Sl.

no Tooling Details Operation

Feed in
mm/min
Speed (S)
in RPM
Sl. no
1
Dia.100 mm milling
cutter
Rough
milling
1600 to
2240
675 1
2
Dia.100 mm milling
cutter
Finish
milling
4800 800 2
3 Dia. 80 boring bar
Rough
boring
238 564 3
4 Dia. 100 boring bar
Rough
boring
246 575 4
5 Dia. 101 boring bar
Rough
boring
380 762 5
6 Dia. 104 boring bar
Rough
boring
250 716 6
7 Dia. 90 boring bar
Rough
boring
282 640 7
8 Dia. 97 boring bar
Rough
boring
262 653 8
9 Dia.25 mm U drill drilling 200/254 1273 9
10 9.5 Burnnishing drill Dowelling 600 3344 10
11
Dia. 25.2 excentric
boring bar
Boring 150/1000 850/1100 11
12 Finish Dia. 90/100/101 F. Boring 180 1273 12
13 Dia. 90 boring bar F. Boring 200 1238 13
14 Dia. 80 boring bar F. Boring 230 1393 14
15 Dia. 104 boring bar F. Boring 171 1064 15
16
Dia.19 mm burnishing
Drill
drilling
516/65
/170
2065/300/
1000
16
17
18
18
19
20
TAFE TR.CASE TAFE CENTRE HSG.
Tooling Details Operation
Feed in
mm/min
Speed (S)
in RPM
Dia.100 mm milling
cutter
Rough
milling
2200 600
Dia.100 mm milling
cutter
Finish
milling
3200 716
Dia. 15.88 drill Drilling 300 2231
Dia. 100 mm Milling
Cutter for Egle milling
Milling 796 696
Dia. 100 mm Milling
Cutter for S/F
Milling 1150 960
Dia. 100 mm Milling
Cutter FOR LH/RH
Rough
boring
1800/2800 764
Drill Dia. 10.7 mm Drilling 800 3570
Drill Dia. 6.5 mm
Rough
boring
500 2500
5/16 18 UNC Tap Tapping 847 600
17.5 Burnnishing drill Drilling
1050/60/90
/75/90
720
Drill Dia. 9.3 mm Drilling 150 1500
Drill Dia. 17.465 mm drilling 150 1800
Dia. 107 boring bar R. Boring 100 200
Dia. 50.5 boring bar R. Boring 120 410
Dia. 334 boring bar R. Boring 60 133
7/16 16 UNC Tapping 544.285 300
Dia. 334 boring bar F. Boring 60 354
Dia. 15.95/20.65 Drilling 335 2002
Dia. 14.27/20.65 Drilling 180 1750
Dia. 75/82 mm Boring 544 300
3/4 16 UNF Tapping 396.88 250
TAFE CENTRE HSG.
Opn.
No.
Machin
e
Operation
Existing
CT in
min
Direct
Man
power
in nos
Observations
80
SPM
Drilling
Rear face and HLC face
drilling
4 min 3
90
SPM
Tapping
Bottom,Rear,sleeve face
and HLC face Tapping.
4.5 min 3
100
SPM
Tapping
LH and RH face tapping
in two set ups
5.5 min 3
0
27
1.All bore finish boring
and Dia.41.25 mm bore
rough to finish.
2.PPS milling, drilling and
reaming 3.
Axle bore finish boring.
4. 5/16 Tapping
6 min
70
SPM
Drilling
with
Double
Station.
1st Station: RH side,
sleeve pinion face and
dowel hole drilling. 2nd
Station : Bottom 4 hole
drilling
5.5 min 3
For SS operation
CT become 9
minand 54 sec
1.All bore Rough boring
except Dia.41.25 mm
bore. 2.sleeve
face facing,hub face
rough to finish 3.
Axle bore rough boring
6 min
3
60
SPM
Drilling
with
Double
Station.
1st Station: PTO Cover
drilling,Drain plug and
TCFF face drilling.
2nd Station : Yoke yole
drilling
5 min 3
50
1 HMC
(a81
Makino)
(2 pallet of
same set
up)
3
For SS operation
CT become 9
minand 54 sec
30
1 HMC
(a81
Makino)
(2 pallet of
same set
up)
1.Rough and Finish
Milling - LH/RH Axle face
milling.
2.Crown face and side
face rough and finish
milling.
3. Top and bottom egle
milling. 4.
LH side 15 hole drilling
with champer.
5. 6.53mm LH/RH drilling.
6 min
and
side
shift 9
min
3
Dia.125 mm Side
face milling cutter
is using for Egle
milling.
40
1 HMC
(a81
Makino)
(2 pallet of
same set
up)
In TAFE (SEBM)
TAFE CH PROCESS AND CYCLE TIME
20
HMC
Hundai.
KH630
(2 pallet of
same set
up)
1.Rough Milling - Front
(TCFF) & Rear face
2. Rough & Finish Milling-
SBFF & Bottom
3. Drilling 14 hole at HLC
FF and Dowelling 2 holes.
5 min,
53 sec
3
1. 4 side Hyd.
clamping
(Outside)
2. Machining
allowance 3 to 5
mm.
Op. No. Machine
CT in
min.
Direct
man
power
Connec
ting
load in
HP
Connecti
ng load
in KW
Usage
load in
KW
1 20 Duplex 7.15 39 29.25 11.7 Evaluation criteria Data
Saving/
loss
2 30 Duplex 7.5 37 27.75 11.1 1.Through put Time in min. 112
3 40
MSD 3 way
5.45 16.16 12.12 4.8 2. Capacity/day in nos. 151
4 50
MSD 2 way
3 20.66 15.5 6.2 3. Manpower (Direct) in nos 36
5 60
Horizontal
Milling
7.45 40.75 30.56 12.2 4. Manpower (In direct) in nos 3
6 70
Horizontal
Milling
7 6 4.5 1.8
5. Production Qty / Workmen in
nos.
3.87
7 75 Milling 3 10 7.5 3.0 6. Connected Load in KW 226
8 80
Horizontal
R Boring
7 13 9.75 3.9 7. Usage Load in KW 88
9 90
Horizontal
F Boring
7.6 14 10.5 4.2
10 100
Duplex
Milling
7.45 15 11.25 3.4 8 No. of machines 18
11 110
Horizontal
Boring
7.25 13 9.75 3.9
12 120 MSD 6.75 33 24.58 9.8
13 130 R-Drill 6.5 3 8 6 2.4
14 140 R-Drill 7 3 8 6 2.4
15 150 R-Drill 7.6 3 8 6 2.4
16 160 R-Drill 7 3 8 6 2.4
160A 4.3 2.4
165 3 0.0
18 185
Leak
testing
7.6 3 5 6
Total 112 36 302.57 226 88
3
3
3 6 8
Date :25.1.14
17
FOR Capacity 150 per day.
TAFE Transmission Case New Proposal
Existing line- SPM and GPM Route
R-Drill
3
3
3
3
0
1
2
3
4
5
6
7
8
9
10
2
0
4
0
6
0
7
5
9
0
1
1
0
1
3
0
1
5
0
1
6
0
A
C
y
c
l e
T
i m
e
i n

