5 Effect of Rejects on the Time Taken for the Production of Air Ducts

7/31/2019 5 Effect of Rejects on the Time Taken for the Production of Air Ducts

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5.1

5. EFFECT OF REJECT ON PRODUCTIONTIME

5.1 Introduction

The effect of the rejects on the production time, are major, on the production

time, which will increase in the time taken for the production of the automobile air ducts.

Before considering the effects of rejection on production, time, the parameters

causing the rejection should be very well known, to the individual. These parameters

should be well characterized, and thus its effect on the production time can be predicted.

After the characterizing, we found out that the parameters are of three types.

1. Parameters, that causes defects, but cannot be controlled by taking theprecautions, but the severity of such failure can be reduced by taking the

remedies.

Example: Blow molding machine malfunction, & receiving of raw

material, and failure of transport during dispatch of the finished Goods

2. Parameters, that causes defects, but can be controlled by taking theprecautions, and the occurrence of such failure can be avoided by taking

precautions

Example: rejection due to wrong clamping

If the above parameters are taken care of, the production time will increase that

will increase the yield of the company, generating more revenues of the company.

For, further examination of the effect of rejects on the production time a detailed

fishbone is to be constructed, which will help us, to understand the failures that causes

the rejection, Main causes that creates those failures, and the sub causes that are

responsible for the main cause. The tabular for mat of the same is shown in Table 5.1.

The fishbone of the problem will be constructed and then, studied in figure 5.1.,

and the parameters will then be identified under the above category.


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5.2


3/28

5.3

Table 5.1.1 Effect of rejection on Product Manufacturing time

Cause: 02 Cause: 03 Cause: 04

Wrong or improper die setting Improper excess material removal Wrong clamp fitting Wrong a

Unskilledworker

Dimensions notknown toworker

Unskilledworker

Inexperience worker

difficultyinidentification dueVerysimilarlookingclamp LH &RH

Burdononworkerdue torepetitive task

in shorttime

Workerdonthaveknowledge ofassembl

processs

Wrong clamp usage Wrong foam / glue used

Damagedclampused forassembly

Wrongmaterialsupplied bysupplier

Wrongmaterialordered

Wrongmaterialsuppliedby supplier

Wrongmaterialordered

Damaged Die used Machine Breakdown

Impropermaintenance of die

Improperstorageof Die

Improperpreventivemaintenan

ce ofmachines

Partsnot

available atstore

In-housemaintenance person

notavailable

Improper excess material

removal

Dimension

s not

known to

worker

Unskill

ed

worker

Over heating of blow molding

machineImproper Goods storage

Ventilationis not proper

Machinecooling system

not working

improperstoragetemperatur

e

excess moisture inthe air damages thegoods


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5.4

Wrong process

parameters setting in

Blow molding machine

Wrong or improper die

setting

Wrong


removal

People

Inexperience

worker

Machine operating

illiteracy

Unskilled

worker

Unskilled workerDimensions

not known to

worker

Inexperience

worker

Difficulty in

identification

due Very

similar looking

clamp LH & RH

Burdon on workre etitive task i

Wrong

selection ofsub parts for

assembly

Improper selecti

temp for heatin

Storage

Finished

at wrong

Wrong foam /

lue used

Wrong

material

ordered

Wrong materialsupplied by

supplier

Equipmen

Wrong process parameters setting

in Blow molding machine


removal

heating of blow molding

ne

Raw material damaged

Method

Improper storage temperature

Excess moisture in the air damages the material

Ventilation is not proper

Machine cooling system not working

oper storage temperature

d clamp used for assembly

Process parameters are not validated

Process parameters are not available at machine

Unskilled worker

Dimensions not known to worker

Machine Malfunction

Non - calibrated machine

Wrong process Parameters


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5.5

Some, parameters are identified, and considered for the reducing the rejects, and

increasing the time taken for the production. They are as follows.

