Process at a Glance

Team Members: Abhijit Nair, Ronak Mehta, Rahul panchal Production Location PaaG Product Cycle Time Line TAKT Time
(minutes) (minutes)

Process Type: Sub Assembly 83

Description: C-50 PORTABLE MACHINE - AIR-END ASSEMBLY Date Created: 20-07-22

Revision Number: Revision Date:
Program: Model: C-50 Options:
Sequence Number 10 20 30 40 50 60 70 80 90 100 110
Work station Identification SUB-ASSLY STATION 1 SUB-ASSLY STATION 1 SUB-ASSLY STATION 1 SUB-ASSLY STATION 1 SUB-ASSLY STATION 1 SUB-ASSLY STATION 1 SUB-ASSLY STATION 1 SUB-ASSLY STATION 1 SUB-ASSLY STATION 1 SUB-ASSLY STATION 1

Completed Assembly

Assembly Process Steps

Assemble Oil filter nipple, Control

silencer fitting on airend shaft Connect straight connection and Assemble the female part of the
Process Sequence Unpack the airend from Box Place Airend on assembly fixture connect male part of coupling mount the housing on the air end Assemble Intake controller set, temperature switch, Fit discharge fitting Unpacking Engine
seal cover tee coupling on the engine
Discharge connection
ENGINE YANMAR 4TNV88-BKCP HEX.HEAD SCREW ISO4017 M 8X
COMPRESSOR BASE GD4 DLT040X silencer COUPLING Housing C50 MANIFOLD ID90 DOUBLE NIPPLE GD4 T-CONNECTOR 6MM THR. SCR. JOINT DL 42
NON-EU 16 8.8 GALV
FEM.ROTOR LOCK.DISK M 8, ST.
CYLIND.SCREW M 10 X 25 PIPE SEAL.R.108 X 3 FKM 80 CONTROL SET 55 DEG C EK140 NOZZLE 1,5MM
FLZNNC
STRAIGHT TUBE FITTING 6MM-
CYLIND.SCREW M 16 X 45 LOCKING SCREW G 1/8 A VITON
G1/8
LOCK DISK NORD-LOCK M16, ST.
TEMPERATURE SWITCH 115C
Parts Used FLZNNC
names SEALING RING A 14 X20

ZS1187842 (1) ? ZS1199700 (1) 47772226001 (1) A11869574 (1) A11865374 (1) ZS1159467 (1) A93581140 (1) ZS1181389 (1) A93014800 (8)
A93040670 (7) A93195040 (1) 100010134 (1) ZS1188112 (1) A93149600 (8)
A93041170 (4) A93060450 (1) ZS1159463 (1)
A93149530 (4) A13229374 (1)
Part Numbers Used
A93189460 (1)

Act. Cycle Time 600 100 100 140 110 320 410 105 100 150 230
(in seconds)

Mistake Proofing
Poke-Yoke

eye bolt M16 - 2# allen key 5mm Box socket 13mm Allen socket 16mm Allen key 22mm Open end spanner 11 mm Open end spanner 55 mm 13 mm rachet Box spaner
torque wrench 48Nm torque wrench 48Nm Open spanner 22mm Open end spanner 13 mm torque wrench 160Nm torque wrench 24Nm
Tools Used during Step Box spanner 41mm Open spanner 36mm open end torque 14Nm
torque wrench 100Nm

locking Nut for Nipple

Fixtures

Material Presentation

Equipment or Machines Crane Crane na Induction Heater pneumatic or Electric gun pneumatic or Electric gun crane

Safety & Ergonomic Key Use helmet during crane Use helmet during crane Use helmet during crane
tighten till fix do not use torque Use heat resistant gloves
Points operation operation operation

Bolts should be tightened

Quality Key Points loctite 577
diagonally opp to each other

Check for Non CCN parts that

Do not over tight the temp switch
Information Flow locktide 572 comes with engine as scope of
- may lead to damge of switch
supply.
 120 130 140 150 160 170 180 190 200 210 220 230
SUB-ASSLY STATION 1 SUB-ASSLY STATION 1 SUB-ASSLY STATION 1 SUB-ASSLY STATION 1 SUB-ASSLY STATION 1 SUB-ASSLY STATION 1 SUB-ASSLY STATION 1 SUB-ASSLY STATION 1 SUB-ASSLY STATION 1 SUB-ASSLY STATION 1 SUB-ASSLY STATION 1 SUB-ASSLY STATION 1

Pic to add Pic to add

Assemble the engine top base mount the engine on assembly

Assemble Engine speed regulator Assemble Drain plug Loosen bolt for removal of belt Remove belt Remove bolt from pulley Assemble fan shaft refitt and tighten the belt Set engine belt tensioning Assemble Fan Assemble the engine with air-end
mounting fixture

STUD BOLT M10 X 75 8.8 GALV

ENGINE BASE TOP PART THREAD.CONN.PIECE 6MM-G1/8 Oil Drain Valve FAN SHAFT DLT0408 FAN WHEEL
DIN 939
LOCK SCREW W158 M10 X 25 HEX.HEAD SCREW ISO4017 M 8X HEX.HEAD SCREW ISO4017 M 6X
T-CONNECTOR 6MM LOCK.DISK M10, ST. FLZNNC
F100 VZ 16 8.8 GALV 16 8.8 GALV
CYLINDER DISK B 8,4 DISK A/B 6,4 HEXAGON NUT M10
LOCK SCREW W158 M10 X 25
SPEED REGULATOR DLT0408
F100 VZ
DISTANCE PLATE DLT0408
RETAINER OPER.CYLINDER
DLT0408
NOZZLE 1,8MM
CYLIND.SCREW ISO4762 M 5 X 12
8.8ZP
HEXAGONAL NUT M5 , THIN

ZS1068492 (2) ZS1159471 (1) ZS1184126 (1) ZS1068484 (1) A13137374 (1) A93024160 (8)

A93019800 (8) ZS1159467 (1) A93014800 (4) 47775361001 (4) A93149540 (8)
ZS1188110 (1) A93130090 (4) A93139270 (4) A93120100 (8)
ZS1068494 (1) A93019800 (8)
ZS1068496 (1)
ZS1068495 (1)
ZS1188113 (1)
A93040160 (1)
CC1131992 (1)

150 90 600 180 300 50 100 400 300 230 190

Box spanner 13mm RACHET SPANNER 8 MM BOX SOCKET 16MM (50Nm) BOX SPANNER 12 MM (26 Nm) BOX SOCKET 10 MM open end torque wrench 14Nm 10mm Box spaner Box spanner 13mm
torque wrench 48Nm RACHET SPANNER 10 MM PNEUMATIC / ELECTRIC GUN OPEN SPANNER 14 MM (29Nm) rachet spanner open end spanner 10mm 3/8" racheting spanner torque wrench 48Nm
RACHET SPANNER 13 MM TORQUE WRENCH OPEN END TORQUE WRENCH torque wrench 14Nm
OPEN SPANNER 32 MM BOX SOCKET 1/2" - 27 MM PNEUMATIC / ELECTRIC GUN
OPEN SPANNER 17 MM (2)

crane Pneumatic Gun Belt tighting fixture pneumatic Gun

Use helmet during crane CHECK THE MOVEMENT OF CHECK THE POSITION OF
operation PISTON LOCTION OF THE ALTRENATOR

All Studs should have locktide

applied to them

torque to be done on the Fan placement should as per

(Set belt tension 110-120 pound) loctite 242
tightness feel of the connection clockwise rotation