Manpower Management at Axle Assembly Shop(TATA Motors)

SUMMER TRAINING PROJECTON

MANPOWER MANAGEMENT IN AXLE ASSEMBLY SHOP

Submitted To:Mr. Somesh

NathAXLE

ASSEMBLY

Submitted By:Mir Shahjahan

B.Tech(MAE): 3rd Year

Amity University, Lucknow

by MIR SHAHJAHANDECLARATION

I hereby declare that the project work entitled MANPOWER MANAGEMENT IN AXLE ASSEMBLY SHOP is an authentic record of my own work carried out at TATA MOTORS, LUCKNOW as requirements of six week summer training project, under the guidance of MR. SOMESH NATH(Divisional Manager, Axle Assembly) ,during 24TH MAY 2016 to 5TH JULY 2016.

Dated: 05.07.2016 Mir Shahjahan B.Tech(MAE)- 3rd Year


Certified that the above statement made by the student is correct to the best of our knowledge and belief.

Mr. Somesh NathDivisional ManagerAxle AssemblyTata Motors, Lucknow

by MIR SHAHJAHANAcknowledgement

Industrial training is a crucial period in engineering curriculum since it exposes a student to the real world which he or she is going to enter after the completion of the graduation. This is the period during which an engineer actually becomes an engineer by gaining the Industrial experience. I am very thankful to God who has given me the opportunity to get training in TATA MOTORS, LUCKNOW, one among the most renowned organizations of India. I would like to express my deep gratitude to my Project Head Mr. Somesh Nath (AXLE ASSEMBLY) for having provided me with the wonderful & conductive environment to work in and realize what really industry is. They have always been helpful and supportive. I would also like to thank Mr. Shashi Kant Shula, Mr. Subash Suman and Mr. Manish Sharma for helping me throughout my training. I will always remain indebted to them for their generous ways of dealing with Summer trainees.

Mir ShahjahanB.Tech (MAE)6th Semester


by MIR SHAHJAHANCompany Profile

Tata Motors Limited is India’s largest automobile company, with consolidated revenues of Rs.2.625 Trillion(USD 42 billion) in 2014-15. It is the leader in commercial vehicles in each segment, and among the top three in passenger vehicles with winning products in the compact, midsize car and utility vehicle segments. The company is the world's fourth largest truck manufacturer, and the world's third largest bus manufacturer.Tata Motors helps its employees realize their potential through innovative HR practices. The company's goal is to empower and provide employees with dynamic career paths in congruence with corporate objectives. All-round potential development and performance improvement is ensured by regular in-house and external training. The company has won several awards recognizing its training programs.Established in 1945, Tata Motors is India's largest and only fully integrated automobile company. Tata Motors began manufacturing commercial vehicles in 1954 with a 15-year collaboration agreement with Daimler Benz of Germany. Since 1969, the company's products have come out of its own design and development efforts.Today, Tata Motors is India's largest commercial vehicle manufacturer with a 59 per cent market share and ranks among the top six manufacturers of medium and heavy commercial vehicles in the areas of business Tata Motors' product range covers passenger cars, multi-utility vehicles as well as light, medium and heavy commercial vehicles for goods and passenger transport. Seven out of 10 medium and heavy commercial vehicles in India bear the most trusted TATA mark.

by MIR SHAHJAHAN

Manufacturing Unit

Head Quarters

by MIR SHAHJAHANCommercial Vehicle Business unit (CV Unit) :

The company has over 130 models of light, medium and heavy commercial vehicles ranging from two tones to 40 tones, buses ranging from 12-seaters to 60-seaters, tippers, special purpose vehicles, off-road vehicles and defense vehicles.

Passenger Car Unit :The Company’s passenger car range comprises the hatchback Indica, the Indigo sedan and the Marina, its station

wagon variant, in petrol and diesel versions. The Tata Sumo, its rural variant, the Spacio and the Tata Safari (the country's first sports utility vehicle) are the company's multi-utility offerings. The Tata Indica, India's first indigenously designed and manufactured car, was launched by Tata Motors in 1999 as part of its ongoing effort towards giving India transport solutions that were designed for Indian conditions. Currently, the company's passenger cars and multi-utility vehicles have a 16-per cent market share. . In addition to the growth opportunities in the buoyant domestic market, the company is pursuing growth through acquisitions (it acquired Daewoo Commercial Vehicles, Korea, in 2004) and alliances (it has entered into a tie-up with MG Rover, UK, to supply 1, 00,000 Indicas to be budged as City Rover) in other geographies. Research and Development :

Tata Motors invests up to 1.3 per cent of its annual turnover on research and development, with an emphasis on new product / aggregates development and technology up gradation. Its Engineering Research Center in Pune has India's only certified crash-test facility and hemi-anechoic chamber for testing of noise and vibration.

by MIR SHAHJAHANThe company also draws on the resources of leading international design and styling houses like the Institute of Development in Automotive Engineering, SPA, Italy and Stile Bertoni, Italy. The company has also been implementing several environmentally sensitive technologies in manufacturing processes and uses some of the world's most advanced equipment for emission checking and control.

