Integrated Bogie Assembly Line automation - Nagraj V Pandit
The Godrej Group today • Touches the lives of over 1.1 billion consumers everyday, across the globe • Generates revenues of USD 5 billion, annually • Constantly builds and leverages the brand Godrej that is synonymous with: • Trust, Reliability, Integrity and Innovation • Employs over 20,000 people globally - The Godrej ‘ Parivaar ’ • Maintains a campus of about 3000 acres of land in Mumbai, India Godrej at Vikhroli, Mumbai
… and over 60 lines of business Home and Personal care Tooling Defense & Aerospace Process Equipment Security Solution Industrial Chemicals Real Estate Material Handling Precision Engineering Warehousing Solutions Foods & Grocery Agriculture Furniture for Homes Software Home Appliances and Offices
Godrej & Boyce Mfg Co. Ltd Business Verticals Industrial Products Consumer Products Services Tooling Locks Construction Material Handling Equip. Furniture & Interior Tech Services Process Equipment Security Equipments Property development Precision Engg. Systems Prima communication Enviro-tech Services Precision Components & Solutions Electrical & Electronics Systems Appliances Storage Solutions 4 I Godrej I Title of presentation I Date
Integrated Bogie Assembly Line automation
The journey started…… • Collaborative approach by Railways • Technical inputs from MCF officials in concept development Area of concerns (MCF) Offered solution by Godrej Lower out turn of bogies per shift. Increase in productivity by 100% Conventional way of assembly Assembly line concept as used in Auto industry. Manual data recording, storing & IoT enabled line. retrieval Online Data acquisition & storage on server Automatic report generation, easy access & retrieval. Difficulty in component tracking Easy to track the component due to QR codes. Operator fatigue Effortless handling and improved ergonomics Material flow from different locations Improved material flow for assembly line 5’s on shop floor
Salient Features After Before Transfer of component through Trolleys Bogie Rotation manipulator Streamlined assembly flow 7 I Godrej I Title of presentation I Date
Salient Features After Before High precision transducerized Power tools improve operator efficiency & Quality Daily production dashboard Component tracking and automatic report generation 8 I Godrej I Title of presentation I Date
5’S by customised Pallets & Tables
Industry 4.0 • Wireless data connectivity • Smart IoT enabled tools & sensors • Establishment of digital record 1970 • Data storage in cloud • Easy root cause analysis and its mitigation plan. • Step towards smart manufacturing 10 I Godrej I Title of presentation I Date
Industry 4.0 4 key components in Industry 4.0 Acquire master Visualize data in Sense ID and Interpret via data / transactional Dashboards / parameters Analytics and data from ERPs Control towers Models to Aid Decision Making Torque value & Component ID IoT / Industry Component, Vendor, Torqueing program selection Torque, Production date 4.0 Implementation at MCF Raebareli Station 1 Station 2 Finished 11 I Godrej I Title of presentation I Date
Industry 4.0 – IoT Journey Objectives Approach Solution • Ensure right amount of • Use Track and Trace platform • QR code based system to torque delivered for every ( dataSAVI ) to deliver solution build traceability. possible bogie component • Consider Robust handheld • Close loop system to deliver • Bring maximum possible devices like industrial exact amount of torque traceability scanners, torque guns • Live Production dashboards • Generate Report with • Use QR code instead of maximum automation Barcode for better scanning • Cloud enabled solution (Monitor production from • Use Server based Data anywhere in the world) Logging instead of classical data loggers • Ability to further Add Analytics Layer over time as • Seamless integration the System matures between devices and cloud 12 I Godrej I Title of presentation I Date
Industry 4.0 – IoT Journey Benefits Opportunities / Future Enhancements within MCF • System generated SIP report for each bogie with torque data • Consider Other Processes for similar Track and Trace • System generated Traceability report • Integration with existing ERP • Better Uptime monitoring • Leverage actuals for PPC • Plan vs Actual monitoring • Statistical Process Control • Process capability index • Warranty Management • Better Traceability leading to better Maintenance Management 13 I Godrej I Title of presentation I Date
Component QR coding – Schematic Process QR code Component Component QR code QR code – Bogie Sticking on Torqueing Generator Printing components Mapping Scan Component Report Supervisor Operator 14 I Godrej I Title of presentation I Date
Production Dashboard – Real Time Updated System Available on Cloud and Mobile App 15 I Godrej I Title of presentation I Date
SIP Report – Automated Report from System 16 I Godrej I Title of presentation I Date
Station 4 Assembly Line Layout – Plan View • Cross section Handling & fitment • Lateral bump stop Fitment. • Centering disc (Upper & Lower Handling) • Bolster sub-assembly Flow ofAssembly • Fork arm & longitudinal fitment • Lifting of Inverted Bogie Bolster • Placement on secondary suspension • Rod link & fork fitment by 50T press • Center pivot & traction center fitment Station 0 • Lateral Dampener fitment. • Placement of Inverted • Secondary Dampener Fitment Station 2 Bogie frame over • Primary Suspension Handling Trolley • Upper Control Arm Assembly • Pneumatic piping Station 3 Station 1 • Handling of wheel axle Tightening & Handling of • Lower Control Arm Assembly • Traction Center Assembly • Phonic wheel fitment • Anti Roll bar Assembly • Control Arm Side Cover Fitment • Brake Caliper Assembly • Fitment of earthing device • Lifting of Bogie Frame • Removal of Trolley • Bogie Frame Inversion
Integrated Bogie Assembly Line
Thank you 19 I Godrej I Title of presentation I Date
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