PROJECT SEMESTER REPORT

Undertaken at
DY AUTO INDIA PVT. LTD
Sector-4, Plot no.-31, Manesar, Haryana

on
DEVELOPMENT & DOCUMENTATION OF
COOLING FAN MOTOR (CFM)

Submitted by
Achint Gupta
1217405

Under the Guidance of

Mr. Amit Kumar Mr. Kripal Singh

Assistant Professor Quality Manager
JMIT Quality Engineering

2019

MECHANICAL Engineering Department

SETH JAI PRAKASH MUKAND LAL INSTITUTE OF
ENGINEERING AND TECHNOLOGY (JMIT)
Affiliated to Kurukshetra University, Kurukshetra (Approved By AICTE)
RADAUR, Distt. Yamuna Nagar-135133
Haryana (India)

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 DECLARATION

I hereby declare that the project entitled “Development and documentation of Cooling Fan
motor (CFM)” is an authentic record of my own work carried out at DY AUTO INDIA
PVT. LTD.,as requirements of project semester for the award of degree of B.E. Mechanical
Engineering, JMIT, Radaur, Yamuna Nagar, under the guidance of Mr.Kripal Singh, Sr.
Engineer and Mr.Amit Kumar, Assistant Professor during: 03-06-2019 to 13-07-2019.

Date:

Achint Gupta

1217405

This is to confirm that I have read the report and that the information enclosed is correct
and contains no confidential information.

Mr. Amit Kumar Mr. Kripal Singh

Assistant Professor Quality Manager
JMIT Quality Engineering
(Faculty Coordinator) (Industry Mentor)

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 ACKNOWLEDGEMENT

The internship opportunity I had with DY AUTO INDIA PVT. LTD was a great chance
forlearning and professional development. Therefore, I consider myself as a very
luckyindividual as I was provided with an opportunity to be a part of it. I am also grateful
forhaving a chance to meet so many wonderful people and professionals who led me
though thisinternship period.

I would like to convey my heartiest thanks to Mr. Kripal Singh; quality manager, who
heartily welcomed me for the internship, Mr. Pradeep who guided and encouraged me all
through the summer training and imparted in-depth knowledge of the programme. Also I
would like to thanks Mr. Amit; Mr. Manish; Mr. Pankaj who assigned and guided me
whenever I Needed. I would like to thank all the department for giving their precious time
and valuable guidance during my internship programme.

I am extremely thankful to Er. Pankaj Sharma, Er. Rajneesh Choudhary and Mr. Amit
Kumar(HOD), of the Mechanical engineering Department, Seth Jai Prakash Mukand Lal
Institute of Engineering and Technology(JMIT), Radaur for providing me facilities to work
in without which this work would not have been possible.

I perceive as this opportunity as a big milestone in my career development. I will strive to

usegained skills and knowledge in the best possible way, and I will continue to work on
theirimprovement, in order to attain desired career objectives. Hope to continue
cooperation with
all of you in the future.

Best Regards,

Achint Gupta

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 ABSTRACT

Industrial training is an important phase in student life.A well planned,

properly executed and evaluated industrial training helps a lot in developing
professional attitude. It develop an awareness of industrial approach to
problem solving, based on broad understanding of process and mode of
operation of organization. During a period of forty-five days at DY AUTO
INDIA PVT. LTD. Most of the theoretical knowledge has been put to test.
Since the company deals with Cooling Fan Motor (CFM) and thus involves
dc motor concepts along with the learning of different child parts which
constitutes the whole structure of motor. Being an semi and fully automatic
machines, the experience and knowledge takes one more step towards
learning of Error proofing and testing. Discussion with quality team increases
diversification in knowledge of quality issues facing at customer end and
finding root cause analysis. Using Japanese tools on becoming more and more
efficient helped in developing skill and Psychology towards continuous
improvement. Documentation helps in improving excel skills and knowledge
on building of important engineering documents. Since the company is ready
to launch two more products and thus installation of machines in the same
tenure helped me towards learning new project development, its installation
and preparation of engineering documents. During the tenure, working at each
and every machine of all lines have further helped in analyzing process very
clearly. Thus the tenure has been very helpful for all round development
which is beneficial to Future life.

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 PREFACE
Every student of Bachelor of Technology in Mechanical Engineering, has an
essential requirement to do 45 days of internship in any of the well reputed
organization. The purpose of this program is to acquaint the students with
practical applications of theoretical concepts taught to them during conduct of
their course.

Really, it was a nice opportunity to have a close comparison of theoretical

concept in practical field. This report may depict deficiencies on my part but
still it is an output of a student’s efforts, for which I beg pardon.

The output of my analysis is summarized in a shape of internship the contents

of the reports shows the detail sequence of these.