1. Raw material receiving & transportation of the finished goods to the customer.2. Blow Molding Machine functionality3. Reduction in the rejects due to wrong clamping

The first two parameters are characterized in category one, while the third

parameter is characterized in category two. The effect of category two on the process is

much more severe than the category one, but the occurrence level is low, thus it results in

moderated RPN. Similarly the category two has less severity, but its occurrence is high,

so, RPN value will be moderate, but both these parameter has impact on the time for

production, so cannot be neglected. After the FMEA implementation, its impact can be

observed in the production time, by calculating the initial and final production time.

5.2 Receiving raw material from the supplier and transporting

of the finished goods to the customer

5.2.1 Receiving raw material from the supplier

The process of manufacturing of the air ducts starts from the receiving of raw

material from the supplier to the transportation of the finished goods to the customer.

The first and the last operation are major operations that should be taken care.

Completing the whole operation of manufacturing and dispatch of the goods is not

possible, if these two major operations are avoided.

No manufacturing of any product can start if the raw material is not received on

time. If inventory management, is not followed by any organization, the late receiving of

the raw material will directly add in the idle time of the company, which will directly add

in the losses of the company, and no operation can be started can be started without raw

material receiving.

In the FMEA, as the occurrence of this type of potential failure is less, also, the

detection is easy, both the occurrence an detection are rated low. The severity of this

kind of failure will be rated high, as it will have severe effect on the operation followed.


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5.6

The RPN, i.e. the product of severity, occurrence and detection comes out to be low

again, due to low ratings of occurrence and detection. But the severity in this operation

is very high, which cannot be neglected due to adverse effects on other operations.

The effect of the failure mode will be different at different levels of production.

The next operation will be impossible to perform, at assembly the material will not

available for the assembly, at customer level more time taken to fulfill the orders that

will cause dissatisfaction, while the end customer will be dissatisfied.

There are two potential causes to the failure due to material not received on time

1. Transport malfunction2. Material not dispatched by the supplier on timeThe current process control or prevention method for the potential failure of raw

material not received on time would be asking the delivery well before the time of its

utilization; also proper intimation should be given to the supplier for delivering the raw

material on time. This creates a chance that will avoid such a situation to rise.

5.2.2 Transportation of the finished goods to the customerThe dispatching procedure, in which the finish goods are dispatched from the

industry to the customer, should be taken particular care. There are many disadvantages

if proper care is not taken; some of them are as follows

a. The late dispatch will result into late delivery, which will result in an unhappyand dissatisfied customer.

b.

Industry will lose its reputation on its punctuality, in the market, and spoils itsmarket value.

c. If the product gets spoiled during dispatching, then the market value of thecustomer will be spoiled, also, it will result in customer dissatisfaction.

d. It can also affect further relationship with the customer company, due to latedelivery, or product getting spoiled during the process of dispatching.

The reasons which can cause these types of disadvantages should be concerned

about, and proper precautions should be taken to make sure that these types of


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5.7

disadvantages do not occur. This has to be done as the severity of these disadvantages

are very high and can create major problems to the company and its reputation in a long

run.

Table5.2.1 FMEA analysis for the Raw material not received on time

ProcessFunction

Requireme

nts

Actions

Taken

S e v

Oc c

D et

RPN

Raw

ma

teri

lal

no

t

rece

ive

don

time

NextOperation-

im

poss

ible

toperform

nex

tope

ration

Assly

-

ma

teria

lno

tava

ila

ble

for

theassem

bly

.

Customer-

more

time

tak

en

tofulfil

ltheorders

disa

tis

fation

.

