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Time study of engine components manufacturing process

Article in International Journal of Applied Engineering Research · January 2015

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 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.33 (2015)
© Research India Publications; httpwww.ripublication.comijaer.htm

TIME STUDY OF ENGINE COMPONENTS MANUFACTURING

PROCESS
1 1 1 1
B.Vignesh ,B.Srinivasan , L. Vinothkumar , Suresh kumar , Tamil
1 2,* 3, #
Selvakumar , A. Pandiyan and G.Arunkumar
1
Students, Department of Automobile Engineering, Saveetha School of Engineering,
Saveetha University, Chennai – 602 105, India
1
Students, Department of Mechanical Engineering, Saveetha School of Engineering,
Saveetha University, Chennai – 602 105, India
2
Associate Professor, Department of Mechanical Engineering, Saveetha School of
Engineering, Saveetha University, Chennai – 602 105, India
3
Professor, Department of Mechanical Engineering, Saveetha School of Engineering,
Saveetha University, Chennai – 602 105, India
* - Author for correspondence Email
id: [email protected]
Telephone: 91- 9894970549

ABSTRACT:
Feeble layout design is finding as a major problem contribution in small and medium Industry. These
particular problems will affect the productivity and the line efficiency as well. The objective of
throughout the study is to proposed new layout to improve time schedule, efficiency, increase their
productivity and decrease the man power. The major step is to identify a bottleneck workstation in
Current layout. After identify related problems, the current layout is redesign by formulating the
standard time and processing time in each workstation. In each Workstation the processing time is
different and the longest time consumption is Workstation will be identified as a bottleneck
workstation. This related line is studied by Time study techniques. The time is taken by stopwatch.
The goal of the thesis is to seek the best Layout in terms of line efficiency and productivity rate hence
proposed to the company. Throughout the study, 2 layouts have been achieved. Among 2 layouts only
one will be propose to the company. This layout has better line efficiency and rate of productivity.

Keywords:workstation, balancing algorithm, efficiency, productivity.

1. INTRODUCTION: be decreased the line efficiency and the targeted run
rate [1]. In preventing these problems, engineers
Dynamatic Technologies Limited is an India-based should come out with a solution in order to fix
company. The Company is in the business of these problems. There are many ways to improve
manufacturing automotive components, hydraulics process line in manufacturing department. Line
gear pumps, aerospace components and wind farm balancing is one of the approaches to rebalance the
power generation. The company and its subsidiaries process line to enhance the productivity in each
employ around 50 scientist and 500 engineers with workstation [2]. This aim is to minimizing
expertise in Mechanical Engineering, Advanced workloads and workers on the assembly line while
Computer Aided Engineering, Materials and meeting a required output. In order to achieve this
Metallurgical Engineering, Fluid Dynamics and objective, assembly line should be design to make
Defence and Aerospace Research. sure the flow is smoothly. Workers on assembly
Bottle necking and excessive workers are common line are specialized person in particular area. Most
problems rose in assembly line [1]. These are the of them have been exposed to various tasks and
major problems that encounter and yet need to be skilled have been developed. A new layout is
overcome as soon as possible. Assemblers are often proposed to make sure the assembly line achieved
encounters this problems and if this happen it will required rate. The layout will include the number of
workers, the workloads and the flow of the

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 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.33 (2015)
© Research India Publications; httpwww.ripublication.comijaer.htm

products. Normally any changes of the layout already and are in existence with various other
depend on type of product, environment and components but we ensure that our work hasn’t
company policies. Layout will be design based on been in exist in the past for this same particular
the regulation provided by company. Software engine component and same concept in not used for
application also involve in the design since any same component.
changes will affect the productivity. Simulation
become necessary tool in designing layout based on 3.1 Compressor housing:
it capability to evaluate and improving current
layout. The component is shown in Fig. 1.

Analysis on assembly is important in order to

achieve targeted productivity. Assembly line should
be design smoothly and simulation should be done
to predict the line efficiency and productivity
difference between new layout and current layout.

Reducing line efficiency.

