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OPTIMIZATION OF MATERIAL HANDLING IN ROOF SHEET ASSEMBLY FOR RAILWAY COACHES

A PROJECT REPORT Submitted By ABINESH MARAN. T VASANTHI. R VENKATRAJ. N VIGNESH. M 20061401 20061436 20061438 20061439

in partial fulfillment for the award of the degree of BACHELOR OF ENGINEERING in MANUFACTURING ENGINEERING

DEPARTMENT OF MANUFACTURING ENGINEERING COLLEGE OF ENGINEERING, GUINDY ANNA UNIVERSITY CHENNAI::CHENNAI 600 025 MAY 2010
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ANNA UNIVERSITY CHENNAI::CHENNAI 600 025

BONAFIDE CERTIFICATE
Certified that this project report on OPTIMIZATION OF MATERIAL HANDLING IN ROOF SHEET ASSEMBLY FOR RAILWAY COACHES is the bonafide work of ABINESH MARAN. T VASANTHI. R VENKATRAJ. N VIGNESH. M 20061401 20061436 20061438 20061439

who carried out the project work under my supervision.

Dr.T.V.MOORTHY PROFESSOR AND HEAD

Dr. M. OMKUMAR SENIOR LECTURER

Department of Manufacturing Engg. College of Engineering, Guindy Anna University Chennai Chennai 600025

Department of Manufacturing Engg. College of Engineering, Guindy Anna University Chennai Chennai 600025

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ABSTRACT
Degree Branch Month and year of submission Course Title of the project : Bachelor of Engineering : Manufacturing Engineering : May 2010 : MN483 Project Work : Optimization of Material Handling in roof sheet assembly for Railway coaches Name of the students : Abinesh Maran. T Vasanthi. R Venkatraj. N Vignesh. M Name and Designation of guide : Dr. M.Omkumar Senior Lecturer, Dept. Of Manufacturing Engineering, College Of Engineering, Guindy Anna University, Chennai Chennai 600 025 20061401 20061436 20061438 20061439

The topic deliberated here mainly deals with the optimization of the production process at the Integral Coach Factory, Chennai. The crux of the topic here is that the amount of material handled in the shop floor is generally 9 times more than that
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is actually used to produce the final product. Hence this project is aimed at reducing the work in progress inventory to the least. Also, to device a method to store the work in progress inventory (steel sheets). This project includes optimizing algorithms, facility planning for efficient production and systematic study on various storage techniques for steel sheets to finally zero in on the most economical way of storage not compromising on quality and safety, therefore helping the organization in increasing the productivity, reducing the cost and reducing scrap in the form of rust. Date: Place: Chennai ABINESH MARAN. T 20061401

VASANTHI. R 20061436

VENKATRAJ. N 20061438

VIGNESH. M 20061439
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ACKNOWLEDGEMENT

We would like to sincerely thank Dr.M.OMKUMAR, senior lecturer , Department of Manufacturing Engineering for his invaluable guidance, support, encouragement and keen interest, which helped us in the successful completion of our project.

We wish to thank Dr.T.V.MOORTHY, professor and head, Department of Manufacturing Engineering, for providing support towards the completion of the project.

We solemnly thank Dr.S.GOWRI, Professor, project coordinator and Mr.G.SHAKTHINATHAN, Lecturer, Department of Manufacturing Engineering, for their valuable suggestions.

We are very much thankful to Mr.RAMAKRISHNAN, sectional engineer, ICF, for his immense care and guidance from the start of the project and till the completion of it.

We also wish to express our hearty thanks to all the faculty members of Department of Manufacturing Engineering for their time being help and encouragements towards the successful completion of our project.

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TABLE OF CONTENTS
CHAPTER NO. TITLE ABSTRACT LIST OF FIGURES LIST OF TABLE 1. 1.1 2. INTRODUCTION PAGE NO. iii ix x

Integral Coach Factory- A Short Presentation

CRUX OF THE CONUNDRUM

2.1 2.2 2.3 2.4

3.

Current Scenario Problems Objective of the Project Aim of the Project

OPTIMIZATION OF PLANT LAYOUT

3.1 3.2 3.3 3.4 3.4.1

Plant layout Objective of Plant Layout Factors Affecting Plant Layout Types of Plant Layout and Function Process Layout

3.4.2 Product Layout 3.4.3 Combination Layout

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3.4.4 Fixed Position Layout 3.4.5 Cell Layout 3.5 3.6

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Procedure for Design of Plant Layout Process Flow

AUTOMATED LAYOUT DESIGN PROGRAM

4.1 4.2 4.3 4.4 4.5

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Relationship Chart Steps of ALDEP Data Collected Relationship Chart for Data collected Filling The Cells
MATERIAL HANDLING

5.1

Material Handling Equipment 5.1.1 Transport Equipment 5.1.2 5.1.3 5.1.4 5.1.5 Positioning Equipment Unit Load Formation Equipment Storage Equipment Identification and Control Equipment Principles of MHE Automatic Guided Vehicles

5.2 5.3

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5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 5.3.7 5.3.8 5.3.9 5.3.10 6 6.1 6.2 6.2.1 6.2.2 6.2.3 6.3
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Navigation Wired Sensor Guide Tape Steering Control Path Decision Frequency Select Mode Path Select Mode Magnetic Tape Mode Vehicle Types Common AGV Applications
GALVINIZING PROCESS

Types of Surface Protection Elements of Galvinizing Process Surface Prepartion Galvinizing Inspection Benefits of Galvinizing Process
CONCLUSION REFERENCE

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LIST OF FIGURES FIGURE No. 2.1 2.2 4.1 4.2 5.1 5.2 TITLE Stack of materials Assembly fixture Existing layout Proposed machine cell layout Transport equipment AGV moving in shop floor PAGE No.

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LIST OF TABLES TABLE No. 2.1 4.1 4.2 4.3 TITLE Assembly time Closeness value Area of each machine cell Relationship chart PAGE No.

