDENTIFIED PROBLEMS SOLUTION TO THE PROBLEMS
STATION 1: MCV& TANKS MOUNTING
FEEDER 1 : SUB ASSEMBLY BLOCK,FEEDER 8 : MCV SUB ASSEMBLY
TRANSPORT 2 1. TRANSPORTATION OF CHASSIS FROM FEEDER 1 TO STATION 1 USING CRANE2. TRANSPORTATION OF FUEL/HYDRAULIC TANKS FROM FEEDER 8 TO STATION 1
1. USAGE OF TROLLEY TO TRANSPORT THE CHASSIS FROM FEEDER 1 TO STATION 12. STORAGE OF BOTH THE TANKS NEAR THE STATION 1 ITSELF
INVENTORY 1 1. SHORTAGE OF FASTENERS & HOSES KEEP TRACK OF INVENTORYMOVEMENT NIL NILWAITING 1 1. DUE TO SLOW WORKING OF THE
RESPECTED FEEDER UNITS THE STATION 1 IS LEFT PENDING
1. EFFICIENT WORKING OF THE FEEDER UNITS SO THAT THERE IS NO WAITING
OVER PRODUCTION
NIL NIL
OVER PROCESSING 1 1. DRAINING OF OIL FROM THE MCV AND CONNECTION OF HOSES ARE DONE SEPARATELY
1.BOTH THESE OPERATIONS COULD BE DONE ON A SINGLE PLATFORM(DESIGNED) ITSELF
DEFECTS & REWORKS
2 1.IMPROPER CONNECTION OF HOSES TO MANIFOLDS2.IMPROPER DRAINING OF THE OIL IN THE MCV
1. SKILLED LABOUR REQUIRED SO THAT THE PROPER CONNECTION OF HOSES ARE DONE.2. THE OIL SHOULD BE DRAINED PROPERLY
STATION & WASTES CLASSIFIED QUANTITY IDENTIFIED PROBLEMS SOLUTION TO THE PROBLEMS
FEEDER UNDER
STATION 2: ENGINE MOUNTING
FEEDER 2 : BOTTOM PLATE SUB ASSEMBLY,FEEDER 9 : ENGINE SUB ASSEMBLY
TRANSPORT 2 1. LIFTING THE ENGINE FROM THE GROUND LEVEL TO THE ASSEMBLY LINE BY FASTENING THE BRACKET TO THE ENGINE 2. ALL THE ENGINE PARTS ARE PLACED TOO FAR OFF
1. DESIGNING THE ENGINE IN SUCH A WAY THAT IT CAN ACCOMMODATE TWO HOOKS FOR LIFTING 2. PLACE THEM AT CONVINIENT POSITIONS
INVENTORY 1 1. SHORTAGE OF FASTENERS AND HOSES 1. KEEP TRACK OF INVENTORYMOVEMENT 1. NIL 1. NILWAITING 1 1. DUE TO SLOW WORKING OF THE FEEDER
UNITS THE STATION 2 IS LEFT PENDING2. BOTTOM PLATE IS LEFT PENDING
1. EFFICIENT WORKING OF THE FEEDER UNITS SO THAT THERE IS NO WAITING2. THE SEAT AND CONSOLE HAVE TO BE ASSEMBLED QUICKLY
OVERPRODUCTION NIL NILOVER PROCESSING 2 1. A/C UNIT IS LIFTED USING CRANE
2. REMOVING OF CAPS FROM HOSE BEFORE FITTING IT
1. CAN BE LIFTED USING HAND ITSELF2. A PNEUMATIC GUN DESIGNED TO REMOVE CAPS FROM THE HOSE
DEFECTS & REWORKS 1 1.THE OIL DRAINING IN THE PEDALS MAY NOT BE DONE PROPERLY
1. EFFICIENT DRAINING OF THE OIL MUST BE DONE
STATION& FEEDER WASTE CLASSIFIED UNDER
QUANTITY
IDENTIFIED PROBLEM(S) SOLUTIONS TO THE PROBLEMS
STATION 3: RADIATOR & BOOM CYLINDER MOUNTING
FEEDER 3 : BOOM CYLINDER AND RADIATOR SUB ASSEMBLY
TRANSPORT NIL NIL
INVENTORY SHORTAGE OF FASTENERS AND KEEP TRACK OF INVENTORY
MOVEMENT MANY NUMBER OF STEPS FOR BOOM CYLINDER ATTACHMENT
COMBINE BOOM CYLINDER SUB ASSEMBLY AND STORAGE IN FEEDER 3
WAITING ONLY ONE RADIATOR IS STORED IN FEEDER 3
STORE TWO RADIATORS INSTEAD OF ONE AS THERE IS SPACE
OVERPRODUCTION
OVERPROCESSING UNNECESSARY TORQUING OF FASTENERS
USE ADVANCED PNEUMATIC GUN
DEFECTS AND REWORK
BOOM CYLINDER MAY NOT BE ATTACHED IN CORRECT POSITION
RECTIFY AND ENSURE THAT TRAINED PERSONEL OPERATE
STATION& FEEDER WASTE CLASSIFIED UNDER
QUANTITY IDENTIFIED PROBLEM(S) SOLUTIONS TO THE PROBLEMS