Environmental responsibility :Tata Motors has led the Indian automobile industry's anti-pollution efforts through a series of

initiatives in effluent and emission control. The company introduced emission control engines in its vehicles in India before the norm was made statutory. All its products meet required emission standards in the relevant geographies. Modern effluent treatment facilities, soil and water conservation programmes and tree plantation drives on a large scale at its plant locations contribute to the protection of the environment

Exports : Tata Motors' vehicles are exported to over 70 countries in Europe, Africa, South America, Middle

East, Asia and Australia. The company also has assembly operations in Malaysia, Bangladesh, Kenya, South Africa and Egypt.

by MIR SHAHJAHANProducts

Passenger cars and utility vehicles

• Tata Sierra (Discontinued)• Tata Estate (Discontinued)• Tata Sumo/Spacio• Tata Sumo Grande• Tata Safari• Tata Indica• Tata Vista• Tata Indigo• Tata Manza• Tata Indigo Marina• Tata Winger• Tata Magic• Tata Nano• Tata Xenon XT• Tata Aria• Tata Venture• Tata Iris• Tata Tiago (recently launched)• Tata Zest (recently launched)

by MIR SHAHJAHAN Concept vehicles:• 2000 Aria Roadster

• 2001 Aria Coupe • 2002 Tata Indiva

• 2004 Tata Indigo Advent

• 2005 Tata Xover

• 2006 Tata Cliffrider

• 2007 Tata Elegante • 2009 Tata Prima

• 2010 Tata Versa

• 2010 Tata Essota

• 2011 Tata Pixel

• 2016 Tata Hexa

• 2016 Tata Kite

by MIR SHAHJAHANCommercial Vehicles

Commercial vehicles Tata Ace Tata TL/Telcoline/207 DI Pickup Truck Tata 407 Ex and Ex2 Tata 709 Ex Tata 809 Ex and Ex2 Tata 909 Ex and Ex2

Tata 1109 (Intermediate truck) Tata 1512 (Medium bus chassis) Tata 1612/1616 (Heavy bus chassis) Tata 1618 (Semi Low Floor bus chassis) Tata 1623 (Rear Engined Low Floor bus chassis) Tata 1613/1615 (Medium truck) Tata 2515/2516 (Medium truck)

by MIR SHAHJAHAN Tata Starbus (Branded Buses for city) Tata Divo (Fully built luxury coach) Tata CityRide (12 - 20 seater buses for intra-city use) Tata 3015 (Heavy truck) Tata 3118 (Heavy truck) (8×2) Tata 4018 (Heavy truck) Tata 4923 (Ultra-Heavy truck) (6×4) Tata Novus (Heavy truck designed by Tata Daewoo) Tata Prima (The World Truck designed by Tata Motors and Tata Daewoo) Military vehicles:: Tata 4018 (Heavy truck) Tata LSV (Light Specialist Vehicle) Tata Mine Protected Vehicle (4×4) Tata 2 Stretcher Ambulance Tata 407 Troop Carrier, available in hard top, soft top, 4×4, and 4×2 versions Tata LPTA 713 TC (4×4) Tata LPT 709 E Tata SD 1015 TC (4×4) Tata LPTA 1615 TC (4×4) Tata LPTA 1621 TC (6×6) Tata LPTA 1615 TC (4×2)

by MIR SHAHJAHANTata Motors Lucknow Plant

by MIR SHAHJAHANThe plant, rolls out commercial vehicles and is specialized in the designing and manufacturing of a range of modern buses which includes Low-floor, Ultra Low-floor, CNG & RE Buses.

The Lucknow facility also specializes in manufacturing HCBS (High capacity Bus System) buses.

In light of Company’s aggressive growth plans, they are currently in expansion phase and production at Lucknow would grow many-fold in near future. The expansion shall be in the areas of painting, welding, vehicle assembly & testing and utility services, driven by latest technology. To achieve these plans they invite people who have good Technical Knowledge, seek Challenging Opportunities and have a Drive for Engineering Excellence to come and partner us in our journey.

by MIR SHAHJAHANDepartments of TATA Motors Lucknow

Planning Technical services Central tool room Central procurement Dispatch Central logistics Factory logistics group-CV Factory logistics gear-transmission Factory logistics Gr-sumo SQIG Engineering services Central maintenance FPIG - CV factory FPIG-transmission factory Central quality (CQ) Area office, Lucknow Regional sales office (Lucknow) Service depts., Lucknow works Plant head office Manufacturing head office Human resources

Training Business excellence Finance Internal audit ERC Lucknow Administration Construction

by MIR SHAHJAHANAXLE ASSEMBLY SHOPAn Axle is a central shaft for a rotating wheel or gear. Axles are an integral component of most practical wheeled vehicles. In a live-axle suspension system, the axles serve to transmit driving torque to the wheel, as well as to maintain the position of the wheels relative to each other and to the vehicle body. The axles in this system must also bear the weight of the vehicle plus any cargo. A non-driving axle, such as the front beam axle in heavy duty trucks and some 2-wheel drive light trucks and vans, will have no shaft, and serves only as a suspension and steering component. Conversely, many front wheel drive cars have a solid rear beam axle

by MIR SHAHJAHANStations at Axle Assembly

Shop

There are primarily four

stations or assembly areas

in the Axle Shop:

• Dummy Hub Assembly • Front Hub Assembly• Dummy Axle Pre Assembly• Front Axle Pre Assembly• Dummy Axle Assembly• Front Axle Assembly• Axle Paint Shop

by MIR SHAHJAHANPLANT LAYOUT OF AXLE ASSEMBLY SHOP

axle maintenance area Material trolley Parking area

walk way

Front Hub Sub-

assembly

Front hub

washing machine

Dummy hub

washing m/c

Dummy Hub Sub-

assembly

FASTERNER

STORAGE AREA

line side material walkway grill

Axle Paint Booth

axleclearing zone

station 12

station 11

station 10

station 9

station 8

station 7

station 6

station 5

station 4

station 3

station 2 station 1 Hub trolley

parking area walkway grill

line side material

Material trolley Parking area

axle dryer area

axle loading

area

axle unloading

area

GANG WAY GANG WAY

Dispatch axle storage

gate

Axle booking

areagallery area Drum storage area

GATE

Kingpin assembly

area

Beam preparation

area

Dummy beam

storage area

Shim storage area

VQA Area

GATE

strong room

AXLE PRE ASSEMBLY AREA empty drum

storage area

Axle inspection area Drum storage area Anchor plate, Hub & Beam storage area

by MIR SHAHJAHANHub AssemblyA Wheel hub assembly (WHA), also referred to as hub assembly, wheel hub unit, wheel hub bearing, etc., is an automotive part used in most cars, passenger vehicles and light and heavy trucks.

It is located between the brake drums ordiscs and the drive axle.On the axle side, it is mounted to the holding bracket from the chassis;on the disc side, the wheel is mounted to the bolts of theWHA. When replacing, a wheel hub assembly should be torquedto the vehicle's specifications to prevent failure.

by MIR SHAHJAHANProcesses involved in Hub

Assembly

Hub Washing Bearing Pressing

Bearing Greasing

Oil Seal & Pole Wheel

PressingBolt InsertionBolt Pressing

Shim Selection Shim Insertion Hub Cap Greasing

*Pole Wheel Pressing is for Front Hub only

by MIR SHAHJAHANWashing & Drying• Two hubs at a time are washed in the Hub Washing Machine having

water at 70*C (approx.) mixed with other cleansing agents. The washing and drying machines are located in the same compartment so while two hubs are getting washed, the previous two hubs are getting dried

Bearing Pressing • After the hubs are washed and dried, they’re brought to station-1

where the bearing pressing machine compresses the two pre placed collars (one on top side and other on bottom) with a 20 Tonne force

by MIR SHAHJAHAN

Washing Bearing Pressing

by MIR SHAHJAHANBearing Greasing • The bearing greasing is done outside the assembly line so as to avoid

occurrence of hindrance for the next station. A worker puts two bearings – one small and one big, bearing in the greasing machine and then passes it to satation-2

Oil seal and Pole Wheel Pressing • After receiving the greased bearing from the previous station, the operator

places them on top and bottom side along with the pole wheel (for front hub only) and oil seal which is then pressed under a compressive force of 2 Tonnes

by MIR SHAHJAHAN

Bearing Greasing Oil Seal & Pole Wheel Pressing

by MIR SHAHJAHANBolt Insertion• A worker puts a circular frame on the circumference on

the top of the hub and inserts 10 bots in the provided holes

Bolt Pressing • After the bolts have been inserted in the provided space,

the next station machine presses these bolts under a compressive load of 80 Tonnes

by MIR SHAHJAHAN

Bolt Insertion Bolt Pressing

by MIR SHAHJAHANShim selection • After the bolts have been inserted and pressed, the next station

worker checks the hub play and accordingly marks the ideal shim for that hub

Shim insertion • Once the suitable shim size has been assigned to the hub, the next

station worker matches the shim arrangement and puts in the hub play

Hub Cap greasing • The last station involves greasing of the hub caps with a grease gun.

The prescribed amount of grease to be filled in the hub caps is 90 gm to 110gm

by MIR SHAHJAHAN

Shim Selection Shim Insertion Hub Cap Greasing

by MIR SHAHJAHANManpower Allocation in Hub Assembly (Front and Dummy)

PROCESS NO. OF PEOPLE ON THE JOBHub Washing 2Unloading of washed hubs and sending to STN #1 1 (often done by one of the member who is involved in hub washing)Bearing Pressing 1Bearing Greasing 1Oil Seal & Pole Wheel Pressing 1Bolt insertion 1Bolt Pressing 1Shim Selection 1Shin Insertion 1Hub Cap Greasing 1Unloading the ready hubs 1

by MIR SHAHJAHANAverage Time taken to complete one Hub (Front)

