Session1 Case2

A Presentation by
Sundaram – Clayton Limited,

Die Casting Division,Chennai.
Sundaram-Clayton Limited 1 20.08.2010

Die Casting Division, Padi Plant
INTRODUCTION
TS 16949,OHSAS Certified

COMPANY PROFILE
Sundaram Clayton - Journey
TS 16949
Certification -
2005
Started Collaborative
product development
with MNC Customer -
2001
Commissioned
Alloying plant -
Started as Captive 2000
unit with OHSAS
Aluminium Gravity Certification -
Die casting – GDC- Started 2006
Global Supply started -
1968 Supplies to
2000
Honda - 2003
Started
Aluminium
Pressure Die
Casting - 1983
60 65 70 75 80 85 90 95 2000 2005
COMPANY PROFILE
Products and Customers

Die Casting Division

Project title : Productivity Improvement in Compressor
cover machining cell to meet the increase in customer
demand without additional capital investment.
Team leader : Rajmohan J
Team members : Department
Subha K Online Production engineering

Bhavan Kumar K Production
Chitra V Online Production engineering
Ramesh G Quality assurance
Gosu Ramaiah Production
Purushothaman .P Production engineering

Product detail
Product Name : Compressor Cover
Casting Type : Gravity Die Casting
Customer Name : Cummins Turbo Technologies
Application : Turbo Charger assembly part
Delivery condition : Machined Component

Approach
7 step approach
Step 7. Horizontal deployment
Step 6. Standardization
Step 5. Implementation & Verification
Step 4. Analysis & Improvement plan

Step 3. Selecting opportunities
Step 2. Understanding the current situation.

Step 1. Problem identification

Step 1 – Problem identification
Increase in customer demand from 7100Nos to 15900 Nos/Month

17000
15900
100%
Increase in
No. of components
14000
demand
11000
CAPACITY
7100
8000
5000
Current demand Future demand
Importance of problem:
 100% share of business for this product is with SCL and hence shortfall
in supply will result in customer line stoppage.
 Additional investment of Rs. 50 Lakhs required to meet the future demand

which will affect the bottom line.

Step 2- Understanding the current situation
Takt time calculation

Description Current Future
Available time in a month(Sec) 1721250 1721250
Average monthly demand(nos.) 7100 15900
Takt time(sec) 243 108
Output/shift 94 212
Takt time = Available time

Customer demand Takt time
250
Time in seconds 200
150 243
100
50
108
0
Current Future

Process flow – Compressor cover machining line
Inlet machining
Diffuser side
machining
Machining
Lathe-3
Lathe-2
Lathe-1
hole drilling
Name plate
Outlet
Part Feeder
TANK
tank
tank
DIP
Dip
Dip
Gauge Gauge Gauge
Gauge Final
VMC Leak Washing
inspect Heater Cooler Packaging
Drilling,R testing machine
-ion
eaming &
Tapping
No. of operators per day = 9

No. of Lathes =3
No. of VMCs =1
Space occupied = 1120 sq.ft

Ex: Man- machine chart from Video study – For first operator
15900

Man – machine time
300
Bottleneck machines
250
Current Takt time – 243 Secs
17
200 12
Time in Secs
150
Future Takt time – 108 Secs
218
100 199
13
60
50
70 81 10 72
60 50 60
30 25 34 30
0 7 9 15
Gauging
final
NP drilling
Outlet m/cing
Washing
Diffuser
Air cleaning
Inlet m/cing
Deburring
Aircleaning
Milling,drilling
Deburring
Air cleaning
Marking
m/cing
Leak testing
& reaming
AUTO TIME
Operator 1 Operator 2 Operator 3
MANUAL TIME

Methodology
ECRS Methodology
E - Eliminate
C – Combine
R – Reduce
S – Simplify
From ECRS Methodology these themes were identified

Improvements – Classification by themes
Methodology
Theme E C R S
Improved tooling - A
Parameter optimization -B
Combining tools - C

How to de-bottleneck ?
Milling, Reaming and Tapping operation in VMC

Machine time - existing
300
250
Current Takt time – 243 Secs
17
200 12
150
Future Takt time –108 Secs 218

Time in Secs
100 199
13
60
50
81
34
0
Outlet m/cing
Diffuser
Inlet m/cing
Milling,drilling
m/cing
& reaming
AUTO TIME
MANUAL TIME

