AN

INDUSTRIAL INTERNSHIP REPORT

AT

“Castco”
(Mayura Group)

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT

FOR THE AWARD OF DEGREE OF BACHELOR OF MECHANICAL ENGINEERING
AS LAID DOWN BY SHIVAJI UNIVERSITY, KOLHAPUR DURING ACADEMIC
YEAR 2023-2024.

SUBMITTED BY

Mr. Rushikesh Balasaheb

Mohite

UNDER THE GUIDANCE OF

Prof. S. V. Lingaraju

DEPARTMENT OF MECHANICAL ENGINEERING

TATYASAHEB KORE INSTITUTE OF ENGINEERING & TECHNOLOGY,
Warananagar, Dist. Kolhapur 416 113 (M.S.)
2023- 2024

1
 TATYASAHEB KORE INSTITUTE OF ENGINEERING &
TECHNOLOGY, WARANANAGAR
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify That The “Internship Report” Submitted by Mr. Rushikesh Balasaheb
Mohite (GRN No. 21UDME20585) is work done by him and submitted during 2023-24
academic year, in partial fulfilment of the requirement for the award of the degree of Bachelor
of Technology in Mechanical Engineering, at CASTCO (Mayura Group) Top Sambhapur.

Prof. S. V. Lingaraju Dr. P. V. Mulik

(Internship Coordinator ) (Head of Mech. Engg. Dept.)

Mr. Ravi Dolli Dr. S. V. Anekar

(General Manager) (Principle)

2
 ACKNOWLEDGEMENT

I express my deepest thanks to Mr. Vikram Bodake , General Manager Moulding & Quality
for taking part in useful decision & giving necessary advices and guidance and arranged all
facilities to make life easier. I choose this moment to acknowledge his contribution
gratefully.

It is my radiant sentiment to place on record my best regards, deepest sense of gratitude to

Mr. Ajay Bansode, Mr. G Khot, Mrs. Pragati Ekale, and Mr. Ravi Dolli for their careful and
precious guidance which were extremely valuable for my study both theoretically and
practically.

It is indeed with a great sense of pleasure and immense sense of gratitude that I
acknowledge the help of these individuals.
I would like to thank Prof. S. H. Patil, College internship coordinator, Prof. S. V. Lingaraju,
internship mentor for their support and advices to get and complete internship in above
said organization.

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

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

Sincerely,

Rushikesh Balasaheb Mohite

3
 TABLE OF CONTENTS

Sr.No. Topic Page Number

1 Introduction of Company: Castco 7-8
3 Soft Ring Operations 10-11
4 DGBB CH 12 Operations 12-29
5 DGBB CH04 Operations 30-44
6 Presetting Operations 45
7 5S Methodology 46-50
8 DGBB CH12 5S Implementation 50-58
Customers & Applications
9 59

10 Results 60
11 Conclusion 61

Charts used

Sr.No. Chart Description Page Number

1 Material flow and process for DGBB 08

2 Grinding Area Operations 12
3 Assembly area operations 13
4 Excess Vibrations Result 22

4
 Tables Used

Sr.No. Table Description Page Number

1 DGBB Type 6207 HT Specifications 11
2 Laser Machine Print Format for 6205 25
3 Laser Machine Print Format for 6208 43
4 Minor Flaws 47
5 Unfulfilled Basic Conditions 48
6 Inaccessible Places 48
7 Laser Machine Print Format for 6208 49
8 Quality Defect Sources 49
9 Unnecessary and Non-Urgent Items 50
10 Unsafe Places 50
11 Search-Location Table 51
12 Deviation Table for DGBB CH12 56

Images Added

Sr.No. Image Description Page Number

1 Supply Store 09
2 Heat Treatment Area 10
3 IR Buffer Table 14
4 IR SGP M/C 14
5 SHG-1 (855), SHG-2 (1001) 15
6 ABG- Auto Bore Gauge 15
7 IRL M/C 16
8 Oiling M/C 16
9 OR Buffer Line 17
10 OD Width PokaYoke 17
11 SSA-787 18
12 FSF 922 F&R, FSF 955 F&R 19
13 R&S Ball Filling Unit 20
14 HIT 21
15 Oiling M/C 21
16 MVM 23
17 MYD 24
18 Han’s Laser M/C 25
19 Washing M/C 26
20 Auto greasing M/C 27
21 Z&R Seal Filling 28