Washing Time taken to send the hub to Stn-1

Bearing Pressing

Bearing Greasing

Oil Seal & Pole Wheel Pressing

Bolt Insertion

Bolt Pressing

Shim Selection

Shim Insertion

Hub Cap Greasing

Unloading the ready hub

Trial-1 79.00 8.02 44.07 17.83 44.71 31.56 34.57 31.45 12.18 14.85 13.63

Trial-2 81.00 7.76 43.69 16.25 47.20 30.21 31.18 26.68 11.70 12.92 12.20

Trial-3 77.00 9.25 45.01 18.32 48.38 32.57 32.61 29.32 12.39 14.09 13.29

Trial-4 77.60 8.11 44.30 19.26 51.33 29.62 37.27 33.00 14.03 15.86 14.70

Trial-5 78.30 7.34 47.18 17.08 49.00 33.17 38.03 27.70 12.24 13.92 12.63

Mean 78.58 7.17 44.85 17.75 48.12 31.43 34.73 29.63 12.51 14.33 13.29

by MIR SHAHJAHANGraphical Representation

Washing

Time ta

ken to

send th

e hub to St

n-1

Bearing Pressi

ng

Bearing Greasin

g

Oil Seal &

Pole Wheel P

ressing

Bolt Inserti

on

Bolt Pressi

ng

Shim

Selecti

on

Shim

Inserti

on

Hub Cap Greasing

Unloading the re

ady hub

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00

by MIR SHAHJAHANFrom the data, the possible areas where time taken can be

reduced are :-

by MIR SHAHJAHANWashing

The machine time is approximately 59 seconds which cannot be altered. However, the manual work time which includes attaching the tackle to the hub, lifting it and then placing

it on the washing platform which is around 14.8 seconds can be reduced.

The operator often has trouble attaching & removing the tackle to the hub.

The polythene packaging on the delivered hubs often gets stuck on the outer edges of the hub.

Sometimes the operator is often seeing gossiping with other worker or calling over phone.

by MIR SHAHJAHANUnloading the washed Hubs –

After the hubs are washed and dried, they are send to the bearing pressing station. One worker has to push the hub to Station – 1 and the time taken is around 15.89 seconds.

Usually the operator on the washing area has to unload the hubs and send it to Station -1. (seen 4 out of 6 times)

If the same person has to wash as well as send the hubs forward, he has to pass beneath the roller platform connecting

drying area and Station – 1, this consumes time.

Often inventory of 8 to 10 hubs gets accumulated on the roller platform.

by MIR SHAHJAHANBearing pressing (temporary issue)

The washed hubs are send to station-1 for bearing pressing. The average time taken to complete this process comes out to be 44.85 seconds.

Out of 6 readings, 5 times it was observed that the bearing pressing machine was behaving erratically.

The worker reported that the machine was probably not able to generate the desired amount of load (20 Tonnes).

This caused overheating and automatic shut down off the machine.

The worker had to press the reset button every time the machine switched off.

by MIR SHAHJAHANBolt Insertion

From the recorded data, it can be clearly seen that the worker who inserts ten bolts in the hub is under loaded. It was also seen that this worker tends to create inventory for the next station.

Bolt insertion takes less than 30 seconds after which the worker is sitting ideal for next 12 seconds(approx.).

The worker inserting the bolts in the hub finishes his job earlier and is often seen working with his mobile phone.

We can configure the frame (using which the bolts are inserted in the hub) in a manner in which it can get loosely attached to the

ram of the bolt pressing machine.

In this case the work will be done by the same worker and will also save around 7 seconds.

by MIR SHAHJAHANShim Insertion

After the desired shim has been assigned to the hub, the next worker arranges the shim rings and inserts it in the hub. The time taken to insert the shim is 12.61 seconds which can be brought down

to 8 seconds (approx.)

Say the shim to be inserted is of 170 microns. The person who inserts the shim has to make this in pairs, like 100 + 50 + 10 + 10

The shim rings are already tested and approved for their printed dimensions.

Still the worker uses an analog Vernier calliper to cross check which is not required as out of 6 readings, the shim dimensions were matching with

their printed dimensions.

by MIR SHAHJAHANPossible output after removing the

constraints

Washing

Time ta

ken to

send th

e hub to St

n-1

Bearing Pressi

ng

Bearing Greasin

g

Oil Seal &

Pole Wheel P

ressing

Bolt Inserti

on

Bolt Pressi

ng

Shim

Selecti

on

Shim

Inserti

on

Hub Cap Greasing

Unloading the re

ady hub

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

by MIR SHAHJAHANComparison

Washing

Time ta

ken to

send th

e hub to St

n-1

Bearing Pressi

ng

Bearing Greasin

g

Oil Seal &

Pole Wheel P

ressing

Bolt Inserti

on

Bolt Pressi

ng

Shim

Selecti

on

Shim

Inserti

on

Hub Cap Greasing

Unloading the re

ady hub

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00

Current Time Optimized Time

by MIR SHAHJAHANAverage Time taken to complete one Hub (Dummy)All readings in seconds