Step 3- Selecting opportunities
Milling, Reaming & Tapping in VMC

Cycle time details with improvements identified
Operation Cycle Proposed
S.NO description Speed Feed time improvement The me
Milling cutter
(Carbide) Big Milling cutter Small
1 Holder (75 mm) 4000 600 28 Holder (60 mm) B
2 6.8 Carbide Drill 3000 0.15 27 6.8 Parabolic Drill A & B
High speed W alter
3 M8 Tap 800 1.25 26 taps A & B
4 4 Dia Drill 3000 0.15 23
4.395 c arbide
5 Reamer 5000 0.02 57 4.395 PCD Reamer A & B
6 1.6 Centre Drill 2000 0.1 16 1.7 center drill and
7 1.7 Drill 2000 0.08 19 drill C
8 1.95 Reamer 2000 0.06 16
Door close&open 6
218
220
200 16
180 19
16
Time in Secs
160
140 57 Future Takt time -108Secs
120
100 23
80
26
60
40 27
20 28
0
Before improvem ent
M il l ing 6 . 8 d r i l l i ng M 8 T a p pi ng
4 di a dr i l l 4 . 3 9 5 r e a m i ng 1. 6 c e n t r e d r i l l
1. 7 d r i l l 1. 9 5 r e a m e r Ta k t t i me

Milling, Reaming & Tapping in VMC

Cycle time details
Operation Cycle
S.NO description Speed Feed time
Milling cutter
(Carbide) Big
1 Holder (75 mm) 4000 600 28
2 6.8 Carbide Drill 3000 0.15 27 1
3 M8 Tap 800 1.25 26
4 4 Dia Drill 3000 0.15 23
4.395 carbide
5 Reamer 5000 0.02 57 2
6 1.6 Centre Drill 2000 0.1 16
7 1.7 Drill 2000 0.08 19 3
8 1.95 Reamer 2000 0.06 16
Door close&open 6
218

Step 4- Analysis & Improvement
1.Theme A – Improved tooling & B – Parameter optimization

Description : Dia 6.8 drilling
BEFORE OBSERVATION
Maximize cutting parameter

• Standard 6.8 drill
Poor tool life
Tool wears off faster
Higher temperature at cutting edge
High temperature
Speed :3000 RPM
Feed : 0.15mm/rev

Improvement details ( Theme A &B)

Description : 6.8 Parabolic drill for blind hole to help chip evacuation
Theory Idea 1 Idea 2
Burnishing drill Parabolic drill
Cutting edge • Additional relief on
• Can go at high tool.
parameters • Enhanced coolant flow
• Good tool rigidity & life • This improves chip
• Good surface finish evacuation and hence
• Best suited for core reduces temperature at
cutting edge.
holes (PDC Castings) Additional
relief for
Chip flow • Poor chip evacuation coolant flow
direction when l/d is high/ Blind
Hole/ material allowance
Coolant flow direction
is high

Step 5- Implementation and verification
Solution identified – Parabolic drill

BEFORE AFTER BENEFITS
Standard 6.8 drill Parabolic drill Cycle time
210
205 >5 %
205
Time in Secs
200
195 192
190
185
180
Before After
Cycle time saved – 13 Secs
Speed :3000 RPM Speed :4000 RPM * No impact on tool life &
Feed : 0.15mm/rev Feed : 0.25mm/rev tool cost per component


Description : Carbide reamer (4.395 ± 0.02) for finishing
close tolerance of 40 microns
BEFORE OBSERVATIONS
Carbide reamer
 Built-up edge formation.
 Poor repeatability.
 Poor life for close tolerances.
Speed :5000 RPM

Feed : 0.02 mm/rev
Tool life : 1500 Nos
Cp < 1.67
Improvement details (Themes A& B)

Description : Carbide reamer to PCD reamer (4.395 ± 0.02) to address close
tolerance of 40 microns ( Reduce thermal wear)
Theory Solution
PCD reamer
The cutting material
should
 Have good heat resistant

property at high temperatures.
 Have good repeatability.
 No built up edge formation.
 Performs better at high cutting

parameters (200-250m/min).
 15 times the life of carbide.

Solution identified – PCD Reamer

BENEFITS
Cycle time Tool life Tool cost / component
25150 0.65
180
>15 Times
No. of components
171 20000
170 >20% 20150 0.6 15%
Cost in Rupees
0.6
Time in Secs
160
15150
150 0.55
10150
140
131 0.5
5150 0.5
130
1200
120 150
0.45
Before After Before After
Before After
Cycle time Tool life : 15000 Nos Speed :7900 RPM

saved – 40 Secs Cp =2.67 Feed : 0.25mm/rev

3.Theme C – Combining tools

Description : Elimination of Roll pin pre drill
T1 - Centre drill T1 - Centre drill with 1.7

Cycle time
T2 - 1.7 Pre drill predrill 135 131
T3 - 1.955 Reamer T2 - 1.955 Reamer

