Essay: TO REDUCE THE REJECTION RATE AND IMPROVE THE PRODUCTIVITY BY IMPLEMENTING TIME STUDY IN ASA LTD=

CHAPTER 1- INTRODUCTION
1.1 Problem Statement
‘To Reduce The Rejection Rate and Improve The productivity by Implementing Time Study in ASA Ltd.’.
1.2 Research Objective
The aim of this project is to improving productivity, reducing rejection rate and reducing cycle time of sheet metal components and assemblies in an industry whose name is ‘automotive Stampings and Assemblies Limited’. This project works for minimize cycle time in assembly line (weld shop) and reducing rejection rate which is very important for any firm to being a successful. Our purpose is to reduce this cycle time and rejection rate by using various methods.
In this project, follow step by step procedure which includes first time study method. When used properly may get all the information about the assembly line like assembly time of various sheet metal components, all movement of worker and products.
First we would study about all the machines, equipments, testing machines. Also the study about step by step work in to the industry of all departments like, planning department, purchase department, store, inspection department etc.
Now on point, we do time study on automotive stampings and assemblies ltd. First we choose various assemblies of CN-100 for this study. Then calculate one by one all operation which done on it with time. For calculation of time stopwatch may be used. The time which calculating are consist of machining time, assembly time, load-unload time, workpiece traveling time.
After that we collect all the data according to plant layout and also do time study. We were calculating necessary motion of the worker, unnecessary motion of the worker. This all data calculate according to the reference road of the firm. Then we would arrange this all data. Now our main work is to be starting to minimize the whole assembly time according to method which we adopt.
Chapter 4- Work Done Till Date
4.1 Data Collection
In data collection phase, our objective is to reduce cycle time, reduce rejection rate and maximize the profit. So for reduction of cycle time first we note the all timing which has in production of CN-100 assemblies. So for that we adopt time study method.
The data is collected by means of observation and readings during the work period. We would collect all machining time, assembly time, load/unload time and inspection time. For this process we used standard stopwatch of mobile phone.
Here all the data represented which were studied. But first of all we understand about the time study.
In this time study, we choose CN-100 assemblies for the research work. The number of operations which performed on these assemblies are also divided.
The data collection procedure is done with the continuous production of ASAL. So as per continuous production of CN-100, the data of CN-100 assemblies are represented in various table forms.
4.1.1 Time study during the period (July to September)
To measure the cycle time, by time studies of various assemblies which carry each operations are represented. Here the time study is carried out for CN-100 assemblies.
By observing time study analysis we can find the maximum time consuming operation done for completion of an object.
This type of data analysis is carried out for getting primary observation and being practiced for time study.
Here all the operation which performed on the product is divided properly with appropriate time and this data is calculate during the period of July to August.
4.1.1.1 Time study of Bracket – S/GR 24549509+ 24550856 PLATE ‘FRT SUSP C/MBR
The data analysis is shown in following tables. The time study for Bracket – S/GR 24549509+ 24550856 PLATE ‘FRT SUSP C/MBR which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.1.
All time consuming operations with its proper timings as shown in table 4.1.
Table 4.1- Time Study of Bracket – S/GR 24549509+ 24550856 PLATE ‘ FRT SUSP C/MBR
SR.NO. 1
Part Name Bracket – S/GR 24549509+ 24550856 PLATE ‘ FRT SUSP C/MBR
Operation Mig welding
Welding Fixture One Mig welding fixture
Weld Gun Separate Mig M/C
No. of Spot/Stud Welding 6
Stages Stage 1
Pin up(Sec) 3
Loading(Sec) 8
Clamp up(Sec) 10
Welding/Inspection(Sec) 12
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10
Cycle Time(Sec) 53
Qty/day 80
Welder(To do only welding) 1
Helper(To load/unload the job + helping for gun holding) 0
Fixture Qty 01
Actual production
4.1.1.2 Time Study of BRACKET-FRT SUSP C/MBR24549507/24549508 + PLATE-FRT SUSP C/MBR24549794
The data analysis is shown in following tables. The time study for BRACKET-FRT SUSP C/MBR24549507/24549508 + PLATE-FRT SUSP C/MBR24549794 which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.2.
All time consuming operations with its proper timings as shown in table 4.2.