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Table of Contents:

 Declaration
 Acknowledgement
 Abstract
 Preface

1. Introduction

2. DC Motor
2.1 Principle
2.2 Working
2.3 Back ENF
2.4 Equation

3. Assembly Line
3.1 Stator Line(STR)

3.1.1 Stator Bonding & Magnet Inserting

3.1.2 Stator Bond Hardening
3.1.3 Stator bearing Caulking
3.1.4 Laser Cleaning

3.2 Armator Line(ATR)

3.2.1 Insulation Disk Insertion

3.2.2 Shaft &Commutator Fitting
3.2.3 Winding
3.2.4 Fusion
3.2.5 Fitting & Forming
3.2.6 Turning
3.2.7 Shaft Check
3.2.8 Winding Tester
3.2.9 Balancing

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 3.3 CFM Line

3.3.1 Stop Ring Insertion

3.3.2 Magnetizing
3.3.3 Armature Fitting
3.3.4 Ball Bearing Fitting
3.3.5 Brush Pin Removal
3.3.6 Inspection
3.3.7 End Bracket Caulking
3.3.8 Final Inspection
3.3.9 Packing

4. Quality Line
4.1 Machine Used for Quality Checking

4.1.1 Universal Testing Machine

4.1.2 Rockwell Hardness Tester
4.1.3 Video Measuring System
4.1.4 Height Gauge
4.1.5 Push or pull Gauge
4.1.6 Vernier caliper
4.1.7 Roundness testing Machine

5. Bill Of Material

6. Error Proffing Checking Procedure

7. Statistical Process Control

8. Model Change Procedure

9. MTTR & MTBF- Record and Analysis

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10.Basic Quality Concepts
10.1 5S & Safety

10.1.1 Sort
10.1.2 Set In Order
10.1.3 Shine
10.1.4 Standardize
10.1.5 Sustain

10.2 3M(Muda,Muri,Mura)

10.2.1Muda
10.2.2Muri
10.2.3 Mura

10.3 PDCA( Plan, Do, Check, Act)

10.3.1Plan
10.3.2 Do
10.3.3 Check
10.3.4 Act

11. Conclusion

12.References

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1 Introduction
DY AUTO INDIA PVT. LTD is a Korean- based motor manufacturing
company established in India in 2010. Though company deals in varied types
of motor but till now in India they have focused on Cooling fan motor (CFM).
Child parts used in making motor came from various suppliers across the
globe but mainly from India, China, and Korea. The motor manufactured is
thus send to its customers (Doowan, HVCC, VASI, and Delphi) where they
fit the load fan and send further to end users (MARUTI, HYUNDAI). Now in
2019, two of more motors Power Window motor (PWM) and Front Wiper
system (FWS) will also hit the Indian market. PWM and FWS machines have
already reached from Korea. installation of PWM is already completed
whereas FWS system is still in progress.

CFM, a small 12V dc based motor configure to rotate a fan which in turn
provides cooling to the machine. Quality of CFM depends on cooling
performance, Power consumption, noise performance, size and weight it
carries. In DY AUTO manufactured CFM, there are 17 different models in
which company deals with depending on the demand of customer

The whole Production floor is divided into 3 assembly lines namely:

 Stator line ( STR)

 Armature line (ATR)
 Motor line (CFM)

It also includes training room, PQE ( performance quality engineering) , Final

Quality Inspection and P.O waiting area.

Machines in these assembly lines are semi-automatic or fully automatic.Total

27 machines put together having 21 different process completes the
production of cooling fan motor. Average production count of CFM in a day
is 2800nos. Monthly target is to complete 1,20,000nos. motors to meet the
customer demand.

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Presently for PWM , armature line has not been set up , it directly transit from
Korea. Thus it simply has two lines ( Stator and motor line). Proposed
Production for PWM will be in August 2016. HYUNDAI is its end user and
they have already passed the document audit. For FWS, motors will be
directly import from Korea and here the system will be assembled and given
to GMI (General motors India). Its production will be in Nov. 2016 . This
report includes the process at different assembly lines of CFM , tools used,
working of motor and important documents which needs to be follow for
proper management. All
Quality practices like 5S, 3M, PDCA, Kaizen etc. are being followed so as to
provide the best quality to end users. Training on such practices are also
provided to lower management people like operators so as to maintain shop
floor uniformity.

Project at DY AUTO INDIA PVT. LTD includes the development and

documentation of Cooling Fan Motor. As the prior experience was in the field
of motor, the opportunity was adequate to took up this internship and explore
more in this arena practically. It was also important as the prescribed training
also involves work on new project development where the area of interest lies
. This allured towards this internship.

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2.DC Motor

2.1 Principle:

According to Fleming’s Left Hand rule, whenever a current carrying conductor is

placedinside a magnetic field, there will be a mechanical force experienced by that
conductor

F= B×I×L , ...(1)

where B is magnetic field,

I is current through conductor and

L denotes length of conductor.

2.2 Working:

Lets take a permanent magnet based DC motor having N and S poles.Suppose

armatureconductors under N- poles of field magnet are carrying current downwards (cross)
and thoseunder S poles are carrying upwards (dot). By applying Fleming’s left hand rule,
the directionof force F experienced by the conductor under N poles and force experienced
by conductorunder S poles can be determined. It is found that at any instant the force
experienced by theconductors are in such a direction that they tend to rotate the armature.

