DR.

BABASAHEB AMBEDKAR MARATHWADA UNIVERSITY, AURANGABAD

SHREEYASH COLLEGE OF ENGINEERING & TECHNOLOGY,

AURANGABAD

A Project Report
On

“COST AND CYCLE TIME REDUCTION OF BALL TURNING

OPERATION OF CARDAN SHAFT”
Submitted by

ISHWAR TUKARAM NIKAM

Under the Guidance of

Prof. DEEPAK PAWAR

(Asst. Professor)

Submitted in partial fulfillment of the requirement for the degree of

Bachelor of Engineering (Mechanical)

Department of Mechanical Engineering

Year 2016-17
 CERTIFICATE
This is to certify that the project report entitled

“COST AND CYCLE TIME REDUCTION OF BALL TURNING

OPERATION OF CARDAN SHAFT”
Submitted by

ISHWAR TUKARAM NIKAM

Has completed project as per the requirement of

Dr. Babasaheb Ambedkar Marathwada University

In partial fulfillment of degree B.E. (Mechanical)

Prof. Deepak Pawar Prof.K.T.Patil Prof. G.S. Dhage Dr. R. S. Pawar

Academic Guide Project Coordinator H.O.D Principal

Department of Mechanical Engineering

Shreeyash College of Engineering & Technology, Aurangabad

Year 2016-17
 A

PROJECT REPORT

ON

“COST AND CYCLE TIME REDUCTION OF BALL TURNING

OPERATION OF CARDAN SHAFT”
Submitted in the partial fulfillment of the requirements for the degree of

BACHELOR OF ENGINEERING (MECHANICAL)

By

ISHWAR TUKARAM NIKAM

Under the Guidance of

Prof. Deepak Pawar Mr. V. D. Deshpande

Academic Guide Company Mentor

Department of Mechanical Engineering

SHREEYASH COLLEGE OF ENGINEERING & TECHNOLOGY,

AURANGABAD

AND

Varroc Engineering Pvt. Ltd. (INDIA) VEPL-VII (F)

L-4, MIDC Industrial Area, Waluj, Dist. Aurangabad-431136,

Maharashtra
(2016-2017)
 ACKNOWLEDGEMENT

It is intended a matter of pride for me to get selected for the project work
activity in such an esteemed organization.

I would like to express my deep sense of gratitude towards the Mr. Ashwini
Maheshwari Sir – President – BU (Forging), Mr. Sanjay Shinde Sir – Plant Head –
VEPL VII (Forging), our mentors from Varroc Engineering Pvt. Ltd. – VII (F), Mr.
Vijay Deshpande Sir – Asst. Manager - (Prod.), Mr. Narendra Bagde Sir –
Executive Engineer - (Prod.) and Late.Santosh Talikhedkar– Senior Officer – HRD
for giving me such attention and time.

At the same time, I express my sincere thanks towards all the persons from
Varroc Engineering Pvt. Ltd. – VII (F), for their guidance and encouragement.

I also thank Dr. R.S. Pawar – Principal, Prof. G. S. Dhage – Head of the
Department & Prof. Deepak Pawar – Guide. Shreeyash College of Engineering &
Technology, Aurangabad for their constant supervision.

Ishwar Tukaram Nikam (41146)

i
 ABSTARCT

In Varroc Engineering Pvt. Ltd., Plant VII in Forging Business Steering

Cardan shaft is one of the major products. It undergoes sequence of operations. It
includes the forging process and heat treatment as well. In Forging the processes
which are of major concern are as follows:

 Upsetting i.e. ball formation

 Ball turning
 Slot milling

During observation I came up with a conclusion that productivity of CNC used

for ball turning is comparatively lesser which caused the use of running load on next
operation that is Slot milling and thereby reducing its overall equipment efficiency
(OEE). Here I found the scope of improvisation in order to reduce the cycle time to
increase the productivity. Previously insert of 0.8 mm radius was used which was
later replaced by insert of 1.2 mm radius and also the number of strokes required to
turn the ball were reduced to 2 from 3 reducing the cycle time from 30 seconds to 21
seconds.