Table 4.2- Time Study of BRACKET-FRT SUSP C/MBR24549507/24549508 + PLATE-FRT SUSP C/MBR24549794
SR.NO. 2
Part Name BRACKET-FRT SUSP C/MBR24549507/24549508 + PLATE-FRT SUSP C/MBR24549794
Operation Spot welding
Welding Fixture one common Spot welding fixture
Weld Gun one common weld gun
No. of Spot/Stud Welding 8
Stages Stage 1
Pin up(Sec) 3
Loading(Sec) 8
Clamp up(Sec) 10
Welding/Inspection(Sec) 32
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10
Cycle Time(Sec) 73
Qty/day 80
Welder(To do only welding) 1
Helper(To load/unload the job + helping for gun holding) 0
Fixture Qty 1
Actual production
4.1.1.3 Time Study of OUT PUT OP 40
The data analysis is shown in following tables. The time study for OUT PUT OP 40 which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.3.
All time consuming operations with its proper timings as shown in table 4.3.
Table 4.3- Time Study of OUT PUT OP 40
SR.NO. 3 3 3 3 3
Part Name OUT PUT OP 40 OUT PUT OP 40 OUT PUT OP 40 OUT PUT OP 40 OUT PUT OP 40
Operation Mig welding
Spot welding
Mig welding
Spot welding
Spot welding
Welding Fixture Common Mig welding fixture for OP30 &OP50.
one Spot welding fixture
Common Mig welding fixture for OP30 &OP50.
one common Spot welding fixture
one Separate Spot welding fixture
Weld Gun One robo for OP30/Op50
one separate weld gun
One robo for OP30/Op50
one Common weld gun
one Separate weld gun
No. of Spot/Stud Welding 14
25 30 36 38
Stages Stage 1 Stage 1 Stage 2 Stage 2 Stage 3
Pin up(Sec) 3 3 3 3 3
Loading(Sec) 20 20 4 4 8
Clamp up(Sec) 10 10 10 10 10
Welding/Inspection(Sec) 28 100 30 144 152
Pin down(Sec) 5 5 5 5 5
Unclamp(Sec) 5 5 5 5 5
Unloading(Sec) 10 10 10 10 10
Cycle Time(Sec) 81 153 67 181 193
Qty/day 80 80 80 80 80
Welder(To do only welding) 1 1 1 1 1
Helper(To load/unload the job + helping for gun holding) 0 0 0 0 0
Fixture Qty 1 1 1 1 1
Actual production
4.1.1.4 Time Study of PLATE-TRLR HITCH CR BAR MTG
The data analysis is shown in following tables. The time study for PLATE-TRLR HITCH CR BAR MTG which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.4.
All time consuming operations with its proper timings as shown in table 4.4.
Table 4.4- Time Study of PLATE-TRLR HITCH CR BAR MTG
SR.NO. 4
Part Name PLATE-TRLR HITCH CR BAR MTG
Operation CO2 welding
Welding Fixture Separate welding fixture
Weld Gun Separate welding machine
No. of Spot/Stud Welding 30
Stages Stage 1
Pin up(Sec) 3
Loading(Sec) 16
Clamp up(Sec) 10
Welding/Inspection(Sec) 60
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10
Cycle Time(Sec) 109
Qty/day 80
Welder(To do only welding) 1
Helper(To load/unload the job + helping for gun holding) 0
Fixture Qty 0
Actual production
4.1.1.5 Time Study of OUTRIGGER-U B FRT S RL
The data analysis is shown in following tables. The time study for OUTRIGGER-U B FRT S RL which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.5.
All time consuming operations with its proper timings as shown in table 4.5.
Table 4.5- Time Study of OUTRIGGER-U B FRT S RL
SR.NO. 5
Part Name OUTRIGGER-U B FRT S RL
Operation Spot welding
Welding Fixture Common welding fixture for LH/RH
Weld Gun Common weld Gun for LH/RH
No. of Spot/Stud Welding 24
Stages Stage 1
Pin up(Sec) 3
Loading(Sec) 8
Clamp up(Sec) 10
Welding/Inspection(Sec) 120
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10
Cycle Time(Sec) 161
Qty/day 160
Welder(To do only welding) 1
Helper(To load/unload the job + helping for gun holding) 0
Fixture Qty 1
Actual production 100
4.1.1.6 Time Study of REINFORCEMENT U/B FRT S/RL FRT
The data analysis is shown in following tables. The time study for REINFORCEMENT U/B FRT S/RL FRT which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.6.
All time consuming operations with its proper timings as shown in table 4.6.