STATION 4: SHEET METAL FIXTURE
FEEDER 4: COWL FRAME SUB ASSEMBLY
TRANSPORT 0 NIL NILINVENTORY 1 SHORTAGE OF FASTENERS KEEP TRACK OF INVENTORY
MOVEMENT 2
1. BATTERY PLACEMENT IN STATION 4
2. COMMON HARDWARE TROLLEY USED FOR STATION 3 AND 4 IN RH
SIDE MAKES IT TEDIOUS
1. BATTERY CAN BE MOUNTED IN STATION 4 SO THAT SPACE IS CREATED TO PLACE HARDWARE TROLLEY IN
STATION 4
2. USE SEPERATE HARDWARE TROLLEY FOR STATION 4 IN RH SIDE
WAITING 1 COWL FRAME ASSEMBLY TAKES MORE TIME
EMPLOY ONE MORE PERSON TO MAKE IT QUICKER
OVERPRODUCTION 0 NIL NIL
OVERPROCESSING 1UNNECESSARY FRICTION PLATE
ATTACHMENT IN THE COWL FRAMEREDESIGN THE SHEET METAL FOR FRICTION TO SAVE
METAL, MONEY AND TIME
DEFECTS AND REWORK
1 LEAKAGE OF HYDRAULIC OIL IF HOSE NOT FIXED PROPERLY
MONITOR HOSE ASSEMBLY PROPERLY
STATION&FEEDER WASTE CLASSIFIED QUANTITY IDENTIFIED PROBLEM(S) SOLUTIONS TO THE PROBLEMS
UNDER
STATION 5: DOCKING OF LOWER AND UPPER FRAME
FEEDER 10: LOWER FRAME SUB ASSEMBLY
TRANSPORT 1 TEDIOUS TRANSFER OF LOWER FRAME ASSEMBLY FROM FEEDER
TO MAIN ASSEMBLY LINE
TRANSFER CAR CAN BE MADE TO DOUBLE AS A HYDRAULIC LIFT THAT CAN SWIVEL DIRECTLY INTO
THE MAIN ASSEMBLY LINE
INVENTORY 1 SHORTAGE OF FASTENERS KEEP TRACK OF INVENTORY
MOVEMENT 0 NIL NIL
WAITING 1 DOCKING DELAY AS U/F ASSEMBLY TAKES MORE TIME
SYNC TIME TAKEN FOR BOTH ASSEMBLIES TO MAINTAIN PRODUCTIVITY
OVERPRODUCTION 1 LOWER FRAME ASSEMBLY TAKES LESSER TIME
SYNC TIME TAKEN FOR BOTH ASSEMBLIES TO MAINTAIN PRODUCTIVITY
OVERPROCESSING 1 UNNECESSARY TORQUING OF FASTENERS
USE ADVANCED PNEUMATIC GUN
DEFECTS AND REWORK 0 NIL NIL
STATION& FEEDER WASTE CLASSIFIED UNDER QUANTITY IDENTIFIED PROBLEM(S) SOLUTIONS TO THE
PROBLEMS
STATION 6: FUEL & HYD OIL FILLING, AC CHARGING
FEEDER 5: SWING MOTOR SUB ASSEMBLY
TRANSPORT 0 NIL NIL
INVENTORY 1 SHORTAGE OF FASTENERS KEEP TRACK OF INVENTORY
MOVEMENT 0 NIL NIL
WAITING 0 NIL NIL
OVERPRODUCTION 0 NIL NIL
OVERPROCESSING 1UNNECESSARY TORQUING OF FASTENERS IN SWING
MOTOR ASSEMBLY
USE ADVANCED PNEUMATIC GUN
DEFECTS AND REWORK 2
1. HYDRAULIC OIL LEVEL MAY VARY
2. OIL HOSE MAY NOT BE CONNECTED PROPERLY
1. ENSURE CORRECT LEVEL OF HYDRAULIC OIL IN TANK
2. ENSURE WELL SUPERVISED LABOUR FOR CORRECT FASTENING OF HOSE
STATION & WASTE CLASSIFIED QUANTITY IDENTIFIED PROBLEM(S) SOLUTIONS TO THE PROBLEM(S)
FEEDER UNDER
STATION 7: COUNTER WEIGHT
MOUNTING
(NO FEEDER FOR THIS PARTICULAR
STATION)
TRANSPORT 1TRANSPORTATION OF COUNTER
WEIGHT FROM THE WARE HOUSE TO THE ASSEMBLY LINE
REDUCE THE DISTANCE OF TRAVEL FROM THE WARE HOUSE TO THE ASSEMBLY LINE
INVENTORY SHORTAGE OF FASTNERS ETC. KEEP TRACK OF INVENTORY
MOVEMENT2 USAGE OF PNEUMATIC GUN AND
SPANNERNIL
WAITING 1 SUPPLY OF COUNTER WEIGHT SUPPLY OF COUNTER WEIGHT TO THE ASSEMBLY LINE OF TIME
OVER PRODUCTION - NIL NIL
OVERPROCESSING 4
1. UNNECESSARY TORQUING
2. ROTATION OF THE COUNTER WEIGHT WHILE ASSEMBLING IT ON THE MACHINE
1. SOPHISTICATED PNEUMATIC GUN- THE PNEUMATIC GUN CAN BE DESIGNED SUCH THAT A LIGHT INDICATOR CAN BE USED TO INDICATE PERFECT TORQUING.