130
20 %
Time in Secs
125
120
115
110 106
105
100
95
90
Before After
Cycle time saved – 25 Secs
3 Tools reduced to 2
and parameters
optimized • No significant impact
on Tool cost / component
Tool cost : Rs. 488 Tool cost : Rs. 475

Cycle time reduction in VMC – operation wise
240
220 17 >50 %
16
200 Takt
19
180 E&C 16
time
160 achieve
Time in Secs
140
57 d
R
120 Takt time – 108 Secs
100
23 17
80 11
R 26 13
0
60 13
40 R 27 13
11
20 28 11
R 13
0
Before improvement After improvement
Milling 6.8 drilling M8 Tapping 4 dia drill

4.395 reaming 1.6 centre drill 1.7 drill 1.95 reamer
Manual time Takt time

How to de-bottleneck ?
Diffuser side machining in CNC lathe 1

Machine time - existing
300
250 Current Takt time – 243 Secs
200 12
150
Time in Secs
Future Takt time –108 Secs

100 199 17
13
60
50 89
81
34
0
Outlet m/cing
Diffuser
Inlet m/cing
Milling,drilling
m/cing
& reaming
AUTO TIME
MANUAL TIME

Diffuser side machining

Cycle time details with Improvements identified
Operation Speed Feed Cycle Proposed
S.NO description rpm mm/rev time improvement The me
Step cutter to finish
1 Ris er m/c 1600 0.15 42 in s ingle pass A & B
2 Roughing 2000 0.3 38 Dia 25 to 32 shank B
3 Circlip grooving 800 0.06 24 Carbide to PCD A & B
4 Pre openout-4g 1500 0.1 12 Eliminate
Combination tooling
& parameter
5 Openout 'v' tool 1200 0.15 18 optimization A,B &C
6 Angular grooving 600 0.05 22
Parameter
7 Finishing vcmw 1800 0.15 38 optimization B
Door opening &
8 closing 5
199
200 38
180
160 22
Time in Secs
18
140
12
120
24
Future Takt time -108 Secs
100
80
58
60
40
20 42
0
Before improvem ent
Pre machining Roughing Circlip grooving
Pre open out Open out Angular grooving
Finishing Takt time

#2 Diffuser side machining

Operation Speed Feed Cycle

S.NO description rpm mm/rev time
1 Riser m/c 1600 0.15 42 1
2 Roughing 2000 0.3 38 2
3 Circlip grooving 800 0.06 24
4 Pre openout-4g 1500 0.1 12
5 Openout 'v' tool 1200 0.15 18 3
6 Angular grooving 600 0.05 22
7 Finishing vcmw 1800 0.15 38
Door opening &
8 closing 5
199


Description : Elimination of multiple passes in riser machining
due to large material removal in GDC
BEFORE OBSERVATIONS
Single point turning tool  Lower depth of cut
 Lower parameter.
Speed :1600 RPM
Feed : 0.15mm/rev
 More no. of passes - 12

Improvement details ( Theme A& B)
Description : Elimination of multiple passes in riser machining (due to large

material removal in GDC)
Idea 1 Idea 2
Option 1 – U drill with bigger Multipoint stepped insert type
insert progressive cutter.
 No of passes reduced from

 Load gets uniformly distributed
12 to 6
between the 5 steps
 But tool life reduced due to
 The subsequent step gets engaged
higher depth of cut.
only when the previous step finishes
its cut.Hence the operation is smooth
 Multiple passes to single pass.
 High cutting parameter.

Improvement details ( Themes A& B)

Description : Elimination of multiple passes in riser machining due to large
material removal in GDC
BENEFITS
Tool life Tool cost / component
Cycle time
210 25150 0.45
199 >10 % >15 Times 20000 10 Times
200
No. of components
20150
Time in Secs
Cost in Rupees
190
15150
180 173
10150
170
160 5150 0.05

1200
150 150 0
Before After Before After Before After
86 86
Cycle time saved – 26 Secs Before After

Holder cost(Rs) 9100 23000
Insert (Rs.) 542 728
Holder is one time investment.

