1 | P a g e GUJARAT TECHNOLOGICAL UNIVERSITY LUKHDHIRJI ENGINEERING COLLEGE MORBI A Project Report On Cycle time reduction and mould change time reduction B.E. Semester –VII (Industrial Engineering Department) Group ID:- 23900 Submitted by Aditya Rajeshbhai Patel Prof. H.D.Santoki Prof.
N.N. Garvalia (Faculty Guide) (Head of department) Academic Year 20182 | P a g e PROJECT REPORT Phase-1: Problem Definition -ADITYA R. PATEL3 | P a g e Acknowledgement I would like to express my special thanks of gratitude to all the faculties involved for helping me to make this project and internship successful. I express my gratitude towards faculty guide Prof.H.
D. Santoki sir for providing proper guidance and also I thank our Head of Department of Industrial Engineering, Prof. N. N. Garvalia sir to provide such a great opportunity for providing internship in one of the top most company in the world. I am thankful to Mr.
Rahul sir (HR Dept.) to confirm my internship letter and allowing me to gain such a great knowledge and try out my best to be successful in this internship. Also I want to thank Mr. Aroh Vadnerkar sir(I.E. Dept.
) to help me out at each and every step along with Mr. Bhavesh Sharma sir(I.E. Dept.) for giving in depth knowledge and clearing all the doubts. I also acknowledge all the other faculties at Apollo Tyres Pvt Ltd.for all kind of support and help. Aditya R.
Patel4 | P a g e Abstract This report focuses on the Industrial Training along with project internship at Apollo Tyres Pvt. Ltd. This project includes information regarding company profile, role of industrial engineers, various processes in the industry along with type of products. Also some of the problems are listed along with their probable solutions in order to achieve success and profit for the company.5 | P a g e 1.
INDUSTRIAL ENGINEERING: 1.1 Industrial Engineer’s Role: ? Support in approving and organizing all supply and labor; prepare report to keep the track of all labor work.?? Analyze cost of all products and assist to reduce negative discrepancy on the same; plan for strategies to reduce wastage and labor cost in all engineering projects.?? Determine and evaluate execution of all projects and administer all methods and procedures as per the required systems and supply standards.?? Create salary model budgets for all procedures of industrial engineering and provide assistance to all supreme manufacturing facilities; develop plans for the analysis of smooth flow of factory processes; analyze plans for all waste elimination from the factory.
?? Support industrial engineering department in the preparation of all required reports on monthly as well as weekly basis; design business plans and carry out all communication with the production department.?? Evaluate and carry out investigation on discrepancies for all actual as well as planned industrial procedures and keep track of all data; ensure integrity of results.?? Stay updated with knowledge of industrial engineering procedures, associate with various projects of manufacturing and production, keep track of all productivity, design various processes and ensure that all procedures are carried out by following the safety standards.?? Provide an effectual interface to all departments; design all strategies and provide assistance to all key staff.?? Monitor reporting procedures on a daily basis; keep track of regular work activities of each employee and ensure all processes are executed by considering the fiscal budgets; prepare strategic models.?? Team up with the quality manager in assuring microbiological control of processing, goods, storage and handling.?? Supervise the preventive maintenance schedules, inventory parts and daily consumable usage.?? Plan and assign work strategies in the production schedule that covers maintenance of process equipment and inspection at proper intervals.
?? Assist with equipment installations and project planning.? Some industrial engineers, called manufacturing engineers, focus entirely on the automated aspects of manufacturing processes. They design manufacturing systems to optimize the use of computer networks, robots, and materials. Industrial Engineers serve as managers in small and medium sized industries because they understand the management of people and resources, internal and external customer perspectives, effective communication skills, and important business practices and ethics. Most of all, they have the ability to continuously improve the entire system, from working with materials, tools, and technologies to successfully managing staff and human resources. 1.