WashingUnloading washed hubs

Sending to Stn#1

Bearing Pressing

Bearing Greasing

Oil Seal & Pole Wheel Pressing

Sending to Bolt Insertion

Bolt Insertion

Bolt Pressing

Shim Selection

Shim Insertion

Unloading ready hub

Trial-1 79.00 7.36 8.02 58.37 17.83 40.68 3.1 44.55 54.43 60.06 15.24 13.98

Trial-2 81.63 6.55 7.76 57.21 16.25 39.26 4.26 45.81 53 53.82 13.01 12.74

Trial-3 77.00 7.01 9.25 60.1 18.32 40.8 5.26 46.29 52.66 57.24 13.97 12.91

Trial-4 76.32 6.87 8.11 61.31 19.26 42.13 6.15 41.25 51.37 54.86 14.22 14.85

Trial-5 78.30 5.64 7.34 55.01 17.08 41.17 2.91 47.13 52.81 52.12 14.05 12.16

Mean 78.45 6.686 7.17 58.4 17.75 40.81 4.34 45.01 52.85 55.62 14.1 13.33


Washing

Unloading washed hubs

Sending to

Stn#1

Bearing Pressi

ng

Bearing Greasin

g

Oil Seal

Sending to

Bolt Inserti

on

Bolt Inserti

on

Bolt Pressi

ng

Shim

Selecti

on

Shim

Inserti

on

Unloading ready h

ub0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00


reduced are :-

by MIR SHAHJAHANSending the washed Hubs to Station #1 – From the data, the average time taken to reach one washed hub to station – 1 is 13.89 seconds. There is a possibility

to reduce this time to almost half of the current time.

It is often seen that the person who unloads the hubs to roller platform

tend to send then in a pair of 4 hubs, which means the station – 1 worker has to wait for almost 12 seconds to

obtain the fifth hub for further processing.

The roller platform, unlike front hub’s platform, lacks

inclination which means the worker has to push each and

every hub all the way to station – 1.

Often inventory of 9 to 10 hubs gets accumulated

making it little more difficult to push the hubs.

The washed hubs are often seen unattended after unloading them to

the roller platform and even after drying is completed.

by MIR SHAHJAHANUnloading the washed Hubs

After the hubs are washed and dried, they are send to the bearing pressing station. One worker has to push the hub to Station – 1 and the

time taken is around 14.14 seconds.

The tackle used to lift the washed hubs and place them on the roller

platform can be made more efficient as it tend to close its jaws on its own

when not held by the hand.

Use of springs to keep the jaws open and close can be helpful.

Often inventory of 6 to 7 hubs gets accumulated on the roller

platform.

by MIR SHAHJAHANPresence of Oil catcher machine(minor issue)

In the dummy hub assembly line, an oil catcher station is present right next to

the oil seal and pole wheel pressing machine. This station is used for

removing excess oil in the case of rear axle hub which, presently, is not

manufactured in the Shop.

The time consumed to send the hub from station – 2 to

bolt insertion station is around 4.34 seconds.

If the oil catcher station wouldn’t have been a hindrance, this time

wouldn’t have existed.

The only possible solution is to dedicate this line to the rear

hub assembly whenever it will be functional and setup a

separate line for dummy hub assembly.

by MIR SHAHJAHANBolt Insertion

From the recorded data, it can be clearly seen that the worker who inserts ten

bolts in the hub is under loaded. It was also seen that this worker tends to create

inventory for the next station. Bolt insertion takes around 31 seconds after which the worker is sitting ideal for next

8 to 10 seconds.

The worker inserting the bolts in the hub finishes his job earlier and is often seen

working with his mobile phone.

We can configure the frame (using which the bolts are inserted in the

hub) in a manner in which it can get loosely attached to the ram of the

bolt pressing machine.

In this case the work will be done by the same worker and

will also save around 7 seconds.


constraints

Washing


Sending to

Stn#1

Bearing Pressi

ng

Bearing Greasin

g

Oil Seal

Sending to

Bolt Inserti

on

Bolt Inserti

on

Bolt Pressi

ng

Shim

Selecti

on

Shim

Inserti

on

Unloading ready h

ub0

10

20

30

40

50

60

70


Washing


Sending to

Stn#1

Bearing Pressi

ng

Bearing Greasin

g

Oil Seal

Sending to

Bolt Inserti

on

Bolt Inserti

on

Bolt Pressi

ng

Shim

Selecti

on

Shim

Inserti

on

Unloading ready h

ub0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00


by MIR SHAHJAHANRECOMMENDATIONS/IMPROVEMENTS

FOR HUB ASSEMBLYConstructing an Inclined pathway for hubs to travel from washing

station to bearing pressing station:-• The washed hubs are sent to station no.-1 for bearing pressing via a roller

pathway.• This pathway facilitates the ease of movement of hubs.• However, the hub still requires the assistance of one worker to transfer it from

washing area to station no.-1• If we alter the position of this pathway and instead of keeping it horizontal,

provide it with some inclination on one side (where washed hub is loaded), then the worker will just have to push the hub slightly from one end and it will travel without any support to station no.-1

by MIR SHAHJAHAN

Proposed arrangement of the pathwaywith inclination on one side

by MIR SHAHJAHANReducing the length of roller belt pathway from washing

station to bearing pressing station:-• The length of the pathway used to transfer the hubs from washing area to station no.-1 is around 300 cm.• This length creates inventory of 9 to 10 hubs for station no.-1 as the ramp isn’t inclined either and the hub has to be pushed all the way to station no.-1• We can bring the washing station closer to bearing pressing station and re-build the pathway with a length of not more than 120 to 130 cm.• In this manner the maximum allowance for inventory wouldn’t be

more than 3 or 4 hubs.

by MIR SHAHJAHAN

Proposed arrangement of the pathwaywith reduction in length

by MIR SHAHJAHANInsertion of collars in the hub by the same worker who

unloads them from the washing area:-• The worker who unloads the hub from washing area and

puts them on the roller pathway can insert the collars as well.