2. COPLANAR PLACEMENT OF THE COUNTER WEIGHT NEAR THE ASSEMBLY LINE
DEFECTS AND REWORK - NIL NIL
STATION & FEEDER
WASTE CLASSIFIED UNDER QUANTITY IDENTIFIED PROBLEM(S) SOLUTIONS TO THE PROBLEM(S)
STATION 8: CABIN MOUNTING
FEEDER-6:CABIN SUB ASSEMBLY
TRANSPORT 2
1. TRANSPORTATION OF CABIN FROM THE WAREHOUSE TO THE
FEEDER STATION2.TRANSPORTATION OF THE CABIN TO THE ASSEMBLY LINE FROM THE
FEEDER LINE.
NIL
INVENTORY -SHORTAGE OF FASTNERS ETC.
(APPLICABLE FOR STATION AND THE FEEDER)
KEEP TRACK OF INVENTORY
MOVEMENT 31.CONNECTING THE ACCESSORIES
2.TIGHTENING THE FASTNERS(APPLICABLE FOR STATION AND
THE FEEDER)
NIL
WAITING 1 SUPPLY OF COUNTER WEIGHT TO THE ASSEM
ADDITIONAL LABOUR CAN SAVE TIME
OVERPRODUCTION - NIL NIL
OVERPROCESSING 2
1.UNNECESSARY TORQUING WHILE ASSEMBLING THE CABIN TO
THE CHASSIS
2. REMOVING THE FASTNERS, GLASS ETC. TO FIX THE
ACCESSORIES AND AGAIN TIGHTENING IT
1. SOPHISTICATED PNEUMATIC GUN- THE PNEUMATIC GUN CAN BE DESIGNED SUCH THAT A LIGHT INDICATOR CAN BE USED TO INDICATE PERFECT TORQUING.
2.EXTERNAL POSITIONING OF FASTNERS TO CONNECT THE CHASSIS AND THE CABIN
STATION & FEEDER
WASTE CLASSIFIED UNDER
QUANTITY IDENTIFIED PROBLEM(S) SOLUTIONS TO THE PROBLEM(S)
STATION 9: BOOM,ARM & BUCKET MOUNTING
FEEDER-7: BOOM AND ARM DOCKING
TRANSPORT 2
1.TRANSPORTATION OF BOOM AND ARM TO THE FEEDER LINE
FROM THE WAREHOUSE. 2.TRANSPORTATION OF BUCKET FROM THE WAREHOUSE TO THE
ASSEMBLY LINE.
THE ARM ASSEMBLY CAN BE DIRECTLY TRANSFERRED TO THE ASSEMBLY LINE RATHER THAN TRANSFERRING IT TO
OPPOSITE SIDE OF THE FEEDER LINE.
INVENTORY SHORTAGE OF FASTNERS ETC. KEEP TRACK OF INVENTORYMOVEMENT 1 CONNECTING THE HANDRAIL TO
THE MAIN ASSEMBLY THE PROCESS CAN BE COMPLETED IN THE PREVIOUS
STATION
WAITING 1ASSEMBLY OF THE BOOM AND
ARM MUST BE COMPLETED FOR THE BUCKET TO BE ASSEMBLED TO
THE MAIN MACHIINE
ADDITIONAL LABOUR CAN SAVE TIME
OVERPRODUCTION - NIL NIL
OVERPROCESSING 1 UNNECESSARY TORQUING SOPHISTICATED PNEUMATIC GUN- THE PNEUMATIC GUN
CAN BE DESIGNED SUCH THAT A LIGHT INDICATOR CAN BE USED TO INDICATE PERFECT TORQUING.
DEFECTS AND REWORKS
- NIL NIL