2 Skills: ? Ability to understand, apply and implement concepts and lean tools to the company production system for improvement.?? Demonstrate potential to design, analyze and implement industrial engineering techniques.?? Must have skills of maintaining mechanical, electrical, welding, pneumatics and refrigeration.
?? Excellent oral and writing communication skills, as these experts have to team up with suppliers and other engineers.?? Proficient in using computer for drafting records?? Ability to lead the team by mentoring and building a maintenance department to assist the overall development of the plant operation.?6 | P a g e 2. COMPANY PROFILE: Apollo Tyres Limited is engaged in manufacturing and sale of automotive tires. The Company’s segments include India, Europe and Others. The Indian segment includes manufacturing and sales operations through India.
The European segment includes manufacturing and sales operations through the plant at the Netherlands along with its subsidiaries. The Others segment includes the subsidiary in the United Arab Emirates, South Africa, Thailand and other operating subsidiaries. It manufactures tires, tubes and flaps. a.
Awards/Recognition: ? Awarded as the Best Brand 2009 by Auto India?? Awarded as a Best Brand 2008 by Auto India?? Automotive Product of the year Award for Acelere Sportz at NDTV Car & Bike Awards?? Apollo Safe Drive campaign won the IRTE Road Safety Award?? National Award for Excellence in Water?? Management 2006 – Awarded by CII to Limda, Gujarat?? Kerala State Energy Conservation Award 2006 to Apollo Tyres, Perambra Plant?? First manufacturer in South Africa to be awarded the ISO 14001? b. Products: 1. Passenger Vehicle: ALNAC, ALNAC 4G, AMAZER 3G MAXX and AMAZER 4G 2.
Commercial Vehicle: AMAR, AMAR AT-RIB, AMAR DLX, AMAR GOLD and CARGO PLUS XR 3. Off Highway Tyre: AGREX 85, BHIM, DHRUV, FX 515 (ROW CROP) and FX 525 c. Processes: As this industry manufactures tyres, the process for manufacturing tyres is shown as below: 1. Mixing- Here raw material for the tyres like rubber and synthetic rubber is mixed with chemical compounds. 2. Extrusion- Here tread, sidewalls, inner liners which all are parts of a tyre are made by the extrusion process.
3. Bead Winding- Here a part known as bead is made. 4. Tyre building- Here all the parts are assembled so it is also known as assembling.
Final product is Green Tyre after this process. 5. Curing- Here Green Tyre is moulded in a press at a specified temperature and then through conveyor it travels ahead. 6.
Trimming- Here extra parts or extra fibers inside and outside the tyres are removed. 7. Final finishing- Here all basic inspections are done and then tyre is passed on for final inspection which is quality check. 8. Quality check- Here quality of each and every tyres is checked and then moved to warehouse.7 | P a g e 3.
OBSERVATION FOR PROBLEMS: As this is a huge industry so of course there are pros and cons everywhere. Few problems which I noticed were as below: 1. In tyre building and curing areas, too much material handling occurred which resulted in internal panics between the workers. 2. In curing area, there are total of 110 presses in which mostly all of the press have their own cycle time.
Cycle time consumption was also done by the press itself like the arms of the press which picks up the Green Tyre and places them inside the mould had more travel time and in mostly all of the presses, travel time of arms was different and they didn’t moved together which increased the cycle time. ? Also the mould change time for the presses was too much if considered idle time which included rest for workers, slow drain of platen hose pipes, bypassing the press, some of the keys or buttons of press not working resulting them in manual work.?3. Cycle time of extrusion machines was high due to errors during the process which increases the idle time of the machine. 4. Overall efficiency of the Fischer Cutter was low due to loading and unloading of the cassete in let of unit which took approximately 7-8 minutes which increases the idle time for the machine thus increases the cycle time.