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22 Visual Inspection Station 29
23 Autoloading Station 29
24 IR Buffer & NDT Master Ring Poka yoke M/C 30
25 SPC M/C 30
26 SGB Troubleshooting & SGB M/C 31
27 Grinding Stone, SGB M/C inside 32
28 SHG-1, SHG-2 CH04 32
29 FGM 35, 36, 95 33
30 FGM 35 inside 34
31 OR Buffer Line CH04 35
32 SPD M/C OR 36
33 SHG M/C OR 37
34 FSF M/C 38
35 R&S Ball Fill M/C 39
36 HIT CH04 40
37 Oiling M/C CH04 41
38 Assembly PokaYoke CH04 42
39 Han’s Laser M/C and Laser Marking 43
40 Tooling trolley: PEEP Implementation CH01 53
Locker Unit and SPC Grinding Wheel Stand:
41 53
Marking done CH01
42 Before (L), After (R) CL660 (1) 57
43 Before (L), After (R) CL660 (2) 57
44 Before (L), After (R) IRL-864 58
45 Before (L), After (R) Trench 58

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 Introduction of company: CASTCO

Mayura Group of Industries, Chairman- Chandrashekhar Dolli, a Visionary & Core Industrialist,
had Envisioned the Fast Consumable Ground Engaging tools, the Wear resistant & abrasive
resistance castings market, 4 decades back, in the early 80's.
With his Business Punch line WORK IS WORSHIP, he founded number of factories under his
Leadership and this Family run businesses is being Led with a team of expert engineers &
his son Ravi.

Factories under the flagship of Mayura are

 ALLOY STEELS, Kolhapur

 BIG CASTINGS PVT LTD,
 MAYURA STEELS PVT LTD -UNIT 1,
 MAYURA STEELS PVT LTD -UNIT 2,
 CASTCO,

Chairman’s long term planning of being Number One in TOOTH POINTS - Ground Engaging tools, the
Wear resistant & abrasive resistance castings in India , being a strategic Longterm supplier to all the
Mining and Construction Equipment has come true and we all are proud of him. Now his stance to be on
the World Map and GAIN the FAITH OF OVERSEAS CUSTOMER is in the happening.

Mayura Group has been Manufacturing & supplying Steel Castings specially Ground Engaging Tools,
Tooth points, Sprockets, Idlers, bucket link, & boom parts, As a Single Source & a long-term Strategic
Supplier to Original Equipment Manufacturers of Hydraulic Excavators and Wheel Loaders and Rope
shovels, to customers like CATERPILLAR, TATA HITACHI, SANDVIK, JOHN-DEERE, L & T
CONSTRUCTION, KOMATSU, BEML, VOLVO, JCB, CASE NEW HOLLAND, KOBELCO, SANY,
LEEBOY, HYUNDAI, DOOSAN, SCHWING STETTER, MAHINDRA CONSTRUCTION,
LIUGONG.DAIMLER VEHICLE, WABTEC CORPORATION,

Mayura Group has been into this foundry business since last four decades and is certified for Integrated
Management System (ISO 9001, 14001, 18001), Mayura Group has dispatchable capacity approx 20000
metric tons per annum, with more than 750 skilled disciplined workers & 100 talented techno commercial
staff that deliver the best Quality products & coordinate towards Timely Delivery & fulfill the needs of
ever demanding customers’ requirements.

State of art world class manufacturing facilities & processes are adopted & modernized upgradation of
infrastructure as per the market demand is always being done in stipulated period of time. All the
equipment’s for Quality Testing, Heat Treatment, Machining, induction hardening, Finishing & painting
are under one roof.

7
One of the USP of Mayura Group is its Continuous Heat Treatment Furnace.And an in-house machine
shop.

Mayura is First Steel Casting Supplier in INDIA to achieve SQEP, a GOLD LEVEL CERTIFIED &Long
Term Strategic Supplier to CATERPILLER USA

Vision

Create competent Automobile technocrat to take up challenges of ever-changing global standards

and serve local industrial and social requirements

Mission
 To develop employable automobile technocrat with professional skilis and ethical and
social values
 To associate with industry and alumni for mutual benefits like training, internship and
expert lectures for the students.
 To encourage students for higher studies in recognized institutes
 To inculcate entrepreneurial attitude and values with lifelong learning

8
Casting Process

 Core Making

 Molding

 Melting

 Pouring

 Shakeout

 Shot Blasting 1

 Knock Off

 Fettling

 Normalizing

 Hardening & Tempering

 Shot Blasting 2

 MPI

 Hardness Inspection

 Painting

 Dispatch

9
 1. Core Making
Core making is the process which forms the interior part of the casting. The mould provides a space for
the molten metal to go, while the core keeps the metal from filling the entire space. Cores can be used to
extend mould projections to create extra mould sections, or to block out and create negative drafts

A core is a sand or metal insert used to shape any part of a casting that cannot be shaped by the primary
removable pattern. When a pattern is pressed into sand and then extracted it leaves a concave impression.
Liquid metal fills this void and cools. Cores are created to allow more complexity in the design. Well-
constructed cores create holes or chambers in a casting. Automotive engine Molds might have up to five
cores in them to create the chambers necessary for the working of a combustion engine.

