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Expander Changeover element

Opn
No

Op Op Op
1
2
3

Operation sequence

10

Waiting for operator to keep the last finished coil

20
30
40
50
60

Close the expander door


Searching for tools
Loose bolts
Search the spanner
Loose bolts

70

remove & wear gloves

80
90

opern the expander door


Bring tools

100

Displace table

110

Open #01 bolt with Allen T

120

Open #01 bolt with Allen T

130

Go to RH side of expander door

140

Open #02 bolt with Allen T from other side

150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330

Go to LH side of expander door


Bring tools
Flaring adjustment setting LH side
Go to RH side of expander door from behind
Flaring adjustment setting RH side
Go to LH side of expander door
Take Expander ram upside
Displace control panel
Bring tools
Back support plate bolt loose #04 with spanner
Keep Back plate down
Transfer back plate to storage area
Remove #04 bolts from expander after backplate unl
Back support plate bolt loose #04 with spanner
Keep Back plate down
Bolt adjustment for back plate mounting
Back plate mounting
Back plate assembly with adjustment
Expander Mandrel #01 insertion

340
350
360
370
380
390
400
410
420
430
440
450
460
470
480
490
500
510
520
530
540
550
560
570
580
590
600
610
620
630
640
650
660
670
680
690
700
710
720
730
740
750
760
770

Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander
Expander

Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel
Mandrel

#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01
#01

insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion
insertion

780
790
800
810
820
830
840
850
860
870
880
890
900
910
920
930
940
950
960
970
980
990
1000
1010
1020
1030
1040
1050
1060
1070
1080
1090
1100
1110

Expander Mandrel #01 insertion


Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Waiting for operator
Inspection for mandrel insertion
Move control panel
Take Expander ram downside
Inspection for mandrel insertion
Take Expander ram downside
Mandrel adjustment & locking
Take Expander ram upside
Inspection for mandrel insertion
Take Expander ram upside
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Take Expander ram downside
Mandrel adjustment & locking
Take Expander ram upside
Collet assembly
Take Expander ram downside
Cleaning of mandrel end
Expansion bullet assembly
Ram vertical height setting wrt coil height
First piece
Front plate setting
Receiver setting
Receiver placing on front plate
Receiver setting

r Changeover elemental study


Cycle
time
(Sec)

Cycle
time
(Sec)

23

0.4

9
60
17
21
98

0.2
1.0
0.3
0.4
1.6

18

0.3

12
16

0.2
0.3

0.1

26

0.4

19

0.3

0.1

38

0.6

5
15
29
20
21
5
25
2
4
70
5
27
115
48
7
115
8
210
60

0.1
0.3
0.5
0.3
0.4
0.1
0.4
0.0
0.1
1.2
0.1
0.5
1.9
0.8
0.1
1.9
0.1
3.5
1.0

Cumulati
ve
I/E Comments/Actions
time
(sec)
Operator should stand outside
23
E expander door for last coil
removal
32
I
92
E Tool trolley to be provided
109
I
130
E Tool trolley to be provided
228
I Electrical gun to be provided
No removal of gloves in
246
E between changeover,
insruction to operators
258
I
274
E Tool trolley to be provided
No displacement of table,
281
E
location to be defined
Sliding type bolt arrangemtn
307
I
to be used
Sliding type bolt arrangemtn
326
I
to be used
331
E
Sliding type bolt arrangemtn
369
I
to be used
374
E
389
E Tool trolley to be provided
418
I
438
E
459
I
464
E
489
I
491
E
495
E
565
I
570
E
597
E
712
I
760
I
767
E
882
I
890
I
1100
I
1160
I

Cycle
Target
time
ed
saving
cycle
potenti
time
al
0

23

9
5
17
5
60

0
55
0
16
38

18

11

26

19

38

10

40
30
30
30
45
35
90
50
35
40
27
60
30
35
30
33
37
50
20
22
28
20
15
28
17
17
17
18
17
17
22
16
17
15
20
22
20
37
16
18
19
16
22
20