EndCustomer-

dissa

tifa

ction

8

1.

transporta

tion

ma

lfun

tion

2.

ma

teria

lno

t

dispa

tch

ed

on

time

by

the

supp

lier

1

supp

lier

sh

ou

ldb

e

given

regu

lar

inima

tion

rece

iving

departmen

t

info

rms

the

pro

duc

tion

superv

isor

2

16

ActionResults

10Receiving

inspectiono

f

raw

materia

l

Current

Process

controls

Prevention

Current

Process

controls

Detection

D et e

R P N

Recom

mended

Action(s

)

Respon

sibility&

Target

Complet

Potential

FailureMode

PotentialEffect(s)o

fFailure

S e v

Cl a s

Potentialcause(s)/

Mechanism(s)of

Failure

Occ

ur


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5.8

5.3 Blow Molding Machine functionality

As blow molding is the main manufacturing process that is being considered inthe manufacturing of the air ducts. It is a process that is to be taken special care. If any

one out of the five blow molding machine fails in the industry, it will cause 20 % loss to

the total production and process, for the manufacturing of the Air Ducts. This will also

contribute a huge amount in the down time and the total losses incurred to the company.

To avoid this kind of failure or similar kind of failure to occur, the proper

maintenance schedule as directed by the blow molding machine manufacturer, should be

adopted and followed, for the proper functioning of the machine, also to avoid the

unwanted situation such as total machine repair time, to occur.

Though in FMEA, which we have done earlier, I have not considered a lot

potential causes in the blow molding machine functionality, since the occurrence is less,

bit the same cannot be neglected as the severity ratings are very high and cannot be

ignored.

The following the hydraulic circuit for the blow molding machine operation, the

maintenance schedule chart will depend on this hydraulic circuit.

When the solenoid 1 will be actuated, the first stage of the 4/2 DCV, will be

actuated, in that case the pressure will be in line 1. The line 1 consist of 3/2 DCV which

is roller actuated, and the closed position will be actuated, when the cylinder expands in

the forward position till platens 2. When the solenoid 2 will be actuated, the second

stage of the 4/2 DCV, will be actuated, in that case the pressure will be in line 2. The line

2 does not contain any 3/2 DCV so the cylinder will directly be actuated and will move

in the reverse direction.


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5.9

Figure5.3.1 control circuit for the Blow Molding Machine

Table 5.3.1 Maintenance steps for the blow molding machines

Repair Indicators

Service Options

Possible Causes Service Options

Leaks System pressure too high

Scored or bent cylinder rod

Failed or incorrect seals

Improperly torqued hose

connection

Worn or damaged hoses,

tubes and fittings

Missing guards

Hose service

Thorough visual machine

inspection

Maintenance and diagnostic

services

SOS Services

Custom Hydraulic Service

Excessive cylinder

drift

Valve adjustment needed

Scored cylinder

Failed seal or seals

Scored valve

Identification and

measurement

Diagnostic services

SOS Services

um

Line 1Line 2

4 2 DCV

3 2 DCV


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5.10

Contaminated oil Custom Hydraulic Service

Slow cycle times Engine performance

Faulty valve

Low fluid level

Worn system components

Contaminated oil

Machine measurements

compared to specs

Diagnostic services

SOS Services


Noisy operation Engine performance

Low fluid level

Restriction in system

Aeration


Faulty relief valve


inspection

SOS Services


System overheating Faulty oil cooler

Low fluid level

Plugged filter


Faulty relief valve

Wrong viscosity or

contaminated oil

Restriction in system

Poor operator habits


inspection

Maintenance and diagnostic

services

SOS Services


Loose cylinder joints Worn rod or cylinder Component inspection/repair


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5.11

eye/trunnion

Poor lubrication

Improper preventive

maintenance schedule


SOS Services High levels of wear

elements, dirt and

other contaminants in oil will

accelerate

component wear and erodesystem efficiency

Preventive maintenance

schedule consultation


5.3.1 Trouble shooting for the blow molding machines

Dirty Oil

1) Components not properly cleaned after servicing.

2) Inadequate screening in fill pipe.

3) Air breather left off. (No air breather provided or insufficient protection of air

breather).

4) Tank not properly sealed.