CHAPTER 1 INTRODUCTION

1.1 INTEGRAL COACH FACTORY: A SHORT PRESENTATION

Started in 1952, the Integral Coach Factory (ICF) is located in suburbs of Chennai, India. Its primary products are rail coaches. Most of the coaches manufactured are supplied to the Indian Railways, but it has also manufactured coaches for railway companies in other countries, including Thailand, Burma, Taiwan, Zambia, Philippines, Tanzania, Uganda, Vietnam, Nigeria, Mozambique and Bangladesh. Recently, ICF exports coaches to Angola and Sri Lanka. The coach factory provides a number of different coaches primarily for the Indian Railways, primarily first and second class coaches, pantry and kitchen cars, luggage and brake vans, self propelled coaches, electric, diesel and mainline electric multiple units (EMU, DMU, MEMU), metro coaches and Diesel Electric Tower Cars (DETC), Accident Relief Medical Vans (ARMV), Inspection Cars (RA), Fuel Test Cars, Track Recording Cars, the latest coaches are for the Deccan Odyssey (a luxury train of the Indian Railways), and coaches for MRVC (world class coaches). An organization of such a potential is only able to make a profit of approximately Rs. 20,00,000 a year. This is mainly because of huge work-in-progress (WIP) inventories and huge loss due to scrap caused by corrosion of the sheet metals. Thus need of the hour is to prevent the above two problems as far as possible.

CHAPTER 2 CRUX OF THE CONUNDRUM

2.1 CURRENT SCENARIO

It takes three shifts to produce the roof for one bogie. The roof is totally made of 7 sets of sheet metal and each set contains 3 sheet metals profiled and welded together. A deeper investigation reveals that the roof sheet assembly requires not only the sheets but a skeleton to provide structure to it and an L stiffener and U stiffener for support and strength. Hence the skeleton assembly alone takes one full shift and the grinding and hammering of the final assembly requires another shift, which leaves the roof sheet assembly with only a shift. In the single shift the sheet metal must be straightened, cut to length, bent to the required profile, seam welded, bent at the edges and with all this process it must be routed to various machines and if anyone of the machines is not in a state to process the WIP inventory then it piles up quiet next to the machine causing the material to get exposed to the environmental conditions leading to corrosion as shown in fig 2.1.

Fig 2.1 Stack of materials Another problem is that work in process is not routed progressively, which means the machines required for processing are not sequentially placed that leads to multiple transactions of the same material back and forth. Hence there is a huge loss of time in this process. So, the Overall production rate is 1400 coaches per year. The number of shifts taken, hrs per shift and the number of laborers for different types of coaches is given in table 2.1.
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Type of coach BG SCN SLR DC/DMU

Hrs per shift 6.7 7.0 7.2 7.5

No. of shifts 3 3 3 3

No. of laborers 10 10 10 10

Table 2.1 Assembly time The following calculation quantifies the above: Consider BG (Broad Gauge): No. of sheets required = 7*3 = 21 Total hrs = 20.1 Laborers: 4 fitters and 6 welders 20.1hrs distributed for structure building, handling, and welding, hammering and finishing operations. The above quantification is only for the assembly and prior to each part of the assembly, the respective forming and fabrication must be done within the scheduled time. The assembly fixture for the roof sheet is shown in fig 2.2.

Fig 2.2 Assembly fixture

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2.2 PROBLEMS
The efficiency of material handling system at present, in the existing shop floor layout is less than 10% i.e., the material handled is nine times the material being processed. A lot of human effort is being exploited in the handling of the WIP. This leads to huge lead times and at a point of time either the machine or the WIP is Idle within the shop floor.

2.3 OBJECTIVE OF THE PROJECT

The main aim of this project is to optimize the material handling by reducing the number of trips in which the material is being handled. Also to suggest a method to protect the Work-inProgress (WIP) inventory from getting corroded. Finally reducing the lead time in the production process and increasing the productivity.

2.4 AIM OF THE PROJECT

To increase the rate of production. This can be achieved by reducing the WIP which in turn is brought about by optimizing the process layout. To reduce the number of accidents which is possible by devising a proper material handling equipment which carries the material from the start till the end progressively and reducing the manual handling

To reduce the level of inventories. To reduce the overall material handling time. Implement a new material handling system for hand ling roof sheets.

2.5 SUMMARY
This chapter explains the current existing scenario in the shop floor for the manufacture of roof sheets and also lists out the various problems faced by the workers, both directly as well as indirectly during the manufacturing process. The main aim and objective of this project is also discussed in detail in this chapter.

CHAPTER 3 OPTIMIZATION OF PLANT LAYOUT

3.1 PLANT LAYOUT

Plant Layout means the physical arrangement of the various Industrial facilities (equipment, material, manpower, etc.) within the plant. This arrangement includes the spaces needed for material movement, storage, indirect laborers and all other supporting activities or services as well as operating equipment and Personnel. Plant Layout is the basis of industrial

activity since it determines the efficiency. Generally what is being achieved is arrangement of work areas and equipment which is the most economical and at the same time safe and satisfying employees. Plant Layout is concerned with the analysis, planning, and design of the physical facilities utilized in the production of goods and services. Material Handling deals with that phase of the operations which involves the movements of the material used in carrying on the activities of the enterprises. No two aspects of industrial activity are more closely related. Actually, Material Handling is a Major part of nearly all Plant Layout work. This close relationship is emphasized in the following definition of Plant Layout: Plant Layout may be defined as planning and integrating the paths of the component parts of a product to obtain the most effective and economical inter relationships between men, equipment and the movement of material from receiving, through fabrication, to the shipment of the finished product, (H.A.HARDING, 1997). Plant layout planning includes decisions regarding the physical allocation of the economic activity centers in a facility. An economic activity center is any entity occupying space. The objective of plant layout planning is a more effective work flow at the facility, allowing workers and equipment being more productive. Facility layout techniques apply to the case where several physical means have to be located in a certain area, either industrial processes or services. The objective of the chapter is not only plant layout but re-layout also (most common situation for a company). To carry out an appropriate plant layout, its important to take into account the business strategic and tactical objectives. Example: space requirements / cost per m2 in Malls;

accessibility/ privacy in offices. To make a decision about layout planning, 4 different questions must have an answer: Which centers do we have to consider? How much space and capacity is required for each center? If there is not enough space, productivity may be reduced. Too much space is expensive and may also reduce productivity. How must the space be configured at each center? Space quantity, shape and the elements of the work center are related to each other. Where should each center be located at within the facility? The allocation of the different centers may affect productivity. The plant layout process starts at an aggregate level, taking into account the different departments. As soon as we get into the details, the different issues arise, ant the original configuration may be changed through a feedback process. Most (if not all of them) layouts are designed properly for the initial conditions of the business, although as long as the company grows and has to be adapted to internal and external changes, a re-layout is necessary.

