A Process Capability Improvement of Machining Parameters of Ten Ton Compactor'S Rear Chassis
A Process Capability Improvement of Machining Parameters of Ten Ton Compactor'S Rear Chassis
A Process Capability Improvement of Machining Parameters of Ten Ton Compactor'S Rear Chassis
Process quality is the building block to any organization for ensuring the quality on which the customer
thrives and establishing a good relationship between a manufacturer and a customer. The basic three capability indices
commonly used in manufacturing industries are Cp, Cpk, Cpm and Cpmk. Process capability indices are intended to
provide single number assessment of the ability of a process to meet specification limits on quality characteristics of
interest. Thus, it identifies the opportunities for improving quality and productivity. Therefore, understanding the
meaning of quality and efforts taken towards its improvement plays a pivotal role in the growth of a company’s
business. The most effective way towards the improvement of the quality of the product in hand is by eliminating the
defects from the process to make it more accurate and precise. Improvement of a process is a long term task which
includes problem definition, the source of a problem, root causes which include both primary and secondary and the
Original Article
steps taken towards the optimization. The identification of the problem is possible either by visual inspection or through
statistical process control. Process capability analysis is one of the major tools used to determine the process
performance as capable or incapable within a specified tolerance which is used for improving the process.
KEYWORDS: Process Capability, Process Capability Analysis, Process Quality, Rear Chassis & Ten Ton Compactor
Received: Dec 05, 2018; Accepted: Dec 25, 2018; Published: Jan 14, 2019; Paper Id.: IJMPERDFEB201938
1. INTRODUCTION
A ten ton compactor is build up on the basis of a rear chassis and a front chassis which are termed as the
major component in a ten ton compactor. A compactor is a road roller type engineering vehicle used to compact
soil, gravel, concrete or asphalt in the construction of roads and foundation. The first compactors were horse-drawn
and were probably just borrowed from implements. Compactors use the weight of the vehicle to compress the
surface being rolled (static) or use mechanical advantage (vibrating). It can be of a single drum or of two drums,
weighing 5-54 tons. Drums are available in width ranging from 24 to 84 inches. Now over here we are basically
dealing with a ten ton compactor in which improvement of machining of a rear chassis of a compactor is our main
aim. This change in quality may be due to a number of factors most important variation being in a certain process
[1].
• Reduction in cost of production by eliminating the out work and setting up of tools.
• Increase in production.
• To enable stability during machining operations by clamping and fixing the heavy and complex parts to be
machined.
Traverse X-axis
axis : 5000 mm
Y-axis
axis : 3500 mm
Z-axis : 1600 mm
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A Process Capability
ty Improvement of Machining Parameters 395
of Ten Ton Compactor's Rear Chassis
Firstly the process involved in the manufacturing of rear chassis before the new fixture is:
Now for the development of one rear chassis the time involved in all process to be completed are as shown below:
So this basically brings out the total time taken to finish the entire job which is:
= 18.33 hrs.
= (2.5)*(440)
= 1100 mins
As we know that 1 shift = 7.33 hrs, which is further equal to 440 mins.
Figure 2:
2 Rear Chassis of a Ten Ton Compactor
The above figure represents a rear chassis of a ten ton compactor on which we are basically focusing for the above
formulated problem and to further gain our objectives in the right manner.
3. METHODOLOGY
3.1 Procedure for Manufacturing Compactor
The new fixture has been designed by keeping in mind that it will increase the production rate of the rear chassis
c
and with this it will also increase the production rate of compactor. Even the tolerance value of the process is improved.
The different views for this fixture in auto cad design are:
are
Figure 3:
3 Auto Caed Design of the New Fixture
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A Process Capability
ty Improvement of Machining Parameters 397
of Ten Ton Compactor's Rear Chassis
Figure 4: Top View of Improved Fixture Figure 5: Front View of Improved Fixture
4. PROCESS CAPABILITY
Y ANALYSIS
Since we are changing the process of manufacturing of rear chassis, so first we need to check whether the process
is capable or not. So for this we need to calculate the Cp and Cpk value. Understanding
Understanding the process and assessing the
process performance are essential towards quality improvement initiatives [2].
Cp=(USL-LSL)/6σ
Where over here USL= upper specification limit & LSL= lower specification
speci limit.
