BANGALORE INSTITUTE OF TECHNOLOGY

Department of Mechanical Engineering

PRODUCTIVITY IMPROVEMENT
OF AN ASSEMBLY LINE
Guide:
Dr. Honne Gowda
Associate Professor
Department of Mechanical Engineering
Bangalore Institute of Technology, Bangalore

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
Product Information

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
PF45 Product Information & Application

PF 45 pump Common rail system Deutz engine Volvo Truck & Bus Off-Highway
PF 45 pumps are designed and developed by Bosch ltd. as part of Common Rail Fuel Injection
System
 Operating pressure at 1600 bar SOP in 2005 & 2000 bar SOP in 2010 for up to 6 cylinder engines.

 EURO IV - Emission norms for clean & green environment

 Customer – DEUTZ Germany

 Application – Volvo trucks & Bus

VIII SEMESTER B.E.
MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
We have approached the problem with 12 steps methodology of QCFI

12 step Approach
Step 1 Problem definition
Plan / Project selection
Step 2 Selection of problem
Step 3 Definition of problem
Step 4 Analysis of problem – Current situation
Do / Situation analysis Step 5 Cause & effect analysis
Step 6 Root cause analysis – (Why – Why)
Step 7 Analysis on Root cause

Check / Solution Step 8 Development of solution

Development Step 9 Foreseeing probable resistance

Step 10 Trial implementation & validation
Act / Implementation Step 11 Regular implementation

And Results Step 12 Follow up / Review & prevention of recurrence

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering

Problem Selection
Step 1: Problem Identification

QUICK CHANGE OVER(QCO) ISSUE IN PF-45 TEST

BENCHES DUE TO ROLLER TAPPET GETTING
STUCK AND HIGH CHANGE OVERTIME

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering

Step 2: Definition of the problem

Step 3: Analysis of problem
Step 4: Cause & effect analysis
Step 5: Root cause analysis
Step 6: Analysis on root cause

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering

Problem description:

 Roller tappet getting stuck & difficulty during

Changeover.

 Inconsistency & high changeover time

Theme:
PF45 functional test bench
 Improvement in Quick Change Over in PF45
functional Testing

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
Process flow chart

OK I/O valve preparation & Ultrasonic

Repair / Not OK Cleaning for
Dismantling Station DVH – O ring
I/O valve Not OK
Sub assembly

OK OK OK Low pr.
DURR Selective assembly DVH Assy. & BSP
Name sticker Assy. Tightness
cleaning of element. tightening Assembly
check

OK

OK OK
OK Functional
Log Packing Visual inspection Static Flushing
Testing

Not OK Not OK

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
Current situation:
 Inconsistency in change over time due to roller getting stuck inside the cam box
 Laborious process & difficulty in removal of roller tappet during change over
 High change over time of 4 hrs.

Impact of the problem:

 Increased downtime during change over
 Difficulty in planning for type change over in PF45 testing
 Resulting in type vise fulfilment failure
 Associate fatigue
 Safety concern

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
Objective:
 To reduce machine down time due to change over
 To improve planning & type vise fulfilment
 To reduce fatigue of the associates working in PF45 testing
 To improve safety & morale of the associates 10
9
8
7
6
5 4 hrs.

Goal setting: 4
3

 To reduce the change over time from 4 hrs. to 2

1 < 20 min.
< 20 minutes. 0
Bafore After
 Change over time consistency

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
WHAT Inconsistency & high change over time in testing

WHERE PF45 functional testing

WHO Associate working in PF45 functional testing

WHEN During change type change over, Since July - 2015

HOW Support from TEF2 ( Technical function ) tool & fixture design

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
PF45 pump testing cam box – One cam box 03 different QCO Roller tappet to
match the BDC for testing

In PF45 we have two main types

 PF45-16 – 1600 bar pump
 PF45-20 – 2000 bar pump
In PF45-16 there are 3 types
 005 with BDC of 147 mm
 006 with BDC of 143 mm
 007 with BDC of 122 mm
In PF45-20 there are 2 types
 998 with BDC of 122 mm
 999 with BDC of 143 mm

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
Cam box for testing PF45 pump  The cam is used n PF45 pump functional
testing to simulate the engine test condition

PF45 pump
 The PF45 pump fuel discharge is measured
by pressurizing the PF45 pump up to 1600
Cam box
& 2000 bar @ specified Rpm & supply of
Roller Tappet Inlet fuel pressure.
guide bush
 The Roller tappet is the change part in
QCO testing during Type change over
Roller Tappet
 The Roller Tappet is the driving member
of the pump which converts rotary motion
into reciprocating movement.
Cam shaft

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
Roller Tappet removal during change over  Roller Tappet is situated 100 mm
deep inside the cam box

 The nose plier jaws grips inside the

BSP seat bore of Roller Tappet &
extracted out of cam box

Concern:
Roller tappet stuck inside the cam
box after usage for few shifts

 Dismantling of cam box top plate

for removal of stuck RT & replacing
new one

 Resulting in high down time during

Extraction of RT by using long Nose plier Extraction tool change over

 Safety concern & fatigue during

dismantling of cam box.
VIII SEMESTER B.E.
MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering

Man Machine

Improper loading Wrong RT selection Lubrication failure

of pump
Over heating of
Improper handling Lub. Oil cam box
of RT No instruction contamination
New associates Inconsistency &
High change over
time in PF45
Alignment Issue functional testing
Usage of improper
tool bet. pump & RT
RT removal process Usage of
Not defined Wrong RT QCO RT problem &
sticky
QCO RT Cam box change Cam box top
removal issue Over process not defined plate alignment

Process Cam box

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
Why – Why analysis for potential cause 1. QCO RT problem & sticky after usage

Why? - Uneven wear pattern in RT guide bush

Why?- The contact area is more between RT & Guide bush

Why?- The guide bush length is more

Why?- By Design

Root cause 1 : Inadequate design of RT guide bush for the new QCO RT

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
Why – Why analysis for potential cause 2. QCO RT removal issue

Why? - QCO RT getting stuck inside the guide bush after usage for few shifts

Why?- The removal tool slips, As it has to grip inside the RT bore

Why?- Insufficient grip on RT by the tool

Why?- By design – Removal tool design not upgraded for QCO RT

Root cause 2 : Inadequate grip of RT removal tool to over come the stickiness &
proper alignment during removal of RT

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
Root cause 1 : Inadequate Design of RT guide bush for the new QCO RT
 When ever there is change over from 007 to 005 or 006 the 007 QCO RT easily slides out of the
guide bush.
 The 007 RT is 23 mm more in length when compared to 005 or 006 & reciprocating length more
than the guide bush.
Conclusion:
 The 005 & 006 RT is shorter than the guide bush & oscillates with in guide bush length, Resulting
in the abnormal wear in the bore of the guide bush by the edges of RT
guide bush ( Cast iron)

QCO Roller Tappet

( Hardened steel)

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering
Root cause 2 : Inadequate grip of RT removal tool

 The newly replaced RT are easily removable by the existing tool ( long nose plier),
 After the usage of cam box for few shifts, The removal tool slips & RT removal becomes dif
Conclusion:
 The removal tool design to be improved for better gripping of RT while removing

Bore of RT

RT removal tool
RT : Roller Tappet

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN
 BANGALORE INSTITUTE OF TECHNOLOGY
Department of Mechanical Engineering

THANK YOU

VIII SEMESTER B.E.

MECHANICAL ENGINEERING NAME OF THE STUDENT
BATCH – 20__ - 2014 USN