Description : Alternate holder for roughing operation ( to improve rigidity)

SCLC Single point SCLC Single point
Cycle time
turning holder turning holder
of shank Dia 25 of shank Dia 32
180
173
15 %
175
35 mm 170
35 mm 165
160
155 153
150
145
140
32 mm 135
25 mm 130
Before After
86 86
Speed :2000 RPM Speed :2800 RPM Cycle time saved – 20 Secs
Feed : 0.3mm/rev Feed : 0.6mm/rev

Process capability report for critical dimension

G Dimension
9.037
8.997 USL G Dimension
8.957
8.917
8.877
8.837 Cp – 3.607
8.797
8.757 Cpk- 3.390
8.717 LSL
8.677
8.637
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
We monitor the performance of the capable dimensions
using a run chart.
Bearing bore diameter
80.04 USL
Bearing bore
80.02 Diameter
80 Cp – 2.73
LSL
Cpk- 2.44
79.98
1
7
9
11
13
15
17
19
21
23
25
27
29
31

3.Themes A& C –Combination & improved tooling & B – Parameter optimization
Description : Pre open out tool
BEFORE PROCESS / TECHNOLOGY AFTER

•Groove open out- ‘V’ • ‘V’ Cum Flat tool
tool Open
out
Back Finishing
Tool cost –
Rs1750 chamfer
•Groove finishing - Flat

tool
Both open out and
Process finishing done in the
 Combining both the V same tool.
Tool cost – and the flat tools. Cpk –1.8
Rs 2079  Reduces one tool
Indexing time. Tool cost – Rs 2850
Tooling cost – Rs 3829
Improvement details (Theme A , B & C)

Description : Elimination of pre-open out tool
BENEFITS
Cycle time Tool life Tool cost / component
145
142 1750
8% 2.5
No. of components
1450 1500
140 1550
2.4
24 %
Cost in Rupees
1350
Time in Secs
135 1150
130 950
130 1.9
750 1.9
125 550
350
120 150 1.4
Before After Before After Before After
Cycle time saved -12 Secs

Before After
Tool cost(Rs) 3829 2850
Tool cost saving – Rs. 979

Cycle time reduction Diffuser side machining- after improvement
300
Gap of
250
12 Secs
211 >40 %
200 12
Time in Secs
15 0
120
12
10 0 199
Takt time – 108 Secs
50 108
0
Before
improvement
After implementation of all identified improvements After
There was a still a gap of 12 Secs to achieve the Takt time

Phase 2 : Study of dimensions, achieved in diffuser side machining

Tolerance
Dimension <50microns 50-100 Microns >100 Microns
Diameter 80.035/80
Dia W 39.55/39.45
F Dimn 8.45/8.35
Groove position
4.795/4.745
Groove width
2.125/2.075
G dimn 9.329/9.229
Angular groove
width 2.75/3.25
Observation & Inference : Tolerance of angular groove

is wider (above 200 microns) and hence this could be
done in a different set up
Solution identified – Transfer angular grooving operation

from diffuser side machining to inlet side machining
BEFORE PROCESS / TECHNOLOGY AFTER
•Forward machining •Reverse machining

Done in diffuser side Done in inlet side
machining machining
36mm
56mm
 Insert direction reversed.

 The bore ID is 42mm.
 Tool holder modified to
suit the application

Angular grooving operation transferred from diffuser side machining

to inlet side machining to de-bottleneck it.
BENEFITS
Cycle time
120
108
20 %
110
Time in Secs
100
90 86
80
70
60
Before After
Cycle time saved - 22 Secs
*No significant impact on Tool life & Tool cost/component

Step 5 - Verification
Cycle time reduction in diffuser side machining – operation wise
240
220 12 >50 % Takt time
200 R was
38
180
achieved
22
Time in Secs
160
E,C & R 18
140
12
120 Takt time – 108 Secs
R 24
100
12
80
R 58 23
60 0
11
0
40 13
42 18
20 R&S
16
0
Before improvement After improvement
Pre machining Roughing Circlip grooving

Pre open out Open out Angular grooving
Finishing Manual time Takt time

Step 5 - Verification
Machine time- After improvement
300
Op 30 Becomes
250 Op 20 was a bottleneck
debottlenecked
200
Time in Secs
150
#3 Takt time – 108 Secs
13
100 17
12
60
50 103
86 89
34
0
Op 20
Op 30
Op 40
Op 50
AUTO TIME
Consistent output obtained from op :20.
Op 30 becomes bottleneck due to transfer of grooving operation
MANUAL TIME

#3 Inlet side machining

(Horizontal deployment of learning)
BEFORE AFTER
Operation Cycle Proposed Cycle
S.NO description Speed Feed time improvement Speed Feed time Theme
Eliminate based on
1 OD rough turning 1600 0.15 32 stock removal 0
Single tool gippa
2 OD finishing 1700 0.2 26 rough and finish 2000 0.25 38 B
3 Facing 25 boring 1600 0.15 23 Dia 32 holder 2000 0.25 11 B
Shifted to this
4 Angular grooving operation 600 0.05 22
81 71
Takt time was achieved
A - Improved tooling B – Parameter optimization C – Combining tools

Step 5- Verification
Machine time – achieved after improvements
200
150

Time in Secs
100 17
12
13
60
50
86 89
71
34
0
Op 20
Op 30
Op 40
Op 50
AUTO TIME
MANUAL TIME
Consistent output obtained from all four operations.

