The Effective Usage Of Lean Manufacturing Techniques And Strategies In The Improvement And Usage Of Crankshaft Producing System At The Case Industrial Plant Essay

This is an analysis clarifying about the effective usage of lean manufacturing techniques and strategies in the improvement and usage of crankshaft producing system at the case industrial plant. Crankshaft fabricating is a basic procedure and it includes 13 activities beginning from confronting and focusing, where the datum is made to complete the process of grinding of journal diameter and pin diameter, washing and oiling. The vision of the organization was to expand the export deals by 30 %. After analyzing current value stream mapping, we can see that several processes are taking more time than they are supposed to. The crank shaft was manufactured and assembled in three different locations which are Turning cell, Oil hole drilling cell and Grinding cell. All turning machines were placed in zigzag position and because of that material flow is zigzag which take more process time plus more movement. The workload was not distributed to those three cells. There was a stock of 10 numbers in the middle of the machines and 1000 numbers was put away toward the finish of the cell. There were 2 administrators in the turning cell. The turned crankshaft was moved in batches of 1000 numbers to oil hole drilling cell put at a separation of 10 meters away. Turning machine cell and Grinding machine cell had 2-2 Operators while Oil drilling machine is operated by only one operator with the same amount of inventory and storage. Moreover, the distance between Grinding cell and Oil drilling machine cell is 25 meter which cause lack of communication between operators. there was a stock of 1000 numbers kept up between the cells. The dismissal rate was high and there was no correspondence between the turning, oil drilling machine and grinding machine operators to adjust the deformities. These all reasons cause following wastes in present crank shaft manufacturing system.

  1. High additional Process time
  2. Improper material flow
  3. Excessive Inventory
  4. Additional Workers
  5. High dismissal rate
  6. High Cycle time.

Crankshaft for the local market is being manufactured in batch production mode beginning with the facing and turning task to journal rough turning and pin rough operation in turning cell and the turned crankshafts are then moved to oil hole drilling activity lastly the bored crankshafts are then moved to the oil hole grinding cell for oil hole drilling task lastly the penetrated crankshafts are moved in batches to the grinding cell for finish journal grinding and pin grinding tasks. Mapping begins from the client requirements. The client requirement is 12000 numbers for every month. The takt time for the demand of 12000 numbers is 126 seconds also, the day by day prerequisite is 545 numbers for each day. Once the client informs the 3 months firm calendar prerequisites through mail, the marketing department informs the production department to plan for the next month’s production. The production division advises the forging provider to get ready for the raw material and sends the schedule for the supply of forgings. The production office additionally advises the value stream responsible for the crankshaft line to anticipate the assets including labor and consumables. The forgings from the provider touch base at the approaching assessment region and after the example for inspection the crankshaft forgings are then moved to the turning cell.

The recognized research work was taken for arrangement of future state value stream map from the current state value stream map, instruments and methods of Lean Production System were utilized to build up the single piece stream in the line, by actualizing kaizen.

Analytic hierarchical process was taken as a guide for advocating the choice taken in the Kaizen change and eventually the required goals were acquired. A few kaizens were actualized for implemented for reducing cycle time, number of workers, inventory and scrap. Earlier Crankshaft for the local market is being manufactured in batch production mode beginning with the facing and turning task to journal rough turning and pin rough operation in turning cell and the turned crankshafts are then moved to oil hole drilling activity lastly the bored crankshafts are then moved to the oil hole grinding cell for oil hole drilling task lastly the penetrated crankshafts are moved in batches to the grinding cell for finish journal grinding and pin grinding tasks.

Mapping begins from the client requirements. The client requirement is 12000 numbers for every month. The takt time for the demand of 12000 numbers is 126 seconds also, the day by day prerequisite is 545 numbers for each day. Once the client informs the 3 months firm calendar prerequisites through mail, the marketing department informs the production department to plan for the next month’s production. The production division advises the forging provider to get ready for the raw material and sends the schedule for the supply of forgings. The production office additionally advises the value stream responsible for the crankshaft line to anticipate the assets including labor and consumables. The forgings from the provider touch base at the approaching assessment region and after the example or inspection the crankshaft forgings are then moved to the turning cell.

In the export crankshaft producing cell, the procedure begins from crankshaft forging receipt at the approaching stores and it is moved in a trolley containing 98 numbers to the facing and centering machine. The datum is made at both the finishes of the crankshaft in facing and centering machine and single piece flow exchange to the grooved end journal turning machine, thread end journal turning machine, grooved end pin turning machine, threaded end pin turning machine, oil hole drilling machine, dia. 5mm hole drilling machine, deburring, grooved end journal finish grinding machine, thread end journal finish grinding machine, grooved end pin grinding machine, thread end pin grinding machine, deburring, washing and oiling station with a single piece in between the machines. Only 3 operators are utilized when contrasted with 5 operators when the crankshaft machining was done in batch mode. The material travelling distance decreased from 98 meters to 50 meters.

After using some tools of lean manufacturing like Value stream mapping and KIZEN they have eliminated or reduced 8 non-valued wastes like over production, waiting, unnecessary transport movement, defects and unused employee creativity from manufacturing system. They introduced KIZEN to eliminate several unnecessary processes and they combined some manufacturing processes to reduce cycle time. For example, in facing and centering machine, the milling head and drilling head are utilized, and this would result in more cycle time like 135 seconds. But by building special tool with cartridges fitted with embeds mounted on the tool-face and a center drill mounted on the tool center, the plunge facing, and centering operation was completed on both sides of the journal. They have actualized the altered procedure by improving the procedure parameters and actualized the adjusted procedure by tooling change and present CNC machine. They have taken several steps to improve process.

  1. Line balancing
  2. Eliminating face milling
  3. Single Piece flow introduction
  4. Replacing with pin turning machining
  5. Cell manufacturing
  6. TPM introduction
  7. Push to pull and frequent lot transfer
  8. Poka yoke introduction
  9. Introduction of standardize work
  10. Introduction of hydraulic clamping
  11. Combine Operation.

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