Ford India - Time and Motion Study Project - Final Report
Ford India - Time and Motion Study Project - Final Report
Ford India - Time and Motion Study Project - Final Report
Submitted by
R.GURU PRASAD (90105114012)
PRADEEP GOPAKUMAR (90105114031)
S.RAGHAVENDAR (90105114034)
AC.SANTHOSH (90105114042)
IN
MECHANICAL ENGINEERING
APRIL 2009
BONAFIDE CERTIFICATE
SIGNATURE SIGNATURE
DATE: PLACE:
ii
ABSTRACT
iii
ACKNOWLEDGEMENT
And we thank all the line engineers, zone leaders and operators of TCF who
helped directly or indirectly a lot in the progress of the project.
iv
CHAPTER TITLE PAGE NO
ABSTRACT iii
ACKNOWLEDGEMENTS iv
TABLE OF CONTENTS v
LIST OF TABLES viii
LIST OF FIGURES ix
LIST OF ABBREVIATIONS x
LIST OF TABLES
LIST OF FIGURES
ix
LIST OF ABBREVATIONS
x
1
1. INTRODUCTION AND OBJECTIVES
1. Productivity
2. Quality
3. Cost
4. Delivery
5. Safety
6. Morale
3. Movement reduction.
6. Symmetric assembly
acclaimed Ford Mondeo in India in the year end 2001. Mondeo is imported
from Belgium plant as a complete built unit and sold in India. Ford India also
launched Ford Endeavour, Ford Fusion, and Ford Fiesta.
FORD IKON
o 1.3 SOHC-Flair
FORD FIESTA
o 1.4 Duratec-Petrol-EXI
o 1.4 Duratec-Petrol-ZXI
o Duratec- Petrol-SXI
FORD FUSION
FORD ENDEAVOUR
o 4x4
o 4x2
5
1.3 TCF:
The assembly shop process in Ford India is broadly classified into 3 areas.
1. Trim.
2. Chassis.
3. Final.
Shop is divided in to 9 teams .Each individual team has their own objectives in
the form of SQDCME format.
The assembly shop process starts from pre trim. Assembly shop gets painted car
bodies from paint shop. Here the initial process starts. Paint inspection is done
here. Major process here is triggering the cars. Then the car body will be stored
in the banks. There are 3 banks which contains 33 cars.
From here, by sequence cars will go to trim 1 line for trim process. Major
processes involved are: VIN punching, door wiring, Loom routing, Roof liner,
Steering column, Side trims, seats, windshield and backlit fitment. Then the car
goes to the trim 2 by transfer car. Here major processes are electrical test and
trim buyoffs.
Then the car moves to clamp shell for under body operations. Major functions
are axle fitment, bumper fitments, brake pipes, disc, engine mounting, and
wheel and tyre assembly.
Then car body will come down to running conveyor for final line operations.
Door setting, Coolant, PAS oil, AC, Brake fluid filling will be done here. Then
the finished car will be inspected for appearance, functionally. This area is
called FAI (final acceptance area) which is one of the Ford’s internal indicators.
Then the car will undergo several processes like wheel alignment, head lamp
aiming, rolls and brake, squeak and rattle, lock to lock test, water test. Here the
assembly process finishes and quality inspection followed by CAL review
(CAL-customer acceptance line) starts. In CAL, engineers will be checking only
the customer issues which were driven from pre delivery inspection.
BLANKING
STAMPING
BODYSHOP
PAINTSHOP
TCF
QUALITY
MP& L
Fig 1
7
1.3.1 TCF LAYOUT
Fig 2
8
Fig 3
1.3.2 STATION:
A station is a pre defined working area for an operator on the
assembly line. Its length is about 5.5 metre. A station has been divided in to LH
side and RH side. Each zone is divided into 10-15 stations approximately. The
beginning of every station is marked by a yellow line, a blue and yellow line
represents 70% of the station length and at the end it is marked by a yellow line
which also indicates the beginning of the succeeding station.