Again, due to this rotation the conductors under N poles come under S poles and
theconductors under S poles comes under N poles. While the conductors shifts, the
direction ofcurrent through them is reversed by means of commutator. Due to this reversal
of current, allthe conductors under N pole carry current in downwards and all the
conductors come under S pole carry current in upward direction as shown in figure. Thus
every conductor under these poles experiences force in the same direction.
Thisphenomenon helps to develop continuous and unidirectional torque and motor rotates.

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 Figure 1. DC Motor Working

2.3 Back EMF:

According to fundamental law of nature, no energy conversion is possible until there is

something to oppose the conversion. When armature of motor is rotating, the conductors
arealso cutting the magnetic flux lines and hence according to electromagnetic induction
law, anE.M.F induces in the armature conductors in opposite direction and makes motor
self-regulating.

2.4 Equations :
V=I×R + Eb ....... (2)

T=K×I ....... (3)

Eb= K×w ....... (4)

Eb= (P×Φ×N×Z)/60A ........ (5)

where, V= voltage applied

I= current through conductors

R= armature resistance

Eb= Back E.M.F

T= Motor torque

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 K= constant of proportionality

w= Speed of motor

P= no. of poles

Φ= flux per pole

Z=no. of conductors

A=no. of parallel paths

3. ASSEMBLY LINE

3.1 Stator line (STR)

3.1.1 Process 10- Stator bonding and magnet inserting

This process includes bond (adhesive) spread on stator and magnet insertion. There are
total 18 types of stator and 5 types of magnet

 The stator is put to rotational table jig and bond will automatically be applied to
statorthrough dispenser nozzle.

 Magnets to be manually inserted to jig along with a spring and stator is put on the
jig.Push the button and cylinder will move down fitting magnet and spring into stator.

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 Stator is now move to conveyor belt for hardening the bond.

3.1.2 Process-20- Stator Bond Hardening

The stator sub assembly is put to conveyor and is introduced in oven divided into 4 zones
ofvarying temperatures. The assembly travels for 40 min. at a speed of 260mm/minute.

 Zone 1: 158±10°[C]
 Zone 2: 178 +5-10°[C]
 Zone 3: 178 +5-10°[C]
 Zone 4: 158±10°[C]

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3.1.3 Process 30- Stator Bearing Caulking

Stator sub assembly to be put on rotation table jig. Automatically bearing would be
placedfollowed by washer and caulking punch. Missing of any part will cause alarm
signifying errorproofing working.1 ball bearing(D or Z depends on model) and 1 washer is
inserted into the stator sub assembly along with 6 point caulking punch.

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3.1.4 Process 40- Laser Cleaning

The stator sub assembly to be put on rotation table jig. Automatically stator goes under the
laser beam originator and laser beam marks a position or remove the coating on a stator to
give a defined position on which the final assembly goes around.

Missing of any part or any type error like mechanical error occur will cause alarm
signifying error proofing working.

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3.2 Armature Line (ATR)

3.2.1 Process-10a-Insulation disk insertion

 Two insulation disks are inserted into the core below and above. Manually assemble
thetwo disks and put them on cylinder. Machine will fit the assembly

 Core is of 3 types (13T, 15T, 18T) that is 13mm, 15mm, 18mm thickness. It is made
uplaminated stainless steel. Core is an assembly of slits of width 0.5m. Insulation disk
issame for all models.

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3.2.2 Process- 10 – Shaft and commutator I Fitting

 Here shaft is inserted to core and put it in jig I . After shaft fitting this is put to jig II
andcommutator to upper machine jig. The machine will fit the shaft and commutator to
therequired depth according to model inserted in PLC.

 Angle of commutation also checked here through testing equipment. It should be

within0-1.5°.

 Total 12 types of shafts and 4 types of commutator are available.

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3.2.3 Process- 20- Winding

 Here the winding of armature takes place. Armature sub assembly is inserted to the
colletand machine will automatically wind into the slots.

 Wire diameter needs to be checked as there are three types of wire that are being
used( diameter with 0.55mm, 0.57mm, and 0.65mm). Turns will decide by
machineaccording to the data saved in PLC and model entered through HMI.

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3.2.4 Process- 30- Fusion

 In this process high current is passed to fuse riser with commutator. Through this
thewire comes in contact with commutator. Precaution needs to be taken just after fusion
asthe commutator gets heat up.

 For GB commutator :Current passed= 3150±250A,

 For CM commutator :Current passed= 3500±250A

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3.2.5 Process- 40- II fitting and forming.

 The commutator and shaft are further pressed to the required specification as per
model.Since this is the final fitting it is also called final fitting process. If shaft does not fir
torequired depth, load fan will not be able to fit and if commutator is not fit to spec.
carbonbrushes will not be able to make proper contact leading to running performance
issues.

 Forming is done to compress the loose winding (if any) so as to decrease the height
ofcoil. If forming doesn’t happen properly required putty will be more which causes noise.

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3.2.6 Process- 50- Turning

It is divided into 6 units as shown in fig.