This way we can say that all these KAIZENS will prove to be efficient in terms
of reducing the cycle time and thereby increasing the productivity also reducing the
cost till some extent.

ii
 INDEX

Chapter Chapter Particulars Page

No No
a) Acknowledgement I
b) Abstract II
c) Index III
d) Figure Index V
e) Graph Index VI
f) Table Index VII
1 Introduction 1
1.1 Introduction to Company. 1
1.2 Company profile 2
1.3 Major Products 3
1.4 Clients 3
1.5 Products Of Company 3
1.6 Engine Valve Business 4
1.7 Forging Business 5
1.8 Vision 5
1.9 Mission 6
1.10 Quality 6
1.11 Environment, Health & Safety 6
2 Literature Review 7
3 Varroc Engineering PVT LTD-VII (Forging division) 8
3.1 Plant layout 8
3.2 Processes on cardan shaft 9
3.2.1 Annealing 9
3.2.2 Shot blasting 9
3.2.3 Puls coating 9
3.2.4 Up-set 1 10
3.2.5 Pre-machining 10
3.2.6 Gear extrusion 10
3.2.7 Facing at CNC 1 11

iii
 3.2.8 Ball formation on Up-setter 2 11
3.2.9 Slot milling on AMS 11
4 Project on Ball Turning Machine (CNC) 13
4.1 Study of Machine 13
4.2 Problem definition 14
4.3 Kaizen idea 14
4.3.1 Problem status 14
4.3.2 Kaizen 14
4.4 Program before kaizen 15
4.5 Tool History 18
4.6 Raw material 20
4.7 Program after kaizen 23
4.8 Reduction in cycle time 26
4.9 Comparative table of parameters before and after kaizen 26
4.10 Test to ensure that the quality of product is maintained 26
even after changing the specification
4.11 Benefits 27
4.11.1 Cost saving 27
4.11.2 Productivity increases 28
4.11.3 Time saving 29
4.12 Kaizen sheet 30
5 Results 31
6 Conclusion…...…………………………………………….. 32
References…………………………………………………. 33
Appendices 34
A In Plant Training Certificate 34
B Paper publish Certificate 35
C Article Review Card 36

iv
 FIGURE INDEX

Figure No. Figure Particulars Page No.

1.1 Corporate office of Varroc PVT LTD 1
1.2 Products of company 3
1.3 Valves machine 4
1.4 Forging machineries 5
3.1 Plant layout 8
3.2 Cardan shaft 9
4.1 CNC for ball turning operation 13
4.2 Internal view of ball turning machine 18
4.3 Insert 22

v
 GRAPH INDEX

Graph No. Graph Particulars Page No.

4.1 Tool life (NOS) Vs Speed (rpm) 18

vi
 TABLE INDEX

Table No. Table Particulars Page No.

4.1 Selection of insert 20
4.2 Comparative table of parameters before and after kaizen 26
4.3 Quality chart 1 26
4.4 Quality chart 2 27

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 Cost and Cycle Time Reduction of Ball Turning Operation of Cardan Shaft

CHAPTER 01

INTRODUCTION

1.1 Introduction to Company

Fig. 1.1 Corporate office of Varroc PVT LTD

Varroc was founded in 1990, Varroc group is an emerging

global automotive component manufacturer and supplier of exterior lighting systems,
power-trains, electrical, body and chassis parts to leading passenger car and
motorcycle segments worldwide. With 35 world-class manufacturing facilities, 11
engineering centers, 10000 employees and 760 engineering experts in 10 countries,
Varroc group is on an exponential growth trajectory clocking sales of 1.3 billion USD
in 2014-15. The company is a leading global passenger car lighting supplier and the
number one 2-wheeler automotive component supplier in India. Varroc offers best
design solutions that give customers a competitive edge in their markets.

