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JCB INDIA LTD

Robin Singh Bhinder 40707028 INE-MBA 3rd Year

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

Elementary Process Sheet - EPS


I was involved with the formulation of the Elementary Process Sheet (EPS) of P-106. It states the smallest possible amount of work done during the process It deals with part numbers, quantities of the parts, TAKT times, method of operation and the process of production being followed. It lays down the basic procedure of production. It also gives details about the tooling required for the process. Used only for reference at managerial level The details of EPS are very helpful for formulation of Standard Operation Process , Work Combination Charts and in time studies. It is also very useful in dividing the work content between the workers at a stage

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.

Fixture Design, Testing & Installation


The P106 is a compact machine as compared to the normal 3DX machine . Therefore all the dimensions are different. Thus all the fixtures, tackles and trolleys to be used on M Line, Assembly Line and paint shop were to be designed. In all a total of 6 Tackles, 3 Sub Assembly Trolleys and 5 component Trolleys and 4 Fixtures were designed I was involved in the designing and testing process of all the fixtures, tackles and trolleys. This was done with the help of drawings of different components. The software used was AUTO CAD 2010.

BOOM DIPPER SUB ASSEMBLY FIXTURE

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 Management System


I was involved in the process of improving the health of the workers. The basic aim of this system was to reduce the complaints regarding high fatigue levels For this movement of every worker was captured along with the amount of weight and the amount of bending he has to do using a Health Card and Movement Chart Stage wise concerns were then developed and actions taken through Problem Counter Measure approach

Health Card
Sr. No. 1 Description Maximum Lifting of Weight Permissible 8 Kg. Actual

Body Posture while working


Walking

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

Assembly Line - Movement Chart (Feb'10)

Stages/Operator

Health Card Summary A Line


700

600

500

400

Score

January February March

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

ANDON Work Station

King Post Coupling (KPC)


Since the demand of JCB 3DX model has been increasing continuously, therefore to meet the demand a new KPC assembly area is required. The new assembly area is designed while keeping in mind that the amount of manual lifting required is minimum and that the problems faced in the current system are not present Special care has also been given to the fact that the worker does not have to bend in order to reach the tools, parts The new system is designed to be safer and is easy to maintain

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

Kaizens & Improvements


Improvement is a continuous process in JCB I was involved in various kaizens implemented in the company Some of the Kaizens implemented are-

1. Installation of new axial fans on the shop floor


AdvantageBetter air circulation and flow on the shop floor. Eliminates the problem of low air pressure in the ducts

Axial Fan

2. Developed new light weight tackle to lift king post


AdvantageReduces operators fatigue level while lifting the king post

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