In flow line production the product moves to one
workstation due to time restriction. Once its get
stuck due to accumulation in certain workstation, it
exceeds the cycle time in that station. Faster station
is limited by slowest station, thus, decreasing the
rate of productivity. Fig. 1. Compressor housing

Unbalance workloads After raw casting the following operations are

done.
Due to starving, the workers need to wait the i).Machining (Boring, Drilling, Facing, Forming,
products to come. Milling & Turning).
Two objectives are expected in the end of ii).De-burring (Remove the sharp corners).
the project: Tools: Pencil grinder (needle), Countersink bit
1.2.1 To improve productivity and efficiency of (CS12), Knife (K10)
existing layout and new layout iii).Washing (Load the de-burr components into the
1.2.2 To meet unpredictable demand [1]. water tank).
Tools: Cleaning liquid- DM water mixed with
2. METHODOLOGY Henkelneutropenia sol. 20.
The research conducted at manufacturing based iv). Air Leak Test: ok - green, not ok – red. TOOL:
company in Dynamitic. Specifically in automobiles Dry type.
manufacturing company. v).Pin & Bracket Assembly (Pin height: max - 1.80,
1. Comparison between existing and new layout. min - 1.40).
2. Proposing new layout (2 layout and the best is Tool: Torque gun.
chosen). vi).Final Inspection: Visual inspects -100%
3. Stopwatch is used to take the time Table 1: Time chart for housing compressor

Four components have been analysed for time Cycle Loading/

Man
Opn Process flow time unloading Movement
study and work study as mentioned below: (sec) (sec)
work
a. Compressor housing Vigel 202 6 - -
b. Exhaust manifold PA 10 Clamping
29.3 - - -
confirmation
c. Exhaust manifold PB
20& Vigel 215 5 - -
d. Inlet manifold Clamping
30 27.5 - - -
confirmation
35 Engraving 5 3 - 4
3. RESULTS AND DISCUSSION
40 De-burring - - 50 4

By this study it is found out that idle time can be 50

Washing 30 4 - 2

utilized for other works thereby increasing the Air blowing - - 8 1

productivity/efficiency of plant. 60 Leak testing 15 4 - 2
Final
70 - - 45 5
Inspection
As according to research found that our work is 80 Pin assembly - - 30 3
based on the merging work considering idealness of 90
Bracket
- - 6 2
worker he similar way of journals are published assembly

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 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.33 (2015)
© Research India Publications; httpwww.ripublication.comijaer.htm

3.2. Exhaust manifold PA:

The component is shown in Fig. 2.

Fig. 3. Exhaust manifold PB

Fig. 2. Exhaust manifold PA
iv).Air Leak Test: Ok-green, not ok-red
In automotive engine, an exhaust gases from Tools: Dry type
multiple cylinders into one pipe. Exhaust manifold v).Final Inspection: Visual inspects 100%
are generally simple cast iron or stainless steel units The time taken for various operations is indicated
which collects engine exhaust from multiple in Table 3.
cylinders.
After raw casting, Table 3: Time chart for exhaust manifold (PB)
i).Machining: (Mounting facing, Spot facing, M6 Opn Process Cycle Loading/ Man Movement
boss milling& Muffler milling). flow time unloading work
(sec) (sec)
ii).De-burring: (Remove the sharp corners).
10 Machining 315 8 - -
Tools: Pencil grinder (needle), Countersink bit
(CS12), Knife (K10). 20 Machining 352 8 - -
iii).washing: temp- 50’c
30 Deburring - - 60 -
Tools: Cleaning liquid- liquid water mixed with
CIMTEC D-18 oil @100:1. 40 Washing - - 40 2
iv).Air Leak Test: Ok-green, not ok-red
50 Air Leak 25 6 - 4
Tools: Dry type
v).Final Inspection: Visual inspects 100%. 60
Final
Inspection
- - 72 6
The time taken for the operations is indicated in
Table 2.
3.4. Inlet manifold:
Table 2 Time chart for exhaust manifold (PA) The component is shown in Fig. 4.
Cycle Loading/ In automobile engineering, an intake or inlet
Man
Opn Process flow time unloading
work
Movement manifold is the part of an engine that supplies the
(sec) (sec)
fuel/air mixture to the cylinder.
10 Machining 315 7

20 Machining 352 6

30 Deburring 6 60

40 Washing 40 2

50 Air Leak 40 6 4
Final
60 45 6
Insepection

3.3. Exhaust manifold PB:

The component is shown in Fig. 3.
After raw casting,
i).Machining: (Mounting facing, Spot facing, M6
boss milling& Muffler milling).
ii).De-burring: Remove the sharp corners. Fig. 4. Inlet manifold
Tools: Pencil grinder (needle), Countersink bit
(CS12), Knife (K10). The primary function of the intake manifold is to
iii).Washing: temp- 50’c evenly distribute the combustion mixture to each
intake port in the cylinder head. The intake
Tools: Cleaning liquid- liquid water mixed with
CIMTEC D-18 oil @100:1.

