Rane TRW Steering System Pvt Ltd Use of Modular Fixtures for - PowerPoint PPT Presentation

Winner of Deming Winner of Japan Prize in 2005 Quality Medal in 2011 IMTMA - ACE MICROMATIC PRODUCTIVITY CHAMPIONSHIP Rane TRW Steering System Pvt Ltd Use of Modular Fixtures for Productivity Improvement in machining Pumps 1 OF 30

Rane TRW Milestones Rane TRW won Japan Quality Medal (JQM), now called as Deming Grand Prize (DGP) in 2011. 1 st in Rane Group, 3rd in Indian Company & Vision 5th in Overseas company “ To be a Leader in Domestic Hydraulic Power Steering Business, Enhance Global Presence and Diversify for growth with Technology” Products SGD OSD Airbags Reservoir Power Steering Seat Belts PR&P Gear Pump CV Gear 2 OF 30 Fluid

Product Details The Pump plant has different product segments such as 12 LPM (Cast Iron Pumps), 5, 7 & 16 LPM (Aluminium Pumps) 3 OF 30

Brief Description of the project Objective: To meet the sudden ramped up Customer demand and to sustain the market share Trigger for the project:  Market buoyancy due to GST & BS4 Demand increased from 42k to 57k implementation . per month  IR issues at competitor place.  Demand to a level of 39% more than the current capacity.  Shorter Lead time to meet the demand.  Unpredictable Schedule fluctuations in both domestic and export market 4 OF 30

Challenges faced :  New Machine Investment:  High Lead time for building new machine.  Proving the model in the new machine.  Global market demand with the machine makers  New machine investment will impact the profitability of the business .  Environmental challenges:  Outsourcing challenges:  High lead time & development cost.  Increased carbon foot print level.  Low probability of sustaining good  Increase in Energy Quality consumptions.  Increased use of chemicals, oils and wastes. 5 OF 30

Solution Generation & Innovation Innovative approach – Earlier approach Productivity improvement 1. Productivity improvement 1. By Process redesign. 2. Outsourcing of parts 2. Creating Cell Flexibility by introducing modular 3. Refurbishing of equipment's fixtures (SMED). 3. Deskilling the process 4. New facilities addition 6 OF 30

FY 2018-2019: Regular running models : 46 Additional NPD models : 12 We need to meet Customer Demand with increased NPD Models Current Capacity – 220 nos/day. Current Capacity – 350 nos/day. Demand – 320 nos/day Demand – 450 nos/day 7 OF 30

The following actions are taken to meet the customer demand; 1. Productivity improvement in 12 LPM Pump Housing (Cast Iron) Cell 2. Cell Model Flexibility in Isuzu (5 LPM Aluminium Pump) Line for 7 LPM Pump 3. Change over time reduction in 12 LPM Housing cell-3 4. Introduction of New process for Internals 8 OF 30

1. Productivity improvement in 12 LPM Pump Housing ( Cast Iron) Cell Aim: To increase 12 lpm Housing machining cell capacity from 220 nos to 320 nos per day. Concern :  Loading and Unloading time high because of multiple operations done with multiple fixtures in same machine  Machining time high Action : 1. Loading and Unloading time reduction: HYDRAULIC CLAMPING IN  Combined multiple operations in same fixture SLOW MOTION with Rotary table. Hence by single loading, all operations can be completed 2. Machine Time reduction:  By mitigating to rigid clamping setup (hydraulic clamping) and using new generation tooling, Cycle time was reduced. 9 OF 30

3. Combination tool was introduced to reduce the no of tools . 4. Thru coolant drill was used to increase the cutting feed rate . Result : Cell 323 Capacity increased Horizontally Through to 323 nos deployed to coolant drill per day all 5 lines OUTPUT OUTCOME FINANCIAL 1. Cost Saving of Rs. 50L 12LPM HSG Cell by eliminating new Capacity Increased 100% Delivery machine procurement. From 220 nos/day To 2. Sub Contract Cost 323 nos/day Saving Rs66L per Annum 10 OF 30

2.Cell Model Flexibility in Isuzu (5 LPM Aluminium Pump) Line: Aim: Increase the capacity of the 7 LPM pump from 350 nos to 450 nos per day in Isuzu (5 LPM) line. Concern :  No free space at the top of the cradle plate.  Bottom side has the hydraulic pipe routing.  Normally bottom of cradle plate will not be used because of lack of space Action :  MAKINO: Innovatively designed hydraulic fixture on both sides of the cradle and hydraulic pipelines are suitably redesigned.  Cradle plate height from the bed increased & space created for mounting multiple fixtures on both sides 11 OF 30