 Input unit: It takes the armature from conveyor and put on to V- block.

 I Cutting: Commutator length is cut down to just less than the desired length.

 II Cutting: Commutator length is further cut down to desired length and shaping is to
bedone.

 Lapping: It is only done in bigger models just to give an extra finishing to the surface
ofcommutator.

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 Brushing : Brushing is done so as to remove copper chips from the commutator
whichmay be introduced during cutting. If not removed it will show less segment
resistance asit short circuits the two segments.

3.2.7 Process- 60- Shaft check

In this process shaft length and commutator Depth is check using master samples so as
toverify specified dimensions to be under tolerance.It is done by setting zero in HMI via
zero orOK master for the particular model. Verification is also done using digital
VernierCalliper forchecking length and depth.

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3.2.8 Process- 70-Winding tester

The armature thus passed from verification of its physical dimension now undergoes for
testof its performance parameters. Since the motor can be subjected to any surge, or high
voltage, corona, thus when we place the armature on to the jig of this machine, Leno pins
comeforward and inserts into the slots of armature. Following parameters check so as to
maintainthe best possible performance:

 Resistance test: Segment resistance between commutator is checked . Minimum

safevalue considered is 20mΩ. Below this, the machine will alarm which can be
occurreddue to chips remaining between segments short-circuiting it.

 Surge Test : It is performed to check the motor stability due to irregular or

inconsistentsurge which may be occurred during motor operation. It is performed at 0.5kV
impulse.

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 Puncture test: It is done so as to check the leakage test and is done at 0.6kVrms. .
Thecurrent should be below 3mA.

 Insulation test: Wire insulation test is done at 500Vdc. Resistance should be

above100MΩ. Resistance below this specified value signifies coil insulation is damaged or
coilhas been broken.

It is performed in two phases. Firstly to left jig where segment resistance is checked and
onthe right jig where the rest of tests are checked. Monitor will display the status of “OK”
or“NG” status.

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3.2.9 Process-80- Balancing

The process objective is to match or minimize center of mass to the center of rotation. If
therotating assembly does not rotate around its center of mass, it will cause huge vibrations
andthus performance of motor reduces considerably. Balancer (putty) is applied in order
tobalance all the sides of armature. Precautions needs to be taken while applying putty as
height of attachment matters during balancing. It should be less than 8mm(for 120W
models) and 9mm (for rest of the models). More height will touch the end-bracket
assembly and thus willcause unfitting at CFM line.

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3.3 CFM LINE

3.3.1 Process-10- stop ring insertion

The process simply involves the insertion of stop ring upto which the shaft will fit into
stator.Without stop ring, shaft will fit to higher length which will cause unfitting during
end bracketassembly or during loading at final quality inspection.

3.3.2 Process-20-Magnetizing

Here the stator is magnetized and clamp height is checked (for some models).
Magnetizationvaries with different models and is measured in MAXWELL. It is done by
applying verylarge magnetizing voltage and high impulsive current so as to align all the
dipoles in onedirection and making unmagnetized magnets magnetized.jkkjFlux level
varies as per model. Ifthe flux level introduced becomes low as per specification speed will
increase as Back EMFis constant.

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3.3.3 Process-30-Armature fitting

Here the armature coming from stop ring insertion fits into the magnetized stator.
Armature isfitted through suction and placed in the stator. DG force meter shows the
increasing forcerequired to fit the shaft. The shaft will fit upto where the stop ring is
inserted. Any deviationto the specified trend (with tolerance) will cause the product to be
NG.

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3.3.4 Process-40-Ball Bearing fitting

Bearing is fitted (only in 120W models) as second ball bearing is not there in its
E/Bassembly.For rest of the models this machine does not operate as bearing is already
present intheir End-bracket.Fitting force is measured and analyzed through DG force
meter. Its graphshows the variation of fitting force with depth of fitting.

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3.3.5 Process-50-Brush Pin removal

End/Bracket is placed over motor sub assembly and pins are removed so that carbon brush
came into direct contact with commutator through spring.While placing E/B to motor sub
assembly, key home should be matched as mismatching would lead to improper contact of
brushes leading to poor performance or no operation of motor. Mica capacitors and
inductorcoils are placed in assembly of bigger size models to provide stability during
transientconditions.

3.3.6 Process-60-I inspection

Motor is now inspected here initially. Insulation resistance, noise, vibration, voltage, no
loadcurrent, commutator surface wave, direction of rotation are checked and verified from
standard specifications. Any mismatch or difference out of spec. will cause machine to
alarm.Problems in motor performance parameters will then be moved to PQE ( process
qualityengineering) for analysis and rework.

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3.3.7 Process-70-End Bracket Caulking

Here 3 point caulking is done so as to fix end bracket and motor sub assembly. This will
ensure motor will not open during rotation. Height of caulking punch should be checked as
per model. Caulking force value varies with depth and is measured through DG force
meter.