Cores can also help create angles that would be impossible with a pattern. Any overhang above an empty
space would make it impossible to withdraw the pattern without breaking the overhang. In these instances,
a core can be used.

Castings using internal cores usually have some opening in the outer shell of the moulding to extract the
core after casting, though this opening might be plugged mechanically during finishing.

Cores made of sand are designed to break down; internal cores are quite literally shaken out of the casting
at the end of the process. The “shakeout” opening is also helpful for the placement of the core. Any place
the core touches the mold is a place where molten metal cannot flow, so to get a consistent thickness of
metal a core must “bridge” the space to be filled without touching any sides. To achieve this, the core
normally is longer than the casting, and held into place by divots in the sand outside the casting pattern.

10
 2. Molding

A mold is made by shaping a suitable sand mixture around a pattern of the desired form. A metal or
wood box (flask) is used to retain the sand. The pattern is then removed from the sand, leaving a cavity
in the sand into which the molten metal can be poured. The molder's skill is the basic skill of the
foundry.

Process of Sand Casting

1) Place Mold Pattern in Sand. ...

2) Set Up the Gating System. ...
3) Remove the Mold Pattern. ...
4) Pour Molten Metal into Mold Cavity. ...
5) Wait for Metal to Cool. ...
6) Break Open Mold to Remove the Metal Casting.

3. Melting
The process includes melting the charge, refining the melt, adjusting the melt chemistry and tapping into a
transport vessel. Refining is done to remove harmful gases and elements from the molten metal to avoid
casting defects.

11
Melting processes in metallurgy are high-temperature processes, and in those areas exposed to thermal
stresses, materials are required that can reliably withstand application temperatures from 600 to around
2000 °C over economically viable periods. For special applications in the NF metal industry, components
made of oxide and non-oxide ceramics are used, which, besides their suitability for high-temperature
processes, offer other application-specific properties.

4. Pouring
The pouring process typically works as follows. Recycled scrap metal is melted into a liquid within a
smouldering hot furnace. Its resulting contents are poured into a ladle, from which it is then transferred
into moulds. Once the metal cools - and solidifies an iron casting is born from said mould.
In a foundry, molten metal is poured into molds. Pouring can be accomplished with gravity, or it may
be assisted with a vacuum or pressurized gas. Many modern foundries use robots or automatic pouring
machines to pour molten metal. Traditionally, molds were poured by hand using ladles.

12
 5. Shakeout
After the casting has solidified in the mold, the casting is removed from the sand mold by a
process called "shake-out." Typically the entire mold is vibrated to "shake" lose the sand
from the metal casting. Additional clean-up of mold material can be accomplished by
abrasive blasting. With the Ice Cleat, the part was allowed to solidify and then conveyed to a
mechanical vibrator. The mold and part were shaken for several minutes until the majority of
the sand was removed. The sand from the mold is then recycled to make new molds. The
part, still very hot, is then removed from the vibrator and allowed to continue cooling. Before
the finishing process begins, the part is abrasive blasted to remove the remaining sand.

6. Shot Blasting
Shot blasting is a mechanical surface treatment process. In the investment casting
process, shot blasting is a post-production finishing service. It is processed by the
rapid impact on the surface of investment castings with an abrasive material. Its
purpose is to remove various impurities from different surfaces. It is a faster and
more efficient process when compared to filing for flash removal that remained on
investment castings.

Shot blasting is a cold treatment process. It can be divided into shot blasting and shot
peening. Shot blasting is to remove the surface oxide and other impurities to improve the
appearance quality and shot blasting makes the surface of the workpiece reach a certain
degree of roughness. Make the workpiece beautiful, or change the welding tensile stress of
the workpiece to compressive stress and improve the service life of the workpiece.

Shot blasting is using the centrifugal force of the impeller on the throwing head of the shot
blasting machine at high speed. Then to shoot the abrasive at a very high linear velocity on
the surface of the treated steel to produce a striking and grinding action to remove the oxide
scale on the steel surface and rust.
13
Super Cooling: It is the process of rapidly lowering the temperature of a workpiece. In this
setup we cool the workpiece 800 degree to 6-10 degree Celsius.
Washing: After supercooling, the component is undergoing washing again so as to remove
any excess oil or deposits which may have stuck to the workpiece during heating and
quenching.
Tempering: It is the process of treating metals through heating in order to enhance
toughness. For a given component (IR 63/28) Tempering time is specified as 170 degree
Celsius for Zone 1,2 & 3 respectively.
After Heat Treatment we have to do 2 major operations namely:
1. Facing
2. OD Grinding
Facing: When we get soft material from the supplier, for extra caution we have excess
material left on the component. To remove this material and make the surface shiny and
clean, we do face operations.
OD Grinding: As there is excess material on the surface, the diameter required as per
company specifications is not maintained. To get uniformity in operations and maintain
company standards and ease of fitment, outer material is removed using Grinding process
and final diameter is checked with the help of UD Apparatus.