The reasons for a re-layout are based on 3 types of changes: Changes in production volumes Changes in processes and technology Changes in the product

3.2 OBJECTIVES OF PLANT LAYOUT

These main objectives are reached through the attainment of the following facts: Congestion reduction Elimination of unnecessary occupied areas Reduction of administrative and indirect work Improvement on control and supervision Better adjustment to changing conditions Better utilization of the workforce, equipment and services Reduction of material handling activities and stock in process Reduction on parts and quality risks Reduction on health risks and increase on workers safety Moral and workers satisfaction increase Reduction on delays and manufacturing time, as well as increase in production capacity All these factors will not be reached simultaneously, so the best solution will be a balance among them.

3.3 FACTORS AFFECTING PLANT LAYOUT

The final solution for a plant layout has to take into account a balance among the characteristics and considerations of all factors affecting plant layout, in order to get the maximum advantages. The factors affecting plant layout can be grouped into 8 categories: Materials Machinery Labor Material handling
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Waiting time Auxiliary services The building Future changes

3.4 TYPES OF PLANT LAYOUT AND FUNCTION

There are five different types of plant layouts each serving a particular purpose and has its own advantages as explained below.

3.4.1 PROCESS LAYOUT OR FUNCTIONAL LAYOUT

It is characterized by keeping similar machine or similar operations at one location (Place). In other words, all lathes will be at one place, all milling machine at another and so on that is machine are to be arranged according to their function. Process layout for two products is shown in the fig 3.1. This type of layout is generally employed for industries engaged in job order production and non-repetitive kind of maintenance or manufacturing activities.

Drilling (1) (2)

Planning (2) (3) (5)

Grinding (5)

Milling (1)

Welding

Assembly

(3)

(4)

(4)

(6)

(6)

Product A: Product B: Fig 3.1 Process Layout

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Advantages of Process Layout

1) Better Machine utilization allows lower investment on equipment. 2) It is better to maintain continuity of production in event of (a) Machine breakdown (b) Storage of Raw material (c) Absence of workers 3) It comes up with varying production schedules. 4) It is adopted to a variety of products and to frequent changes in sequence of operations.

3.4.2 PRODUCT LAYOUT OR LINE TYPE LAYOUT

It implies that various operations on a product are performed in a sequence and the machines are placed along the product flow line, i.e., machines are arranged in the sequence in which a given product will be operated upon. This type of layout is preferred for continuous production, i.e. involving a continuous flow of in-process material towards the finishing product stage. A line layout for two products is given below in fig 3.2.

Lathe Product A (1)

Drill (2)

Grinder (3)

Assembly (4)

Paint shop (5)

Planer Product B (1)

Grinder (2)

Miler (3)

Lathe (4)

Welding (5)

Fig 3.2 Product or Line Layout

Advantages of Product Layout

1) Less Handling of Material. 2) Less material in process allows lower investment in materials. 3) More effective use of labor (a) Through greater job specialization (b) Through ease of training
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(c) Through wider of labor supply 4) Easier control (a) Of production allows less paper work. (b) Over workers allows easier supervision

3.4.3 COMBINATION LAYOUT

A combination of process and product layout combines the advantages of the both types of layouts. A combination layout is possible where an item is being made in different shape and sizes. In such cases machinery is arranged in a Process Layout but the process grouping is than arranged in a sequence to manufacture various types and sizes of product. The point to note here is that, no matter the product varies in size and type, the sequence of operations remain same or similar.

3.4.4 FIXED POSITION LAYOUT

In other types of Layouts discussed earlier, the product moves past stationary Production Equipment, whereas in these cases the reverse applies; men and equipment are moved to the material, which remains at one place and the product is completed at that place where the material lies. For e.g., aircraft manufacture, ship building, big pressure vessel fabrication. Fixed position layout for ship building industry is shown in fig 3.3

Ship building yard

inputs

Finished products (ship)

Fig 3.3 Fixed Position Layout

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3.4.5 GROUP OR CELL LAYOUT

In a group or Cell Layout, the layout design is in not according to functional characteristics of machine, but rather by group of different machines (called Cells) that are necessary for the production of families of parts.

3.5 PROCEDURE FOR DESIGN OF PLANT LAYOUT

The ideal procedure for a plant layout is to build the layout around the productive process and then design the building around the layout. This may not be possible always, because the plant building may already be existing or the shape of plant site may not permit the construction of building to house the productive process, etc. Ultimately, one has to strike to balance between the two approaches. However various procedural steps involved in plant layout have been listed below: a. Accumulate basic data b. Analyze and coordinate basic data c. Decide the Equipment and Machinery required d. Select the material handling system e. Sketch plan of plot for making factory building f. Determine a general flow pattern g. Design the individual work stations h. Assemble the individual layout into the total layout i. Calculate the storage space required. j. Make flow diagram for workstations and allocate them to areas on plot plan, k. Plan and locate service areas, l. Make master layout, m. Check final layout, and n. Install the approved layout.

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3.6 PROCESS FLOW Sheet metal cutting

Seam welding to join the sheet metals

Bending along the sides for the flow of rain water

Alignment over the roof jig and welding

Finishing operations hammering and buffing

Fig 3.4 Process Flow Chart

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3.7 SUMMARY:
This chapter gives the basic definition for plant layout and explains the various types of plant layouts in detail along with their pictorial representations and advantages. This chapter also explains the procedure and the relevant data required in order to design a new plant layout or even to modify the existing plant layout in order to overcome the disadvantages in the existing layout. Finally this chapter explains the flow of operations in the shop floor for the manufacturing of roof sheets.