Table 4.6- Time Study of REINFORCEMENT U/B FRT S/RL FRT
SR.NO. 6
Part Name REINFORCEMENT U/B FRT S/RL FRT
Operation CO2 welding
4.1.1.7 Time Study of REINFORCEMENT ASM-U B FRT S RL FRT
The data analysis is shown in following tables. The time study for REINFORCEMENT ASM-U B FRT S RL FRT which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.7.
All time consuming operations with its proper timings as shown in table 4.7.
Table 4.7- Time Study of REINFORCEMENT ASM-U B FRT S RL FRT
SR.NO. 7
Part Name REINFORCEMENT ASM-U B FRT S RL FRT
Operation Spot welding
Welding Fixture Separate welding fixture
Weld Gun one Common weld gun for LH/RH
No. of Spot/Stud Welding 11
Stages Stage1
Pin up(Sec) 3
Loading(Sec) 30
Clamp up(Sec) 10
Welding/Inspection(Sec) 55
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10
Cycle Time(Sec) 188
Qty/day 80
Welder(To do only welding) 1
Helper(To load/unload the job + helping for gun holding) 1
Fixture Qty 1
Actual production 70
4.1.1.8 Time Study of RAIL ASM-U B FRT SI
The data analysis is shown in following tables. The time study for RAIL ASM-U B FRT SI which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.8.
All time consuming operations with its proper timings as shown in table 4.8.
Table 4.8- Time Study of RAIL ASM-U B FRT SI
SR.NO. 8 8
Part Name RAIL ASM-U B FRT SI RAIL ASM-U B FRT SI
Operation Spot welding
Re-Spot welding
Welding Fixture Separate welding fixture
Separate welding fixture
Weld Gun Two Common weld gun for spot / respot Two Common weld gun for spot / respot
No. of Spot/Stud Welding 34 17
Stages Stage-1
Stage-1
Pin up(Sec) 3 3
Loading(Sec) 75 4
Clamp up(Sec) 15 10
Welding/Inspection(Sec) 238 119
Pin down(Sec) 5 5
Unclamp(Sec) 5 5
Unloading(Sec) 10 10
Cycle Time(Sec) 351 156
Qty/day 80 80
Welder(To do only welding) 1 1
Helper(To load/unload the job + helping for gun holding) 1 0
Fixture Qty 1 1
Actual production 50 50
4.1.1.9 Time Study of PANEL ASM-U B FRT S RL CLOSEOUT
The data analysis is shown in following tables. The time study for PANEL ASM-U B FRT S RL CLOSEOUT which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.9.
All time consuming operations with its proper timings as shown in table 4.9.
Table 4.9- Time Study of PANEL ASM-U B FRT S RL CLOSEOUT
SR.NO. 9
Part Name PANEL ASM-U B FRT S RL CLOSEOUT
Operation Spot welding
Welding Fixture Separate welding fixture
Weld Gun one separate weld gun & one common with OP 100(common gun for LH/RH)
No. of Spot/Stud Welding 5
Stages Stage-1
Pin up(Sec) 3
Loading(Sec) 20
Clamp up(Sec) 10
Welding/Inspection(Sec) 30
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10
Cycle Time(Sec) 83
Qty/day 80
Welder(To do only welding) 1
Helper(To load/unload the job + helping for gun holding) 1
Fixture Qty 1
Actual production 100
4.1.1.10 Time Study of PANEL ASM-FRT W H PNL FRT
The data analysis is shown in following tables. The time study for PANEL ASM-FRT W H PNL FRT which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.10.
All time consuming operations with its proper timings as shown in table 4.10.
Table 4.10- Time Study of PANEL ASM-FRT W H PNL FRT
SR.NO. 10
Part Name PANEL ASM-FRT W H PNL FRT
Operation Spot welding
Welding Fixture Separate welding fixture
Weld Gun One separate weld gun
No. of Spot/Stud Welding 5
Stages Stage 1
Pin up(Sec) 3
Loading(Sec) 12
Clamp up(Sec) 10
Welding/Inspection(Sec) 20
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10
Cycle Time(Sec) 65
Qty/day 80
Welder(To do only welding) 1
Helper(To load/unload the job + helping for gun holding) 0
Fixture Qty 1
Actual production 150
4.1.1.11 Time Study of BRACKET ASM-ECM
The data analysis is shown in following tables. The time study for BRACKET ASM-ECM which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.11.
All time consuming operations with its proper timings as shown in table 4.11.
