Elimination of ergonomics risks for Valve &

Injection Timing Setting Operation in

QSK60/QSK45 Engine
Category : Engineering

Team Members :Malhari Gaikwad, Kiran Shinde, Umesh Inamke,

Rajendra Kajarekar,

HHP RC Phaltan, India, Asia.

Contact Email. malhari.gaikwad@cummins.com ; Contact no: +919763700898

Regional Representative :Chandrashekhar Kulkarni

Email: chandrashekhar.Kulkarni@cummins.com ; Contact no: +918888848589

Ergo Cup Award

 Problem Description
P.S: Please refer;
1) Problem Description 1 (PD1) for Valve Setting
2) Problem Description 2 (PD2) for Injection Timing

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PD1-1/3 : Valve setting QSK45/60 6 ergo hit list

Engagement of manual 3 People Engagement is required

barring bar with flywheel for cr.shaft rotation & mark checking

Continuation of rotation till damper valve lettering matches the mark

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PD1-2/3 : Valve setting QSK45/60

Problem Statement
Manual rotation
of crank shaft to
adjust gap between
rocker lever &
cross head or
injector.
Repetition is for
12 OR 16 Times per
Engine.
Pls refer next slide
for video
Once the lettering matches the mark, complete the valve setting process.
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PD1-3/3 : Valve setting video QSK45/60

Please click on video to start.

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PD2-1/3 : Injection Timing 6 Ergo hit list

Engage the manual barring bar Rotate cr. shaft & check injection
with flywheel timing. 2 People Engagement

In absence of compression (due to absence of rocker lever & injector) moment required to
rotate the crank shaft is manageable by single operator.
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PD2-2/3 : Injection Timing
Problem Statement
Manual rotation
of crank shaft to
adjust injection
timing.
Repetition is for
4 Times per
Engine.
Please refer next
Slide for video

Crank shaft need to be rotated clockwise & anti clockwise to check the injection timing
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 PD2-3/3 : Injection Timing video

Please click on video to start.

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Risk Analysis: Quantitative Analysis (Initial)
Valve Setting (PD1) Injection Timing (PD2)

Strenuous activity of manually rotating crank shaft by two individuals at a time has high potential to induce
stress & pain in; Back, Shoulders, Wrists, Forearms, Legs.
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Risk Analysis: Ergonomics hit list (Initial)
Valve Setting / Injection Timing (PD1 & PD2)

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Risk Analysis: Ergonomic job analysis worksheet.
Valve Setting / Injection Timing (PD1 & PD2)
ERGONOMIC JOB ANALYSIS WORKSHEET
Job Title: Valve setting and Injection timing adjustment Job Location: Station 2 of HHP Engine Assembly Line at
for QSK45/60 engine. HHP RC, Phaltan
Cycle: 160 min ( 9600 Sec )
page 1 of 3
Please refer
Date of Analysis: 18.11.2014
Tools: Manual Barring bar,9/16 socket,Pnuematic
gun,Injection timing tool
attached file for
PPE- Hand Gloves, Goggles, Safety Shoes and Helmet
detailed view.

Parts: Partial assembled engine till cylinder head

Materials: Marker

Environmental Conditions: Good working

environment ( Better illumination, air quality etc. )

Provision of
Hydraulic
Element Description Risk Factors Causes Possible Solutions
(Number and describe each element)
1. Remove all(16) valve cover from engine
(by element & body part)
REP - Wrist and Shoulder
(by element & risk factor)
REP- Height of engine and Pnuematic tool
(by cause & risk factor)
Reduce engine mounting stand height and provide
pistol type pnuematic gun
arrangement for
2. Insert manual barring bar in to barring adaptor POS - Wrist and Back POS - Lower height of block Increase height of block mounting stand

3. Ratate crankshaft clock wise till match mark on POS - Wrist,back,shoulder,knee POS - Force to rotate engine crank Hyadraulic arrangement to rotate engine
engine rotation is
damper to pointer crankshaft
4. Perform valve adjustment for cylinder number as per POS- Shoulder
damper mark. CON- Arm
POS- Height of Block
CON-movement of hand
Reduce engine mounting stand height and full sleeve
gloves finalized.
5. Perform injector adjustment for cylinder number as POS- Shoulder POS- Height of Block Reduce engine mounting stand height and full sleeve
per damper mark. CON- Arm CON-movement of hand gloves
6. Repeat step 3, 4,5 16 times to complete valve and REP - 16 times REP - Multiple cycles
_
injector adjustment

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Conceptualization & finalization of hydraulic
mechanism for valve setting & injection timing
Manual moment
application to
rotate the crank
shaft will be
eliminated.

Hydraulic power Hydraulic Motor Direction control valves for

pack controlling direction
(forward/reverse) hydraulic
motor 12
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PD1 Solution: Valve Setting

Hyd motor
operating lever

Engage the hydraulic motor with With hyd. power pack & DCVs
flywheel ring motor can drive the cr. Shaft in
CW & ACW direction

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PD1 Solution: Valve Setting (Video)

Cummins Confidential Please click on video to start. 14

PD2 Solution : Injection Timing

Engage the hydraulic motor with With hyd. power pack & DCVs
flywheel ring motor can drive the cr. Shaft in
CW & ACW direction

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PD2 Solution: Injection timing (Video)

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Please click on video to start. 16
Result
PD1 : Valve Setting PD2 : Injection Timing

Reduction in risk priority score Reduction in risk priority score

from 81.3 to 7.5 from 44.8 to 4.8
No Ergonomic hit list in valve setting as well as injection timing
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 Result
Valve setting (PD1) operation can be performed by one operator instead
of three & one operator in injection timing(PD2) instead of two.
HIRA risk score reduced from 272 to 45.
Cycle time reduction by 16 min.
Increased employee morale.
Ergonomics risk factors eliminated substantially.
Lady employee can perform these operations.

Such projects helps to sustain target

of incident free days

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Supplier Information for Engine Barring
Mechanism
Supplier Details:
Metal Craft
603, Shukrawar Peth,
Near Yadav Vyapar Bhavan.
Pune- 411002, Maharashtra, India.
Contact Person: Rajendra P. Dharmadhikari
Phone No: +919422031798
E mail: metalcraft13@yahoo.com

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 Thank You!

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