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CHAPTER 4 AUTOMATED LAYOUT DESIGN PROGRAM

Automated Layout DEsign Program (ALDEP) is a construction type algorithm. This algorithm uses basic data on facilities and builds a design by successively placing the department in the layout. After placing all the departments in the layout a score is computed. This is nothing but the sum of the closeness rating values of different neighboring department in the layout. This algorithm is repeated for a prespecified number of times and the best layout is selected based on the maximum layout score. The basic data required for this algorithm are listed below 1. Total number of department 2. Area of each department 3. Length and width of layout 4. Closeness rating of various pairs of department in the form of Relation chart 5. Minimum department preference ( MDP) value. 6. Sweep width 7. Number of iterations to be performed 8. Location and size of each restricted area in the layout if present.

4.1 RELATIONSHIP CHART

This chart is a triangular matrix whose elements represent the closeness relationships among the departments. The following notations as shown in table 4.1 are used to indicate the various degrees of closeness.

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Closeness Absolutely necessary Especially important Important Ordinary closeness OK Unimportant Not desirable

Notation A E I O U X

Value 64 16 04 01 00 -1024

Table 4.1 Closeness value

4.2 STEPS OF ALDEP:

The ALDEP procedure is explained as follows: Step 0. Input: 1. Number of departments in the layout. 2. Area of each department. 3. Length and width of the layout. 4. REL-CHART (Relationship chart). 5. MDP value. 6. Sweep width. 7. Number of iterations to be carried (N). 8. Current iteration number (1), 1. 9. Locations and sizes of fixed departments if present. 10. Score of the current layout (It is assumed as a very high negative value before performing the first iteration). Step1. Select a department randomly and place it in the layout. Step2. Scan the relationship (REL) - chart and classify the unselected departments into lists, namely List A and List B. List A contains the unselected departments whose relationship values in relation to the lastly selected departments are less than the MDP value.

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List B contains the unselected departments whose relationship values in relation to the lastly selected departments are greater than or equal to the MDP value. Step3. Is the List B empty? If so, go to step 4; otherwise, go to step5. Step4. Select a department randomly from List A and place it in the layout. Go to step 6. Step5. Select a department from List B which has the maximum REL value in relation to the lastly selected department and place it in the layout. Step6. Whether all departments are placed in the layout? If not go to step2; if yes, go to step7. Step7. Compute the score of the layout. Step8. Is the score of the layout more than the score of the current best layout? If yes, update the new layout as the current best layout and store the corresponding score. Otherwise, drop the new layout. Step9. Is the current iteration number I=N? I f yes, go to step 10; otherwise, increment the iteration number by one (I=I+1) and go to step 1. Step10. Print the current best layout and the corresponding score.

4.3 DATA COLLECTED:

The distance between the various machine cells and the area occupied by them in the shop floor is collected and presented in fig 4.1 and table 4.2. Also the process flow chart for the manufacture of roof sheet is shown in fig 3.4.

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Fig 4.1 Proximity diagram for machine cells

DEPARTMENT NAME Cut To length Machine Profile Bending Seam Welding Press Break 1 Press Break 2 Assembly

AREA in Sq.Ft 115 x 32 = 3680 ~ 3600 25 x 40 = 1200 30 x 52 = 780 ~ 800 24 x 25 = 600 24 x 25 = 600 80x 40 = 3200

NUMBER OF SQUARES 36 12 8 6 6 32

Table 4.2 Area of each machine cell

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4.4 RELATIONSHIP CHART FOR DATA COLLECTED

The proximity relationship between the various machines are specified using the notations A,E,I,O and U in table 4.3. cut to Profile Bending length machine 0 A length A E A A O 0 A U U I Seam Welding E A 0 U U E Press Break 1 A U U 0 I E Press Break 2 A U U I 0 E Assembly

cut to machine Profile Bending Seam Welding Press Break 1 Press Break 2 Assembly

O I E E E 0

Table 4.3 Relationship Chart

Assumptions:
Each machine in the shop floor is assigned a number and this number is used to represent the particular machine in the ALDEP table as shown in the iterations. 1 - Cut to length machine 2 - Profile bending 3 - Seam welding

4 - Press brake 1 5 - Press brake 2 6 -Assembly

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List:
There are two lists A and B. list A contains the machines having least proximity values (o,u) and list B contains the machines having maximum proximity values (a,e,i). List A {o,u} List B {a,e,i}

Relationship values:
A E I O U 64 16 04 01 00

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Fig 4.2 Existing layout

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4.5 FILLING THE CELLS Iteration 1 (Existing Layout):

1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1

2 2 1 1 1 1 1 1 1 1

2 2 1 1 1 1 1 1 1 1

2 2 2 2 3 3 3 3 4 4

2 2 2 2 3 3 3 3 4 4

6 6 6 6 6 6 5 5 5 4

6 6 6 6 6 6 5 5 5 4

6 6 6 6 6 6 6 6 6 6

6 6 6 6 6 6 6 6 6 6

Relationship Score:
1 2 = 64 2 3 = 64 2 6 = 04 3 6 = 16 3 1 = 16 4 1 = 64 43=1 45=4 5 6 = 16

For cell 1: list A {6}, List B {2, 3, 4, 5} For cell 2: list A {4, 5}, List B {3, 6} For cell 3: list A {6}, List B {4, 5} For cell 4: list A {6}, List B {5}