5) Pipe lines not properly covered while servicing machine.

6) Improper tank baffles not providing settling basin for heavy materials.

7) filter dirty or ruptured.

Fire resistant fluids

1) Incorrect seals cause binding spools.

2) Paint, varnish or enamel in contact with fluids can cause sludge deposits on

filters and around seal areas.


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5.12

3) Electrolytic action is possible with some metals. Usually, zinc or cadmium.

4 ) Improve mixtures can cause heavy sludge formations.

5) High temperatures adversely affect some of the fluids, particularly the water

base fluids.

6) Adequate identification of tanks containing these fluids should be provided so

that they will be refilled with the proper media.

7) As with mineral base oils, nuisance leaks should be remedied at once.

8) Make certain replacement parts are compatible with fluid media.

Foaming Oil

1) Tank line not returned below fluid level.

2) Broken pipe.

3) Line left out between a bulkhead coupling and the bottom of the tank after

cleaning.

4) Inadequate baffles in reservoir.

5) Fluid contaminated with incompatible foreign matter.

6) Suction leak to pump aerating oil.

7) Lack of anti-foaming additives.

Moisture in Oils

1) Cooling coils not below fluid levels.

2) Cold water lines fastened directly against hot tank causing condensation

within the tank.

3) Soluble oil solution splashing into poorly sealed tanks or fill pipes left open.

4) Moisture in cans used to replace fluid in tanks.

5) Extreme temperature differential in certain geographical locations.


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5.13

6) Drain not provided at lowest point in tank to remove water collected over

possibly long operating periods.

Overheating of System

1) Relief valve set too close to compensator pressure setting.

2) Water shut off or heat exchanger clogged.

3) Continuous operation at relief setting.

a. Stalling under load, etc.

b. Fluid viscosity too high or too low.

4) Excessive slippage or internal leakage.

a. Check stall leakage part pump, motors and cylinders.

b. Fluid viscosity too low.

5) Reservoir sized too small.

6) Case drain line from pressure compensated pump returning oil too close to

suction line.

a. Re-pipe case drain line to opposite side of reservoir baffling.

7) Pipe, tube or hose I.D. too small causing high velocity.

8) Valving too small, causing high velocity.

9) Improper air circulation around reservoir.

10) System relief valve set too high.

11) Power unit operating in direct sunlight or ambient temperature is too high.

Oil leakage around pump

1) Shaft seal worn.

2) Head of oil on suction pipe connection connection leaking


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5.14

3) Pump housing bolts loose or improperly torque.

4) Case drain line too small or restricted (shaft seal leaking).

Excessive pump wear

1) Abrasive dirt in the hydraulic oil being circulated through the system.

2) Oil viscosity too low.

3) System pressure exceeds pump rating.

4) Pump misalignment or belt drive too tight.

5) Air being drawn in through inlet of pump.

Troubleshooting Solenoid Valves

Solenoid failures

1) Voltage too low. If voltage is not sufficient to complete the stroke of the

solenoid, it will burn out the coil.

2) Voltage too high. Excessive voltage can also burn out coils.

3) Signal to both solenoids of a double solenoid valve simultaneously. One or

both of the solenoids will be unable to complete their stroke and will burn out. (Make

certain the electrical signal is interlocked so that this condition cannot exist).

4) Mechanical damage to leads. (Short circuit, open connections, etc.)

5) Tight spool or other mechanical parts of the valve being actuated can prevent

the solenoid from completing its stroke and subsequently burning out.

6) Replacement springs too heavy in valve. Overloads solenoid and shortens

life.

7) Dirty contacts may not supply sufficient current to solenoid to satisfy inrush

demands.

8) Low voltage direct current solenoids may be affected by low battery capacity

on cold mornings directly after starting cold engine. (DC)


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5.15

9) Long feed lines to low voltage solenoids may cause sufficient voltage drop

to cause erratic operation.