Table 4.11- Time Study of BRACKET ASM-ECM
SR.NO. 11
Part Name BRACKET ASM-ECM
Operation Spot welding
Welding Fixture Separate welding fixture
Weld Gun One common weld gun
No. of Spot/Stud Welding 15
Stages Stage 1
Pin up(Sec) 3
Loading(Sec) 12
Clamp up(Sec) 10
Welding/Inspection(Sec) 60
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10
Cycle Time(Sec) 105
Qty/day 80
Welder(To do only welding) 1
Helper(To load/unload the job + helping for gun holding) 0
Fixture Qty 1
Actual production 150
4.1.1.12 Time Study of GUSSET-F/CMPT OTR S/RL
The data analysis is shown in following tables. The time study for GUSSET-F/CMPT OTR S/RL which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.12.
All time consuming operations with its proper timings as shown in table 4.12.
Table 4.12- Time Study of GUSSET-F/CMPT OTR S/RL
SR.NO. 12
Part Name GUSSET-F/CMPT OTR S/RL
Operation Spot welding
Welding Fixture Separate welding fixture
Weld Gun One separate weld gun
No. of Spot/Stud Welding 9
Stages Stage 1
Pin up(Sec) 3
Loading(Sec) 8
Clamp up(Sec) 10
Welding/Inspection(Sec) 36
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10
Cycle Time(Sec) 77
Qty/day 80
Welder(To do only welding) 1
Helper(To load/unload the job + helping for gun holding) 0
Fixture Qty 1
Actual production 150
4.1.1.13 Time Study of PANEL ASM-FRT W/H FRT
The data analysis is shown in following tables. The time study for PANEL ASM-FRT W/H FRT which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.13.
All time consuming operations with its proper timings as shown in table 4.13.
Table 4.13- Time Study of PANEL ASM-FRT W/H FRT
SR.NO. 13
Part Name PANEL ASM-FRT W/H FRT
Operation Spot welding
Welding Fixture NA
Weld Gun Separate spot welding gun
No. of Spot/Stud Welding 2
Stages Stage 1
Pin up(Sec) 3
Loading(Sec) 12
Clamp up(Sec) 10
Welding/Inspection(Sec) 8
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10
Cycle Time(Sec) 53
Qty/day 80
Welder(To do only welding) 1
Helper(To load/unload the job + helping for gun holding) 0
Fixture Qty 0
Actual production 400
4.1.1.14 Time Study of PANEL ASM-FRT W H
The data analysis is shown in following tables. The time study for PANEL ASM-FRT W H which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.14.
All time consuming operations with its proper timings as shown in table 4.14.
Table 4.14- Time Study of PANEL ASM-FRT W H
SR.NO. 14 14 14 14
Part Name PANEL ASM-FRT W H PANEL ASM-FRT W H PANEL ASM-FRT W H PANEL ASM-FRT W H
Operation Spot welding
Spot welding
Spot welding
Spot welding
Welding Fixture Common welding fixture for petrol/Diesel
Separate welding fixture
Common welding fixture LH/RH
Separate welding fixture
Weld Gun Two common weld gun One Separate weld gun Two common weld gun One Separate weld gun
No. of Spot/Stud Welding 16 12 21 9
Stages Stage-1
Stage-2
Stage-3 Stage-4
Pin up(Sec) 3 3 3 3
Loading(Sec) 8 12 12 5
Clamp up(Sec) 10 10 10 15
Welding/Inspection(Sec) 64 48 84 72
Pin down(Sec) 5 5 5 5
Unclamp(Sec) 5 5 5 10
Unloading(Sec) 10 10 10 10
Cycle Time(Sec) 105 93 129 120
Qty/day 80 80 80 80
Welder(To do only welding) 1 1 1 1
Helper(To load/unload the job + helping for gun holding) 1 1 0 1
Fixture Qty 1 1 1 1
Actual production 100
4.1.1.15 Time Study of BRACE ASM-U B S RL CR
The data analysis is shown in following tables. The time study for BRACE ASM-U B S RL CR which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.15.
All time consuming operations with its proper timings as shown in table 4.15.