0.7
0.5
0.5
0.5
0.8
0.6
1.5
0.8
0.6
0.7
0.5
1.0
0.5
0.6
0.5
0.6
0.6
0.8
0.3
0.4
0.5
0.3
0.3
0.5
0.3
0.3
0.3
0.3
0.3
0.3
0.4
0.3
0.3
0.3
0.3
0.4
0.3
0.6
0.3
0.3
0.3
0.3
0.4
0.3

1200
1230
1260
1290
1335
1370
1460
1510
1545
1585
1612
1672
1702
1737
1767
1800
1837
1887
1907
1929
1957
1977
1992
2020
2037
2054
2071
2089
2106
2123
2145
2161
2178
2193
2213
2235
2255
2292
2308
2326
2345
2361
2383
2403

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I
I
I
I
I
I
I
I
I
I
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I
I
I
I
I
I
I
I
I
I

20
20
18
24
180
20
4
100
40
95
440
20
5
22
27
10
9
7
9
9
10
133
65
21
140
12
35
218
300
550
963
76
150
140

0.3
0.3
0.3
0.4
3.0
0.3
0.1
1.7
0.7
1.6
7.3
0.3
0.1
0.4
0.5
0.2
0.2
0.1
0.2
0.2
0.2
2.2
1.1
0.4
2.3
0.2
0.6
3.6
5.0
9.2
16.1
1.3
2.5
2.3

2423
2443
2461
2485
2665
2685
2689
2789
2829
2924
3364
3384
3389
3411
3438
3448
3457
3464
3473
3482
3492
3625
3690
3711
3851
3863
3898
4116
4416
4966
5929
6005
6155
6295

I
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I No waiting of operator while C/
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I Stackable crate
I

91.75

Operator 1 - Permanant
Operation sequence
Cycle
Waiting for operator to keep the last finished coil
Close the expander door
Searching for tools
Loose bolts
Search the spanner
Loose bolts
remove & wear gloves
opern the expander door
Bring tools
Displace table
Open #01 bolt with Allen T
Open #01 bolt with Allen T
Go to RH side of expander door
Open #02 bolt with Allen T from other side
Go to LH side of expander door
Bring tools
Flaring adjustment setting LH side
Go to RH side of expander door from behind
Flaring adjustment setting RH side
Go to LH side of expander door
Take Expander ram upside
Displace control panel
Bring tools
Back support plate bolt loose #04 with spanner
Keep Back plate down
Transfer back plate to storage area
Remove #04 bolts from expander after backplate unl
Back support plate bolt loose #04 with spanner
Keep Back plate down
Bolt adjustment for back plate mounting
Back plate mounting
Back plate assembly with adjustment
Waiting for operator
Inspection for mandrel insertion
Move control panel
Take Expander ram downside
Inspection for mandrel insertion
Take Expander ram downside
Mandrel adjustment & locking
Take Expander ram upside
Inspection for mandrel insertion
Take Expander ram upside

time (Sec)
23
9
60
17
21
98
18
12
16
7
26
19
5
38
5
15
29
20
21
5
25
2
4
70
5
27
115
48
7
115
8
210
180
20
4
100
40
95
440
20
5
22

Expander Mandrel #01 insertion


Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Take Expander ram downside
Mandrel adjustment & locking
Take Expander ram upside
Collet assembly
Take Expander ram downside
Cleaning of mandrel end
Expansion bullet assembly
Ram vertical height setting wrt coil height
First piece
Front plate setting
Receiver setting
Receiver placing on front plate
Receiver setting

Total engagement

27
10
9
7
9
9
10
133
65
21
140
12
35
218
300
550
963
76
150
140

4910

Operator 2
Operation sequence
Cycle
Back support plate bolt loose #04 with spanner
Keep Back plate down
Transfer back plate to storage area
Remove #04 bolts from expander after backplate unl
Back support plate bolt loose #04 with spanner
Keep Back plate down
Bolt adjustment for back plate mounting
Back plate mounting
Back plate assembly with adjustment
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion

time (Sec)
70
5
27
115
48
7
115
8
210
60
40
30
30
30
45
35
90
50
35
40
27
60
30
35
30
33
37
50
20
22
28
20
15
28
17
17
17
18
17
17
22
16