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3.3.8 Process-80-Final Inspection

After E/B caulking motor is finally inspected in terms of performance parameters such as
voltage, no load current, no load speed, insulation resistance, commutator surface wave,
direction of rotation, noise and vibration . This is done in noise proof room so as to
critically
focus on noise issue. Any difference with respect to desired specification is critically
analyzed so as to finally pass the best quality motor.

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3.3.9 Process-90-Packing

Finally the motor is paste with label and put into box or bins and sent to logistics
departmentfor further packing.Operator also marks caulking points with green marker so as
to ensure 3point caulking to the end/bracket.

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33
4. Quality Line

4.1 Machines Used For Quality Checking

4.1.1 Universal Testing Machine

A universal testing machine (UTM), also known as a universal tester, materials testing

machine or materials test frame, is used to test the tensile strength and compressive
strength of materials. An earlier name for a tensile testing machine is a tensometer. The
"universal" part of the name reflects that it can perform many standard tensile and
compression tests on materials, components, and structures 

The specimen is placed in the machine between the grips and an extensometer if required
can automatically record the change in gauge length during the test. If an extensometer is
not fitted, the machine itself can record the displacement between its cross heads on which
the specimen is held. However, this method not only records the change in length of the
specimen but also all other extending / elastic components of the testing machine and its
drive systems including any slipping of the specimen in the grips.

Components of Universal Testing Machine are:

 Load frame
 Load cell
 Cross head
 Means of measuring extension and deformation
 Output device
 Conditioning

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4.1.2 Rockwell Hardness Tester

In Rockwell hardness testing, the hardness of a material is determined by pressing an

indenter against the material be tested with a predefined force. The hardness of the material
can then be determined by measuring the indentation depth.

Rockwell hardness tester classifications based on Rockwell Scales:

Rockwell hardness tester: HRA, HRB, HRC 
Plastic Rockwell hardness tester: HRE, HRL, HRM
Twin Rockwell hardness : HRA, HRB, HRC,15N, 15T, 15W, 15X, 15Y, 30N, 30T, 30W,
30X, 30Y, 45N, 45T, 45W, 45X, 45Y 

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4.1.3 Video Measuring System (VMS) Machine

Vision Engineering has packed massive technical capabilities into a small and compact
system, yet Falcon is still one of the most intuitive, easy to use video measuring systems
available. From simple, single-feature operation to multi-point video edge detection,
Falcon delivers accurate and repeatable results in 3-axis of small, intricate parts, quickly
and simply.

§ High repeatable accuracy 3-axis measuring machines, with advanced capabilities as

standard

§ Powerful and intuitive, delivering accurate results with confidence

§ High resolution indexed zoom optics offer precision and flexibility

§ Large field of view for easy sample orientation

§ Factory-completed NLEC* and SLEC** calibration

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§ High repeatable accuracy 3-axis measuring machines, with advanced capabilities as standard
Powerful and intuitive, delivering accurate results with confidence

§ High resolution indexed zoom optics offer precision and flexibility

§ Large field of view for easy sample orientation

§ Factory-completed NLEC* and SLEC** calibration

4.1.4 Height Gauge

A height gauge is a measuring device used for determining the height of objects, and for
marking of items to be worked on.

37
These measuring tools are used in metalworking or metrology to either set or measure
vertical distances; the pointer is sharpened to allow it to act as a scriber and assist
in marking out work pieces.
Devices similar in concept, with lower resolutions, are used in health care settings (health
clinics, surgeries) to find the height of people, in which context they are
called stadiometers.
A height gauge is a measuring device used for determining the height of objects, and for
marking of items to be worked on.
These measuring tools are used in metalworking or metrology to either set or measure
vertical distances; the pointer is sharpened to allow it to act as a scriber and assist
in marking out work pieces.
Devices similar in concept, with lower resolutions, are used in health care settings (health
clinics, surgeries) to find the height of people, in which context they are
called stadiometers.

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4.1.5 Push or Pull Gauge

A force gauge (also force gage) is a measuring instrument used to measure forces.

Applications exist in research and development, laboratory, quality, production and field
environment. There are two kinds of force gauges today: mechanical and digital force
gauges. Force Gauges usually measure pressure in stress increments and other dependant
human factors

An example of a digital force gauge is a load cell (this is often combined with software and
a display). A load cell is an electronic device that is used to convert a force into an
electrical signal. Through a mechanical arrangement, the force being sensed deforms
a strain gauge. The strain gauge converts the deformation (strain) to electrical signals. The
software and electronics of the force gauge convert the voltage of the load cell into a force
value that is displayed on the instrument.

4.1.6 VernierCalliper

The Vernier caliper is an extremely precise measuring instrument; it is used to measure

internal and external distances extremely accurately –  the error may be  as little as  0.05
mm – depending on the make.The VERNIER is a small movable graduated scale for
obtaining fractional parts of subdivisions on a fixed main scale of any measuring
instrument. With a normal scale we may be able to measure down to 0.50 mm or so, while

39
with a vernier scale the least count may be 0.10 mm. Usually vernier calipers have both
imperial (inches) and metric (mm) scales.

