By: Ashish Sinha Nithin H S Pratik Tilak Ramakrishna Anantha

Objectives of Our Project

Reducing Traffic density in Gangways
Creating a centralized system in order to improve

traffic condition.

Root causes for Traffic Jam

Problem 1 Under utilized gangway between engine Jundate and engine sub assembly line
Root Cause:

Tow motor is being parked in that gangway, while driver is fixing hose pipes for engine. Solutions: Shifting the parking place and inventory shelf towards engine sub assembly line. Benefits: Diversion of Chassis frame tow motor and engine sub assembly line supplies to weld shop gangway through this route.

Present Situation
Gangway is blocked by the parking of Tow motor

3650

3900

Tow motor with engine

Engine Jundate

chorokyu

Pneumatic cylinder

Proposed Idea

Tow motor with engine

chorokyu

Engine Jundate

Pneumatic cylinder

Problem -2 Parking of Dollies near IP Sub assembly line obstructing the gangway 1
Root Cause

There is no space available for dollies while replenishing the stock. Solution Introducing Set Pallet System for IP sub assembly line. Benefits It will remove traffic congestion near IP sub assembly line.

Problem - 3 Parking of Dollies near Engine Sub assembly line obstructing the weld shop Gangway
Root Cause

There is no space available for dollies while replenishing the stock. Solution Introducing Set Pallet System for Engine sub assembly line. Benefits It will remove traffic congestion near Engine sub assembly line.

Kaizen -1 Increasing the Rear Axle lot size from 4 to 5

Number of movements can be reduced are -

19

Increased movement of Assembly line employee is

30 cms

Kaizen -2 Shifting the tow motor parking place which is obstructing the traffic in the junction

Problem - 4
Traffic Jam at Junctions
To many tow motors are coming from different

direction at the same time causing an average traffic jam of 1.2 mins.

Centralized Inventory and Traffic monitoring system

Based on the real time inventory at assembly line each tow

motor agent is assigned dynamically with a priority. The priority is completely automatic and it can be set manually in the master centralized control unit by using the key pad and an LCD display. IR transmitter is installed on each Tow motor and IR receiver is installed on each road near the common interface. The agent continuously transmits its ID code and when the tow motor approaches the common interface IR signal from the agent is detected by the road unit.

Contd..
The road unit then transmits the ID of an agent to the

centralized control unit. The control units then processes on the ID to find out its priority, based on the priorities received by other IDs the centralized unit assigns proceed/ stop traffic signal agent and sends it to each agent via GSM unit. The GSM information containing the traffic signal then switches the GREEN/RED/YELLOW light in the agent.

Real time Inventory manipulator

Sensors used for finding out inventory at Assembly line

Long range IR Proximity sensor

Ultrasonic Sensor Error 0.5cms

Motion sensor

Bending Beam Load Sensor Error 1% of its capacity

 Ultrasonic sensor: List of workstations

Fortuner SPS dolly Carpet Roof mould Weighing sensor: List of workstations: Stabilizer bar Rear axle Propeller shaft Exhaust center pipe Radiator Proximity sensor: List of workstation: Tyre LH Tyre RH Motion sensor: List of workstation: Modular dolly IP dolly Engine

Ultrasonic Sensor working Principle

Centralized system

20 mts

Real time inventory data

-- Tow motor -- Base station -- Zig bee Transreceiver

-- Micro processor

-- EEPROM

Centralized system

Real time inventory data

Inventory at assembly line

14 32

Real time inventory data

4 15 3 2

Real time inventory data

Lack of Communication Between tow motors

SPS 1. Tow motor moves from SPS to A/S line for part delivery, 2. Tow motor waiting in A/S line for part delivery , 3. Second Tow motor is coming to A/S line for part delivery , The parking of Tow motors causing traffic congestion in Gangway, because there is no proper communication between two tow motors.

Proper Communication Between tow motors

SPS 1. Tow motor moves from SPS to A/S line for part delivery, 2. Tow motor waiting in A/S line for part delivery , 3. First tow motor inform the Second Tow motor to stop near SPS until it inventory get consumed to fixed quantity , The parking of Tow motors can be eliminated with proper communication between two tow motors.

Benefits
Low cost and efficient system
Long range sensors Reprogrammable cmos

It can minimize traffic Jam with real time data

Reduction of traffic congestion at each junction. Proper information sharing between tow motors.

Alternative method of finding the inventory using programme

Logic will be calculating the inventory of each part at work

station based on production output and number of trips. Number of trips will be counted by bay station. Central system will be counting vehicle output.
Inventory = (No. of trips * lot size) (Output * Consumption/unit)

Estimated project cost for one junction

Centralized Unit:

Cost: Rs.15,000/unit
Vehicle Unit:

No. of tow motors: 14 Total cost per unit :Rs.7,000 Total cost : Rs.98,000
Road Unit:

No. of road units required=3 Total cost per unit= Rs.4,500 Total cost: 4500*3= Rs.13,500
Total cost for this junction= Rs.1,26,500

Estimated total cost centralized traffic system

Centralized unit: Rs.15,000/unit
Vehicle unit:

No. of tow motors=33 Total cost per unit= Rs.7,000 Total cost: 7000*33= Rs.2,31,000
Road unit:

No. of units required= 13 Total cost per unit= Rs.4,500 Total cost: Rs.58,500 Total project cost= Rs. 3,04,500

Estimated cost of Real Time Inventory system

a) Ultrasonic sensor: List of workstations: Fortuner SPS dolly Carpet Roof mould
Estimated cost for using Ultrasonic sensor: No. of sensors= 3 Cost per sensor= Rs.1,100 Total cost= 1100*3= Rs.3,300

Estimated cost of Real Time Inventory system

b) Weighing sensor: List of workstations: Stabilizer bar Rear axle Propeller shaft Exhaust center pipe Radiator
Estimated cost for using Weighing sensor: No. of sensors per workstation= 4 Cost per sensor= Rs.5,000 Junction box= Rs.6,000 Total cost per workstation= Rs.26,000 Total no. of workstations= 5 Total cost required= 5 * 26000= Rs.1,30,000

Estimated cost of Real Time Inventory system

c) Motion sensor: List of workstation: Modular dolly IP dolly Engine
Estimated cost for using Motion sensor: No. of sensors per workstation= 2 Cost per sensor= Rs.2,500 Total cost per workstation= 2*2500= Rs.5,000 Total no. of workstations= 3 Total cost required= 3*5000= Rs.15,000

Estimated cost of Real Time Inventory system

d) Proximity sensor: List of workstation: Tyre LH Tyre RH

Estimated cost for using Proximity sensor: No. of sensors required in each workstation : Tyre LH= 15 Tyre RH= 10 Cost per sensor= Rs.500 No. of sensors required= 25 Total cost required= 25*500= Rs.12,500

Estimated total Project cost

Total cost of central system= Rs.15,000
Total cost of Real Time Inventory Manipulator= Rs.1,75,800 Estimated total cost required for entire project:Total cost= Cost of Centralized System + Cost of Real Time Inventory Manipulator. Total= Rs.3,04,500 + Rs.1,75,800= Rs.4,80,300.

Thank you