STUDY AND IMPROVEMENT OF SMALL

SCALE INDUSTRY SYSTEM

By
RAJNEESH KUMAR SINGH
2011123
SUPERVISOR(S):
AWADHESH KUMAR SINGH
VINOD KR. VAID

MECHANICAL ENGINEERING
INDIAN INSTITUTE OF INFORMATION TECHNOLOGY, DESIGN
AND MANUFACTURING JABALPUR
(3RD, SEPTEMBER 17TH, SEPTEMBER)

INTRODUCTION

This report tells us about the existing problems in the industry that have serious impact on the
production, quality, turnover, safety to the workers. We had done a full analysis of industry in
the last 15 days and highlighted the problem which have serious effect. It is necessary to
identify the elements of problem in the industry, by eliminating them we can make the best
use of human resource, increase the turnover, increases the production rate increases the
quality of products, lower the costs and make them long lasting or durable.
By eliminating these problems we can make the industry reach to new heights. In this report
we had identified the problems relating to the production of the industry, we had studied the
time taken by different machines to complete the operation. By studying these operations we
can identified the defects in the production and manufacturing systems and will eliminate the
defects to enhance the production rate of the industry and enhance the production. On
increasing the actual production rate many existing problems can be eliminated in the
industry like turnover of industry, enhance the good will of the industry.
Lets move further in our problem exploration and see what are the problems existing in the
industry economic system.

PRESENT INVESTIGATION REPORT (15 DAYS)

In this report we have studied the processes that are existing in the industry and which are
used in the manufacturing of the various parts. The manufacturing of parts takes stage by
stage just like in lean manufacturing model. Lets see how the system works does. Firstly
each power press machine is reserved for only one operation, each power press is set side by
side and each power press is allocated to a worker.
For example if we see the manufacturing of box then the processes involved in the production
of box are punching holes, cutting, bending, making foundation, drilling, welding. Punching
of holes is mainly done on power press (PP1) of 5 tons. Cutting and bending are done on 10
tons power presses (PP2, PP3, PP4 and PP5). Foundation making is mainly done on 20 and
30 tons power press machines like PP7 AND PP8. On a particular day only punching, cutting
and bending is done and after this all parts are stored and next day the foundation making is
done on the parts. In the above picture we see that two power press machines of 20 and 30
tons are idle and no work is been done on them on that particular day. On the day of
foundation making only two power presses are used and that are 20 and 30 tons and the rest
power press machines are idle. The welding machine and drilling machines are also idle as it
welds and drills the boxes after all manufacturing operations are finished so we can see that
there are idle machines on which no work is being done and it results in low production of the
industry. It also increases the production time of the industry. By removing the problem of
idle machines we can make the best use of resources of the industry. So to increase the
production we had suggested the concept of assembly line production or more popularly
known as lean manufacturing.
In this method of production the raw material firstly goes to PP1 and the first operation of
punching is done, after that the partially finished part is set by side by the worker for the
operation on second machine, the partially finished part is taken by the second worker and the
next operation is done on PP2 that is cutting, after doing the next operation the worker places
the part for the next operation and it is taken by the next worker for subsequent processing,
this cycle repeats itself until the final part is manufactured. In this process all the machines
are used and no one is idle and thus the production rate is increased. By performing

operations one by one a part is produced and this cycle repeats itself for manufacturing of
number of inner parts, outer part and boxes.
If we see in the former process the machines are idle. For e.g. lets assume take that an order
of 10000 boxes came to be delivered. If we see the former process then we can see that holes
are punched in a day, estimating the time for punching it takes about 5 seconds to punch the
appropriate number of holes. Working time is 9 hours and 15 minutes for everyday. Then we
can see that 6660 parts are punched in a day and remaining pars are punched next day. On
next day cutting and bending operations are done on these punched parts. Power press of 10
tons are reserved for this operations. Roughly the cutting and bending takes 23 seconds to
complete, then we can see that on that day only 1450 are produced and it takes 7 days to do
bending and cutting on all parts. After cutting and bending the parts are gone to foundation
making, 4 foundation slots are punched and it takes roughly 10 seconds time for one
foundation slot, so from above we can imply that for foundation making on all parts it takes
2 days to complete the foundation making. After foundation the parts are gone for drilling,
drilling takes roughly 15 seconds and there is only one drill for making the boxes, so
finishing all takes 5 days. After drilling the parts are gone for spot welding, spot welding
roughly takes 25 seconds to complete and so to complete welding on 10000 parts it will take
8 days to finish the welding operation. In total it takes 2+7+2+5+8=24 days.
In the above processes we see that some machines are idle on a day and the need to be used to
increase the production rate of the industry. We had suggested the industry to have one extra
drilling machine to make the production faster there is extra welding machine which is not
useable and needs to be repaired to increase the production rate. We had suggested the
assembly line production for fully use of resources and to decrease the time of production. In
my suggestion there are two times in the production and that are handling and machining
time. Handling time is the time taken by the workers to handle the material and machining
time is time taken by an operation on the machine. For e.g. If an order came for MCB boxes
in the industry then the order completion takes as follows. Firstly the required number of
inner part is produced, after finishing the inner part, outer part is manufactured in the required
number and after that box is manufactured and at last everything is assembled and delivered.
Let us move forward and see what are the time taken for manufacturing of each part and time
consumed by each operation.