• This will help in saving 10 seconds (approx.) at the bearing pressing station as the worker will now, only has to operate the bearing pressing machine.

by MIR SHAHJAHANEliminating the bolt insertion station:-

• As shown in previous slides, the bolt insertion worker is under loaded.• By little modification to the bolt pressing machine, we can do insertion as well as pressing of bolts at the same station.• The bolt pressing machine can be configured in such a way that the circular frame gets firmly attached to the mounting points which will hold the bolts.• After this, as the machine is started, the ram will come

down and press the bolts in their position.

by MIR SHAHJAHANReducing the distance between bolt

pressing station to shim selection station:-• The distance between station no.-3 and shim selection point is 140 cm.• This results in accumulation of an

inventory of 4 to 5 hubs.• This distance can be reduced to about

60 cm.• This will allow maximum allocation of

not more than 2 hubs.

by MIR SHAHJAHANCarrying 4 hubs instead of 6 :-

• Time required to fill the trolley with 6 ready hubs is 7 minutes and 18 seconds (7:18)

• Time required to fill the trolley with 4 ready hubs is 4 minutes and 9 seconds (4:09)

• Both readings are for one side only (LH).• Carrying 4 hubs to the axle assembly will not create any

hindrance for the axle assembly.• It will also be less tiring for the worker pushing the trolley.

by MIR SHAHJAHANInstallation of a fixed guideway for the hub carrying trolley :-• A simple pathway can be created for transferring the ready hubs to

axle assembly line.• Similar to railway tracks, this guide way can be constructed similar to

that of BIW shops used to carry the frame, body, etc. of the truck.• This guide way can be constructed from dummy hub assembly point ,

connecting the front hub assembly area and end at station no.-6 of Axle Assembly where the hubs are installed on the axle.

• This will reduce the travelling time of worker from 45 sec (for front hub) and 71 sec (for dummy hub) to almost half as the loaded trolley, then, wouldn’t require too much force to be pushed forward.

by MIR SHAHJAHAN

Proposed arrangement for a guided pathway from hub to axle assembly line

by MIR SHAHJAHAN

Washing

Time ta

ken to

send th

e hub to St

n-1

Bearing Pressi

ng

Bearing Greasin

g

Oil Seal &

Pole Wheel P

ressing

Bolt Inserti

on

Bolt Pressi

ng

Shim

Selecti

on

Shim

Inserti

on

Hub Cap Greasing

Unloading the re

ady hub

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00


Possible output after implementing The recommendations

by MIR SHAHJAHANCONCLUSIONS

• The average cycle time of axle assembly is around 146 seconds.• This means that after every 2.43 seconds two hubs are required (one

each at LH & RH) at the hub installation station.• With the current arrangement, 7 hubs are taking around 7:19 minutes

to reach the axle assembly area (one side only).• Consumption of the hubs at current cycle time left very little

safe/allowance time for the hub installation area which means after every 7:18 minutes, another trolley of ready hubs should be present before hand. In case of any delay, the line is forced to stop which affects the production rate.

by MIR SHAHJAHAN• By adopting the method of carrying 4 hubs instead of 7 will result in

elimination of delay time at axle assembly line.• It will also reduce the fatigue of the worker especially if the fixed

guideway method is adopted.• Also, it will provide 40 to 50 seconds of safe/allowance time in case

there is any obstruction/breakdown at hub assembly area.

by MIR SHAHJAHANBeam AssemblyA beam axle, rigid axle or solid axle is a dependent suspension design, in which a set of wheels is connected laterally by a single beam or shaft. Beam axles were once commonly used at the rear wheels of a vehicle, but historically they have also been used as front axles in rear-wheel-drive vehicles.

Beam assembly can also be understood as the pre assembly of axle where the stub is mounted on wither sides of a dead beam making it

by MIR SHAHJAHANProcesses Involved in Beam

AssemblyStub

InstallationBearing

InstallationShim

InstallationAngle

Setting

Kingpin Installation

(kingpins are precooled)

Number punching

Joint bolt insertion & Tightening

Dust Cover Installation

Number Punching

Circlip Installation

Sealing Cap Installation

U-Bracket installation

U-Bracket bending

U-Bracket hammering

Stub Greasing

by MIR SHAHJAHANManpower Allocation in Beam Assembly(front and dummy)

PROCESS NO. OF PEOPLE ON THE JOBSTUB INSTALLATION

2

BEARING INSTALLATIONSHIM INSTALLATION

JOINT BOLT INSERTION & TIGHTENINGKINGPIN INSTALLATION 1

NUMBER PUNCHING 1DUST COVER INSTALLATION

1CIRCLIP INSTALLATIONSEALING CAP INSTALLATION 2U-BRACKET INSTALLATION

1U-BRACKET BENDING

U-BRACKET HAMMERINGSTUB GREASING 1

UNLOADING TO TROLLEY 1CARRYING TO AXLE ASSY. LINE 2

by MIR SHAHJAHANWhile the dead beams are loaded on the working trolley only 1 person is engaged while the rest 11 workers are sitting idle

Since there is no automation and lack of conveyor belt in this area, the wastage

due to walking increases.

