Cold Extrusion 1

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MANJUMANJU

DOGRADOGRA

Reg.No-Reg.No-7080854570808545

Productivity Enhancement onProductivity Enhancement on

the Cold Extrusion Pressthe Cold Extrusion Press


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BRIEF HISTORY OF

THE PROJECTToday, industries are reducing their cost in each area due to

more compitionWe have decided to reduce Set up time on extrusion line because,

we are manufacturing heavy items like Rear axle shaft etc.in whichset up time is important thing

We have already made different quality circle teams in differentdepartments from initial process to final process so we areimproving each area to reduce cost, improve productivity, improve

safety etc.

Here we have taken project To bring down the the Set Up timefrom current average 176 mins to 90 mins.

To eliminate the Straightening Process after ColdExtrusion.


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PROMOD KUMARPROMOD KUMARExtrusion Shop

Project in progressProject in progress

In picturesIn pictures

PROJECT TEAMPROJECT TEAM

TeamTeam

MembersMembers

Manju DograManju DograTeam leaderTeam leader

HARJEET SINGHHARJEET SINGHExtrusion Shop

RAJINDER KUMARRAJINDER KUMARExtrusion Shop


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Project Start : April 2011

Working Area : Extrusion Shop


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5

ProblemStatement

Low Productivityon the Extrusion

Press 350T

BusinessCase

Company ishaving Two

Extrusion Pressesof 350T & 250 T.The Capital Costof the machine isvery high. Thereis strong demand

for the extrudedaxle shafts. If wecan increase theproductivity by10% we cancreate additional

capacity of 20,000axle shafts pa.

GoalStatement

To bring down thethe Set Up time

from currentaverage 176 minsto 90 mins.

To eliminate theStraightening

Process after ColdExtrusion.


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Month Apr - May11

Jun Jul 11 Aug-11

Sl.No.

Activities W1-2

W3-4

W1-2

W3-4

W1-2

W3-4

W1-2

W3-4

W1-2

W3-4

W1-2

W3-4

1 Identifying the Work RelatedProblem PLAN

2 Selection of Problem

3 Define Problem

4 Analysis of Problem DO

5 Identification of Causes

6 Finding out the Root Causes

7 Data Analysis

8 Developing Solution

9 Foreseeing possible resistance CHECK

10 Trial implementation &

MilestonMileston

eses


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ProcessProcess

MappingMapping


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METHODOLOGY FOR PROBLEM SOLVING

Identification of different problems by team members & discussion of problems inIdentification of different problems by team members & discussion of problems in

meetingmeeting

Selection of problem which have more rejection , more wastage & more costSelection of problem which have more rejection , more wastage & more cost

effectiveeffective Identification of concerned members to solve the problem & other departments helpIdentification of concerned members to solve the problem & other departments help

requirement.requirement. Brainstorming by different members to identify the root causes & identification ofBrainstorming by different members to identify the root causes & identification of

suitable root causes of the problems & analysis using different Q.C. Toolssuitable root causes of the problems & analysis using different Q.C. Tools Action plan on the root causes identified as per the target dates decided by teamAction plan on the root causes identified as per the target dates decided by team

MembersMembers Implementation of action plan as per the decided target datesImplementation of action plan as per the decided target dates After implementation, identification of status before & after onAfter implementation, identification of status before & after on

specified formatspecified format

Review & Follow up of action plan implementedReview & Follow up of action plan implemented


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9

Problem FocusProblem Focus


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MAN MATERIAL METHOD

MEASUREMENT MACHINE TOOLING

HIGH SET UPTIME

LONG CYCLETIME

CUMBERSOMETOOLING

IMPROPROPERTOOLING

INADEQUATESURFACE TREATMENT

ABSENTISM

UNSKILLED MANPOWER

NONCALIBERATEDINSTRUMENTS

NON CALIBERATEDGAGES

MACHINEBREAKDOWN

INADEQUATEPROCESSQUALIFICATION

LOWPRODUCTIVIT

Y

HIGH RUN OUT ONOUTPUT AXLE

SHAFTS

Ishikawa Cause & EffectIshikawa Cause & Effect

AnalysisAnalysis


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Root CauseRoot Cause

Analysis-NGTAnalysis-NGT


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Set Up SymptomsSet Up Symptoms


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Set Up Process-AsSet Up Process-As

IsIs


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Month Total

Available Time

Run

Time

Product

ion

Set

UpTime

Down

Time

Waiting

Time (ifany)

