24-09-2014, 02:34 PM
ABSTRACT PROJECT NAME- DESIGN OF STAMPING CARDS In the process lot of pistons are scrapped during the stamping of pistons on a machine. The reduction of this scrap is our aim. Since scrap is one of major problems in this shop, its reduction is must for cost reduction, productivity enhancement, increasing machine life and maintaining quality of piston. This project can be taken as a major step to achieve such targets. It can be seen just by standing beside the machine on which setting is done that it is an unavoidable task to be able to produce good piston without checking the parameters set in the setting, and this checking is to some extend a hit and trail method, which results in scrap. There is basically no problem in operator setting but it can be reduced by the proposed method which is simple and achievable. The stamping is done for codification of different grade or quality of the piston. Stamping can be done with the help of colours paints dots. Mechanical stamps with automatic stamping are done with the help of machine. This problem is solved by designing the sta
1. PROJECT REPORT
1.1 DESIGN OF STAMPING CARDS
1.2 PROJECT AIM
In the process lot of pistons are scrapped during the stamping of pistons on a machine. The reduction of this scrap is our aim.
1.3 SCOPE OF PROJECT
Since scrap is one of major problems in this shop, its reduction is must for cost reduction, productivity enhancement, increasing machine life and maintaining quality of piston. This project can be taken as a major step to achieve such targets.
1.4 PROBLEM IDENTIFICATION
It can be seen just by standing beside the machine on which setting is done that it is an unavoidable task to be able to produce good piston without checking the parameters set in the setting, and this checking is to some extend a hit and trail method, which results in scrap. There is basically no problem in operator setting but it can be reduced by the proposed method which is simple and achievable.
1.5 INTRODUCTION
1.5.1 STAMPING
The stamping is done for codification of different grade or quality of the piston. Stamping can be done with the help of colours paints dots. Mechanical stamps with automatic stamping are done with the help of machine. Type of the stamp on the piston is suggested by the customer.
According to the tolerance required in pin hole given in the drawing, the grades like A, B, C, D, etc. are given to the pistons. These codes are marked by hammering the stamp on the diameters crown of the piston.
Separate from these measurements, Inspection section also has an Ultrasonic Flaw Detector which is very useful in finding the flaws internally in the piston which cannot be detected with checking instruments
The crown portion of the pinions is stamped which shows company name, month of Manufacture and grouping code. After passing through this stringent test only, the good Pistons, which pass through final inspection are sent for packing.
1.5.2 DATA COLLECTION FOR THE ESTIMATING THE SCRAP DUE TO WRONG STAMPING
Pareto Shown Below the Percentage of Scrap Due To the wrong stamping and Various Other Reasons.
1.5.3 PROBLEM CLARIFY
WRONG STAMPING SCRAP TREND
1.6 PROBLEM SOVING TECHNIQUE
1.6.1 DESIGN OF STAMPING CARD
This problem is solved by designing the stamping cards of various pistons separately. Stamping card contains the image of piston with correct stamp as well as its drawing image which helps the operator to correct the way of handling the piston and marking correct stamp on piston without any mistake and also it reduces wastage of time without producing any scrap piston.
It contains the following specifications of piston:
· PITON TYPE
· DRAWING NUMBER
· SET NUMBER
· SIZE
· STAMPIN FIXTUR POKE YOKE
· LOCATION
The stamping cards helps the operator in keeping the piston in right direction on the stamping machine so that operator mark the stamp in proper direction as mentioned on drawing or as told by the customer without making any scrap piston.
1.6.2 STAMPING CARD OF FOLLWING PISTONS ARE DESINED:
· SPLENDOR
· 5TS5
· AN CNG
· AN UG
· BAJAJ JB
· CLASSIC FE
· CT-100
· G12B
· LOMBARDINI LGA-280
· M & M AVL
· MARUTI 800
· MARUTI F8D
· MARUTI P K10B
· RXG-632
· SONALIKA 100 DIA
· SONALIKA 105 DIA
· TATA AC 77 DIA
· TATA CUMMINS E-II
· TATA NANO
· TVS APACHE
· TVS VICTOR
· YAHMA 014
1.7 BENEFITS ACHIVED
· Cost of 1 cast piston (avg.) = $12
· Stamping scrap before = 3.87%
· Stamping scrap after = 1.02%
· Reduction in scrap percentage = 2.85%
= 507 Pistons
· Cost of Scrap Qty. = 507 x $12
= $6084
· Therefore Savings = Rs 3,28,536