Table 4.15- Time Study of BRACE ASM-U B S RL CR
SR.NO. 15
Part Name BRACE ASM-U B S RL CR
Operation Spot welding
Welding Fixture Common fixture for LH/RH
Weld Gun One Separate weld gun
No. of Spot/Stud Welding 2
Stages Stage1
Pin up(Sec) 3
Loading(Sec) 8
Clamp up(Sec) 10
Welding/Inspection(Sec) 8
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10
Cycle Time(Sec) 49
Qty/day 80
Welder(To do only welding) 1
Helper(To load/unload the job + helping for gun holding) 0
Fixture Qty 1
Actual production 400
4.1.1.16 Time Study of BRACKET ASM-U B RR BR
The data analysis is shown in following tables. The time study for BRACKET ASM-U B RR BR which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.16.
All time consuming operations with its proper timings as shown in table 4.16.
Table 4.16- Time Study of BRACKET ASM-U B RR BR
SR.NO. 16
Part Name BRACKET ASM-U B RR BR
Operation CO2 welding
Welding Fixture Separate welding fixture
Weld Gun Separate welding m/c
No. of Spot/Stud Welding 5
Stages Stage 1
Pin up(Sec)
Loading(Sec) 8
Clamp up(Sec) 10
Welding/Inspection(Sec) 14
Pin down(Sec)
Unclamp(Sec) 5
Unloading(Sec) 10
Cycle Time(Sec) 47
Qty/day 80
Welder(To do only welding) 1
Helper(To load/unload the job + helping for gun holding) 0
Fixture Qty 0
Actual production
4.1.1.17 Time Study of RAIL ASM-U B FRT SI
The data analysis is shown in following tables. The time study for RAIL ASM-U B FRT SI which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.17.
All time consuming operations with its proper timings as shown in table 4.17.
Table 4.17- Time Study of RAIL ASM-U B FRT SI
SR.NO. 17 17 17 17
Part Name RAIL ASM-U B FRT SI RAIL ASM-U B FRT SI RAIL ASM-U B FRT SI RAIL ASM-U B FRT SI
Operation Spot welding
Spot welding
Re-Spot welding
Inspection
Welding Fixture separate welding fixture
separate welding fixture
separate welding fixture
Weld Gun Two separate weld gun
Three separate weld gun
Three separate weld gun
No. of Spot/Stud Welding 68 51 43
Stages Stage-1
Stage-2
Stage-1
Stage-1
Pin up(Sec) 3 3 3
Loading(Sec) 40 50 6 5
Clamp up(Sec) 10 10 10
Welding/Inspection(Sec) 476 408 301 60
Pin down(Sec) 5 5 5
Unclamp(Sec) 7 5 5
Unloading(Sec) 15 15 15 10
Cycle Time(Sec) 556 496 345 75
Qty/day 80 80 80 80
Welder(To do only welding) 1 1 1 0
Helper(To load/unload the job + helping for gun holding) 1 1 1 0
Fixture Qty 1 1 1
Actual production 30 30 50
4.1.1.18 Time Study of REINFORCEMENT ASM-U B FRT S RL FRT
The data analysis is shown in following tables. The time study for REINFORCEMENT ASM-U B FRT S RL FRT which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.18.
All time consuming operations with its proper timings as shown in table 4.18.
Table 4.18- Time Study of REINFORCEMENT ASM-U B FRT S RL FRT
SR.NO. 18
Part Name REINFORCEMENT ASM-U B FRT S RL FRT
Operation Spot welding
Welding Fixture Separate welding fixture
Weld Gun One Common weld gun for LH/RH
No. of Spot/Stud Welding 11
Stages Stage 1
Pin up(Sec) 3
Loading(Sec) 30
Clamp up(Sec) 10
Welding/Inspection(Sec) 55
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10
Cycle Time(Sec) 188
Qty/day 80
Welder(To do only welding) 1
Helper(To load/unload the job + helping for gun holding) 0
Fixture Qty 1
Actual production 70
4.1.1.19 Time Study of PANEL ASM-U B FRT S RL CLOSEOUT
The data analysis is shown in following tables. The time study for PANEL ASM-U B FRT S RL CLOSEOUT which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.19.
All time consuming operations with its proper timings as shown in table 4.19.
Table 4.19- Time Study of PANEL ASM-U B FRT S RL CLOSEOUT
SR.NO. 19
Part Name PANEL ASM-U B FRT S RL CLOSEOUT
Operation Spot welding
Welding Fixture Separate welding fixture
Weld Gun one separate weld gun & one common with OP 100(common gun for LH/RH)
No. of Spot/Stud Welding 5
Stages Stage-1
Pin up(Sec) 3
Loading(Sec) 16
Clamp up(Sec) 10
Welding/Inspection(Sec) 30
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10
Cycle Time(Sec) 79
Qty/day 80
Welder(To do only welding) 1
Helper(To load/unload the job + helping for gun holding) 0
Fixture Qty 1
Actual production 100
4.1.1.20 Time Study of PANEL ASM-FRT W H
The data analysis is shown in following tables. The time study for PANEL ASM-FRT W H which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.20.