4 6 = 16 1 3 = 16 Total : 281

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4.6 EXPLANATION:
Iteration 1 gives the existing distribution of the machine cells in the shop floor. The pictorial representation of the existing shop floor is given in fig 4.2. The entire shop floor area and the area occupied by each machine along with the area for material storage are measured. The common factor from all the individual machine cell area is removed and tabular grids are drawn for the remaining area. In our case, 100 sq feet is taken as the common area factor and the remaining total are is calculated to be 100 sq feet. A 10x10 tabular grid is constructed, wherein each cell represents 1 sq feet. The grid is now filled with numbers, which are used to represent each machine cell as explained in assumption. The tabular grid is filled column wise taking two cells of a row at a time and also the filling is done in a continuous way starting from the first two cells of the first row and ending with the last two cells of the last row. The machines are then place in the same order along the shop floor. The best layout can be identified by trying all possible iterations and calculating the relationship score for each iteration. The maximum score corresponds to the most optimized layout. The first machine cell is selected randomly and the area occupied is filled along the tabular grid. Based on the closeness relationship between the filled machine cell and the remaining machine cells, two lists are created. They are known as list A and list B. list A consists of the machine cells having least closeness relationship with the previously filled machine cell and list B consists of machine cells having the maximum closeness relationship with the previously filled machine cell. For instance iteration 1 is started by filling the tabular grid with number 1, which corresponds to the Cut to Length Machine. Now the list A for Cut to Length machine contains the assembly cell and list B consists of the remaining machines. Now, among the machine cells in list B, the one with maximum closeness value with machine cell 1 is selected and filled along the tabular grid. In this way the tabular grid is filled completely with all the machine cells. From the filled tabular grid, the machines which are in direct contact are identified and the relationship values are added together in order to calculate the total score for example: in iteration 1, machines 1 and 2 are in direct contact with each other and there corresponding closeness notation is A, which corresponds to a value of 64. Similarly all the closeness values of the machines which are in direct contact with each other are added and the final score is computed. The final score for iteration 1 is 281. In this way all possible iterations score were calculated and the highest score obtained was 313, which corresponds to iteration 3. Hence

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iteration 3 is considered to be the most optimized machine cell layout and its corresponding machine locations are shown in fig 4.2.

Iteration 2: (Sample Iteration)

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1 4 6 6 6 6 6 6 6 6 6 4 6 6 6 6 6 6 6 6 6 5 5 5 6 6 6 6 6 6 6 5 5 5 6 6 6 6 6 6 6 2 2 2 2 2 2 3 3 3 3 2 2 2 2 2 2 3 4 5 = 04 3 3 3 6 5 = 64 5 2 = 00 6 2 = 04 For cell 1: list A {6}, List B{2, 3, 4, 5} 6 3 = 00 For cell 4: list A {2, 3}, List B {5, 6} Total: 153 For cell 6: list A {}, List B {2, 3, 5} For cell 5: list A {2, 3}, List B {} 1 4 = 64 1 6 = 01 4 6 = 16

Relationship Score

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Iteration 3 (Optimized Layout):

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1 4 5 5 5 2 2 2 2 2 2 4 5 5 5 2 2 2 2 2 2 6 6 6 6 6 6 3 3 3 3 6 6 6 6 6 6 3 3 3 3 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 4 6 = 16 5 6 = 16 2 3 = 64 3 6 = 16 For cell 1: list A {6}, List B {2, 3, 4, 5} 2 6 = 04 For cell 4: list A {2, 3}, List B {5, 6} 2 5 = 01 For cell 5: list A {2,3}, List B {6} 1 5 = 64 For cell 2: list A {}, List B {3} Total: 313 1 4 = 64 4 5 = 04 1 2 = 64

Relationship Score

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Fig 4.2 Proposed machine cell layout

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4.7 SUMMARY:
This chapter deals with the algorithm used to modify the current layout into an optimized one. This chapter gives a detailed introduction about the ALDEP algorithm and explains the step by step procedure for using it. The various data collected from the shop floor, which are used as input to the algorithm, are presented using figures and tables. A pictorial representation of the existing and the suggested optimized layout along with its tabular grid diagram and explanation is also given in this chapter.

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CHAPTER 5 MATERIAL HANDLING

Material Handling involves the movement of material, manually or mechanically in batches or one item at a time within the Plant. The movement may be horizontal, vertical or combination of horizontal or vertical. Material Handling is concerned with motion, time, quantity and space. Basically Material Handling is the art of implementing movement-economically and safely.

5.1 MATERIAL HANDLING EQUIPMENT

Material Handling Equipment (MHE) is all equipment that relates to the movement, storage, control and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption and disposal. Material Handling Equipment is the mechanical equipment involved in the complete system. Material Handling Equipment is generally separated into four main categories: storage and handling equipment, engineered systems, industrial trucks, and bulk material handling. MHE is the most critical component of cargo ground handling; shortages will significantly impact throughput capability. MHE is the primary platform for loading and unloading all DOD general and special cargo, including outsized and oversized components. MHE is the one that reduces manual material handling distances. Also MHE aims in reducing the WIP inventories which affects the productivity and profitability of an Organization /Industry through increased Lead time, Machining cycles etc. MHE is used for the movement and storage of material within a facility or at a site. Every organization in this world is looking for a material handling equipment solutions to improve their productivity, while reducing the potential of workplace injury. MHE is the mechanical equipment involved in the complete system. MHE is used for the movement and storage of material within a facility or at a site. MHE can be classified into the following five major categories:

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5.1.1. TRANSPORT EQUIPMENT

Equipment used to move material from one location to another (e.g., between workplaces, between a loading dock and a storage area, etc.). The major subcategories of transport equipment are conveyors, cranes, and industrial trucks. The basic transportation equipments are shown in the fig 5.1.

Fig.5.1 Transport Equipment The major subcategories of transport equipment are: Conveyors- Equipment used to move materials over a fixed path between specific points. Cranes- Equipment used to move materials over variable paths within a restricted area. Industrial Trucks- Equipment used to move materials over variable paths, with no restrictions on the area covered by the movement (i.e., unrestricted area).

5.1.2. POSITIONING EQUIPMENT

Equipment used to handle material at a single location so that it is in the correct position for subsequent handling, machining, transport, or storage. Unlike transport equipment, positioning equipment is usually used for handling at a single workplace. Material can also be positioned manually using no equipment.

5.1.3. UNIT LOAD FORMATION EQUIPMENT

Equipment used to restrict materials so that they maintain their integrity when handled a single load during transport and for storage. If materials are self-restraining (e.g., a single part or interlocking parts), then they can be formed into a unit load with no equipment.
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5.1.4 STORAGE EQUIPMENT

Equipment used for holding or buffering materials over a period of time. Some storage equipment may include the transport of materials (e.g., the S/R machines of an AS/RS, or storage carousels). If materials are block stacked directly on the floor, then no storage equipment is required.