Varroc has a globally proven track record in the metallic business

with its capabilities in flawless design, development, manufacturing and supply of
high performance and cost-effective components using eco-friendly practices. The
division is a leading supplier of essential machined forgings and engine valves to
leading OEMs in India as well as the global market. The manufacturing capabilities of

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 Cost and Cycle Time Reduction of Ball Turning Operation of Cardan Shaft

forging include hot, warm and cold forging, heat treatment, post heat treatment
machining and soft machining. The division has a dedicated modern crankshaft facility
to cater to the commercial vehicle segment. In addition, a strong program management
capability provides developmental support to its key customers. The manufacturing
capabilities of crankshaft include forging and testing, and the engineering capabilities
include design & drafting, simulation, post processor - tool path and product design.
For that of valves, the manufacturing capabilities include heat treatment, pattern
hardening, extrusion forging, hommel inspection, induction hardening and ultrasonic
inspection. Varroc also operates an international forging plant in Italy that supplies
large forgings to Caterpillar in Europe for construction equipment.

1.2 Company Profile

Name of the Company : Varroc Engineering Pvt. Ltd. (INDIA)

Address : VEPL-VII Forging, L-4, MIDC Industrial Area, Waluj,

Dist. Aurangabad-431136, Maharashtra

Establishment Year : 1990

Nature of Industry : Manufacturing

Present Investment :

Previous Year Turnover : 180 Crore

Website : www.Varrocgroup.com

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 Cost and Cycle Time Reduction of Ball Turning Operation of Cardan Shaft

1.3 Major Products : 1. Engine Valve

2. Crank Pin
3. Cardan Shaft
4. Cam Shaft
5. Spools
6. Connecting Rod
7. Transmission Assembly
1.4 Clients

1) Sauer Danfoss
2) Royal Enfield
3) Eaton
4) Ognibene

1.5 Products of Company

Fig.1.2 Products of company

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1.6 Engine Valves Business

Fig.1.3 Engine valve

Duro-valve, which is part of the Engine Valves division, is the most

preferred supplier of engine valves in India today. With a market share of over 25%, it
is the fastest growing engine valves supplier in India. It supplies to all segments of the
automotive industry and boasts of having a major clientele in the international
markets, wherein nearly half of the engine valves production is exported to Europe.
The division has one manufacturing plant and state-of-the-art technical center in India,
which provides development support to customers in U.S. and is also involved in
development of sodium filled and hollow engine valves.

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 Cost and Cycle Time Reduction of Ball Turning Operation of Cardan Shaft

1.7 Forging Business

Fig. 1.4 Forging business

The Forge business supplies forged and machined parts for engine and
also manufacturing 6 cylinder crankshafts for commercial vehicles and stationary
engines. Key products such as 2, 3 and 4 Wheeler engine parts, which include
transmission gears and assemblies, crank pins, connecting rods, flanges, Ring gears,
Crankshafts, Camshafts, Knuckles, Front Axle Beams and hydraulic components
which are supplied to leading OEMs as well as Tier 1 suppliers in India and is also
exported to Europe. The division has 3 manufacturing plants and an Engineering
center in India as well as 1 manufacturing plant in Italy, which caters to heavy
undercarriage parts.

1.8 Vision

 To be a $4 Billion Globally diversified business in the transportation and allied

industry in 2020:
 Core business will continue to be automotive components
 Global operations will fuel our technology build up in emerging economies
 Select technology products for 4 wheeler industry

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 Cost and Cycle Time Reduction of Ball Turning Operation of Cardan Shaft

1.9 Mission

 Be an affordable and flexible global technology supplier and deliver value to

customer by being the supplier of choice:
 From low cost manufacturing footprints
 By achieving operational excellence
 By investing in safe, light and green technologies

1.10 Quality

The company is committed to maintain quality at every stage, from receipt of

raw material through manufacturing processes to the finished products. The company
has been accredited with ISO 9001: 2000 certification

TPM Policy

TOTAL PRODUCTIVE MAINTENANCE is adopted as a means of creating

safe and participative work environment in which all employees target the elimination
of losses in order to continuously enhance the capacity of its processes, leading to
higher employee morale and greater organizational and customer profitability.