Solenoid valve fails to operate

1) Is there an electrical signal to the solenoid or operating device? Is the

voltage too low? (Check with voltmetertest light in emergency.)

2) If the supply to the pilot body is orificed, is the orifice restricted? (Remove

orifice and check for foreign matter. Flushing is sometimes necessary because of floating

impediment.)

3) Has foreign matter jammed the main spool?

(Remove end caps and see that main spool is free in its movementremember

that there will be a quantity of fluid escaping when the cap is removed and provide a

container to catch it.)

4) Is pilot pressure available? Is the pilot pressure adequate? (Check with

gauge on main pressure input port for internally piloted types and in the supply line to

the externally piloted type.)

5) Is pilot drain restricted? (Remove pilot drain and let the fluid pour into an

open container while the machine is again tried for normal operation. Small lines are

often crushed by machine parts banging against them causing a subsequent restriction to

fluid flow.)

6) Is pilot tank port connected to main tank port where pressures are high enough

to neutralize pilot input pressure? (Combine pilot drain and pilot tank port and check for

operation with the combined flow draining into an open containerblock line to main

tank from pilot valveif this corrects the situation, reroute pilot drain and tank line.)

7) Are solenoids improperly interlocked so that a signal is provided to both

units simultaneously? (Put test light on each solenoid lead in paral lel and watch for

simultaneous lightingcheck electrical interlock. This condition probably burns out

more solenoids than any other factor.)


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5.16

8) Has mounting pad been warped from external heating? (Loosen mounting

bolts slightly and see if valve functions. End caps can also be removed and check for

tight spool.)

9) Is fluid excessively hot? (Check for localized heating which may indicate an

internal leakcheck reservoir temperature and see if it is within machine specifications.)

10) Is there foreign matter in the fluid media causing gummy deposits? (Check

for contaminationmake certain seals and plumbing are compatible with the type of

fluid being used.)

11) Is an adequate supply of fluid being delivered to actuate the load? (Many

times there is sufficient pressure to shift the valve but not enough to actuate the work

load. Check pump supply pressure and volume if necessaryphysical measurement of

flow through relief valve with units blocked may be necessary.)

12) Check circuit for possible interlocks on pressure sources to valve or to pilot.

5.4 Rejects Due To Wrong Clamping

For, constructing Fishbone, there should an identified problem, on which the

work to reduce it has to be done. From the database, of previous FMEA, and also

considering the accounts for the rejects, it has been found out that the maximum rejects

were contributed by mainly one failure that is, Rejection due to wrong clamp fitting in

the air duct. Even if the problem is minor in its size, but is major, when it comes to the

rejection rate calculation.

The main parameters that are contributing to this problem are people, material,

equipment, method, and environment. There are different causes that are been identifiedwith the help of brain storming sessions that were held between the cross functional team

that was formed for the FMEA implementation in the Delta Blow Packs. The following

table 5.1 shows the main parameters and the causes that are contributing to these

parameters, which in whole contributes to the main failure and cause the problem.


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5.17

Table: 5.4.1EFFECT: Rejection due to wrong clamp fitting

(direction)

Sr.

NoParameters Cause: 01 Cause: 02 Cause: 03

1. PeopleInexperience

worker

difficulty in

identification due

Very similar looking

clamp LH & RH

Burdon on

worker due to

recitative task in

short time

2. Material

Only LH or RH

side clamp

available /

purchased

No color coding or

demarcation on

clamp

-

3. Equipment Manual fitting

No separate bins to

store LH & RH

clamp

-

4. Method

Storage clamps

RH &LH) on same

side only

- -

5. EnvironmentLess space for

fitting area- -

From the above table the fishbone diagram or the cause and effect diagram will

be constructed. The skeleton of the fishbone, has different parts that are reserved for the

different parameters that will lead to come across the cause of the failure. The mainspine of the fishbone should be used to show the main failure for which the fishbone is

being constructed. Along the spine bone, of the fishbone, various other bones are

connected, which will be drawn as the branches that will indicate the main parameters

that are contributing to the fishbone. Some of them are people, material, equipment,

method, and environment. The sub branches which are attached to branches that are

drawn earlier will indicate the main causes that are being contributed to the failure to the

medium of parameters.