Modern calipers are digital – in the sense it has an LCD display on which the reading
appears – there is no possibility of human error in reading the scaleThe smallest vernier
caliper that can be bought off-the-shelf is 150 mm – meaning the jaws open to a maximum
of 150 mm. The largest ones go up to 2000 mm.

4.1.7 Roundness Testing Machine

Roundness is the property of a surface of revolution, where all points on the

surface are equidistant from the axis. The roundness of any profile can be specified
only when same center is found from which to make the measurements. The
diameter and roundness are measured by different method and instruments. For
measurement of diameter it is done statically, for measuring roundness, rotation is
always necessary. Roundness measuring instruments are two types.
 
1. Rotating pick up type.
 
2. Turn table type.

40
 These are accurate, speed and reliable measurements. The rotating pick up
type the work piece is stationary and the pickup revolved. In the turn table the work
piece is rotated and pick up is stationery. On the rotating type, spindle is designed
to carry the light load of the pickup. The weight of the work piece, being stationary
and is easy to make. In the turn table type the pickup is not associated with the
spindle. This is easier to measure roundness. Reposition the pickup has no effects
on the reference axis.
 
The pickup converts the circuit movement of the stylus into electrical
signal, which is processed and amplified and fed to a polar recorder. A
microcomputer is incorporated with integral visual display unit and system is
controlled from compact keyboards, which increases the system versatility, scope
and speed of analysis. System is programmed to access the roundness of work
piece with respect to any four of the internationality recognized reference circles. A
visual display of work piece profile can be obtained. Work piece can be assessed
over a circumference, and with undercut surface or an interrupted surface with
sufficient data the reference circle can be fitted to the profile. The program also
provides functions like auto centering, auto ranging, auto calibration and
concentricity

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5. Bill Of Material (B.O.M)- Part characteristics

It is a document which includes the details of child parts which is used in the final outcome
inan industry. For DY AUTO, 17 models in CFM are there and thus detailing about their
childparts which includes dimensions, characteristics, manufacturing firm or supplier
constitutesthe B.O.M.

B.O.M’s can be varied as per the requirement. It can be formed model specific, a matrix
withdifferent permutations and combinations or a virtual and visual B.O.M.

Process characteristics involves the process parameters which is controlled at each

step/process.Like during manufacturing, turns, bond weight, fitting dimensions etc. are
beingcontrolled in different processes.Thus this document involves machine specific data
wherewe control different parameters.

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6. Error Proofing Checking Procedure :

Error proofing, or its Japanese equivalent poka-yoke (pronounced PO-kayo-KAY), is the

useof any automatic device or method that either makes it impossible for an error to occur
ormakes the error immediately obvious once it has occurred.

In almost all machines, there are 1 or more error proofing so as to detect error which can
bebecause of previous operation or due to operator. Daily, at starting of machines error
proofingis also checked so as to ensure the working is appropriate or not. This document
includes thechecking procedure, display and responsibilities regarding functioning. The
checkingincludes doing some wrong operation so that machine will detect and produces
alarm or insome of the testing operations, it is checked by using NG master sample
specially designedfor this purpose. As per machine some display error number in HMI
according to thepredefined problem code in PLC or some machines simply display the
error message. Themachine is set off by resetting through set box or manually (in some
cases)

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7. Statistical Process Control
Statistical Process Control (SPC) is an industrystandard methodology for measuring and
controlling quality during the manufacturing process. Attribute data (measurements) is
collected from products as they are being produced. By establishing upper and lower
control limits, variations in the process can be detected before they result in defective
product, entirely eliminating the need for final inspection.

With real-time SPC you can:

1. Dramatically reduce variability and scrap

2. Scientifically improve productivity

3. Reduce costs

4. Uncover hidden process personalities

5. Instant reaction to process changes

6. Make real-time decisions on the shop floor

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SPC itself will not make improvements. Rather, SPC will give operating personnel a tool
to identify when a special cause of variation has entered the process so that the special
cause can be eliminated (if the special cause has a negative impact on the process) or built
into the process (if the special cause has a positive impact on the process).

With this tool, constant tweaking of the process is eliminated. In addition, SPC can be
helpful in identifying opportunities for improvement that can lead to reduced variation and
processes that are better aimed at their target.

The key tool of SPC is a control chart. While there are control charts for attribute data
(data that must be counted, for example, in terms of number of defective items) and
variable data (data that is take from a variable scale such as length, width, height), variable
data control charts provide more valuable information and should be used wherever
practical.

Variable data control charts typically monitor the process target or mean and the process
variation or range. There are a number of different types of variable data control charts but
the most common chart is the x-bar and R chart.

X Bar Chart

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 R Chart

Common mistakes companies make when they use SPC

Here are the top reasons why SPC does not work:
1. Putting spec limits on control charts.

2. Using control charts only to satisfy customer needs.

3. Plotting data for a control chart in the QA lab, after the process has already been run. It
is like driving your car using your rearview mirror.

4. Using the wrong type of control chart for the process resulting in false signals or muted
signals.

5. Not reviewing control charts and how they are used on the shop floor with operators on
a regular basis.

6. Thinking that if you use a computer program that generates control charts that you don't
need to teach operators how to use SPC.