All time consuming operations with its proper timings as shown in table 4.20.
Table 4.20- Time Study of PANEL ASM-FRT W H
SR.NO. 20 20
Part Name PANEL ASM-FRT W H PANEL ASM-FRT W H
Operation Spot welding
Spot welding
Welding Fixture Separate welding fixture
Separate welding fixture
Weld Gun Two Common weld gun with OP 100 Two Common weld gun with OP 100
No. of Spot/Stud Welding 16 29
Stages Stage-1
Stage-2
Pin up(Sec) 3 3
Loading(Sec) 8 16
Clamp up(Sec) 10 10
Welding/Inspection(Sec) 64 116
Pin down(Sec) 5 5
Unclamp(Sec) 5 5
Unloading(Sec) 10 10
Cycle Time(Sec) 105 165
Qty/day 80 80
Welder(To do only welding) 1 1
Helper(To load/unload the job + helping for gun holding) 1 0
Fixture Qty 1 1
Actual production 100 60
4.1.1.21 Time Study of RAIL ASM-U B FRT SI
The data analysis is shown in following tables. The time study for RAIL ASM-U B FRT SI
which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.21.
All time consuming operations with its proper timings as shown in table 4.21.
Table 4.21- Time Study of RAIL ASM-U B FRT SI
SR.NO. 21 21 21 21
Part Name RAIL ASM-U B FRT SI
RAIL ASM-U B FRT SI
RAIL ASM-U B FRT SI
RAIL ASM-U B FRT SI
Operation Spot welding
Spot welding
Re-Spot welding
Inspection
Welding Fixture separate welding fixture
separate welding fixture
Weld Gun Two separate weld gun
Three separate weld gun
No. of Spot/Stud Welding 66 51 44
Stages Stage-1
Stage-2
Stage-1
Stage-1
Pin up(Sec) 3 3 3
Loading(Sec) 35 50 10 5
Clamp up(Sec) 10 10 10
Welding/Inspection(Sec) 462 408 308 60
Pin down(Sec) 5 5 5
Unclamp(Sec) 7 5 5
Unloading(Sec) 15 15 15 10
Cycle Time(Sec) 537 496 356 75
Qty/day 80 80 80
Welder(To do only welding) 1 1 1 0
4.1.1.22 Time Study of CROSSMEMBER ASM-FRT SUSP
The data analysis is shown in following tables. The time study for CROSSMEMBER ASM-FRT SUSP which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.22.
All time consuming operations with its proper timings as shown in table 4.22.
Table 4.22- Time Study of CROSSMEMBER ASM-FRT SUSP
SR.NO. 22 22
Part Name CROSSMEMBER ASM-FRT SUSP CROSSMEMBER ASM-FRT SUSP
Operation Spot welding
Inspection
Welding Fixture Separate welding fixture
Weld Gun One Separate weld gun
No. of Spot/Stud Welding 57
Stages Stage-1 Stage-1
Pin up(Sec) 3
Loading(Sec) 8 5
Clamp up(Sec) 10
Welding/Inspection(Sec) 228 10
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10 10
Cycle Time(Sec) 269 25
Qty/day 80 80
Welder(To do only welding) 1 0
Helper(To load/unload the job + helping for gun holding) 0 0
Fixture Qty 1
Actual production 60
4.1.1.23 Time Study of PANEL ASM-DA
The data analysis is shown in following tables. The time study for PANEL ASM-DA
which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.23.
All time consuming operations with its proper timings as shown in table 4.23.
