Presentation on

Tool Management System

OBJECTIVES
Tool Changeover Time Reduction Rejection due to tools/setting Reduction Tool Cost Reduction Eliminate Line Stoppage due to want of Tools Tool Inventory Reduction

Line Changeover Time - Trend

170 150 142

Tool Presetting Introduced

112

Time in Minutes

130 120 100

70 60

65 50 41 45 35 30 45 28

Jul

Aug

Sep

Oct

Nov

Dec

Jan

Feb

Mar

Apr

May

Jun 2004

Jul

Aug

Sep

Oct

Nov

2003

Tool Presetting
ToolPresetting Presetting area Presetting Colour Tool codes Fixtures for Machine different tools

Tool Presetting
Old Tool Removed Tool Changed Mounted on Presetter

Tool mounted on M/c

Fine adjustments

Height Adjusted

Tool Changeover Time Reduction

Quick Change Type Spindles BEFORE AFTER

Ready To Mount Preset Tools

Time taken 10 mins

Time taken 2 mins

Tool Changeover Time Reduction

Drill Chuck Type Spindles BEFORE AFTER

Time taken 10 mins

Time taken 3 mins

Tool Changeover Time Reduction

Multi Head Spindles BEFORE AFTER

70

90 70

70

Multi head thickness different Time taken 15 mins

Multi head thickness standardized Time taken 3 mins

Tool Changeover Time Reduction

Boring Spindles BEFORE AFTER

Non adjustable adaptors used Time taken 15 mins

Adjustable Hydro grip adaptors used Time taken 5 mins

Tool Preset Status

286

Total Preset
191 93

277

159

68

Drilling

Tapping

93

CNC

Boring

12

Machining Rejection - Trend

Tool Presetting Introduced

1.90
Rejection in %

1.35 1.25 0.51

0.33 0.32

0.16 0.14 0.09 0.09

Sep Aug Oct Jul

01-02

02-03

03-04

May

Apr

Jun

Tool Cost - Trend

4.5
Rs per Piece

4.2

3.9 2.5 2.7

Tool Presetting Introduced

1.8

1.6

1.5

1.6

1.4

May

Apr

Aug

01-02

02-03

03-04

Sep

Jun

Oct

Jul

Tool Cost Reduction

BEFORE AFTER

Casting improved

M4 X 0.7 St Flute Tap Pre drill

M4 X 0.7 Spiral Tap

Pre drilling operation eliminated by improving casting and by using Spiral Tap

Tool Cost Reduction

BEFORE AFTER

Two Spindle operations combined using a Step Drill

Tool Cost Reduction

BEFORE AFTER

Long Series

Jobber Series

Jobber series tools used instead of Long Series through Fixture Modifications

No of Stoppages

13

01-02 02-03 03-04 Apr May Jun Jul Aug Sep Oct

Line Stoppages due to want of Tools

10 11 8 5 2 0 0 0 0

Tool Inventory Reduction

BEFORE AFTER

Tool storage controlled using containers