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5.18

The Cause & Effect Analysis of the main failure, i.e. wrong clamp fitting, gives

us the main parameters, causes, etc., of the failure, causing it to happen. After the Cause

& Effect Analysis, it is necessary to perform the FMEA, to eradicate the problem.


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5.19

Figure 5.4.1 Fishbone for the Rejection due to Wrong Clamping

5.4.1 Customizing FMEA as a Problem Solving Tool


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5.20

To start FMEA, the main requirement is the cross functional team, and some of

the experts that are require, who are involved in the process, causing these failure. A

sample sheet of FMEA in this process is prepares and is given in the Table 5.3.2

Table 5.4.1.1 FMEA sample sheet

The parameters which were defined in the Fishbone diagram, has been classified

according to the department. The department classification of the parameters, makes it

easy to identify, the cause that is related and plays an important role causing the problem,

as the problem gets restricted to only one department.

The failure mode for the particular department is identified, and the effect of that

failure mode is decided, henceforth. The severity, occurrence and detection is rated by

the brain storming sessions, and the RPN is calculated which is the product of Severity,

Occurrence and Detection.

In analysis, the acceptance or the rejection of the process is taken care off, in

which the processes with more than 200 RPN is not acceptable and needs to be

controlled. The control, action or the actions which are taken to reduce the failure are

introduced and applied for the process with higher RPN only, i.e. about 200. A detailed

FMEA is done and shown in Table 5.3.2

CategoryFailure

ModesEffects Severity Probability Detection RPN Analysis

Action

to

reduce

failure


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5.

21

Table5.4.1.2FMEAbasedontheFishbon

eDiagramofrejectsduetowrongclamp

ing

Category

FailureModes

Effects

Severity

Probability

Detection

RPN

Analysis

Actiontored

ucefailure

Delayinfitting

4

3

2

24

Accept

People01

(Manufacturin

g)

Workerdonthaveknowledgeof

clamp-LH&RHside

Wrongclampfitting

10

3

6

1

80

Control

Alwaysdeploytrainedworkersfor

thejob

People02

(Manufacturin

g)

difficultyinidentificationdueVery

similarlookingclampLH&RH

Wrongclampfitting

10

7

6

4

20

Control

1.Usecoloredbins

tostoreclamps

i.e.Red-LH&Blue-RH

2.Displayvisualsf

orright/wrong

fitting

Delayinwork

4

4

2

32

Accept

People03

(Manufacturin

g)

Burdononworkerduetorepetitive

taskinshorttime

Wrongclampfitting

10

2

6

1

20

Accept

People01

(QC)

Workerdonthaveknowledgeof

clamp-LH&RHside

Wrongclampfitting/dispatched

10

3

9

2

70

Control

Alwaysdeploytrainedworkersfor

thejob

People02

(QC)

difficultyinidentificationdueVery

similarlookingclampLH&RH

Wrongclampfitting/dispatched

10

7

9

6

30

Control

Displayvisualsfor

right/wrong

fitting

Assemblystoppage

4

2

2

16

Accept

Material01

OnlyLHorRHsideclampavailable

/

purchased

Fittingofsameclamponboth

side

10

2

2

40

Accept

Material02

Nocolorcodingordemarkingon

clamp

Fittingofsameclamponboth

side

10

7

7

4

90

Control

Usecoloredbinsto

storeclamps

i.e.Red-LH&Blue-RH

Equipment01

Manualfitting

Moretimetofitclamps

4

2

2

16

Accept

Equipment02

NoseparatebinstostoreLH&RH

clamp

Wrongclampfitting

10

9

7

6

30

Control

SeparatebinsforLH&RH

Method

Storageofclamps(RH&LH)onsam

e

sideonly

Wrongclampfitting

10

5

7

3

50

Control

Prepareassemblya

reainsucha

waythatonLHsideofworkerLH

clampbinandRHsideRHclamp

bin

Environment

Lessspaceforfittingarea

Discomforttoworker

4

6

5

1

20

Accept


22/28


23/28

5.23

= 6 + 6 + 6 + 8

= 26 minutes.... (i)