Number of

Changeovers

Hrs Hrs Numbers

Hrs Hrs Hrs No's

Jan-11600

46419,500 81 10 45 25

Feb-11600

49121,263 76

231 24

Mar-11600

47520,536 79

739 25

Apr-11600

47321,277 62 26 39 25

May-11600

49021,210 67

636 26

TOTALS 3,000 2,393 103,786 366 51 190 125

Set Up TimeSet Up Time

CalculationCalculation


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Set Up TimeSet Up Time

CalculationCalculation


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ActionsActions

ImplementedImplemented

1. Fixed Plate installed instead ofmovable to control the distortions.

2. This plate accommodate allmodels.

3. This reduced the Set Up time.

1. The thickness of the Die ClampingPlate reduced

1. The thickness of the OCD ringincreased

BEFORE AFTER


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Run Out on

Extruded AxleShafts foundvarying from 4~5mm against therequired 1~1.5mm

StraighteningStraightening

High Run Out is onaccount axle shaftbeing dragged byram non-uniformlyafter coldextrusion.

Average Production permonth

20,757

Cost of Straightening2.00

Rs

Total Monthly Cost41,514.40

Rs

Yearly Saving Rs Lacs


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Distortion on pieceson account of piecesgetting dragged by

Top and Bottommovable Plates. Thisdemands for theStraighteningoperation after ColdExtrusion

Distortion AnalysisDistortion Analysis

BEFORE AFTER

Fixed Plate placedthat does not allowany transversemovement of axleshaft during thebackward

movement of RAM.


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BeforeBefore AfterAfter


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S.No.

Set Up Activities Time inMins

Proposed Actions Time in Mins

1 UNSCREWING OFMOVABLE PLATES (2 INNO.)

10.00

UNSCREWING OF OCDRINGS

15.00

2 UNSCREWING OFRESTING BLOCKS(4 INNO.)

36.00

UNCREWING OF DIECLAMPING PLATES

10.00

3 UNSCREWING OF OCDRINGS

10.00

UNLOADING OFSPACERS/DIES

20.00

4 UNCREWING OF DIECLAMPING PLATES

12.00

LOADING OF NEWDIES/SPACERS

20.00

5 UNLOADING OFSPACERS/DIES

20.00

6 LOADING OF NEWDIES/SPACERS

20.00

SCREWING OF DIECLAMPING PLATES

10.00

7 SCREWING OF DIE

CLAMPING PLATES

10.00

SCREWING OF OCD

RINGS

15.00

-8 SCREWING OF OCD RINGS10.00

9 SCREWING OF RESTINGBLOCKS(4 IN NO.)

40.00

10 SCREWING OF MOVABLEPLATES (2 IN NO.)

10.00

-

176 90

Set Up Time-Set Up Time-

Before/ AfterBefore/ After


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GainsGains

1 SET UP TIME REDUCED FROM AVG 176 mins TO 90 mins

2 REDUCING SET UP TIME ON AN AVERAGE CREATED CAPACITY OFADDITIONAL 20,000 AXLE SHAFTS PER YEAR.

3 ELIMINATION OF THE STRAIGHTENING PROCESS THAT LEADS TOANNUAL SAVING OF AROUND Rs. 5 LACS PER ANNUM

4 LEAD TIME FOR THE TOTAL PROCESS REDUCED

5 COST OF THE SET UP REDUCED ON ACCOUNT OF LESSCONSUMTION OF TOOLINGS

6 SIMLIFICATION OF THE SET UP PROCESS LEADS TO HIGH

MORALE OF OPERATORS.

7 THE RESULTS CAN BE IMPLEMENTED ON 250 T PRESS ALSO-HORIZONTAL DEPLOYMENT


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S. No. Equipment Cost-Rs

1 Material cost of newPlates

8000.00

2 Fabrication of Plates 4050.00

3 Cost of Ring Plates-new 2000.00

Total 14,050.00

Cost of ProjectCost of Project

NEWPLATE

RINGPLATE


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Month TotalAvailable

Time

RunTime

Production

Set UpTime

DownTime

WaitingTime (if

any)

Numberof

Changeovers

Set UpTime/Changeover

Production/hr

Hrs Hrs Numbers Hrs Hrs Hrs No's mins No's

Jan-11600 464 19,500

8110 45 25 195 42

Feb-11600 491 21,263

762 31 24 189 43

Mar-11600 475 20,536

797 39 25 190 43

Apr-11600 473 21,277

6226 39 25 149 45

May-11600 490 21,210

676 36 26 156 43

TOTALS3,000 2,393 103,786

36651 190 125 176 43

Month Total

AvailableTime

Run

Time

Producti

on

Set Up

Time

Down

Time

Waiting

Time (ifany)

Number

ofChangeov

ers

Set Up

Time/Changeover

Produc

tion/hr

Hrs Hrs Numbers Hrs Hrs Hrs No's mins No's

JUL-11 600 524 32,55

8

429 25 26 97 62

Impact of theImpact of the

ActionsActions


24/24THANKSTHANKS

Cold Extrusion 1

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