Expander Mandrel #01 insertion


Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Waiting for operator
Mandrel adjustment & locking
Collet assembly
Cleaning of mandrel end
Expansion bullet assembly
Ram vertical height setting wrt coil height

Total engagement

17
15
20
22
20
37
16
18
19
16
22
20
20
20
18
24
180
65
140
35
218
300

2928

Operator 3
Operation sequence
Cycle
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert

time (Sec)
60
40
30
30
30
45
35
90
50
35
40
27
60
30
35
30
33
37
50
20
22
28
20
15
28
17
17
17
18
17
17
22
16
17
15
20
22
20
37
16
18
19

Op1
Op2
Op3

4910
2928
2392

6000
5000
4000
3000
2000
1000
0

Op1

Op2

Expander Mandrel #01 insert


Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Waiting for operator
Inspection for mandrel insert
Move control panel
Take Expander ram downside
Inspection for mandrel insert
Take Expander ram downside
Mandrel adjustment & lockin
Take Expander ram upside
Inspection for mandrel insert
Take Expander ram upside
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Expander Mandrel #01 insert
Total engagement

16
22
20
20
20
18
24
180
20
4
100
40
95
440
20
5
22
27
10
9
7
9
9
10
2392

Column J

Op2

Op3

Opn No
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
360
370
380
390
400

Operation sequence
Cycle time (Sec)
Back plate setting
1100
Waiting for operator to keep the last finis
23
Close the expander door
9
Searching for tools
60
Loose bolts
17
Search the spanner
21
Loose bolts
98
remove & wear gloves
18
opern the expander door
12
Bring tools
16
Displace table
7
Open #01 bolt with Allen T
26
Open #01 bolt with Allen T
19
Go to RH side of expander door
5
Open #02 bolt with Allen T from other si
38
Go to LH side of expander door
5
Bring tools
15
Flaring adjustment setting LH side
29
Go to RH side of expander door from beh
20
Flaring adjustment setting RH side
21
Go to LH side of expander door
5
Take Expander ram upside
25
Displace control panel
2
Bring tools
4
Back support plate bolt loose #04 with s
70
Keep Back plate down
5
Transfer back plate to storage area
27
Remove #04 bolts from expander after b
115
Back support plate bolt loose #04 with s
48
Keep Back plate down
7
Bolt adjustment for back plate mounting
115
Back plate mounting
8
Back plate assembly with adjustment
210
Expander rod setting
2611
Expander Mandrel #01 insertion
60
Expander Mandrel #01 insertion
40
Expander Mandrel #01 insertion
30
Expander Mandrel #01 insertion
30
Expander Mandrel #01 insertion
30
Expander Mandrel #01 insertion
45
Expander Mandrel #01 insertion
35
Expander Mandrel #01 insertion
90

I/E
E
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410
420
430
440
450
460
470
480
490
500
510
520
530
540
550
560
570
580
590
600
610
620
630
640
650
660
670
680
690
700
710
720
730
740
750
760
770
780
790
800
810
820
830
840

Expander Mandrel #01 insertion


Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Waiting for operator
Inspection for mandrel insertion
Move control panel

50
35
40
27
60
30
35
30
33
37
50
20
22
28
20
15
28
17
17
17
18
17
17
22
16
17
15
20
22
20
37
16
18
19
16
22
20
20
20
18
24
180
20
4

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850
860
870
880
890
900
910
920
930
940
950
960
970
980
990
1000
1010
1020
1030
1040
1050
1060
1070
1080
1090
1100
1110

Take Expander ram downside


Inspection for mandrel insertion
Take Expander ram downside
Mandrel adjustment & locking
Take Expander ram upside
Inspection for mandrel insertion
Take Expander ram upside
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Expander Mandrel #01 insertion
Take Expander ram downside
Mandrel adjustment & locking
Take Expander ram upside
Collet & Expansion bullet assembly
Collet assembly
Take Expander ram downside
Cleaning of mandrel end
Expansion bullet assembly
Ram vertical height setting wrt coil
First piece
Front plate setting
Receiver setting
Receiver setting
Receiver placing on front plate
Receiver setting