Cpk = (USL-MEAN)/((3*STANDARD
MEAN)/((3*STANDARD DEVIATION)) &
Cpk = (MEAN-LSL)/((3*STANDARD
LSL)/((3*STANDARD DEVIATION))
Now we have to calculate the values of each specific term, for which we will be requiring a check list table which
will have the value of all the sub groups that will be created to get the desired values. Different sub groups are created each
ea
sub group has three different observations
ions in it.
After the tack welding process is over the different work orders are taken and the values of the perpendicularity
and the co-ordinate
ordinate values of the different work orders are tested to make sure that all the values are lying within the
specification limits or not.
For perpendicularity
cularity the specific value=±0 degree
Now the check list table after tack welding is as follows for co-ordinate test is as follow:
Now the check list table after tack welding for perpendicularity test is as follow:
As we see all the values of the work order are satisfying the specific value of both co-ordinates value as well as
perpendicularity of the chassis. So the check list table values are perfectly under the specification limit as checked in the
newly designed fixture and can be taken for full welding and after that even the values are to be checked again for proper
co-ordinate value and perpendicularity of the chassis.
Now the check list table after the full welding of the chassis for the co- ordinate test is as follow:
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A Process Capability Improvement of Machining Parameters 399
of Ten Ton Compactor's Rear Chassis
So we come to see that the co-ordinate test has been successful and the values can be taken for the calculation
purpose of Cp and Cpk values. For the perpendicularity test the check list table is as follows:
Now we conclude to the checking up of the process capability of the change procedure to rectify that the process
is capable and can we followed for the manufacturing up of the rear chassis.
(635, 634.9, 634.8, 635.1, 634.8, 634.9, 634.8, 634.9, 634.8, 635.1, 635.2, 634.8)
Number of observations= 12
Sub Group 1
= (635 – 634.8)
= 0.2
Sub Group 2
= (635.1 – 634.8)
= 0.2
Sub Group 3
= (634.9 – 634.8)
= 0.1
Sub Group 4
= (635.1 – 634.8)
= 0.3
= 0.8/4
= 0.2.
= (0.2/1.693)
= 0.1181
= (0.4/6*0.1181)
= 0.5644
= 0.7761.
= 0.3528
As we know that the process must be designed in such a way that the Cp value must be greater than Cpk value and
both should be less than 1. So over here the values are satisfying as per the requirement. Hence Cp >Cpk and both the
values are less then one. Process capability is the range over which the natural variation of the process occurs as
Impact Factor (JCC): 7.6197 SCOPUS Indexed Journal NAAS Rating: 3.11
A Process Capability Improvement of Machining Parameters 401
of Ten Ton Compactor's Rear Chassis
4.3 Total Time Required for all the Process to be done after the Improvement of the Fixture
Now the process time required after the improvement of fixture to perform all the work which is tack welding
followed by full welding and machining and further lead by painting process for proper completion of the manufacturing of
the rear chassis. Reduced time involved in various process for the manufacturing of the chassis are as follow:
Further now there is reduction in the number of labours required and thus labour cost got reduced
Profit from the compactor with the help of the improved process is derived as:
= Rs 17,40,000.
= Rs 1,30,000.
As we know that selling price = (profit + direct material cost + factory over head)
So profit from the compactor = (selling price) – (direct material cost + factory overhead)
= Rs 1,30,000
Hence we see that the profit of the compactor is made by the improved process.
5. CONCLUSIONS
Hence we conclude that the improved process is capable and can be practiced for further manufacturing up of the
rear chassis of a ten ton compactor which will further lead us to reduction of manufacturing time, cost and increasing the
production rate. As the per the high market demand this improved process is practiced now in the companies producing ten
ton compactor.
The improvisation done in the fixture yielded out these benefits to the company:
• Production rate of the rear chassis is increased from 25 per month to 40 per month.
• Production rate of the ten ton compactor is increased from 6 per month to 12 per month.
• The process is highly capable as Cp value is greater than Cpk value and it is greater than 1.
• There is a huge reduction from 2.5 shifts to 1.5 shifts in the time required to build up a chassis.
• If profits are increased, more products can be launched into the market so that customers can purchase the item
and customer can get more benefits and discounts.
• Overall safety inventory costs are reduced leading to the profit of the organization.
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Using Composite Material.
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