1.11 Environment, Health & Safety (EHS)

Among Varroc’s top priorities, safety is seen as both a right and a

responsibility for all employees. In September 2008, the Company launched an
Environment; Health & Safety (EHS) plan to be deployed over a 3 years period. This
continuous improvement process is built on four foundations, each sponsored by a
member of the Executive Committee. In addition to equipment conformity, the plan
hopes to bring about behavioral and cultural changes based on an in-depth analysis of
operator practices. In year 2011-12, the centralized system for managing the safety of
people and property received OHSAS certification. With continuous improvement as
its driving force, Varroc’s EHS plan focuses on four key factors: Eliminating exposure
to serious accidents by identifying hazards & reducing the total number of accidents.
Preserving the Company’s industrial assets & complying to all applicable legal norms.
Helping to enhance managerial skills through systematic approach towards training
and development in our own way. Reducing environmental impacts as much as
possible (water, air and soil).
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CHAPTER 02

LITERATURE REVIEW

Sr. No AUTHOR NAME WORK FINDING

1 William B Hetzal Cycle time reduction and Reduced a cycle
strategic inventory placement time by changing
across a multistage process parameter like
speed, feed
2 P.P.Shirpurkar & According to Optimization of Reduced a cycle
S.R.Boeade V.V.Patil turning process parameters time by using tool
by using tool inserts insert
3 Hiten Patil Review on cycle time Reduction in cycle
reduction in manufacturing time
industries

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CHAPTER 03

VARROC ENGINEERING PLANT VII

(FORGING DIVISION) PVT LTD.

3.1 Plant Layout

Fig 3.1 Plant layout

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3.2 Process on cardan shaft

Raw Material

The chemical composition of raw material is 20CrMoS5 which is

provided by a Sangkaj pvt. ltd, Aurangabad in the form of slug.

Fig. 3.2 Cardan shaft

3.2.1 Annealing
Annealing, in metallurgy and materials science, is a heat treatment that alters
the physical and sometimes chemical properties of a material to increase its ductility
and reduce its hardness, making it more workable. It involves heating a material to
above its recrystallization temperature, maintaining a suitable temperature, and then
cooling.

In annealing, atoms migrate in the crystal lattice and the number of

dislocations decreases, leading to the change in ductility and hardness.

In the case of cardan shaft annealing is done on raw material according to

process design for removal of internal stresses and to soften material.

The process of annealing takes near about 16 hours for completion and the
temperature in the annealing furnace is maximum up to 690® C.

3.2.2 Shot Blasting

Shot blasting is a method used to clean, strengthen (peen) or polish metal.
Shot blasting is used in almost every industry. For shot blasting, cut wire steel shots
having size 0.8MM having hardness about 35 -40 BHN are used.
3.2.3 Puls Coating
After shot blasting job is sent for puls coating. Puls coating is done in
order to fill up the micro cracks present on the surface of the job and also to provide
lubrication such that there is an ease in operation of cap formation on hydraulic press.
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The setup consists of 4 tanks containing water, puls solution and dryer
too. Basket should be loaded with 100-150 pieces and should be immersed in water
keeping it there for 3 minutes approx. Basket should be dried then in dryer followed
by immersing it into puls solution. The load is then kept into it for around 5 minutes
and then dried. After unloading it is then send to Up setter I for cap formation on
hydraulic press

3.2.4 Upset –I
Pulse coated slug is pressed under load upto 70 T on the hydraulic press having
capacity of 150 T. This pressure causes the phenomenon of cap formation. The load
applied by the press is not fixed instead it keeps on varying depending upon the
hardness of the slug.

3.2.5 Pre-Machining
Turning is a machining process in which a cutting tool, typically a non-
rotary tool bit, describes a helical tool path by moving more or less linearly while the
work piece rotates. The tool's axes of movement may be literally a straight line, or
they may be along some set of curves or angles, but they are essentially linear (in the
nonmathematical sense). Usually the term "turning" is reserved for the generation of
external surfaces by this cutting action. Turning operation is carried out on cap formed
slug for pre-machining purpose.

3.2.6 Gear Extrusion

Gear Extrusion is a process used to create objects of a fixed cross-
sectional profile. A material is pushed through a die of the desired cross-section. The
two main advantages of this process over other manufacturing processes are its ability
to create very complex cross-sections, and to work materials that are brittle, because
the material only encounters compressive and shear stresses. It also forms parts with
an excellent surface finish. The gear extrusion is carried out on 100 TON Hydraulic
press by applying 35-50 TON pressure.

