15-09-2016, 12:43 PM
[attachment=71004]
Abstract
The objective of this paper is to present an overview on a new combined methodology for the efficient productivity improvement in the industries with the help of lean manufacturing principle and tools. Productivity improvement is an everlasting continuous activity in manufacturing industries. Increasing the productivity based on the customer demand is the major problems faced today. The same problem was faced in that steering knuckle manufacturing unit. On observing the present system of steering knuckle production, the current lead time was calculated and found to be 11.25 minutes. In order to overcome these situation, a proper study has been done and a suitable lean tools like Takt Time and value stream mapping is selected. Finally, in order to check the dimensions of steering knuckle components, Air gauge method is recommended.
Key words: Lean manufacturing, Value Stream Mapping, Takt Time, Air gauge method.
1.Introduction
Productivity has been generally defined as the ratio of an extent of output to the unit of all of the resources use to produce this output. Productivity usually deviates from production. Production concerns with an increment in output over a given spam of time. Productivity is concerned with the ratio of output to an input. Putting in another way, improving productivity has to do with how effectively people combine different resources to manufacture parts and service others dream to purchase. With the correct choice, improved production, higher values and elevated incomes can be accomplished for every hour worked.
Steering knuckle or hub carrier is one of the automotive part on the vehicle and mostly been used in car suspension system. Steering knuckle is a forging that usually includes the spindle and steering arm, and allows the front wheel to pivot. Steering knuckle are components that been used in the vehicle whether in the front or rear axle. The two steering are standard mechanical and rack and pinion steering. Value stream mapping is the process of mapping the material and information flows required to coordinate the activities performed by manufacturing, suppliers and distributors to deliver products to customer.vsm was initially developed in 1995 with an underlying rationale for the collection and use of the suite of tools as being to help researchers or practitioners to identify waste in individual value streams and hence, find an appropriate route to its removal. The measurement system analysis is one of the most important issues in the topic of quality management .air gauge are well known and widely appreciated devices for dimensional measurement.
The objective of lean manufacturing is to reduce waste and highly responsive to customer demand while producing quality products in the most efficient and economical manner. The core idea behind lean manufacturing is maximizing customer value while minimizing waste, thereby achieving manufacturing excellence through the creation of more value with fewer resources. a lean organisation understands customer value and focuses its key processes to continuously increase it. The ultimate goal is to provided perfect value to the customer by eliminating waste along entire value streams, instead of at isolated points, creates processes that need less human effort, less space, less capital and less time to make products and services at far less costs and with much fewer defects, compared with traditional business system. Lean can be applicable to any product or a service for which customer desires. In simple lean is creating value with les work. Lean manufacture has a comprehensive set of elements, rules and tools that focus on the elimination of waste and the creation of valve. It aggressively seeks to eliminate all non valve added activity and tries to instil a philosophy of continuous incremental improvement.
2. Statement of Problem
Operation time is increased due to manual handling of the work piece, therefore Takt Time method is employed in order to optimize the standard time .Sequencing of machines in the machine line are random in nature, therefore VSM is used for proper sequencing of the machines.Manual inspection takes more time and hence it affects the productivity, therefore AGI method is used to accurate and precise calibration of dimensions of steering knuckle components.
3. Objective of the research
a) To increase the productivity and decrease the setting time.
b) To eliminate non valued activities/wastes.
c) To satisfies the customer demand and to minimize the inspection time.
d) To improve the quality of the processes and thereby increasing GDP.
4.Summary Of Literature Review:
a) Productivity of a manufacturing system can be defined as the amount of work that can be accomplished per unit time using the available resources. Productivity improvement is an everlasting continuous activity in manufacturing.
b) The concept of Takt time ensures the stability of the production system and it is used in the typical manufacturing branches like automobile and machine industry.
c) Value stream mapping technique is employed for Reduction in lead time, cycle time and inventory level achieved.
d) Air gauges for dimensional measurements are known for decades which are connected with pneumatic measuring devices able to generate control signals. Air gauges are applied in many technological processes, especially in the system of in process control.
e) Three lean tools namely Takt time, VSM, and Air gauge inspection method is used in machine shop to improve productivity.
Conclusion
Productivity improvement is a practical and down to earth technique aimed at maximizing the effectiveness of facility that we use within our organization. The essence of productivity improvement is team work and its very heart lies the motivation and encouragement of the people who work within the organization. Today thousands of organization all over the world are improving productivity and about hundreds of organization are now doing it in india.By having a complete relook at the whole manufacturing activities encompassing design of the product, its specification, size and shape of material used for the products, application of value analysis and value engineering techniques, optimum utilization of resources including men, machines and material will be able to achieve complete productivity improvement. In short achieving the maximum result for every money spent. In that “productivity improvement in steering knuckle machining line” is carried out by productivity improvement method. The value steam mapping and air gauge inspection method tools is used to found the reason for losses during machining and various other methods are to be adopted to eliminate the losses and to increases the productivity improvement by hydraulic clamp, combine process 2 & 3
Abstract
The objective of this paper is to present an overview on a new combined methodology for the efficient productivity improvement in the industries with the help of lean manufacturing principle and tools. Productivity improvement is an everlasting continuous activity in manufacturing industries. Increasing the productivity based on the customer demand is the major problems faced today. The same problem was faced in that steering knuckle manufacturing unit. On observing the present system of steering knuckle production, the current lead time was calculated and found to be 11.25 minutes. In order to overcome these situation, a proper study has been done and a suitable lean tools like Takt Time and value stream mapping is selected. Finally, in order to check the dimensions of steering knuckle components, Air gauge method is recommended.
