Application of Value Stream Mapping for Reduction of Cycle Time in a Machining Process

AbstractLean manufacturing initiative is being followed by various organizations in the recent years which mainly focuses on improving the efficiency of operations by eliminating and reducing wastes. This paper aimed to explain the implementation of lean manufacturing techniques in the crankshaft manufacturing system at an automotive manufacturing plant located in south India.. A multi criteria decision making model, analytical hierarchy process is applied to analyze the decision making process in the manufacturing system. The objective of the case industry was to increase the export sales. Lean manufacturing system was selected to meet the company“s quality, cost and delivery targets. Crankshaft was manufactured in a single piece flow system with the low cost machines developed indigenously and the results are that the crankshafts have passed the testing, validation and approval by the customer to produce any variant in the company. After implementing lean manufacturing system, the manufacturing lead time reduced by forty percent, defects were reduced, higher process capability achieved, quick response to the customer demand in small lots were achieved

CRYOGENIC AIR CONDITIONING OF MOTOR VEHICLES

Cryogenics is the branch of physics and engineering that involves the study of very low temperatures (below 123 K), how to produce them, and how materials behave at those temperatures. It is frequently applied to low temperature refrigeration applications such as in the study of physical phenomena of materials at temperature approaching absolute zero and in the liquefaction of gases. Liquefied gases such as liquid nitrogen and liquid helium are used in many cryogenic applications. Using liquid nitrogen as a refrigerant reduces chloro-fluorocarbon (CFC) emission in atmosphere and it is an eco-friendly technique. This paper deals with usage of liquid nitrogen in air conditioning of motor vehicles. First the preparation of liquid nitrogen is discussed, followed by its storage and working as a refrigerant in air conditioning system. This is followed by its advantages and draw backs

WORK IN PROCESS OPTIMISATION THROUGH LEAN MANUFACTRING

ABSTRACT Today the global economy has caused a stronger competitive manufacturing environment in all kinds of business. Manufacturing industries face continuous pressure to reduce the price to remain in the market. It eventually results in manufactures need to reduce the profit margins in order to keep a share of the market. The objective of this paper to find the work in process for the optimal size using lean Techniques in a multiproduct single conveyor assembly line of a leading Two Wheeler Manufactures in south India. It is useful to map the dynamics of the supply chain focusing on how the demand information is passed from the final customer, back to the material suppliers and manufactures inside the company. So in this paper attempt has been made to find work in process and reduction of value in terms of Rupees from the current process to the proposed process. A mathematical model developed using general inventory cost model to quantify the Optimal Work In Process for the entire product range in Engine assembly line. Also numerical example is done to demonstrate the mathematical model with the available data. The mathematical results are very much encouraging and it calculated as 40 % reduction in work in process over the current work in process. KEY WORDS: WIP, optimal WIP, inventory cost method, change over time, multi product single conveyor assembly line

Wear evaluation and microstructure analysis of cryogenically treated AISI 440C Bearing steel

In this research work, two types of cryogenic treatment such as deep cryogenic treatment (-196oC) and shallow cryogenic treatment (-80oC) have been adopted for wear resistance to increase in AISI 440C bearing steel. This paper has been focused to increase Wear Resistance (WR) through deep micro structural analyses, and also attention has been made to correlate the microstructure with the wear character of Deep Cryogenic treated (DCT) specimens, Conventional Heat Treated (CHT) specimens and Shallow Cryogenic Treated (SCT) specimens. Micro structural examinations have been carried out in the specimens through Scanning Electron Microscopy (SEM), Energy Dispersive Analysis of X-ray (EDAX) and X-Ray Diffraction (XRD). Wear characteristics of AISI 440C bearing steel has been studied. The outcome of the research disclosed that the DCT specimens have higher wear resistance than SCT and CHT specimens. The effective wear mechanisms recognized were the constitution of white layers and delamination of white layers. The microstructures of the materials have been varied through heat treatment process. The modification of Secondary Carbides (SCs) precipitation characteristics and its reduction of retained austenite in the microstructure have been correlated with wear character and these are the liable mechanism to raise the wear resistance of bearing steels through DCT.The accepted manuscript in pdf format is listed with the files at the bottom of this page. The presentation of the authors' names and (or) special characters in the title of the manuscript may differ slightly between what is listed on this page and what is listed in the pdf file of the accepted manuscript; that in the pdf file of the accepted manuscript is what was submitted by the author

Study on Mixer Grinder’s User Behaviour – A Survey-based Analysis

This work presents the results of a study conducted on the user behaviour of a kitchen appliance (mixer grinder) covering a limited customer base, especially in South India. The user behaviour was evaluated using various parameters. In addition, a hard copy of the questionnaires was prepared, distributed, and collected by co-workers in person. This helped us to reach a wide range of customers. The collected hardcopy data were digitalized using Google docs and was analyzed and plotted using MS Excel., The brand performance was compared. Also, information about the likings, preferences, recommendations, satisfaction of the customers are all analyzed with the help of attainment graphs. The results and information we derived from the present study are explained in detail in this paper

Studies on Mechanical Behaviour of Aluminium-Silicon Carbide-Copper Metal Matrix Composite

Metal matrix composites (MMC) are the combination of two or more dissimilar base metals which in turn gives new metal. Composites have better properties than their base material. Nowadays, composites play the major role in manufacturing industries especially in automotive industry. This paper reveals the reinforcement of Aluminium alloy (6061) with Silicon Carbide and Copper in different ratios to produce new composite using stir casting technique in normal atmospheric temperature. In this work, mechanical behavior of the composite namely tensile strength, hardness and Flexural strength were evaluated. It was observed that sample 2 shows highest tensile strength of 155 MPa with hardness 73. The result shows that the hybrid composite had better mechanical property

Studies on Mechanical Behaviour of Aluminium-Silicon Carbide-Copper Metal Matrix Composite

Metal matrix composites (MMC) are the combination of two or more dissimilar base metals which in turn gives new metal. Composites have better properties than their base material. Nowadays, composites play the major role in manufacturing industries especially in automotive industry. This paper reveals the reinforcement of Aluminium alloy (6061) with Silicon Carbide and Copper in different ratios to produce new composite using stir casting technique in normal atmospheric temperature. In this work, mechanical behavior of the composite namely tensile strength, hardness and Flexural strength were evaluated. It was observed that sample 2 shows highest tensile strength of 155 MPa with hardness 73. The result shows that the hybrid composite had better mechanical property