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3.2.7 Facing At CNC-I

On CNC the facing operation is done after gear extrusion process. The
completion of this operation is carried out in two cut i.e. one is rough and another is
finish, also they use different insert for rough and finish operation.

3.2.8 Ball Formation On Up-setter

Ball Form can simulate electric upsetting with variable electrical current and
pushing pressure. It can simulate the heating by resistance and the deformation by
hydraulic pressure. Electric upsetting is a means of performing bar stock to create an
enlarged diameter on a bar, which can then be forged with no further heating. It has
applications to the production of parts that are conventionally produced by closed die
forging in presses or hammers, and also the production of parts that are conventionally
produced in mechanical upsetting machines.
The cold bar stock (siuge) is placed in the up-setter and clamped by the
gripper jaws. A low-voltage, high-amperage, electric current is passed through the bar
between the anvil and the gripper jaws. As the bar between the contacts heats (by
resistance) and becomes plastic, the axial force applied by the hydraulic cylinder
compresses the bar and enlarges it at the hot end, creating a ball against the anvil. As
the ball becomes larger, the anvil retracts at a rate less than that of the upsetting
cylinder. There is virtually no limit to the amount of material that can be gathered. The
current is constantly applied, so the entire ball is at forging temperature, and since the
resistance heating begins at the center of the bar, scale is minimized. The shaft of the
upset is completely unaltered by the upsetting process.

3.2.9 Slot Milling On AMS

For slot milling operation 16 inserts are used, 6 for upper side finishing, 6 for
lower side finishing, and 4 for grooving purpose.

Slot milling operation is done in two steps:

a) Side and Face Milling

Side and face milling cutters can handle long, deep, open slots in a more
efficient manner, and provide the best stability and productivity for this type of

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 Cost and Cycle Time Reduction of Ball Turning Operation of Cardan Shaft

milling. They can also be built into a “gang” to machine more than one surface in the
same plane at the same time.
b) End Milling
End milling is selected for shorter, shallower slots, especially closed grooves
and pockets, and for milling key-ways. End mills are the only tools that can mill
closed slots that are: Straight, curved or angled Wider than tool diameter, designated
pockets. Heavier slotting operations are often performed using long edge milling
cutters.

After all these processes the job is then sent to heat treatment shop and then
ultimately to Final Inspection Department and then dispatched.

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CHAPTER 04

PROJECT ON BALL TURNING MACHINE (CNC-II)

4.1 Study of machine

The ball turning operation is carried out on CNC machine, which is provided
by FANUC PVT LTD. In this operation two inserts are used one having 0.8 mm
radius and another having 0.4 mm radius which are used for rough & finish cut
purpose respectively.

After operation product characteristics are:-

1) Product length 90.75-90.85

2) Ball centre length 87.25-87.55
3) Ball diameter 22.10-22.15
4) Radius R5 -R15
5) Chamfer at ball end face 0.4x45º
6) Angle 19º -21º

Fig. 4.1 CNC for Ball turning operation

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4.2 Problem Definition

During observation I came up with a conclusion that productivity of CNC used
for ball turning is comparatively lesser which caused the use of running load on next
operation that is Slot milling and thereby reducing its overall equipment efficiency
(OEE). Here I found the scope of improvisation in order to reduce the cycle time to
increase the productivity.

4.3 Kaizen Idea:-

4.3.1 Problem Status:-
1) More cycle time i.e. about 30 second.
2) Set up time & tool adjustment time is more.
3) After every 150 NOS, Set up & tool adjustment is required.
4) Three cut or pass in rough cut operation.