7. Not first conducting a process capability study

8. Not taking random samples from the process or not using a sampling frequency or
sample size that captures the variation in the process.

9. SPC is used to control product characteristics after a part is manufactured and the defect
has been made rather than monitoring key process parameters that affect whether or not a
defect is likely. That's why it is called statistical PROCESS control and not statistical
PRODUCT control.

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Control Points
SPC can easily be used to control anything that can be counted. Before initiating any SPC
program, it is necessary to determine what to count. These are termed control points.
Control points can be related to:

•Process

•Product

•Financials

The first hurdle to SPC is determining propercontrol points based ideally on 32 samplings

Basic Capability Indices

Pp = Process Performance. A simple and straightforward indicator of process performance.

Ppk = Process Performance Index. Adjustment ofPp for the effect of non-centered
distribution.

Cp = Process Capability. A simple andstraightforward indicator of process capability.

Cpk = Process Capability Index. Adjustment ofCp for the effect of non-centered
distribution.

8. Model Change Procedure.

In each process, there are certain jigs and PLC settings which is designed for one or more
particularmodel.Thus during model change these jigs and PLC setting have to be changed
and made synchronized with the ongoing model. Ignoring it, will cause wrong operations
such as fitting depth longer or shorter, turns more or less etc. It can also corrode jigs and
thusproper procedure needs to be followed so as to change model setting.

This documents includes the process on how to change jigs, setting the new PLC changes
andthe place of all the required tools and spare parts. All the jigs has clear distinction as the
labelis placed on them with a unique identity number and name of model where they are
used. Allthe jigs used have to be cleaned before and after the operation as any foreign
material in jigcan corrode the parts of motor.

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9. MTTR and MTBF - Record and Analysis

Mean Time To Repair (MTTR) is a basic measure of the maintainability of repairable

items.It represents the average time required to repair a failed component or
device.Expressedmathematically, it is the total corrective maintenance time for failures
divided by the totalnumber of corrective maintenance actions for failures during a given
period of time.

Mean time between failures (MTBF) is the predicted elapsed time between inherent
failuresof a system during operation. MTBF can be calculated as the arithmetic
mean(average) timebetween failures of a system. The terms is used in both plant and
equipment maintenancecontexts. The MTBF is typically part of a model that assumes the
failed system isimmediately repaired (mean time to repair, or MTTR), as a part of a
renewal process.In DY AUTO, MTTR and MTBF are calculated and displayed monthly
for all assembly linesseparately. Calculation of MTTR involves updated downtime sheet
for the whole monthwhereas calculation of MTBF includes the planned time for each
line/machine. The wholeanalysis includes calculating time, representing machine wise and
line wise through pie chartand bar graph. Finally over MTTR and under MTBF requires
further corrective analysis inwhich root cause and prevention action to be made . In each
progressive the industry targets alower MTTR and higher MTBF

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10. Basic Quality Concepts

There are various quality concepts to make process more and more efficient, safe &
reliable[5]. Some of them are:

 5S & Safety

 3M

 PDCA

10.1 5S & Safety

5S is the name of a workplace organization method that uses a listfive Japanese words:
seiri, seiton, seiso, seiketsu, and shitsuke.Transliterated into Romanscript, they all start
with the letter "S". The list describes how to organize a work space forefficiency and
effectiveness by identifying and storing the items used, maintaining the areaand items, and
sustaining the new order.The decision-making process usually comes from adialogue about
standardization, which builds understanding among employees of how theyshould do the
work.

There are five 5S phases: They can be translated from the Japanese as "sort", "set in order",
"shine", "standardize", and "sustain". The sixth one is safety. It includes PPE ( personal
protective equipment such as glasses at commutator turning).

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10.1.1 Sort
 Remove unnecessary items and dispose of them properly.
 Make work easier by eliminating obstacles.
 Reduce chances of being disturbed with unnecessary items.
 Prevent accumulation of unnecessary items.
 Evaluate necessary items with regard to cost or other factors.
 Remove all parts or tools that are not in use.
 Segregate unwanted material from the workplace.
 Need fully skilled supervisor for checking on regular basis.
 Don't put unnecessary items at the workplace & define a red-tagged area to keep those
unnecessary items.

10.1.2 Set-in-order
 Arrange all necessary items so that they can be easily selected for use
 Prevent loss and waste of time by arranging work station in such a way that all tooling
/ equipment is in close proximity
 Make it easy to find and pick up necessary item
 Ensure first-come-first-served basis
 Make work flow smooth and easy
 All of the above work should be done on regular basis

10.1.3 Shine
 Clean your workplace completely
 Use cleaning as inspection
 Prevent machinery and equipment deterioration
 Keep workplace safe and easy to work
 Keep workplace clean and pleasing to work in
 When in place, anyone not familiar to the environment must be able to detect any
problems within 50 feet in 5 secs

10.1.4 Standardize
 Standardize the best practices in the work area.
 Maintain high standards in workplace organization at all times.
 Maintain orderliness. Maintain everything in order and according to its standard.
 Everything in its right place.
 Every process has a standard.