Table 4.23- Time Study of PANEL ASM-DA
SR.NO. 23 23 23 23
Part Name PANEL ASM-DA PANEL ASM-DA PANEL ASM-DA PANEL ASM-DA
Operation Spot welding
Stud-Welding
Spot welding
Stud-Welding
Welding Fixture Common welding fixture for spot & Stud
Common welding fixture for spot & Stud
Common welding fixture for spot & Stud
Common welding fixture for spot & Stud
Weld Gun Two common weld gun for stage 1/2
Two Common stud gun for stage 1/2
Two Common weld gun for stage 1/2 Two Common stud gun for stage 1/2
No. of Spot/Stud Welding 38 12 62 12
Stages Stage-1
Stage-1
Stage-2 Stage-2
Pin up(Sec) 3 3
Loading(Sec) 49 56
Clamp up(Sec) 10 10
Welding/Inspection(Sec) 228 54 372 60
Pin down(Sec) 5 5
Unclamp(Sec) 6 6
Unloading(Sec) 10 10
Cycle Time(Sec) 290 75 441 81
Qty/day 80 80 80 80
Welder(To do only welding) 1 1 1 1
Helper(To load/unload the job + helping for gun holding) 1 0 0 0
Fixture Qty 1 1 1 1
Actual production 50
4.1.1.24 Time Study of PANEL ASM-PLNM LWR
The data analysis is shown in following tables. The time study for PANEL ASM-PLNM LWR which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.24.
All time consuming operations with its proper timings as shown in table 4.24.
Table 4.24- Time Study of PANEL ASM-PLNM LWR
SR.NO. 24 24 24
Part Name PANEL ASM-PLNM LWR PANEL ASM-PLNM LWR PANEL ASM-PLNM LWR
Operation Spot welding
Stud-Welding
Inspection
Welding Fixture Separate welding fixture
Separate Stud welding fixture
Weld Gun Separate weld gun
One separate stud gun
No. of Spot/Stud Welding 39 24
Stages Stage-1 Stage-1 Stage-1
Pin up(Sec) 3 3
Loading(Sec) 49 7 5
Clamp up(Sec) 10 10
Welding/Inspection(Sec) 234 132 60
Pin down(Sec) 5 5
Unclamp(Sec) 6 6
Unloading(Sec) 10 10 10
Cycle Time(Sec) 317 173 75
Qty/day 80 80 80
Welder(To do only welding) 1 1 0
Helper(To load/unload the job + helping for gun holding) 1 0 0
Fixture Qty 1 1
Actual production 65
4.1.1.25 Time Study of REINFORCEMENT ASM-PROP SHF HNGR
The data analysis is shown in following tables. The time study for REINFORCEMENT ASM-PROP SHF HNGR which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.25.
All time consuming operations with its proper timings as shown in table 4.25.
Table 4.25- Time Study of REINFORCEMENT ASM-PROP SHF HNGR
SR.NO. 25 25
Part Name REINFORCEMENT ASM-PROP SHF HNGR REINFORCEMENT ASM-PROP SHF HNGR
Operation Spot welding
Inspection
Welding Fixture separate welding fixture
Weld Gun Two separate weld gun
No. of Spot/Stud Welding 13
Stages Stage-1
Stage-1
Pin up(Sec) 3
Loading(Sec) 15 5
Clamp up(Sec) 10
Welding/Inspection(Sec) 78 60
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10 10
Cycle Time(Sec) 126 75
Qty/day 80 80
Welder(To do only welding) 1
Helper(To load/unload the job + helping for gun holding) 1
Fixture Qty 1
Actual production 120
4.1.1.26 Time Study of REINFORCEMENT ASM-FRT BPR IMP BAR CTR
The data analysis is shown in following tables. The time study for REINFORCEMENT ASM-FRT BPR IMP BAR CTR which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.26.
All time consuming operations with its proper timings as shown in table 4.26.
Table 4.26- Time Study of REINFORCEMENT ASM-FRT BPR IMP BAR CTR
SR.NO. 26
Part Name REINFORCEMENT ASM-FRT BPR IMP BAR CTR
Operation CO2 Welding
Welding Fixture separate welding fixture
Weld Gun Separate welding machine
No. of Spot/Stud Welding 20
Stages Stage-1
Pin up(Sec) 3
Loading(Sec) 8
Clamp up(Sec) 10
Welding/Inspection(Sec) 50
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10
Cycle Time(Sec) 91
Qty/day 80
Welder(To do only welding) 1
Helper(To load/unload the job + helping for gun holding) 0
Fixture Qty 1
Actual production 237
4.1.1.27 Time Study of BAR ASM-FRT BPR IMP BAR CTR
The data analysis is shown in following tables. The time study for BAR ASM-FRT BPR IMP BAR CTR which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.27.
All time consuming operations with its proper timings as shown in table 4.27.