5.1.5. IDENTIFICATION AND CONTROL EQUIPMENT

Equipment used to collect and communicate the information that is used to coordinate the flow of materials within a facility and between a facility and its suppliers and customers. The identification of materials and associated control can be performed manually with no specialized equipment.

5.2 PRINCIPLES OF MHE

The Seventeen MHE Principles remain constant. 1. Least handling is best handling. The greatest economy in moving materials is secured by keeping handling to a minimum. 2. Standardization of methods and equipment results in the reduction of costs of operation. Maintenance, repair, storage and issue procedures can be simplified. 3. MHE must be selected for a multiple number of applications. Flexibility is the key. 4. Specialized equipment should be kept to a minimum. Normally, first cost, cost of operations and maintenance costs are greater for special equipment than for standard equipment. 5. Volume dictates the method of handling materials. The number of pieces to be moved determines the method of handling. 6. The most essential phase of any program is planning. Material handling is no different. Factors requiring advanced planning include protection against weather and breakage, legal and physical restrictions in reference to transportation, the possibility of using unitized loads,

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the standardization of equipment and methods, the combination of material handling methods and the consideration of safety hazards. 7. The length and number of moves of material should be kept to a minimum. Movement paths should be studies for the possibility of reducing "backtracking" and length of moves, resulting in better utilization of equipment and personnel. 8. Equipment capacities should never be exceeded. Overloading causes excessive wear of equipment and creates accident potential. 9. All materials handling activities should be analyzed for improvement possibilities by elimination, combination or simplification. Combination of operations may result in the simplification and reduction of the number of times material must be handled. 10. The selection of MHE is based on the economies of operation. Greater payloads for each handling operation will result in less handling cost per piece. 11. The "physical state" of materials is a factor in determining MHE. The three physical states of material - solid, liquid and gas - determine the method of containment (pack). This, in turn, influences the selection of MHE. 12. The shortest distance between two given points is a straight line - utilize a straight line flow of materials whenever possible. The time to move materials can be reduced by using a straight line flow. 13. Materials should move continuously along any production line. Choppy or broken flow causes confusion and delay. Most shipping and receiving operations should operate on the principle of continuous flow. 14. All materials handling operations should follow a defined method. The standardization of the method will provide a basis for determining handling requirements. 15. Short, irregular moves lend themselves to manual materials handling. When moves are short, irregular and load capacity of people is not exceeded, it may be more economical to use manpower. 16. Whenever practicable materials should be prepositioned for the handling operations. Prepositioning places containers in position to facilitate picking up and/or moving and materials so they do not obstruct other materials.

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17. Whenever practicable, materials should be moved in a horizontal plane or with the aid of gravity. The ideal lifting position is at the waist. The nearer to the waist that a container or part can be picked up and disposed, the greater will be the efficiency.

5.3 AUTOMATIC GUIDED VEHICLES

An automated guided vehicle or automatic guided vehicle (AGV) is a mobile robot that follows markers or wires in the floor, or uses vision or lasers. They are most often used in industrial applications to move materials around a manufacturing facility or a warehouse. Application of the automatic guided vehicle has broadened during the late 20th century and they are no longer restricted to industrial environments. AGVs increase efficiency and reduce costs by helping to automate a manufacturing facility or warehouse. AGVs can carry loads or tow objects behind them in trailers to which they can autonomously attach. The trailers can be used to move raw materials or finished product. The AGV can also store objects on a bed. The objects can be placed on a set of motorized (conveyor) and then pushed off by reversing them. Some AGVs use forklifts to lift objects for storage. AGVs are employed in nearly every industry, including pulp, paper, metals, newspaper, and general manufacturing. Transporting materials such as food, linen or medicine in hospitals is also done. An AGV can also be called a self-guided vehicle (SGV). Lower cost versions of AVGs are often called Automated Guided carts (AGCs) and are usually guided by magnetic tape. AGCs are available in a variety of models and can be used to move products on an assembly line, transport goods throughout a plant or warehouse, and deliver loads to and from stretch wrappers and roller conveyors.

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5.3.1 NAVIGATION
AGVs in a FMS are used to transport an object from point A to point B. AGVs navigate manufacturing areas with sensors. There are two main sensors AGVs use for navigation, a wired and a wireless sensor.

5.3.2 WIRED SENSOR

The wired sensor is placed on the bottom of the robot and is placed facing the ground. A slot is cut in the ground and a wire is placed approximately 1 inch below the ground. The sensor detects the radio frequency being transmitted from the wire and follows it.

5.3.3 GUIDE TAPE

Many light duty AGVs (some known as automated guided carts or AGCs) use tape for the guide path. The tapes can be one of two styles: magnetic or colored. Magnetic and colored types have its own advantages and disadvantages respectively. The AGC is fitted with the appropriate guide sensor to follow the path of the tape. One major advantage of tape over wired guidance is that it can be easily removed and relocated if the course needs to change. It also does not involve the expense of cutting the factory or warehouse floor for the entire travel route. Additionally, it is considered a passive system since it does not require the guide medium to be energized as wire does. Colored tape is initially less expensive, but lacks the advantage of being embedded in high traffic areas where the tape may become damaged or dirty.

5.3.4 STEERING CONTROL

To help an AGV navigate it can use two different steer control systems. The differential speed control is the most common. In this method there are two sets of wheels being driven. Each set is connected to a common drive train. These drive trains are driven at different speeds in order to turn or the same speed to allow the AGV to go forwards and/or backwards. The AGV turns in a similar fashion to a tank. This method of steering is good in the sense that it is easy to maneuver in small spaces. More often than not, this is seen on an AGV that is used to transport and turn in tight spaces or when the AGV is working near machines. This setup for the wheels is not used in towing applications because the AGV would cause the trailer to jackknife when it turned.
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The other type of steering used is steered wheel control AGV. This type of steering is similar to a cars steering. It is more precise in following the wire program than the differential speed controlled method. This type of AGV has smoother turning but cannot make sharp turns in tight spots. Steered wheel control AGV can be used in all applications; unlike the differential controlled. Steered wheel control is used for towing and can also at times have an operator control it.