Below is a detailed study of the time that each part should take in the assembly line
production. Study is conducted for all three MCB parts i.e. inner part, outer part and the box.
Study is conducted in three tables.

S.NO

OPERATION IN THE

TIME TAKEN BY EACH

MANUFACTURING OF INNER

OPERATION(sec.)

PART

1.

Handling time by the first worker

1 sec

Punching holes on the power press

2.

machine (4 holes).

6 sec

Handling time by first worker +

3.

handling time by second worker

2 sec

Cutting of rectangular chips from the

4.

work piece.

8 sec

Handling time by second worker +

5.

handling time by third worker.

2 sec

6.

Cutting of middle rectangular portion.

4 sec

Handling time by third worker +

7.

handling time by fourth worker

2 sec

Bending along the sides.

8.

12 sec

Handling time by fourth worker +

9.

handling time by fifth worker

2 sec

Manual operations

12 sec

10.

11.

TOTAL TIME = 51 sec.

S.NO.

OPERATION IN THE

TIME TAKEN BY EACH

MANUFACTURING OF OUTER

OPERATION(sec.)

PART

1.

Handling time by the first worker

1 sec

Cutting of rectangular portions from

2.

the corner.

4 sec

Handling time by first worker +

3.

handling time by second worker

2 sec

Cutting of rectangular portion from

4.

the middle of sheet.

4 sec

Handling time by second worker +

5.

handling time by third worker.

2 sec

Bending of the sides from where the

6.

rectangular pieces are cut.

7.

3 sec

TOTAL TIME = 16 sec

The above two tables show the total time and time for each single operation. Above tables
show times of inner part and the outer part. Total time in the manufacturing of inner part
takes about 51 sec approximately while it takes 16 sec approximately to produce one outer
part. Now we will see the production of boxes.

S.NO.

OPERATION IN THE MANUFACTURING

TIME TAKEN BY EACH

OF BOX

OPERATION(sec.)

Handling time by the first worker

1.

1 sec
Punching of holes (4 holes).

2.
3.

5 sec
Handling time by first worker + handling time
by second worker

2 sec

4.

Triangular chip cutting from the sides.

6 sec

5.

Handling time by second worker + handling

time by third worker.

2 sec

6.

Low width strip bending from smaller sides.

4 sec

7.

Handling time by third worker + handling

time by fourth worker.

2 sec

8.

High width bending from larger sides.

6 sec

9.

Handling time by fourth worker + handling

10.

time by fifth worker.

2 sec

Foundation making (4 slots)

5 sec

Handling time by fifth worker + handling

11.

time by sixth worker.

2 sec

Drilling of holes for fitting at the finishing

12.

stage. (5 holes)

7 sec

Handling time by sixth worker + handling

13.

time by seventh worker.

2 sec

14.

Time spent in spot welding operation

12 sec.

15.

TOTAL TIME = 57 sec

RESULTS AND DISCUSSIONS

In the fifteen days account we had studied about all the processes and the time taken by each
process which would help us further in our problem identification. By introducing the
assembly line production we can make use of each and every resource available to the
industry. By introducing the assembly line production we see that it takes only 16 days to
complete 10000 boxes whereas formerly it takes 24 days to complete the same. Since only
punching, cutting and bending are used for production of inner and outer part so there
production remains the same as before. After applying the assembly line production we see
that now order finishes 8 days before and thus increasing the production rate of the industry.
In this report our problem identification mainly deals with enhancing the production rate of
the industry, by identifying the problems related to the manufacturing and the production
section we can solve them and can make the industry more economically prosperous which
will result in the further improvements of the industry. This is our first step towards the
problem identification and solving process and it has more disposition towards the production
of the industry.
By removing these problems we can have a great way for the future of the industry system
and make it more fruitful to the population, the owner, and the workers working there and to
the country.

CONCLUSIONS
In this session we had studied the processes and the manufacturing systems used by the
industry which will help us to identify the problems which the industry is facing today. In the
next session we will identify how to best deal with these problems to make the economy of
the industry more fruitful and affluent. In next session we will identify other problems and
technologies that can be useful to the industry economic system.

AUTHORIZED SUPERVISOR AT INDUSTRY

VINOD KR. VAID
(MOB. 9911385685)
GRADE GIVEN BY SUPERVISOR A+