4.3.2 Kaizen:-

1. By reducing cycle time.

2. By reducing cut or pass of operation.
3. By reducing Set up time & tool adjustment time.

Program used for operation is as follows:-

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4.4 Program before kaizen

00000 ;

N1 ;

G40 ;

T0101 ;

G50 S1800 ;

G96 S240 M03 ;

G0 G40 Z50 M08 ;

X-28.0 ;

Z1.6 ;

G01 X1.5 F0.25 ;

G0 Z2.5 X-28.0 ;

G0 Z1.0 ;

G01 X1.5 F0.25 ;

G0 Z2.0 X-28.0 ;

G0 Z0.5 ;

G01 X2.0 F0.3 ;

G0 Z1.5 X-20.0 ;

G01 Z0.4 ;

G01 G41 X-22.9 ;

G02 X-25.2 Z-3.4 R11.1;

G02 X-23.6 Z-7.3 R11.1 ;

G01 X-17.7 Z-15.35 ;

G03 X-16.4 Z-18.7 R7.0 ;

G01 Z-22.5 ;

G40 G0 X-30.0 ;

G0 Z1.0 ;
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G0.X-20.0 ;

G01 Z0.3 ;

G1 G41 X-21.9 ;

G02 X-23.3 Z-3.4 R11.1 ;

G02 X-22.1 Z-7.3 R11.1 ;

G1 X-16.2 Z-15.35 ;

G03 X-15.2 Z-18.7 R10.0 ;

G1 Z-21.5 ;

G40 G0 X-30.0 Z50.0 M05 ;

M01 ;

N2 ;

G40 ;

T0202 ;

G50 S1800 ;

M04 ;

G96 S210 ;

G0 Z50.0 M8 ;

X25.0 ;

G0 Z0.0 ;

G1 X-3.0 F0.2 ;

G0 X18.5 Z1.0 ;

G1 G42 Z0.0 F0.18 ;

G01 X20.5 F0.15 ;

G1 X21.5 Z-0.5 ;

G03 X22.2 Z-3.15 R11.1 ;

G03 X20.862 Z-7.3 R11.1 ;

G1 X15.0 Z-15.402 ;
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G02 X14.3 Z-18.423 R7.0 ;

G1 Z-24.5 ;

G1 X14.4 Z-26.2 ;

Z-26.8 ;

M09 ;

M05 ;

G40 G0X80.0 Z50.0 ;

M11 ;

M30 ;

Above program is used for ball turning operation.

Hourly production of machine is 72 NOS

 Production per hour 72

 production in 8 hr 72 x 8 = 576 NOS
 production in one day 576 x 3 = 1728 NOS

For reduction in cycle time I changed parameter of CNC like speed, feed & number of
cuts from 3 to 2, but it was affecting on tool life. Production was increased but tool life
decreased at the same time cost of operation was also increased, which ultimately
increased the cost of product.

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Tool life in NOS

160
140
120
Tool life in NOS

100
80
60 Tool life in NOS
40
20
0
2400 2600 2800 3000
Speed in rpm

Graph 4.1 Tool Life (NOS) Vs Speed (rpm)

4.5 Tool history

For rough operation:-

Fig. 4.2 Internal view of CNC machine

In CNC for operation earlier 0.8MM insert of Sandvik coromant was used for rough
operation, which was increasing the cost of operation and cost of product as well.

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Cost of 0.8 mm insert : Rs 270

Tool life of 1 insert : 900 NOS

Operation cost for 1 job : Rs 0.3

For finish operation

For ball turning operation in CNC 0.4 mm insert was used for finishing operation.

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4.6 Raw material

Selection of Insert

According to ANSI (American National Standard Institute) and ISO

(International Standard Organization), both assign meaning to each letter & number in
insert name. But the ANSI is based on inches & ISO on the metric system.

4.1 Table for selection of insert

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Type of insert for general turning

1) Positive type of insert

2) Negative type of insert

First of all, decide Positive whether positive or negative style inserts are going to
be used. A negative insert has an angle of 90° (0° clearance angle), while a positive
insert has an angle of less than 90° (7° clearance angle). The illustration of the
negative style insert shows how the insert is mounted in the holder and tilted.

Some characteristics of the two insert types are listed below:

Positive type insert

1. Single sided
2. Low cutting forces
3. Side clearance
4. First choice for internal turning and for external turning of slender components
5. 7°Clearance angle

Negative type insert

1) Double and/or single sided

2) High edge strength
3) Zero clearance
4) First choice for external turning
5) Heavy cutting conditions

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Fig. 4.3 Insert.

