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    ਸਰਦਾਰ Supreet Singh
    This industrial training report summarizes two projects undertaken by Sandeep Kumar to improve efficiency. Project 1 studied excessive non-value-adding work in an axle assembly station. Project 2 studied an engine testing facility. The report describes current assembly line processes, types of waste, layouts of rear and front axle assembly stations, parameters for engine testing, common causes for engine rejection, and solutions to identify and address issues like incorrect bolt usage during testing.

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    ਸਰਦਾਰ Supreet Singh
    67 views23 pages
    This industrial training report summarizes two projects undertaken by Sandeep Kumar to improve efficiency. Project 1 studied excessive non-value-adding work in an axle assembly station. Project 2 studied an engine testing facility. The report describes current assembly line processes, types of waste, layouts of rear and front axle assembly stations, parameters for engine testing, common causes for engine rejection, and solutions to identify and address issues like incorrect bolt usage during testing.

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    This industrial training report summarizes two projects undertaken by Sandeep Kumar to improve efficiency. Project 1 studied excessive non-value-adding work in an axle assembly station. Project 2 studied an engine testing facility. The report describes current assembly line processes, types of waste, layouts of rear and front axle assembly stations, parameters for engine testing, common causes for engine rejection, and solutions to identify and address issues like incorrect bolt usage during testing.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    67 views23 pages

    SML

    Uploaded by

    ਸਰਦਾਰ Supreet Singh
    This industrial training report summarizes two projects undertaken by Sandeep Kumar to improve efficiency. Project 1 studied excessive non-value-adding work in an axle assembly station. Project 2 studied an engine testing facility. The report describes current assembly line processes, types of waste, layouts of rear and front axle assembly stations, parameters for engine testing, common causes for engine rejection, and solutions to identify and address issues like incorrect bolt usage during testing.

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    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 23

    INDUSTRIAL TRAINING

    REPORT

    SUBMITTED
    BY:SANDEEP
    KUMAR
    HARMEET

    PROJECTS UNDERTAKEN
    PROJECT-1:
    STUDY OF EXCESSIVE NON VALUE ADDING
    WORK DONE BY WORKERS IN AXLE ASSEMBLY
    STATION.
    PROJECT-2:
    STUDY OF ENGINE TESTING FACILITY

    ANUAL ASSEMBLY LINES

    A production line that consists of a sequence of


    workstations where assembly tasks are
    performed by human workers.
    Products are assembled as they move along the
    line.
    At each station a portion of the total work
    content is performed on
    each unit.

    Work Transport Systems-Manual


    Methods:
    Manual methods:
    Work units are moved between stations by the
    workers (by hand) without powered conveyor.
    Problems:
    Starving of stations:
    The assembly operator has completed the assigned
    task on the current work unit, but the next unit has
    not yet arrived at the station
    Blocking of stations
    The operator has completed the assigned task on the
    current work unit but cannot pass the unit to the
    downstream station because that worker is not yet

    ASSEMBLY LINE

    REAR AXLE

    FRONT AXLE

    YPES OF WASTES:
    Following are some of the non-value-adding
    processes during assembly:
    1)Transportation
    2)Inventory
    3)Motion
    4)Waiting
    5)Over-processing
    6)Over-production
    7)Defects
    *WASTES= Activities that dont add any value
    to the final product

    XLE ASSEMBLY STATION:


    The present axle assembly stations layout brought
    many inefficiencies in the production process like :
    LESS FLEXIBILITY
    NON VALUE ADDING WORK
    HIGH PRODUCTION TIME
    NOT PROPER CAPACITY UTILISATION
    Our study was aimed at reducing these
    inefficiencies by making suitable improvements in
    the present layout of workstation.

    PRESENT LAYOUT

    Rear Axle

    SUGGESTED LAYOUT

    BENEFITS OF NEW LAYOUT


    FLEXIBILITY .
    REDUCTION IN NON VALUE ADDING WORK.
    REDUTION IN TIME.
    CAPACITY UTILISATION.

    ENGINE TESTING SETUP

    ENGINE TESTING
    PARAMETERS
    WATER INLET AND OUTLET TEMPRATURE.
    AIR INLET AND EXHAUST.
    INTERCOOLER INLET AND OUTLET

    TEMPRATURE AND PRESSURE.


    LUBRICATING OIL TEMPRATURE AND
    PRESSURE.
    RPM

    RESULTS
    S NO

    Parameters of engine testing

    Output
    1

    Output
    2

    Output
    3

    RPM

    1218

    2000

    2792

    Water outlet temp

    29C

    30C

    30C

    Exhaust temp

    50C

    55C

    62C

    Engine air inlet temp

    45C

    46C

    46C

    Air temp(before intercooler)

    62C

    89C

    136C

    Air temp(after intercooler)

    40C

    40C

    40C

    Intake water temp

    40C

    42C

    45C

    Lubricant oil temp

    113C

    124C

    138C

    Lubricant oil pressure

    1 bar

    1bar

    1bar

    10

    Boost pressure(before intercooler)

    0.084

    0.305

    0.666

    11

    Boost pressure(after intercooler)

    0.067

    0.261

    0.561

    12

    Engine air intake pressure

    -29kg/cm

    -50 kg/cm

    -75 kg/cm

    13

    Intercooler temp

    46.2C

    46.9C

    49.6C

    14

    Idle oil pessure

    1.7 kg/cm

    4.5 kg/cm

    4.9 kg/cm

    CAUSES OF ENGINE REJECTION

    1)Noise from the turbocharger


    2) Engine fails to start
    3) Noise from the bearings of engine
    4) Leakage from oil filter
    5) Engine head noise
    6) Water leakage from engine
    7) Less power output than required
    8) Leakage from cylinder head

    ANALYSIS: FITMENT
    Problem

    Why?

    Why?

    Turbocharger
    making noise
    during the
    testing stage

    Wrong bolts
    used during
    engine testing
    for fitment of
    turbocharger
    duct to the inlet
    of turbocharger.

    Mix-up of bolts
    at engine testing
    for fitment of
    turbocharger
    duct to
    turbocharger.

    ROOT CAUSE IDENTIFIED:


    Wrong fitment of bolts during assembly of duct
    to turbocharger.
    Wrong bolts were used because two different
    kinds of bolts used for testing setup didnt have
    any identification marks.
    The different bolts were not segregated in
    different boxes.

    SUGGESTED SOLUTIONS:
    Use same standardized bolts
    Use standardized tool
    Use color code for bolts
    Put the different bolts in different boxes
    Inspection of all testing arrangements

    IMPACT OF SOLUTIONS:
    Time impact: Less wastage on the rework of
    defected engines.
    Customer satisfaction impact: Higher production
    rates and in-time delivery of the finished product.
    Cost impact: Cost of poor quality would be
    reduced as less amount of rework would be
    needed.

    THANK YOU

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