5.3.5 PATH DECISION

AGVs have to make decisions on path selection. This is done through different methods: frequency select mode (wired navigation only), and path select mode (wireless navigation only) or via a magnetic tape on the floor not only to guide the AGV but also to issue steering commands and speed commands.

5.3.6 FREQUENCY SELECT MODE

Frequency select mode bases its decision on the frequencies being emitted from the floor. When an AGV approaches a point on the wire which splits the AGV detects the two frequencies and through a table stored in its memory decides on the best path. The different frequencies are required only at the decision point for the AGV. The frequencies can change back to one set signal after this point. This method is not easily expandable and requires extra guide cutting meaning more money.

5.3.7 PATH SELECT MODE

An AGV using the path select mode chooses a path based on preprogrammed paths. It uses the measurements taken from the sensors and compares them to values given to them by programmers. An AGV used in shop floor is illustrated in figure 5.2. When an AGV approaches a decision point it only has to decide whether to follow path 1, 2, 3, etc. This decision is rather simple since it already knows its path from its programming. This method can increase the cost of an AGV because it is required to have a team of programmers to program the AGV with the correct paths and change the paths when necessary. This method is easy to change and set up.

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5.3.8 MAGNETIC TAPE MODE

The magnetic tape is laid on the surface of the floor or buried in a 10 mm channel, not only does it provide the path for the AGV to follow but also sort strips of the tape in different combos of the strip tell the AGV to change lane and also speed up slow down and stop with north and south magnetic combos, this is used by TOYOTA USA and TOYOTA JAPAN.

5.3.9 VEHICLE TYPES

AGVS Towing Vehicles were the first type introduced and are still a very popular type today. Towing vehicles can pull a multitude of trailer types and have capacities ranging from 8,000 pounds to 60,000 pounds.

AGVS Unit Load Vehicles are equipped with decks, which permit unit load transportation and often automatic load transfer. The decks can either be lift and lower type, powered or non-powered roller, chain or belt decks or custom decks with multiple compartments.

AGVS Pallet Trucks are designed to transport palletized loads to and from floor level; eliminating the need for fixed load stands.

AGVS Fork Truck has the ability to service loads both at floor level and on stands. In some cases these vehicles can also stack loads in rack.

Light Load AGVS are vehicles which have capacities in the neighborhood of 500 pounds or less and are used to transport small parts, baskets, or other light loads though a light manufacturing environment. They are designed to operate in areas with limited space.

5.3.10 Common AGV Applications

Automated Guided Vehicles can be used in a wide variety of applications to transport many different types of material including pallets, rolls, racks, carts, and containers. AGVs excel in applications with the following characteristics:

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Repetitive movement of materials over a distance Regular delivery of stable loads Medium throughput/volume When on-time delivery is critical and late deliveries are causing inefficiency Operations with at least two shifts Processes where tracking material is important.

Fig 5.2 AGV moving in shopfloor. A few examples of typical leasing costs for different size AGV systems: 1 vehicle CHEP forklift type AGV system with up to 20 load and unload positions and a travel distance of up to 100 meters. Monthly cost for 5 years, with no residual: Rs 2,09,500/month 3 vehicle CHEP forklift type AGV system with up to 50 load and unload Positions and a travel distance of up to 200 meters. Monthly cost for 5 years, with no residual: Rs 4,61,000/month

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5 vehicle CHEP forklift type AGV system with up to 100 load and unload positions and a travel distance of up to 300 meters. Monthly cost for 5 years, with no residual: Rs 7,12,250/month

5.3.11 SUGGESTED AGV SPECS:

Flexible magnet floor tape guidance Travel speed 120 feet/min Tow capacity 2,000 lbs. Carry capacity 1,700 lbs Auto charge Roller decks Towed carts Remote call

5.3.12 AGV SET UP SPECIFICATIONS AND COST:

1 SavantCart Model 100 HD (tow or carrier style) 500 feet magnet floor tape 1 Battery set 1 Battery charge 2 Path branches Savant installation Savant training 1 year warranty 24/7 service hotline TOTAL COST Rs. 26,56,500/ 37

5.4 SUMMARY:
This chapter gives a basic definition for material handling and explains in detail the various means of material handling inside shop floor. The main area of focus in this chapter is the AGV, it explains the various types of AGVs their advantages and rent per month. Finally this chapter concludes with the specifications and cost of the AGV proposed suiting the conditions of the factory.

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CHAPTER 6 MATERIAL HANDLING MECHANISM 6.1 AUTOMATED TABLE ACTUATION

This mechanism is employed for the handling of roof sheets once they are seam welded. The roof sheets are at present being handled manually by picking them and placing them over the trolleys through human effort. This process involves the following steps which are: 1. Placing the roof sheet horizontally over the trolley once the seam weld is made. 2. Manual movement of the trolley to the assembly shop. 3. Changing the orientation of the roof sheet from horizontal to vertical while lifting it using the crane. 4. Then placing the roof sheet over the roof jig horizontally, which involves another change in the orientation. In order to reduce the time consumption due to above steps, we have devised the following material handling system. Which involves the usage of hydraulically actuated table and a mobile bin for the vertical storage of root sheets that can be coupled with the AGVs mentioned above.

6.2 MECHANISM
The mechanism with which the hydraulically actuated table moves, such that the roof sheets are stored vertically inside the mobile bin is explained below

6.2.1 MOBILE BIN

This is used to carry the roof sheets in vertical orientation. The main purpose for designing this mobile bin is to save time in the handling of roof sheets. Since the roof sheets are stored in vertical position there is no wastage of time in changing. the orientation of the roof sheet from horizontal to vertical and then vice versa. This mobile bin can be coupled with the AGV for its movement from the seam welding machine cell to the assembly area.