According to above information i choose negative type of insert made by
carbide having AL2O3 coating with 1.2 mm radius. Above insert provide by TEAGU
–TEC PVT. LTD

Changes in Program:-
For selected material I change parameter in program like feed, speed, and
number of cut or pass, for reducing cycle time of ball turning machine.
Changed program as follow:-

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4.7 Program after kaizen

00000 ;

N1 ;

G40 ;

T0101 ;

G50 S1800 ;

G96 S240 M03 ;

G0 G40 Z50 M08 ;

X-28.0 ;

Z1.6 ;

G01 X1.5 F0.25 ;

G0 Z2.5 X-28.0 ;

G0 Z1.0 ;

G01 X1.5 F0.25 ;

G0 Z2.0 X-28.0 ;

G0 Z0.5 ;

G01 X2.0 F0.3 ;

G0 Z1.5 X-20.0 ;

G01 Z0.4 ;

G01 G41 X-22.9 ;

G02 X-25.2 Z-3.4 R11.1;

G02 X-23.6 Z-7.3 R11.1 ;

G01 X-17.7 Z-15.35 ;

G03 X-16.4 Z-18.7 R7.0 ;

G01 Z-22.5 ;

G40 G0 X-30.0 ;

G0 Z1.0 ;
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G0.X-20.0 ;

G01 Z0.3 ;

G1 G41 X-21.9 ;

G02 X-23.3 Z-3.4 R11.1 ;

G02 X-22.1 Z-7.3 R11.1 ;

G1 X-16.2 Z-15.35 ;

G03 X-15.2 Z-18.7 R10.0 ;

G1 Z-21.5 ;

G40 G0 X-30.0 Z50.0 M05 ;

M01 ;

N2 ;

G40 ;

T0202 ;

G50 S1800 ;

M04 ;

G96 S210 ;

G0 Z50.0 M8 ;

X25.0 ;

G0 Z0.0 ;

G1 X-3.0 F0.2 ;

G0 X18.5 Z1.0 ;

G1 G42 Z0.0 F0.18 ;

G01 X20.5 F0.15 ;

G1 X21.5 Z-0.5 ;

G03 X22.2 Z-3.15 R11.1 ;

G03 X20.862 Z-7.3 R11.1 ;

G1 X15.0 Z-15.402 ;
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Cost and Cycle Time Reduction of Ball Turning Operation of Cardan Shaft

G02 X14.3 Z-18.423 R7.0 ;

G1 Z-24.5 ;

G1 X14.4 Z-26.2 ;

Z-26.8 ;

M09 ;

M05 ;

G40 G0X80.0 Z50.0 ;

M11 ;

M30 ;

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 Cost and Cycle Time Reduction of Ball Turning Operation of Cardan Shaft

4.8 Reduction in Cycle time

Due to change in parameters like speed and feed and reducing the number of
stroke or pass the cycle time gets reduced .Following table indicates how productivity
is increased after the Kaizen.

4.9 Comparative table of parameters before and after Kaizen

Parameters Before Kaizen After Kaizen

(using 0.8mm insert) (using 1.2mm insert)

Cycle Time 30 sec 21 sec

Production (8 Hrs.) 576 NOS. 800 NOS

Insert Life At one corner 150 NOS 400 NOS

Total insert Life 900 NOS 2400 NOS

(at 6-corner)

Insert Cost (1 pcs.) Rs.165.24 Rs.197.81

Cost Of Operation Rs.0.1836 Rs.0.069

(for 1 Nos.)
Table 4.2

4.10 Test to ensure that the quality of product is maintained even after
changing the specification

4.10.1 Quality chart 1

Parameter Sample 1 Sample 2 Tolerance

Run out error 0.089 0.075 0.1mm
length of 0.083 0.079 0.15mm
sample
Table 4.3

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 Cost and Cycle Time Reduction of Ball Turning Operation of Cardan Shaft

4.10.2 Quality chart 2

Sample No. Run out Error Length of sample

(Radius of Ball)
1 5.6 90.76
2 7.2 90.79
3 6.3 90.75
4 8.9 90.82
5 7.3 90.77
Table 4.4

4.11 Benefits

4.11.1 Cost Savings

Before Kaizen

 Parts to be produced in a shift : 576 NOS

 Parts to be produced in a day : 576 x 3 = 1728 NOS
 Parts to be produced in a month : 1728 x 30 = 51840 NOS
After every 900 NOS insert was changed,
 Thus total number of insert required in a month : 51840 ÷ 900 = 58 approx.