2.Cell Model Flexibility in Isuzu (5 LPM Aluminium Pump) Line: Action contd … :  AMS: Fixture layout has been designed in such a way that 7 LPM can also be accommodated T otal machine axis stroke of 500 mm is completely utilized to accommodate the new model. Space identified for 7lpm fixture 7 LPM 500mm Stroke 7 LPM Fixture Isuzu 12 OF 30

Result:  Capacity of 7 LPM increased from 350 to 460 Nos per day. Production trend after Improvement Flexibility 460 500 created for 350 400 7LPM in ISUZU Line Qty / Day 300 for increased 471 demand. 449 447 446 437 200 334 334 100 0 Apr'18 May'18 Jun'18 Jul'18 Aug'18 Sep'18 Oct'18 Month BEFORE AFTER OUTPUT OUTCOME FINANCIAL 1. By Eliminating new 7 LPM Capacity machine procurement : Increased From 350 100% Delivery Rs. 1.34 Cr nos / day to 460 nos / 2. Sub Contract Cost day Saving Rs. 54 L per Annum 13 OF 30

Awards : Standardization : EXCELLENCE AWARD – NATIONAL COUNCIL OF QUALITY CIRCLE Team had participated in QCFI 32nd National Convention held at Gwalior from 21 st to 24 th December 2018 . Team won Excellence Award which is the TOP NOTCH award in QCFI 14 OF 30

3. Change over time reduction in 12 LPM Housing cell-3 Aim: Reduce the Setup change over time in Housng cell-3 Concerns :  Tools searching time  Different Fixtures for Different models  No of Touches more  First Off Inspection Time High 15 OF 30

3. Change over time reduction in 12 LPM Housing cell-3 Action-1: (Preparation)  Proper tooling trolley provided to reduce the tools searching time.  Check sheet to ensure availability of all the Tools & Gauges Action-2: (Setting change) Introduction of Common base plate to accommodate all models in a single fixture 16 OF 30

3. Change over time reduction in 12 LPM Housing cell-3 Action - 3 ( Setting Change) Developed modular Fixture by locating with NRB bore – Ø26 mm (which was redesigned as a common dimension for all models). Action- 4: ( First Off Inspection) * Earlier, CMM used to check multiple Co-ordinates, which leads more first off inspection time. * Online receiver gauge introduced BEFORE AFTER 17 OF 30

Result: Standardization by Changeover SOP : Awards : ABK- AOTS DOSOKAI Competition won the prize 18 OF 30

4. Introduction of New process for Internals: The Internal parts of the Pump undergoes the following process Problems faced in Lapping process:  Lapping contamination.  Size variation, hence selective assembly has to be done.  Additional man power is used for selective assembly.  Rotor face out (>80 micron) & Parallelism >4 microns.  For checking face out 100%, additional man power is used. 19 OF 30

4. Introduction of New process for Internals: We identified a new process called Fine Grinding  Cost of the Imported machine is Rs 4 Crs.  Used in auto industries at Germany and the US.  Discussed with Indian machine manufacturers and built a machine at Rs 72 L locally.  Rotor face-out <30 microns and parallelism <2 microns achieved.  Finally, a new process is introduced in the flow despite the pressure on demand. MAN POWER LAPPING, 4 4 3 FINE GRINDING, 1 2 1 0 LAPPING FINE GRINDING 20 OF 30

Overall Result: • Capacity of 57K Nos per month achieved. 36K Nos 15K Nos 5 LPM - 6K nos Productivity Capacity Increased from 42K to 57K Savings by avoiding new Man Power savings By avoiding out Cost Savings investments = Rs. 5.12 Cr = Rs 21 L sourcing = Rs 1.2 Cr Delivery 100% Customer plan met for past 9 months & sustaining still 21 OF 30

Environmental Impact:  Eliminated 5 New machine investments  Reduced the carbon footprint level by avoiding the additional machines.  Reduced the usage of chemicals such as coolant, oil and also the waste generation is reduced.  Use of Hazardous lapping waste was completely eliminated. Horizontal Deployment:  Similar improvements are implemented in other Rane TRW plants (4 Plants)  Also implemented in our Supplier manufacturing plants 1.Sathya components, Chennai 2. Srivari alloys, Chennai 22 OF 30

TEI – AWARDS 2018-2019 QCFI 32nd National Convention 3 rd SMED Competition organized held at Gwalior by ABK – AOTS DOSOKAI , The team has been Teams won Excellence Award rewarded in which is the TOP NOTCH award in Platinum Category. QCFI 23 OF 30

TEI – AWARDS 2018-2019 Rane 12 th QC Convention Dr. Washio Quality Trophy and the Chairman’s Excellence Award, Rane QC Convention Rolling Trophy . 24 OF 30

TEI – AWARDS 2018-2019 Maintenance Personnel Competition (The Unsung Heroes) on 22 May 2019 at ABK – AOTS DOSOKAI Teams won the Diamond award and Gold award 25 OF 30