10.1.5 Sustain
 To keep in proper working order
 Also translates as "do without being told"
 Perform regular audits

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 Training and Discipline
 Training is goal oriented process. Its resulting feedback is necessary monthly

10.2 3M (Muda, Muri, Mura)

3M is a Japanese concept derived for shop floor improvement. It contains 3 elimination

activities. Since it starts with letter “M” it is called as 3M.

10.2.1 Muda
Muda is any activity or process that does not add value; a physical waste of your time,
resources and ultimately your money. There are 7 wastes in muda(TIMWOOD):
 Transport; the movement of product between operations, and locations.
 Inventory; the work in progress (WIP) and stocks of finished goods and raw materials
that a company holds.
 Motion; the physical movement of a person or machine whilst conducting an
operation.
 Waiting; the act of waiting for a machine to finish, for product to arrive, or any other
cause.
 Overproduction; Over producing product beyond what the customer has ordered.
 Over-processing; conducting operations beyond those that customer requires.
 Defects; product rejects and rework within your processes.

10.2.2 Muri
Muri is to cause overburden, by this we mean to give unnecessary stress to our employees
and our processes. This is caused host of failures in our system such as lack of training,
unclear or no defined ways of working, the wrong tools, and ill thought out measures of
performance.

10.2.3 Mura
MURA stands for any activity that contains inconsistency or ineffective utilization. This
imbalance leads to inefficient use of resources in an organization and thus a waste. It is
alsoone of the reasons of Muri.

All these wastes can be eliminated using various concepts and tools to make our
organizationefficient safe & reliable

10.3 PDCA ( Plan Do check Act)

PDCA (plan–do–check–act or plan–do–check–adjust) is an iterative four-step management

method used in business for the control and continuous improvement of processes and
products. It is also known as the Deming cycle/wheel, or Shewart cycle.

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10.3.1 Plan
Establish the objectives and processes necessary to deliver results in accordance with the
expected output (the target or goals). By establishing output expectations, the completeness
and accuracy of the spec is also a part of the targeted improvement. When possible start on
asmall scale to test possible effects.

10.3.2 DO
Implement the plan, execute the process, make the product. Collect data for charting and
analysis in the following "CHECK" and "ACT" steps.

10.3.3 CHECK
Study the actual results (measured and collected in "DO" above) and compare against the
expected results (targets or goals from the "PLAN") to ascertain any differences. Look for
deviation in implementation from the plan and also look for the appropriateness and
completeness of the plan to enable the execution, i.e., "Do". Charting data can make this
much easier to see trends over several PDCA cycles and in order to convert the collected
datainto information. Information is what you need for the next step "ACT".

10.3.4 ACT
If the CHECK shows that the PLAN that was implemented in DO is an improvement to the
prior standard (baseline), then that becomes the new standard (baseline) for how the
organization should ACT going forward (new standards are enACTed). If the CHECK
showsthat the PLAN that was implemented in DO is not an improvement, then the existing
standard(baseline) will remain in place.

11. Conclusion:

It was really a good experience to work at DY AUTO INDIA PVT. LTD. Since the day of
joining, each day increases my knowledge and leave imprints in my mind. Initially
workingat each machines, analyzing the process , preparing some general documents has
helped meknowing how an organization works and what are the different structures and
theirimportance in achieving a common goal. Later going on onto deep analysis, become
moredepartment specific has helped me in building my skill towards Production
engineering . Inthe same installation of new machines started and thus got a well needed
experience on hownew projects set up, installed , difficulties that came and most
importantly how some veryimportant engineering documents which are to be made.
Making or translating thesedocuments not only made a technical learning but also
improved my excel handling ability.

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Further preparing and giving presentation on quality or process improvements tools to
operators has also given me an insight view on how organization is striving towards
continuous improvements. Giving, preparing and supervising operators has also helped me
inanalyzing my leadership ability and improving my communication skills to all levels of
management on an organization.Being with quality team, got to know about various
quality issues which is being faced atcustomer end due to few electrical or mechanical
mistakes. Preparing MTTR & MTBF hashelped me in analyzing the importance of planned
time and the production count. Duringaudit , the points made by auditor increased my
knowledge towards how much care needs tobe taken and importance of documents in this
field. Since I am highly interested in makingresearch and thus new project development
and documentation has given me a really vastexperience throughout the tenure. At the
same time continuous touch with professors hasfurther channelized my mind to take care
of some of the important things and analyzingthings precisely.
Day to day work in such organization has helped in building a professional attitude, a new
challenge has made my tenure a complete packet of learning in arena of technicality,
leadership, documentation, new project development,etc

12. References:

[1] MTTR & MTBF. Available at working standards

[2] DY AUTO INDIA PVT. LTD work standards.

[3] 5S,3M,PDCA. Available at http://www.slideshare.net. Accessed 24 May 2016

[4] Reflective Diary. Day-to-day work.

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