100
40
95
440
20
5
22
27
10
9
7
9
9
10
133
65
21
405
140
12
35
218
300
550
963
366
76
150
140

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Remarks
Operation sequence
Cycle time (Sec)
Back plate setting
1100
Expander rod setting
2611
Collet & Expansion bulle
405
vertical height setting
300
First piece
550
Front plate setting
963
Receiver setting
366
Total changeover time (
6295

Single
piece Hex
bush

105 min

Chart Title
3000
2500
2000
1500

2
2
2
2

1000
500
0

Back
plate
setting

Expande Collet &


r rod
Expansi
setting
on bullet

vertical
height
setting

First
piece

Front
plate
setting

art Title

rtical
ight
tting

First
piece

Cycle time (Sec)

Front
plate
setting

Receive
r setting

SET UP REDUCTION ON
Sr.
Problem area
No.

Searching of tools for setting

Allen key used for tightening and


loosening of bolts

3
6
7
9
11
15
4

8
10
12
13
14
15
16
17

Confusion in tightening and loosening


direction of bolts
No space to keep back plate after
removing from machine
Improper visualization on scale for
length setting
Less clarity in identification of Front
Plate sizes
No of turns in fixing studs are more in
Front plate.
Excess insertion of hairpins during
lacing causing rework at Expander
Fatigue to operator during loading and
unloading of Back plates
Observed longer set up time in Holding
block setting
Front plate mounting position according
to coil length is not clear
No visual identification on coil side
supports
More time taken in opening and
closing of Lift
More time taken in setting of coil side
support

18
19
20
21
22
23
24
25
26
27
28

SET UP REDUCTION ON MECHANICAL

Improvement actions Decided

Responsibility

1. Tool trolley with proper


identification to be provided
2. Tools pouch to be explored. No of
tools used during changeover to be
noted

Wasif S

Pneumatic tool to be provided for


tightening of all bolts

Ashish B/Sagar S

Need to give training and visual


identification to the operator
Need to explore space utilisation
properly
Eye magnifier to be provided for
proper view of scale
Need to provide size identification
on Front Plates
One Turn tightening bolts to be
explored
Stopper plate to be provided in
Lacing Fixture
Sling to be provided for lifting of
back plates.
Low weight material like Bakelite to
be explored
Low cost automation as like Jingda
Expander to be explored
Coil length wise mounting position
along with scale to be displayed
Visual identification to be provided
on coil side support
Front door locking up to 1000 mm
coils to be explored
Sliding type coil side support to be
explored
List of tools & components to be made
Trolley for expander station to be
selected & ordered
Back plate & front plate storage

EXPANDER

Vinod B / Pinaki G
Sagar S/Pinaki/VInod
Ashish B/ Wasif S
Utkarsh /pinaki
Sagar/Wasif
Ashish B/Pinaki G

Sagar S/Pinaki/VInod
Ashish B/Sagar
S/Vinod
VInod B / Pinaki G
Sagar/Utkarsh

Ashish B/Sagar
S/Wasif S
Ashish B

Side support setting one side fix &


other side setting
Dummy coils for rest of the area of
rods
Battery operated gun to be provided
for operators during changeover
Wedge /mechanical locking for front
plate as like receiver locking
Trolley for rod storage & disposal
Ready to insert rods so that exisitng
internal activity can be converted into
external
activityarrangement to be
Proper lighting
made for better visibility during rod
Single
piece lower bolt for back plate
insertion
adjustment, to be explored for top bolt
Digital
scale/infrared scale for coil fin
also
length setting to be explored
Dowel pin type arrangement for side
supports to be explored
Single piece side support to be
explored

AL

EXPANDER

Status

Tool trolley ordered


8no Allen bolt
tightening gun will be
provided. Long bit
developmnent in
progress.

Eye magnifier
received. assembly to
be done

Sagar
Wk 1 feb installation
will be completed
Trials to be taken on
29th Jan

Scale received, to be
installed

1st wk Feb trolley will


be received

Existing
Target date
cycle time

Target
cycle
time

Cycle
time
acheive
d

Completd
1.5Lavs quotation
received