5. The plant layout of the plant is not fixed which causes more material handling which can result in accidents and also increases material handling time.8 | P a g e 4. PROBLEM SELECTION: 4.1 AREA: Curing 1. Arms of curing press: Here arms of the press are not travelling with each other or say that timing of each arm that is left and right arm is different which results in increase of time for cap opening and closing. Also the height of the arm is much more which can be reduced by programming so that the cap/mould can be closed fast and as per calculation approximately 5-6 seconds can be saved during each cycle by changing programs of working of arms. 2.
Mould change time: This is a big issue where a single press is kept idle for approximately 2-3 hours till mould change so if atleast 3-4 minutes are saved then also the increase in productivity can occur. Process of mould change as per my observation is given below: Sr No. Mould Change Type Mould Change Time(minutes) 1 Segment to Segment 120 2 Two-piece to Two-piece 75 3 Two-piece to Two-piece(all-well presses) 45 4 Segment to Two-piece 150 5 Two-piece to Segment 150 4.2 Activities for mould change: ? Bladder Removal?? Bottom mould guard removal?? Platten hose pipe removal?? Top mould guard removal?? Bottom mould locking screws removal?? Top mould locking screws removal?? Adapter removal?? Exchanging the old mould with the new one?4.3 Time chart for each activity during mould change: (this readings are taken during mould change in press number 9275) Sr No. Activity Left side mould Right side mould 1 Bladder Remove 2.
5 ± 2 min 2.5 ± 2 min 2 Bottom mould guard remove 34-40 sec 40-46 sec 3 Platen hose pipe remove 2± 2 min 2± 2 min 4 Top mould guard remove – – 5 Bottom locking bolts remove 1 min 1 min 6 Top locking bolts remove 1.15±4 min 1.15±4 min 7 Adapter remove 5 min 1.23±3 min 8 L plate attached to top and bottom mould parts 4 min 4 min 9 Full mould removal by forklift 5.3±2 min 3.
20±2 min9 | P a g e Now readings for the reverse process which is assembling the new mould are shown: Sr No. Activity Left side mould Right side mould 1 New mould arrangement 3±2 min 5.51±2 min 2 Removal of L clamps 1 min 1 min 3 Adapter attachment 7.24 ±2 min 4 Platen gap arrangement and centering 10-15 min 5 Top locking bolts 1.
15± 5 min 1.15±5 min 6 Bottom locking screws 1 min 1 min 7 Platen hose pipe attachment 2.12±2 min 1.6±2 min 8 Bottom mould guard attachment 40 sec 40 sec 9 Bladder attachment 2.25±2 min 2.
25±2 min10 | P a g e 5.1 For the arms: 5. PROBABLE SOLUTIONS: ? Programming can be done and height can be changed in order to reduce the open time for the press and also movement of arms can be done together by changing programs.?? Approximately about 8-10 seconds can be reduced by applying this solution which can increase productivity.?5.2 For mould change: ? Workers are using normal bolt openers which takes more strength and man power, in order to remove that automatic screw drivers or openers can be used.?? After all the activities at last when the old mould is removed using the forklift truck if possible it can be replaced by hoist/crane above the press so that time consumed for picking up the old mould and then picking the new one can be minimized.?? Also for lifting the mould, 2 T-screws are attached and a heavy chain is used for lifting it but after placing the old mould on the floor, both the T-screws are removed from it and then attached to the new one which consumes approximately 30-40 seconds.
To avoid that 2 more screws can be used which will be attached to the new one before removing the old mould from the press thus makes process a little faster.?11 | P a g e 6. CONCLUSIONS: Apollo- a symbol of quality which is world wide famous for its tyres of all possible kind of vehicles of world class quality and I feel proud to be a part of it though for a limited period of time. At the start of the internship I thought that it would be the toughest project of my life to find any kind of problem as it follows many principles and methods for quality improvement and material handling. But with the help of faculties of industrial engineering department, I was somehow able to find very minor defects which may not affect the present but may be helpful for future assets.
I promise to dedicate my time and energy and and all possible values to reach the goal for solution of problems defined.