1 product takes 26 minutes, so we have 2250 minutes, i.e. essential tomanufacture 86 products per day.

5.5.1.2Calculation based on the capacity of the blow molding machines.One blow molding machine has the capacity of 0.75 tons

Five blow molding machine has an overall capacity of 0.75 x 5 tons, i.e. 3.75

tons

3.75* 907 *1000 grams = 3401250 grams a day

An assembled product weighs 600 grams, so considering 70% material losses,

1700 products considering only the blow molding time, without considering assembly

and with out the extra material removal time + clamp time.

Ideally, one part should require 2 minutes for the blow molding (Considering

the pauses taken for the die introduction and removal process), without considering

assembly and with out the extra material removal time + clamp time.

Considering an average time for the product removal from the Die + Extra

material removal from the part produced + clamping time per part, which can be taken

as 1 minute per operation.

Total time taken per part = blow molding time per part

+ Time for the product removal from the Die

+ Extra material removal from the part produced

+ clamping time per part

= 2 + 1 + 1 +1

= 5 minutes


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5.24

For each product production, i.e. time for production of center duct

+ Left hand side duct,

+ Right hand side duct,

+ Assembly of these parts, requires,

= 5 + 5 + 5 + 8

= 23 minutes. (ii)

Comparing the actual time and the ideal time there is a loss of 3 minutes per

product produced.

I have succeeded in lessening this gap of 3 minutes by 50 seconds, by different

methods introduced which will be discussed later, in this chapter.

By reducing 50 seconds now, my product will be ready in 25 minutes 10

seconds,

1 product will be produced in 25 minutes 10 seconds, so 2250 minutes will

produce 90 final products, i.e. increment of 4 products per day.

Increment of 4 product per day implies, in a month with 25 working days, will

yield 100 products per month as an increment, which further implies, 1200 product a

year increment.

The savings of 50 seconds per product will yield approximately around 0.18

million of rupees to the company annually.

5.5.2 Points applied, for 50 seconds reduction in total time, for the completemanufacturing of the Air Duct.

1. Implementing the FMEA has also helped in reducing the time, byreducing the potential failures.


25/28

5.25

Reduction of rejects from in process inspection and finalinspection, results in to less re work, and time saving in achieving

the targets.


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5.26

Table 5.5.1 FAILURE MODE AND EFFECT ANALYSIS

e Modes Effects Severity Probability Detection RPN

arameters setting

machine

Defected first piece produced,

then re setting of parameters

8 3 5 120

per die settingDefected first piece produced,

then re setting of parameters10 2 5 100

material removaldefected first piece produced,


ting rejection and rework 5 8 3 120

rejection and rework 10 2 2 40

e Damage or brakage 4 3 2 24

Raw materialRejection 8 3 8 192

age rejection and rework 5 8 3 120

ue used rejection and rework 5 8 3 120

arameters settingmachine

nnel)



ed (Die personnel)Defected first piece produced,

then re setting of parameters

10 2 5 100

ownPersonnel)

Delay in production (production

Personnel)10 2 2 40

arameters settingmachine

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blow moldingtion Personnel)

machine breakdown and delay in

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personnel)

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o Weekly financial appraisalo Appraisal according to the number of product produced

after the target is achieved in the day

Date post:	05-Apr-2018
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5 Effect of Rejects on the Time Taken for the Production of Air Ducts

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