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1.3.3 AREA OF STUDY:
We did time and motion study from zone 1 to zone 4 for
identifying non productive areas and thereby improving the productivity of
these zones.
Major processes done in each zone are given below.
ZONE 1:
1. Parts flowing to zone 1 are entirely different from other zones. Here
parts are supplied by kitting method whereas in other zones parts are
supplied in.
2. Major process in Zone 1 is to stick various tapes, plugs to restrict noise
and to avoid water leakages & wire routing of main loom.
3. Apart from this, major parts that are being fixed into the car are
accumulator, brake booster, door latches, weather strips and floor carpet.
4. Pedal box is sub assembled and fitted to the car in this zone for all cars.
5. Various clips and fasteners are fixed to the cars to hold various parts in
the sub sequent zones.
6. To facilitate the instrument panel insertion door is removed using
manipulator.
1. Front and rear seat fitment is also being done using equipment.
2. This equipment is pneumatically operated.
3. PU is applied on to the wind shield with the help of robot. PU is an
adhesive which helps the wind shield and back lit to stick firmly to the
car body.
4. To maintain constant bead width and height PU application is
automated.
5. The robot is pre programmed. Hence it senses the type of wind shield
and applies the PU according to the variants.
6. After the PU application the wind shield and back lit are fitted manually.
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7. Trim board, arm rest, door bin, weather strip, water sheets, rear seat
cushion, etc are fitted in this zone.
ELECTRONIC CHECK OUT SYSTEM
Current level of all the electrical and electronic devices is checked.
8. Head lamps, interior lamps, power windows, indicators, horn, centre
lock, wiper, boot release are checked for its operation.
9. Front end module (FEM) is sub assembled separately and is fitted to the
car using handling aid.
10.Bolster, radiator, beam are some of the major parts which are used for
subassembly.
11.One of the most important processes in this zone is the transformation of
car from flat conveyor to over-head conveyor.
12.Ski bar which has been used for holding the car in the conveyor line is
removed and is sent back to the body shop again.
ZONE 4:
1. Rear and front bumper, muffler, Bundy bundle, H-bracket, hand brake
cable, heat shields, brake pipe, windshield wiper motor are fitted in this
zone.
2. Brake drum is fitted to the brake shoe assembly in the rear axle.
3. Assembled rear assembly is loaded onto the electro hydraulically
operated decking fixture using a handling aid.
4. After the rear axle is fitted to the car, the decking fixture is manually
brought back to the position and moved back to its original position.
5. Engine from the dressing is transferred to the synchronized decking
conveyor where some of the sub assemblies are done.
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6. Engine is fitted with front axle, drive shaft and strut assembly.
7. Transmission oil is also filled here.
8. Engine is fitted to the car with the help of semi automatic decking fixture.
9. Locators are available in the decking fixture to align the engine to the
car.
10.Once the engine-decking to the car is completed the fixture will
automatically goes around for the next cycle.
11.Wheel and tyre assembly is supplied to the line by Just In Time (JIT)
process based on the requirement.
12.Wheel is picked up with a handling aid and is fitted to the car.
13.Vehicle is transferred from the over head conveyor to flat running
conveyor.
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1.4 QLS:
The QLS data collection menu is used to access the screens used by
inspectors to collect data as they inspect units and record concerns by
repairment to recall the inspector’s data and record repair analysis into and by
drivers to view the inspector’s data to more units from location to location
Collection point:
It is available to inspectors only. The configuration of the collection
point screens depend upon your role as an inspector and the equipment located
on the line or in the zone in which the collection point is located.
Unit repair:
The unit repair screens are available to repairmen only. To begin the
repair process, click on the unit repair button. You are taken to the repair unit
identification screen.
Driver:
The driver screws are available to drivers only. To begin the process of
relocating units, click on the driver button. You are taken directly to the driver
unit identification screens.