m
i n

Operation No.
TAFE Tr.Case existing SPM and GPM route Cycletime Chart
Takt time
7.6 min
Op. No. Machine
CT in
min.
Direct
man
power
Connecti
ng load
in KW
Usage
load in
KW
1 20 Duplex 25 7.15 39 29.25 11.7 Evaluation criteria Data
Saving/
loss
2 30 Duplex 25 7.5 37 27.75 11.1 1.Through put Time in min. 87 25
3 40
MSD2 way
20 5.45 16 12.12 4.8 2. Capacity/day in nos. 151 0
4 50 HMC 225 3 65 48.49 19.4 3. Manpower (Direct) in nos 27 9.00
5 70
Horizontal
Milling
10 7 6 4.5 1.8 4. Manpower (In direct) in nos 3
6 95+75+130+140 HMC 225 7.5 3 65 48.49 14.547
5. Production Qty / Workmen in
nos.
5.03 1.2
7 80
Horizontal
Boring
15 7.45 13 9.75 3.9 6. Connected Load in KW 292
8 90
Horizontal
Boring
10 7 14 10.5 4.2 7. Usage Load in KW 105 -16
9
60+100+160+16
0A
HMC 225 7.6 3 65 48.49 14.547
10 120 MSD 15 6.75 33 24.58 9.8
11 110
Horizontal
Boring
10 6.5 13 9.75 3.9
12 150 RD 10 7 3 8 6 2.4
13 165 RD 10 7.3 3 8 6 2.4
14 185
Leak
testing
10 7.6 3 8 6
87.2 27 391.0 292 105
835
Comparision of AOP proposal w.r.t existing set up
8. No. of machines 14 4
Total
3
3
3
3
Proposal - Add 3 HMC & improve handling by Removing 1 MSD, 3 RD,2 FN2H and 1 small Duplex
0
1
2
3
4
5
6
7
8
9
10
2
0
3
0
4
0
5
0
7
0
9
5
+
7
5
+
1
3
0
+
1
4
0
8
0
9
0
6
0
+
1
0
0
+
1
6
0
+
1
6
0
A
1
2
0
1
1
0
1
5
0
1
6
5
C
y
c
l e
T
i m
e
i n