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 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.33 (2015)
© Research India Publications; httpwww.ripublication.comijaer.htm

manifold has manufactured from aluminium or cast The existing time schedule is given in Table 5.
iron.
After raw casting Table 5: Existing time schedule
i) MACHINING: (Boring, Drilling, Facing, Loading/
Cycle
Forming, Milling, Tapping, Turning, Chamfer, Process unloadin Man Move
Opn time Man
Drill tap, free drill & open drill trimmer). flow g work ment
(sec)
ii) DE-BURRING: REMOVE THE SHARP (sec)
CORNERS TOOLS: Pencil grinder (needle), 10 Machining 235 1 10 5
Countersink bit (CS12), Knife (K10).
20 Machining 235 1 12 7
iii) HIGH PRESSURE CLEANING: temp- 50’c
Tools: Cleaning liquid- liquid water mixed with 30 Machining 235 1 10 7
CIMTEC D-18 oil @100:1 40 Machining 235 1 13 5
vi) AIR LEAK TEST: ok - green, not ok –
red. Tools: Dry type 50 Machining 235 1 11 5

v) Nipple & Cap Seal Assembly: Cap - diameter 60 De- 2 126 14

30, Nipple - diameter 8.6, Height - 15, Press depth- burring
1.5. 70 High 3 60 8
vi) ADAPTER AND M8 STUD ASSEMBLY: pressure
(Stud assembly adapter, Boldfiange assembly cleaning
adapter) 80 Assembly 3 56 4

vii) FINAL INSPECTION: Visual inspects 100%. 90 Air leak 35 4 10

The time taken for various operations is indicated test
in Table 4. 100 Pin 4 62 4
assembly
Table 4: Time chart for inlet manifold
110 Final 5 72
Cycle Loading inspection
Man
Opn Process flow time /unloading Movement
work
(sec) (sec)
10 Machining 235 10 5
20 Machining 235 12 - 7
The new modified layout of man power required
for the manufacturing process of inlet manifold is
30 Machining 235 10 - 7
indicated in Fig. 6
40 Machining 235 13 - 5
50 Machining 235 11 - 5
60 De-burring - - 126 14
70 High pressure - - 60 8
cleaning
80 Assembly - - 56 4
90 Air leak test 35 10
100 Pin assembly - - 62 4
110 Final - - 72 -
inspection

The existing layout of man power required for the

manufacturing process of inlet manifold is
indicated in Fig. 5. Fig. 6. New modified layout

and the modified time schedule is given in Table 6.

Man power is reduced from 5 to 4 for the
Machining &manufacturing Process of Inlet
manifold & totally five lines available for the same
manufacturing progress, which saves equally 5
MAN POWER. Therefore these five services mans
can be utilized for any other Working process.

In this project some of the new and improved time

schedule, improved efficiency and reducing man
power for the manufacturing process of inlet
manifold have been done.
Fig. 5. Existing layout of man work

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 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.33 (2015)
© Research India Publications; httpwww.ripublication.comijaer.htm

It is the basic idea for such a project and future

developing to identify proper line balancing and
unnecessary variation in their work and it can also
helps them see how different roles fit together in a
system.

Table 6: Improved time schedule

Cycle Loading/
Man Move
Opn Process flow time Man unloading
work ment
(sec) (sec)

10 Machining 235 1 10 5

20 Machining 235 1 12 7

30 Machining 235 1 10 7

40 Machining 235 1 13 5

50 Machining 235 1 11 5

60 De-burring 1 126 14

High pressure
70 2 60 8
cleaning

80 Assembly 2 56 4

90 Air leak test 35 3 10

100 Pin assembly 3 62 4

Final
110 inspection 4 72

4. CONCLUSIONS:
Four components such as compressor housing
exhaust manifold PA, exhaust manifold PB, inlet
manifold have been studied for their time and man
work, among which inlet manifold, the time taken
by a product was calculated and the efficiency to
complete the product in a short period of time
improving the man work and time was calculated.

REFERENCES
[1] Hazmil Bin Hapaz, “Productivity Improvement through
line balancing,” Project Report, 2008.
[2] Khairulazam Bin Buhari, “Productivity Improvement through

Line balancing in Aerospace Industry,” Thesis, 2008.

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