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1.5 QPS:
QPS has a table denoting various work elements for a particular station,
work element times (what is to be done to complete the task), key point symbol,
key points (how to complete the work element) and recommended safety
procedures. At the bottom of QPS, calculated cycle time will be indicated.
Technicians, team leaders, safety and maintenance personnel for respective
shifts will affix their signatures at the bottom of the QPS.
1. The broad cast sheet has the VIN (Vehicle Identification number).
2. The broad cast sheet has the wiring codes as per the variant.
3. The broad cast sheet is printed with accessories like ABS as per the variant.
4. The broad cast sheet is printed with wheel specification of the variant.
The operator in every station has to identify the variant through the broad
cast sheet before starting the operations. After identification, the operator can
choose the tools and accessories involved as per the variant.
In station 4RH, the operator scans the bar code printed in the broad cast
sheet. The operator scans the first and top most bar code in the sheet. Scanning
is done with a bar code reader and it is being entered into the computer. A VIN
plate printing machine is connected with the computer. After scanning, the VIN
plate printing machine starts to print the VIN plate. Printed VIN plate is fitted in
the engine compartment area of the car.
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1.9 BLUE Q:
To detect the issues at POF itself, operator will check the concern.
Data will be collected and validated by the team leaders.
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2.PRODUCTIVITY IMPROVEMENT:
This is usually expressed in ratios of inputs to outputs. That is (input) cost per
(output) good / service. It is not on its own a measure of how efficient the
conversion process is.
Productivity is the ratio of output to some or all of the resources used to produce
the output.
Labour productivity=
Capital productivity=
Material productivity=
20
The successful management of this process is ultimately the key to
survival of any organization. It should be the concern and a development goal
for all organizational members, irrespective of their position.
There are six lines of attack to improve the productivity ratio of an organization,
namely:
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2.3 NEED FOR PRODUCTIVITY IMPROVEMENT:
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3. TOOLS USED:
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and fully trained in the specified method will need to perform the job if he or
she works at normal or standard tempo. This time is called the standard time for
the operation.
The equipments needed for time study work are listed below:
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Decimal stop watches:
The decimal-minute stop watch has the dial
divided into 100 equal spaces, each of which represents 0.01 minute, the hand
making one complete revolution per minute. A smaller dial on the watch is
divided into 30 spaces, each of which represents 1 minute, the hand making one
complete revolution in 30 minutes. The hands of the watch are controlled by the
slide and the winding stem. The starting and stopping of the stop watch are
controlled by the slide. It is possible to stop the hand at any point and then start
it again from that position. Pressure on the top of the stem returns the hand to
zero, but it starts off immediately upon releasing the stem. The hand may be
held at zero either by holding the stem down or by pushing the slide away from
the stem.
26
Observation board and observation sheet:
A lightweight board, slightly larger than the
observation sheet, is used to hold the paper and the stop watch. The analyst, in
most cases, must record the data while standing; it is desirable to have the watch
and paper arranged as conveniently as possible.
While taking a time study the observer should hold the board against
the body and the upper left arm in such a way that the watch can be operated by
the thumb and index finger of the left hand. The observer holds the board with
the left hand and arm, leaving the right hand free to record the data. By standing
in the proper position relative to the work being observed, and by holding the
board so that the dial of the watch falls in the line of vision, the observer can
concentrate more easily on the three things that demand attention, namely, the
operator, the watch, and the observation sheet.