Key words: Lean manufacturing, Value Stream Mapping, Takt Time, Air gauge method.
1.Introduction
Productivity has been generally defined as the ratio of an extent of output to the unit of all of the resources use to produce this output. Productivity usually deviates from production. Production concerns with an increment in output over a given spam of time. Productivity is concerned with the ratio of output to an input. Putting in another way, improving productivity has to do with how effectively people combine different resources to manufacture parts and service others dream to purchase. With the correct choice, improved production, higher values and elevated incomes can be accomplished for every hour worked.
Steering knuckle or hub carrier is one of the automotive part on the vehicle and mostly been used in car suspension system. Steering knuckle is a forging that usually includes the spindle and steering arm, and allows the front wheel to pivot. Steering knuckle are components that been used in the vehicle whether in the front or rear axle. The two steering are standard mechanical and rack and pinion steering. Value stream mapping is the process of mapping the material and information flows required to coordinate the activities performed by manufacturing, suppliers and distributors to deliver products to customer.vsm was initially developed in 1995 with an underlying rationale for the collection and use of the suite of tools as being to help researchers or practitioners to identify waste in individual value streams and hence, find an appropriate route to its removal. The measurement system analysis is one of the most important issues in the topic of quality management .air gauge are well known and widely appreciated devices for dimensional measurement.
The objective of lean manufacturing is to reduce waste and highly responsive to customer demand while producing quality products in the most efficient and economical manner. The core idea behind lean manufacturing is maximizing customer value while minimizing waste, thereby achieving manufacturing excellence through the creation of more value with fewer resources. a lean organisation understands customer value and focuses its key processes to continuously increase it. The ultimate goal is to provided perfect value to the customer by eliminating waste along entire value streams, instead of at isolated points, creates processes that need less human effort, less space, less capital and less time to make products and services at far less costs and with much fewer defects, compared with traditional business system. Lean can be applicable to any product or a service for which customer desires. In simple lean is creating value with les work. Lean manufacture has a comprehensive set of elements, rules and tools that focus on the elimination of waste and the creation of valve. It aggressively seeks to eliminate all non valve added activity and tries to instil a philosophy of continuous incremental improvement.
2. Statement of Problem
Operation time is increased due to manual handling of the work piece, therefore Takt Time method is employed in order to optimize the standard time .Sequencing of machines in the machine line are random in nature, therefore VSM is used for proper sequencing of the machines.Manual inspection takes more time and hence it affects the productivity, therefore AGI method is used to accurate and precise calibration of dimensions of steering knuckle components.
3. Objective of the research
a) To increase the productivity and decrease the setting time.
b) To eliminate non valued activities/wastes.
c) To satisfies the customer demand and to minimize the inspection time.
d) To improve the quality of the processes and thereby increasing GDP.
4.Summary Of Literature Review:
a) Productivity of a manufacturing system can be defined as the amount of work that can be accomplished per unit time using the available resources. Productivity improvement is an everlasting continuous activity in manufacturing.
b) The concept of Takt time ensures the stability of the production system and it is used in the typical manufacturing branches like automobile and machine industry.
c) Value stream mapping technique is employed for Reduction in lead time, cycle time and inventory level achieved.
d) Air gauges for dimensional measurements are known for decades which are connected with pneumatic measuring devices able to generate control signals. Air gauges are applied in many technological processes, especially in the system of in process control.
e) Three lean tools namely Takt time, VSM, and Air gauge inspection method is used in machine shop to improve productivity.
Conclusion
Productivity improvement is a practical and down to earth technique aimed at maximizing the effectiveness of facility that we use within our organization. The essence of productivity improvement is team work and its very heart lies the motivation and encouragement of the people who work within the organization. Today thousands of organization all over the world are improving productivity and about hundreds of organization are now doing it in india.By having a complete relook at the whole manufacturing activities encompassing design of the product, its specification, size and shape of material used for the products, application of value analysis and value engineering techniques, optimum utilization of resources including men, machines and material will be able to achieve complete productivity improvement. In short achieving the maximum result for every money spent. In that “productivity improvement in steering knuckle machining line” is carried out by productivity improvement method. The value steam mapping and air gauge inspection method tools is used to found the reason for losses during machining and various other methods are to be adopted to eliminate the losses and to increases the productivity improvement by hydraulic clamp, combine process 2 & 3