Table 4.27- Time Study of BAR ASM-FRT BPR IMP BAR CTR
SR.NO. 27 27 27
Part Name BAR ASM-FRT BPR IMP BAR CTR BAR ASM-FRT BPR IMP BAR CTR BAR ASM-FRT BPR IMP BAR CTR
Operation Spot welding
CO2 Welding
Inspection
Welding Fixture separate welding fixture
Separate welding fixture
Weld Gun separate weld gun
Separate welding machine
No. of Spot/Stud Welding 52 22
Stages Stage-1
Stage-1
Stage-1
Pin up(Sec) 3 3
Loading(Sec) 24 48 5
Clamp up(Sec) 10 10
Welding/Inspection(Sec) 208 50 60
Pin down(Sec) 5 5
Unclamp(Sec) 5 5
Unloading(Sec) 10 10 10
Cycle Time(Sec) 265 131 75
Qty/day 80 80 80
Welder(To do only welding) 1 1 0
Helper(To load/unload the job + helping for gun holding) 1 0 0
Fixture Qty 1 1 0
Actual production 81 164
4.1.1.28 Time Study of BRACKET ASM-P/B BOOS
The data analysis is shown in following tables. The time study for BRACKET ASM-P/B BOOS which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.28.
All time consuming operations with its proper timings as shown in table 4.28.
Table 4.28- Time Study of BRACKET ASM-P/B BOOS
SR.NO. 28
Part Name BRACKET ASM-P/B BOOS
Operation Spot Welding
Welding Fixture separate welding fixture
Weld Gun one common welding gun for LH/RH
No. of Spot/Stud Welding 4
Stages Stage-1
Pin up(Sec) 3
Loading(Sec) 10
Clamp up(Sec) 10
Welding/Inspection(Sec) 20
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10
Cycle Time(Sec) 63
Qty/day 80
Welder(To do only welding) 1
Helper(To load/unload the job + helping for gun holding) 0
Fixture Qty 1
Actual production 150
4.1.1.29 Time Study of PANEL ASM-RKR INR LH
The data analysis is shown in following tables. The time study for PANEL ASM-RKR INR LH which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.29.
All time consuming operations with its proper timings as shown in table 4.29.
Table 4.29- Time Study of PANEL ASM-RKR INR LH
SR.NO. 29 29
Part Name PANEL ASM-RKR INR LH PANEL ASM-RKR INR LH
Operation Spot welding
Inspection
Welding Fixture separate welding fixture
Weld Gun one common welding gun for LH/RH
No. of Spot/Stud Welding 10
Stages Stage-1
Stage-1
Pin up(Sec) 3
Loading(Sec) 18 5
Clamp up(Sec) 10
Welding/Inspection(Sec) 50 60
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10 10
Cycle Time(Sec) 101 75
Qty/day 80 80
Welder(To do only welding) 1 0
Helper(To load/unload the job + helping for gun holding) 1 0
Fixture Qty 1
Actual production 100
4.1.1.30 Time Study of PANEL ASM-F/FDR INR
The data analysis is shown in following tables. The time study for PANEL ASM-F/FDR INR which done by various operations is illustrated.
Here all the operations which performed in assembly of the product are divided in number of elements as shown in table 4.30.
All time consuming operations with its proper timings as shown in table 4.30.
Table 4.30- Time Study of PANEL ASM-F/FDR INR
SR.NO. 30 30
Part Name PANEL ASM-F/FDR INR PANEL ASM-F/FDR INR
Operation Spot welding
Inspection
Welding Fixture separate welding fixture
Weld Gun one common welding gun for LH/RH
No. of Spot/Stud Welding 6
Stages Stage-1
Stage-1
Pin up(Sec) 3
Loading(Sec) 8 5
Clamp up(Sec) 10
Welding/Inspection(Sec) 30 60
Pin down(Sec) 5
Unclamp(Sec) 5
Unloading(Sec) 10 10
Cycle Time(Sec) 71 75
Qty/day 80 80
Welder(To do only welding) 1 0
Helper(To load/unload the job + helping for gun holding) 1 0
Fixture Qty 1
Actual production 150
4.1.2 Rejection Rate of ASAL
Chart 4.1 Rejection Rate of ASAL’
Chapter 5-Expected Outcome & Work Plan
5.1 EXPECTED OUTCOME
In this project work our main aim is to improving productivity, reducing rejection rate and reducing cycle time in Automotive stampings and assemblies Ltd. So for accomplishing this we used time study and also should use Kaizen methodology.