Step 5- Verification
Man – machine time (After improvement)
300
Existing Takt time – 243 Secs

250
200
Time in Secs
150
100 12 17
13
60
50 86 89
70 71 60 10 60 72
34
50
30 25 15 30
0 7 9
Gauging
final
NP drilling
Outlet m/c
Washing
Diffuser
Air cleaning
Inlet m/cing
Deburring
Aircleaning
Deburring
Air cleaning
operations
Marking
m/cing
Leak testing
VMC
ing
AUTO TIME
MANUAL TIME

Step 6- Standardization
Example of Standardization (PCD reamer)
Other standardization points :

 Operation standard and Quality control and Process chart.
 FMEA.
 Man – machine chart.
 Tool list.
Step 7- Horizontal deployment
Horizontal deployment status
Implemented
NA - Not applicable

Step 6 – Results & Standardization
Summary of Improvements
Cell capacity Vs Demand Output per Man per Hour
Number of components
Number of components
17000 8.75
15900 15900 9
15000
>60 %
13000 >100 % 7
11000
5.25
9000 5
7700
7000
5000 3
Before
After
After
Before
Demand before
Demand after
Benefits :
Customer demand met on time without additional investment of Rs.50
lakhs.
Sales to gross fixed asset has improved from 3.2 to 7.25 (126%
improvement)
Productivity (Output/man/hour) improved by 60 %

Intangible benefits
1. High process capability of critical characteristics
achieved
2. Improved utilization of man and machines achieved.
Key learning
1. Progressive multi point stepped cutter
(innovative idea).
2. Parabolic drill ( innovative idea).
3. V cum flat combination insert (innovative idea).

Future plans
 Reduce manual time through introduction of
rotary fixture in VMC and through low cost
automation.

End of presentation


Session1 Case2

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A Presentation by

Sundaram – Clayton Limited,

Sundaram-Clayton Limited 1 20.08.2010

Sundaram-Clayton Limited 2 20.08.2010

Sundaram Clayton - Journey

Products and Customers

Sundaram-Clayton Limited 4 20.08.2010

Team leader : Rajmohan J

Team members : Department

Subha K Online Production engineering

Sundaram-Clayton Limited 5 20.08.2010

Product Name : Compressor Cover

Casting Type : Gravity Die Casting

Customer Name : Cummins Turbo Technologies

Application : Turbo Charger assembly part

Delivery condition : Machined Component

Sundaram-Clayton Limited 6 20.08.2010

Step 7. Horizontal deployment

Step 5. Implementation & Verification

Step 4. Analysis & Improvement plan

Step 2. Understanding the current situation.

Sundaram-Clayton Limited 7 20.08.2010

Increase in customer demand from 7100Nos to 15900 Nos/Month

 Additional investment of Rs. 50 Lakhs required to meet the future demand

Sundaram-Clayton Limited 8 20.08.2010

Takt time calculation

Takt time = Available time

Time in seconds 200

Sundaram-Clayton Limited 9 20.08.2010

Process flow – Compressor cover machining line

No. of operators per day = 9

Sundaram-Clayton Limited 10 20.08.2010

Sundaram-Clayton Limited 11 20.08.2010

Man – machine time

Sundaram-Clayton Limited 12 20.08.2010

From ECRS Methodology these themes were identified

Sundaram-Clayton Limited 13 20.08.2010

Milling, Reaming and Tapping operation in VMC

Sundaram-Clayton Limited 14 20.08.2010

Machine time - existing

Future Takt time –108 Secs 218

Sundaram-Clayton Limited 15 20.08.2010

Milling, Reaming & Tapping in VMC

Sundaram-Clayton Limited 16 20.08.2010

Milling, Reaming & Tapping in VMC

Sundaram-Clayton Limited 17 20.08.2010

1.Theme A – Improved tooling & B – Parameter optimization

Maximize cutting parameter

Tool wears off faster

Higher temperature at cutting edge

Sundaram-Clayton Limited 18 20.08.2010

Improvement details ( Theme A &B)

Sundaram-Clayton Limited 19 20.08.2010

Solution identified – Parabolic drill

Sundaram-Clayton Limited 20 20.08.2010

3.Theme A – Improved tooling & B – Parameter optimization

 Poor life for close tolerances.

Speed :5000 RPM

Improvement details (Themes A& B)

 Have good heat resistant

 Have good repeatability.

 No built up edge formation.