Projects Undertaken
Project 106 (A new backhoe loader designed in India for India) Introduction of Health Cards/ Health Management System in JCB Introduction and Implementation of ANDON System based on supervisory control and data acquisition (SCADA) Designing and commissioning of a new King Post Carriage assembly line Kaizens/ Improvements
Project 106
Preparation of Elementary Process Sequence sheets for every part of the machine Preparation of Standard Operation Procedures for every part of the machine Fixture/ tackle design, testing and installation Tool identification and commissioning of the same
Standard Operation process I formulated the Standard Operation Process (SOP) for P-106 Standard Operation Process gives the exact step by step procedure to be followed by the workers during a procedure/process It is formed by analyzing the drawings of various assemblies It gives all the details like part names, numbers, their quantity It also gives various key points to be followed during the process like use of proper safety equipments, proper handling and quality issues. It gives the critical torque values to be used in the process (if any) It reduces the time required for a new worker to get accustomed to his work. The visitors can use this sheet to understand the process without any enquiry An example of SOP is shown in the next slide.
Tooling Analysis
I analyzed the EPS and SOPs made previously to find out the types and quantity of tools required. Ergonomic and safety points were also considered during selection of tools so that human effort is minimized State of the art DC tools and Oil Pulse tools were procured where the torque values were critical like Rear Axle to Mainframe mounting, Yoke Plate mounting, Cab Fitment and Tyre mounting. In case of bulky tools gravity balancers were employed to reduce the amount of force required to carry/ lift the tool
Health Card
Sr. No. 1 Description Maximum Lifting of Weight Permissible 8 Kg. Actual
Sitting
Bending Stretching 3 4 5 Working Temp. Drinking Water Access Point Kaizen Cell Point
Nil
< 60 Deg 32-35 Deg. C 25 Mtr 25 Mtr
Movement Chart
Distance (mm)
10000
12000
14000
16000
18000
2000
4000
6000
8000
Z1 O p1 p1 p2 p2 p4 p2 p2 p2 p2 Z3 O Z4 O Z5 O Z5 O Z6 O Z7 O Z8 O Z9 O Z1 1O p1 p3 Z1 2O Z1 3O Z1 4O Z1 4O Z1 5O z1 6& 17 p1 p1 p1 p3 p1 Op 1 Z1 9& Z1 8O p1 20 O p2 Z1 1O
Stages/Operator
600
500
400
Score
300
200
100
0 1 2 3 4 5 6 7 8 9 10 11 Stages 12 13 14 15 16 17 18 19 20 21
The health cards were then analyzed and the stages with high values were tackled first For example-
ANDON System
I was involved in implementing and installing the new ANDON system which unlike the previous system is based on Supervisory Control and Data Acquisition (SCADA) That is anyone at any place in the plant can find out about the production status instantly using his workstation or by looking at the display board Thus any kind of problem is notified instantly thereby decreasing the time required to rectify the problem
To make the system easier to maintain, the cranes are only eight feet above ground level The whole conveyor set up is on ground level. Thus the breakdown time is considerably reduced The new system is more spacious, thus there is more room for the worker to maneuver in and the various tools to be used can be placed within the reach of the worker
KPC Layout
Axial Fan