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3.1.6.1 PURPOSES OF MICRO MOTION STUDY:
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3.1.7.1 DEFINITON:
3.1.7.3 CONSTRUCTION:
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FLOW PROCESS CHART MAN TYPE
SUBJECT: SUMMARY
chart begins: ACTIVITY PRESENT PROPOSED SAVING
OPERATION
chart ends: TRANSPORT
DELAY
INSPECTION
STORAGE
METHOD: TIME:
DESCRIPTION SYMBOL
DISTANCE TIME REMARKS
TOTAL
4. No one is overburdened
5. No one is waiting
Fig 6
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4. METHODOLOGY ADOPTED:
4.1. BASIC APPROACH FOR EACH PROBLEM:
The basic approach that we have followed in our
project is a systematic approach that involves the present operation to be:
1. Eliminated 3. Combined
2. Simplified 4. Reduced
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down. The average of the two readings was calculated which can be compared
with the standard time. Each day we studied and noted down time for 4 to 5
stations. For completing our time and motion study it took nearly 10 working
days. A sample work sheet is inserted along with the flow diagram for the
sample station. The following tables from table to table represent the complete
time and motion study.
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the relevant information regarding the proposed method is made on a flow
process chart so as to make a comparison with the original method. It is always
checked that no point have been overlooked. The possible saving can be
expected in terms of the money and the distances travelled by the men and the
materials during the various stages in proposed method. The analysis of the
existing work method can provide a starting point for the synthesis of suggested
improvement in job performance. The technique specially designed for
improving the work method is called the process improvement formula. The
four steps of the formula are.
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4.2.4 IMPLEMENT ACTIONS:
90
4.2.5 CHECK FOR RESULTS:
4.2.6 STANDARDIZATION:
95
The following measures may be taken to ensure that the best method developed
is implemented.
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5. REPORT SUMMARY:
IN ACTUAL 25 20 22 23 90
PROCESS
IN IMPROVED 22 19 19 19 79
PROCESS
1. 6LA
2. 9RH
3. 9LH
4. 12LA
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99
=Rs 2, 75,000(approximately)
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IMPLEMENTED ACTIONS:
1. In Zone 1 and Zone 2 the elimination of the following stations 6LA, 9L and 9R has
been implemented.
2. Automatic scanning of bar code has been implemented in 4R, 20R and 26R instead of
manual scanning.
3. In the actual process two fixtures were used for badge fixing, from our suggestion this
has been replaced by a single fixture.
4. In station 26R the bins and trolley have been relocated in order to reduce the non
value added moments.
5. A rail trolley which moves with the conveyor has been suggested and it is under
study.
6. Variable torque power tool has been implemented instead of single torque power tool.
.
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6. IMPROVEMENT SUGGESTIONS:
6.1. Electric power tool:
The electric power tool or nut runners operate on electric current.
It is portable. These nut runners have to be
charged depending upon their usage.
3. Torque Recovery.
6. Batch Counting.
Low noise.
Low energy consumption.
Reliability & durability.
Soft touch grip surfaces.
Connecting cable delivered with the tool.
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6.2 Electric Multi spindle nut
runner:
Fig 11
Time reduction:
Time can be drastically reduced because it can drive even
four nuts at a time.
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105
6.10 Automatic pick and place robots for rear axle assembly:
Fig 13
106
The above shown diagram is a vertical articulating robot which uses complex
pneumatic gripper for parts assembly. The robots are mainly used for rear axle
assembly.
These robots are used for payloads up to 300 kg and with
working areas up to 15m X 2m. These robots can be controlled by software. The
software includes many special built in functions for work piece handling,
including functions to optimize robot movement according to payload -
minimizing cycle time and robot wear and tear.
Presently the operators are facing the problem of more time consumption in the
assembly of rear axle. By using the rear axle fixing robot, time consumed for
rear axle assembly would be drastically reduced. Moreover burden of work can
be reduced.
6.11 Automatic pick and place robot for underbody and engine fixture:
Fig 14
The above shown robot is mainly used for engine fixing. It is also used for
fixing cross member, pillar, muffler and other underbody components.
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7. CONCLUSION:
Quicker
More effective
Reduced the floor space
Reduced time
Reduced cost
Reduced number of operators
Increase in number of cars manufactured
From our project, we have gained knowledge to some extent and thus it acts as a
learning tree for us.
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REFERENCES