m
i n

Operation No.
TAFE Tr.Case AOP proposal Cycletime Chart
Takt time
7.6 min
Op. No. Machine
CT in
min.
Direct
Man
power
Connectin
g Load in
KW
Usage
load
in KW
Evaluation criteria Data
1 20 Duplex 1 20 7.6 26 11
2 30 Duplex 2 20 7.5 25 10
3 40 MSD 3 WAY 4.0 26 11
4 50 Duplex 3 7.5 30 12
5 55 HMC (SS) 8.0 30 9
6 60 SPM R.Boring 6.5 4 1
7 70 SPM F.Boring 7.3 41 16
8 80 H.Milling 7.0 11 4
9 90 MSD4 WAY 6.8 36 15
10 110 SPM Facing 6.8 21 8
11 100 Simplex 5.0 13 5
12 120 SPM R Boring 7.5 11 5
13 130 SPM F Boring 7.6 10 4
14 140 RD1 7.6 3 6 2
15 150 RD2 7.2 3 6 2
16 160 RD3 6.0 3 6 2
17 160A RD4 5.5 3 6 2
18 170 B TAPFAST1 7.0 3 2 1
19 170 A TAPFAST2 7.2 3 2 1
20 180 TAPFAST3 7.5 3 2 1
21 215 Leak testing 7.6 3 4 1
144.7 39 318 124
Date :25.1.14
151
39
1.Through put Time in min.
6. Connected Load in KW
7. Usage Load in KW 124
Existing line- SPM and GPM Route
145
8. No. of machines 21
2. Capacity/day @ 85% OEE in nos.
3. Manpower (Direct) in nos
3
3
Total
318
3.4
6
FOR Capacity 150 per day.
TAFE Centre housing new proposal
3
3
3
3
4. Manpower (In direct) in nos
5. Production Qty / Workmen in nos.
0.0
2.0
4.0
6.0
8.0
10.0
2
0
4
0
5
5
7
0
9
0
1
0
0
1
3
0
1
5
0
1
6
0
A
1
7
0
A
C
.
T

i
n

m
i
n

Operations no.
TAFE CH existing SPM & GPM Route Cycle time . chart
Takt time 7.6 min.
Op. No. Machine
CT in
min.
Direct
Man
power
Connectin
g Load in
KW
Usage
load
in KW
1 20 Duplex 1 20 7.6 26.37 10.5 Evaluation criteria Data
2 30 Duplex 2 20 7.5 24.75 9.9 1.Through put Time in min. 96
3 40+170 New HMC1 225 6.76 48.4 14.5 2. Capacity/day in nos. 151
4 50+55 Existing HMC 150 7.00 30 9.0 3. Manpower (Direct) in nos 27
5 60 SPM R.Boring 10 6.5 3.5 1.4 4. Manpower (In direct) in nos 3
6 70 SPM F.Boring 10 7.3 40.5 16.2 5. Production Qty / Workmen in nos. 5.03
7 80+90 New HMC2 225 7.60 1.5 48.4 14.5 6. Connected Load in KW 336
8 100 Simplex 10 5.0 11.5 4.60 7. Usage Load in KW 117
9 110 SPM Facing 10 6.8 12.5 5.00
10 120 SPM R Boring 10 7.5 21 8.4 8. No. of machines 15
11 130 SPM F Boring 10 7.6 5 2.0
12
140+18
0
New HMC3 225 6.86 1.5 48.4 14.5
13 160 RD3 10 6.0 3 6 2.40
14 160A RD4 10 5.5 3 6 2.40
15 215 Leak testing 10 7.6 3 4 2
95.5 27 336.32 117.0
336.32
3
3
3
New Proposal- Add 3HMC by Removing 2 MSD,1 DUPLEX,1 FN3H,2 RD and 3 Tapfast machines
3
Total
Comparision of New proposal w.r.t existing set up.
3
0.0
2.0
4.0
6.0
8.0
10.0
2
0
3
0
4
0
+
1
7
0
5
0
+
5
5
6
0
7
0
8
0
+
9
0
1
0
0
1
1
0
1
2
0
1
3
0
1
4
0
+
1
8
0
1
6
0
1
6
0
A
C
.
T

i
n

m
i
n

Operations no.
TAFE CH New proposal Cycle time chart
Takt time 7.6 min.
Date :25.1.14
Benefit /
Loss
49.13
0
12.00
3.00
1.7
7.04
6
New Proposal- Add 3HMC by Removing 2 MSD,1 DUPLEX,1 FN3H,2 RD and 3 Tapfast machines
Comparision of New proposal w.r.t existing set up.