After kaizen

 After every 2400 NOS insert is change

 Thus total number of insert required in a month : 51840 ÷ 2400 = 22 approx.
 Requirement of insert decreased in a month : 58 – 22 = 36
Cost saving in a month due to insert =[ Requirement of insert decreased in a
month] X [cost of one insert]
= 36 x 197.81 = Rs 7121.16
 Cost saving in a year due to insert = 12 x 7121.16 = Rs 85453.92

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 Cost and Cycle Time Reduction of Ball Turning Operation of Cardan Shaft

4.11.2 Productivity increases

 Before kaizen production in 8 hrs : 576 NOS

 After kaizen production in 8 hrs : 800 NOS
 Increase production in 8 hrs : 800 – 576 = 224 NOS
 Increase production in a day : 224 x 3 = 672 NOS
 Increase production in a month : 672 x 30 = 20160 NOS
 Increase production in a year : 20160 x 12 = 241920 NOS
 One operator produces 576 NOS in a shift
 Manpower required to produce 241920 NOS : 241920 ÷ 576 = 420
 Remuneration of one labour : Rs 300
 Cost saving due to increase in production in a year : 420 x 300 = Rs 126000

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 Cost and Cycle Time Reduction of Ball Turning Operation of Cardan Shaft

4.11.3 Time saving

Before kaizen

 After every 150 NOS we changed corner of insert and after using all insert
corners i.e. after 900 NOS an insert was changed.
 Time required for changing an insert for each corner : 5 min ( for 150 NOS )
 Time required for changing an insert for all 6 corners : 30 min ( for 900 NOS )
 Time required for changing insert in one month =[ Total number of insert used
in one month ] X [Time required for changing insert for all 6 corner]
= 58 x 30 = 1740 min (for 51840 NOS )
 Time required for changing insert in one year = 1740 x 12 = 20880 min ( for
622080 )

After kaizen

 After every 400 NOS we change corner of insert and after 2400 NOS we
change an insert.
 Time required for changing insert in one year for 622080 NOS = 21.6 x 30 x
12 = 7776 min
 Total time saving due to changing insert in one year = Time required for
changing insert in one year before kaizen - Time required for changing insert
in one year after kaizen
 = 20736 – 7776 = 12960 min=216 hrs = 9 day

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 Cost and Cycle Time Reduction of Ball Turning Operation of Cardan Shaft

4.12 Kaizen Sheet

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 Cost and Cycle Time Reduction of Ball Turning Operation of Cardan Shaft

CHAPTER 05
RESULTS

1 Increased production in a year : 241920 NOS

2 Cost saving due to increase in production in a year : 126000 INR

3 Cost saving in a year due to insert : 85454 INR

4 Total savings for one machine : 126000+85454

= 211454 INR

5 Total saving for two machines : 211454 x 2

= 422908

6 Total time saving due to changing insert in one year: 12960 min=216 hrs
= 9 days

7 Total time saving due to changing insert in one year for 2 machine : 18 days

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 Cost and Cycle Time Reduction of Ball Turning Operation of Cardan Shaft

CHAPTER 06
CONCLUSIONS

 Reduces cost of operation

 Reduces human efforts

 Achieves OEE of machine

 Reduces downtime and losses

 Productivity increases

 Reduces 30% cycle time of operation

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 Cost and Cycle Time Reduction of Ball Turning Operation of Cardan Shaft

REFERENCE

[1] Optimization of turning process parameters by using tool inserts

- Review by P.P.Shirpurkar & S.R.Boeade V.V.Patil Copyright ©2008 by
IJEIT December 2012,vol. 2

[2] Cycle time reduction and strategic inventory placement across a

multistage process-William B Hetzal© 1993 Massachusetts Institute Of
Technology

[3] Review on cycle time reduction in manufacturing industries - Hiten

patel copyright © 2014 by IJEIT December 2014

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