The equipment trolley is kept at one end and the worker has to carry the tools from trolley to beam. This is done 7 times and the wastage during walking from trolley to beam and back is around 5 minute 30

seconds; 5:30 (including all the processes)

Frequently it is seen that the worker(s) after finishing their task are sitting ideal or gossiping or busy with their phones till the

next lot of 7 beams arrive.

PRIMARY ISSUES AT BEAM ASSEMBLY

by MIR SHAHJAHANRECOMMENDATIONS/IMPROVEMENT

FOR BEAM ASSEMBLY

by MIR SHAHJAHANINSTALLATION OF FIXED GUIDE WAY FOR THE BEAM CARRYING TROLLEY

Instead of depending on the manual processing, installation of a guided lane for the trolley will be more feasible.

This guide way can be constructed on a stretch of 10 meters, having 5 stations from the current dead beam unloading area to the assembled beam area.

The equipment and tools holding trolley will be kept on either sides (LH & RH) so as to eliminate the wastage due to walking.

The point where the beams are finished can then be connected to axle assembly line using this extended guideway.

by MIR SHAHJAHAN

Proposed arrangement for a guided pathway for beam assembly

by MIR SHAHJAHANINSTALLATION OF A CONVEYOR BELT

Similar to that of a guideway installation, a small conveyor belt can be installed at the beam axle assembly at a stretch of 10 metres.

This belt can have 5 stations at a distance of two metres each.

The unloading of dead beam will be done at one end from where the two workers (LH & RH) will start assembly the equipments.

The end of the conveyor belt will have a pre placed empty trolley for carrying the beam to the axle assembly line.

by MIR SHAHJAHANPOSSIBLE IMPROVEMENTS AFTER USING THE RECCOMENDED METHOD

Reduction in manpower from 12 to 5 (shown in next slide)

Elimination of time wastage due to walking back and forth from equipment and tool holding trolley.

Elimination of idle time of workers.

Complete engagement of all workers without any delay.

Reduction in the time taken for completion of 7 beams by 10 minutes.

Elimination of the possibility of stopping of axle assembly line due to beam assembly.

by MIR SHAHJAHANCONCLUSIONS

• Installation of a fixed guideway will eliminate the wastage time of the workers like time spent in walking towards the beam and back to equipment trolley. • It will also reduce the allocated manpower from 12 to 5.• It will eliminate the requirement of additional trolleys for unloading

the dead beams and for transferring the ready beams from beam assembly area to axle assembly line.• Installation of a conveyor belt will ensure a constant speed is

maintained during work• It will also ensure that the axle assembly line is not stopped because

of the beam assembly station.

by MIR SHAHJAHANFront Axle AssemblyFront wheels of the vehicle are mountedon front axles .

It supports the weight of front part of the vehicle. It facilitates steering. It absorbs shocks which are transmitted due to road surface irregularities. It absorbs torque applied on it due to braking of vehicle.

by MIR SHAHJAHANDummy Axle AssemblyDummy Axle unlike the front axle isMounted on the rear portion of the chassis. ItDoes not have any steering functionality instead is used only for load carrying.In various models of the trucks, the dummy axle can also be lifted And lowered as per the load requirement.

by MIR SHAHJAHANProcesses involved in Axle

AssemblyBeam

Unloading

Tie Rod Greasing and Dropping (for

front axle)

Anchor Plate Loading

Anchor Plate Tightening

Angle SettingSlack FitmentHub DroppingHub Fitment

ABS Fitment Drum Fitment Toe In Setting (for front axle) Axle Unloading

by MIR SHAHJAHANManpower Allocation in Axle Assembly (Front and Dummy)

PROCESS NO. OF PEOPLE ON THE JOBBeam Unloading 1Tie Rod Greasing and Dropping (for front axle) 1Anchor Plate Loading 2Anchor Plate Loading 2Angle Setting 4Slack Fitment 4Hub Dropping 2Hub Fitment 2ABS Fitment 2Drum Fitment 2Toe In Setting (for front axle) 2Axle Unloading 1

by MIR SHAHJAHANAverage Time taken to

complete one Axle (Front)All readings in seconds

Station-1

Station-2

Station-3

Station-4

Station-5

Station-6

Station-7

Station-8

Station-9

Station-10

Station-11

Obs 1 35.38 81.03 120.08 163.18 168.80 169.00 133.12 84.63 139.11 60.02 60.07

Obs 2 34.93 103.80 139.10 158.00 130.06 117.00 139.30 99.01 143.00 98.00 101.34

Obs 3 36.32 98.28 141.00 160.00 131.00 138.00 149.00 106.00 136.00 88.60 78.38

Obs 4 48.62 107.00 152.00 159.00 142.00 141.00 146.30 111.00 160.70 97.00 80.26

Obs 5 40.18 106.00 149.18 152.00 131.20 136.00 141.00 109.76 133.00 99.00 79.11

Mean 39.09 99.22 140.27 158.44 140.61 140.20 141.74 102.08 142.36 88.52 79.83


1 2 3 4 5 6 7 8 9 10 11

39.09

99.22

140.27

158.44

140.61 140.20 141.74

102.08

142.36

88.5279.83


reduced are :-

by MIR SHAHJAHANLoading of dead beam

The Axle assembly starts with the loading of dead beam on the platform by one worker. The time taken to do so is approximately 40 seconds.