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6.2.2 HYDRAULICALLY ACTUATED TABLE

This table is designed in such a way that it can tilt itself to a maximum of 45 degrees. The purpose of this table is to automate the movement of the roof sheets after seam welding, to store them in the mobile bin vertically. This table is hydraulically actuated with three links of which one is stationary and the other two are extendable. The height of the table from the ground is 225 cms which in turn is equal to the height of the stationary link and its outer diameter is 25cms. The first extendable link which is in direct contact with the stationary link extends to a height of 200cms and its outer diameter is 22cms. The second extendable link which is in direct contact with the first extendable link extends to a height of 175 cms, whose outer diameter is 20 cms. When the two extendable links are in their maximum extended position the table is lifted to a height of 600 cms from ground, thereby making an angle of 45 degrees with its stationary leg. The assembly of the Table and Mobile bin is shown in fig 6.1.

Fig 6.1 Table and Bin

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6.3 SUMMARY:
This chapter discusses the storage mechanism for the automated vertical storage of the roof sheet in order to reduce the handling time and automate the material handling. This includes the design, construction and working of the mobile bin and the storage table mechanism.

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CHAPTER 7 GALVINIZING PROCESS

Hot dip galvanizing is the process of applying a zinc coating to fabricated iron or steel material by immersing the material in a bath consisting primarily of molten zinc.

7.1 TYPES OF SURFACE PROTECTION

Barrier protection is perhaps the oldest and most widely used method of corrosion protection. It acts by isolating the metal from the electrolytes in the environment. Two important properties of barrier protection are adhesion to the base metal and abrasion resistance. Paint is one example of a barrier protection system. Cathodic protection is an equally important method for preventing corrosion. Cathodic protection requires changing an element of the corrosion circuit, introducing a new corrosion element, and ensuring that the base metal becomes the cathodic element of the circuit. Hot dip galvanizing provides excellent barrier protection as well as cathodic protection.

7.2 ELEMENTS OF GALVINIZING PROCESS

The galvanizing process consists of three basic elements: Surface Preparation Galvanizing

Inspection 7.2.1 SURFACE PREPARATION

Surface preparation is the most important step in the application of any coating. In most instances where a coating fails before the end of its expected service life, it is due to incorrect or inadequate surface preparation.
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The surface preparation step in the galvanizing process has its own built-in means of quality control in that zinc simply will not react with a steel surface that is not perfectly clean. Any failures or inadequacies in surface preparation will be immediately apparent when the steel is withdrawn from the molten zinc because the unclean areas will remain uncoated. Immediate corrective action is taken. Surface preparation for galvanizing typically consists of three steps: caustic cleaning, acid pickling, and fluxing.

1. Caustic Cleaning - A hot alkali solution often is used to remove organic contaminants such as dirt, paint markings, grease, and oil from the metal surface. Epoxies, vinyl, asphalt, or welding slag must be removed before galvanizing by grit blasting, sand blasting, or other mechanical means. 2. Pickling - Scale and rust normally are removed from the steel surface by pickling in a dilute solution of hot sulfuric acid or ambient temperature hydrochloric acid. 3. Fluxing - Fluxing is the final surface preparation step in the galvanizing process. Fluxing removes oxides and prevents further oxides from forming on the surface of the metal prior to galvanizing and promotes bonding of the zinc to the steel or iron surface.

7.2.2 GALVANIZING
In this step, the material is completely immersed in a bath consisting of a minimum of 98% pure molten zinc. The bath chemistry is specified by the American Society for Testing and Materials (ASTM) in Specification B 6. The bath temperature is maintained at about 850 F (454 C). Fabricated items are immersed in the bath long enough to reach bath temperature. The articles are withdrawn slowly from the galvanizing bath and the excess zinc is removed by draining, vibrating, and/or centrifuging.

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7.2.3 INSPECTION
The two properties of the hot dip galvanized coating that are closely scrutinized after galvanizing are coating thickness and coating appearance. A variety of simple physical and laboratory tests may be performed to determine thickness, uniformity, adherence, and appearance.

7.3 BENEFITS OF GALVANIZING PROCESS

Lowest first cost Less maintenance/Lowest long term cost Long life Reliability Toughest coating Automatic protection for damaged areas. Complete protection Ease of inspection Faster erection time A full protective coating can be applied in minutes

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7.4 SUMMARY:
This chapter deals with the concept of galvanization in order to protect the roof sheets from the effect of the atmosphere. This explains the various types and elements of galvanization process and also covers the various advantages of this process..

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CONCLUSION
Through this project we were able to analyse the existing plant layout and various material handling techniques present at the integral coach factory. The major areas addressed here and solved were reduction in the WIP inventories, change in the existing plant layout thereby reducing the operation and assembly time for the same number of roof sheet assemblies or for the same time increase in the number being produced. Though the entire WIP inventory cannot be brought down to zero, we have suggested a technique to protect them from the effect of atmosphere thereby preventing corrosions. We have also suggested a new material handling technique in order to reduce the overall material handling time thereby increasing the productivity from 1400 coaches in the year 2009-2010 to more than 2000 post implementation. The significant improvements made are: Change in the plant layout, thereby decreasing the distance between the work centers, using ALDEP algorithm Increasing the overall productivity by 21.89% Reducing the Idle time of the machines thereby decreasing the overall WIP inventory. Devising a new material handling system bringing it close to automation. Suggestion of Galvanization process for the protection of roof sheets from corrosion.

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REFERENCE
Bley. H and Zenner C. (2005), Handling of process and resource variants in the digital factory CIRP Journal of Manufacturing Systems, No 34 H. 2, p. 187-194. Bley.H, Fritz.J and Zenner.C (2006) Digital factory in automobile industry vol 101, no 12, p 19-23. Blumenau.J and Wuttke.C (2005), Application of the digital factory in the ramp up of production systems by using online-data vol 54, no 34(3), p. 241-245. Bracht.U and Masurat.T (2005), The Digital Factory between vision and reality vol 56, no 4, p. 325-338. Cai,J and Weyrich.M (2004), Digital factory triggered virtual machining process planning for power train production in extended enterprise vol 32, no 3, p 332-342. Cai,J and Weyrich.M (2004), Supplier integrated power train machining process planning in digital factory vol 19, no: 4, p. 565-572. Hummel.V and Westkmper, E (2006), Factory Life Cycle Management vol 107, no 4, p. 178-182. Gausemeier, J and Stollt,G (2006), Digital factory and virtual production vol 101, no 1-2, p. 28-34. ICF official website www.icf.gov.in.

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