However, with little consideration this timing can

be reduced by almost 10 to 13 seconds.

Similar to unloading of hub, the tackle used in beam unloading is not

very efficient as it is merely a pair of claws held together with a

bolt.

The worker is often seen struggling to attach and detach the tackle from

the axle as the two claws would close down even

before they are attached to the beam.

A simple spring mechanism can be used to keep the claws of the tackle open or closed as

per requirement.

by MIR SHAHJAHANDelay in Hub supply

At Station – 6, the worker is supposed to install the hub

(front or dummy) on the mounting section. The hub

loading takes about 12 seconds (one side only). However, this

process often gets delayed due to the following reasons :-

The hubs (6 pieces) are not present at the equipment area for the hub loading worker even when they

were assembled on time.

It is often seen that the worker carrying the pellet containing the assembled

hubs gets obstructed by the fork lifter or the previously

kept empty trolley.

This also results in stopping of the assembly line by

station – 6 worker due to which the later processes

also get delayed.

by MIR SHAHJAHANHub play checking

The worker checking the hub play in the hub at station – 7 completes his task with 14 seconds

and is free for next 20 seconds (approx.).

Instead of assigning different worker for split

pinning bending, the former process can be divided into two tasks.

After completing the hub play inspection, the same worker can insert the split in the hole and

hammer it.

The other worker can use the cross scale to

split the end of the pin so as to lock it perfectly.

by MIR SHAHJAHANABS installation

The worker installing the ABS wire requires less than 13 seconds for

completing his task after which he is vacant for

almost 11 seconds.

For the time he is free, the same

worker can be used for installation of

hub cap.

This will also help in reduction of one

manpower.

by MIR SHAHJAHAN• The angle setting process involves tie rod

fitment and split pin fitment which takes which collectively takes around 140 seconds to complete.

• The prime bottle neck here is the angle setting part as the worker, possible due to lack of choice, takes around 53 seconds to complete this task working at his best efficiency.

• It was often seen that conveyer belt was forced to stop due to the delay by this station (4 out of 7 times).

• 2 out of 7 times, the angle setting worker had to call the shim selection/insertion worker from the hub assembly area as there was some issue in the hub play (front axle only).

• Due to the unwanted stoppage of conveyer belt, almost 90 seconds gets wasted in the assembly and unloading of 7 ready axles.

Angle Setting Station – The

Primary Bottle Neck

by MIR SHAHJAHAN

Assembly Line Stopped due to AngleSetting Station


constraints

1 2 3 4 5 6 7 8 9 10 11

29.00

95.00

134.00

147.00139.00

130.00 129.00

102.00

138.00

88.00

78.00


1 2 3 4 5 6 7 8 9 10 110.00

20.00

40.00

60.00

80.00

100.00

120.00

140.00

160.00


by MIR SHAHJAHANAverage Time taken to complete

one Axle (Dummy)All readings in seconds Station-1 Station-2 Station-3 Station-4 Station-5 Station-6 Station-7 Station-8 Station-9 Station-10 Station-11

Trial-1 71.00 120.80 170.00 120.70 183.00 263.00 105.00 120.90 105.00 58.00 76.00

Trial-2 60.70 133.00 198.00 158.00 191.00 240.40 119.00 136.00 120.10 71.00 74.00

Trial-3 74.00 130.00 180.90 131.00 199.00 258.00 132.00 120.30 108.00 52.00 59.00

Trial-4 60.20 137.00 192.00 138.00 193.00 269.00 120.70 139.00 112.00 56.00 70.00

Trial-5 60.90 152.00 177.00 118.00 180.90 256.00 120.10 131.00 102.00 82.00 58.00

Mean 65.36 134.56 183.58 133.14 189.38 257.28 119.36 129.44 109.42 63.80 67.40


1 2 3 4 5 6 7 8 9 10 11

65.36

134.56

183.58

133.14

189.38

257.28

119.36129.44

109.42

63.80 67.40

by MIR SHAHJAHANFrom the data, the possible areas where time taken can be reduced :-

Loading of dead beam Delay in hub supply

Hub Play Checking Station ABS Installation

Similar to front axle assembly possible area of improvement in dummy axle assembly are :-


constraints

1 2 3 4 5 6 7 8 9 10 11

61.00

130.00

175.00

125.00

179.00

248.00

110.00 115.00

90.00

61.00 64.50


1 2 3 4 5 6 7 8 9 10 110.00

50.00

100.00

150.00

200.00

250.00

300.00


by MIR SHAHJAHAN

Thank You

Manpower Management at Axle Assembly Shop(TATA Motors)

Automotive

Transcript of Manpower Management at Axle Assembly Shop(TATA Motors)