14
DGBB Channel- 12 Line Operations:

DGBB

IR
OR

OD DG 400

CL 660 S

SSB
S

FSF
IR

Washing

Chart (ii): GRINDING AREA OPERATION

15
 Chart (iii): ASSEMBLY AREA OPERATIONS

IR OPERATIONS
1. DG

In IR ring operations, face and OD Grinding is done on the line itself. We get the heat-
treated product from the heat treatment dept according to order and then the first
operation is SPC Operation. This involves face grinding the IR. Before passing through the
SPC Machine we have to ensure that all material used has desired hardness. Therefore,
before passing through the SPC, it is brought to a buffer station and then passed through a
Hardness Testing Machine. If the material is not up to the specified hardness, it will get
rejected.
In the SPC Machine, the face is grinded and polished. The critical parameters are:
i) Waviness
ii) Width
iii) Groove Parameter

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 Pic (3):DG 400
2.SGP
After Facing, the component is then passed on to SGP Machine for OD Grooving. In this
machine, grooving is done with the help of a grinding wheel. Wheel and the workpiece are
under rotary motion and in contact with each other which causes removal of excess
material. This excess material is then thrown out in the form of slag and dirt which requires
periodic clean-up.

Pic (4):IR SGP M/C

3. SSB

After OD Grooving the component is brought to the bore station where grinding of internal
diameter is done to achieve required specifications. There are 4 types of grinding
a) Air Grinding
b) Rough Grinding 1
c) Rough Grinding 2
d) Fine Grinding
Critical Parameters are: Ovality, Bore Diameter and CLA

17
 Pic (5): SSB
On this line we have 2 Bore Machines as the cycle time for boring operation is high, there is
piling up of excess workload which causes less productivity and as to prevent it we add
another bore machine for faster operation. In Boring operation, magnetic clamping is used
and because of this, the workpiece acquires some temporary magnetic properties which is
not desirable. So as to remove these properties, every workpiece undergoes
demagnetisation under a demagnetiser unit.
4. MMK

After the bore operation is complete, we need to check if the operation has been done
according to specifications. That’s where ABG Machine comes into play. ABG Machine (Auto
Bore Gauge) is used to check the bore size. If the bearing is above specified size (Oversize),
and below the specified size (Undersize) it is rejected. Undersize Bearings can be sent to
rework again but Oversize Bearings are sent to scrap because the extra removed material
cannot be replenished.

Pic (6): ABG- Auto Bore Gauge(MMK)

18
5. IRL

After checking parameters, IR is sent for final cutting and polishing. This operation has a
higher cycle time than others, therefore a buffer unit is added so that the machining time
and production can be simultaneous.

Pic (7): IRL M/C

Material removal up to 10 microns is done depending on the bearing model and
specification. Out of this first 8 micron is rough cutting operation and remaining 2 micron is
final finishing operation and hence we get the shine and polished finish on the bearing.
6. Washing Unit

After all operations, for further removing the dirt and dust that may have been accumulated
in the IR, it is passed through the Washing Machine for the final cleaning process using
Honilo-481. After these operations, the IR is sent for Assembly Station.

Pic (8): Oiling M/C

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OR OPERATIONS
Before getting OR on the channel line, it has undergone Face and OD operation at the
previous station itself.

Pic (9): OR Buffer Line

1.Poka Yoke Machine (MMK OR)
To ensure that the component is according to specifications given, checking is done using
Poka Yoke Machine and verified. Tolerance for OD is 0-10. Tolerance for Width is 0-100.

Pic (10): OD Width Poka Yoke

While transporting OR from one station to another, many times small dust particles attach
themselves to the micro cracks and crevices and surface of the ring and when gone under
checking, the machine detects this fault and rejects the sample and because of this OD
Rejection is high. The rejected components are cleaned and again sent under the machine
and the majority pass through without any further issues. Remaining samples which are not
able to pass are then sent to Scrap.
After 500 items, the system needs to be recalibrated.
2.SSB Machine
After checking the parameters, the component undergoes an Inner Groove Grinding
Process. A grinding wheel is attached via a crank to the main motor, which when turned on,
rotates the grinding wheel. Workpiece is fixed during this operation via means of
pneumatic
20
clamping. After the operation, the finished OR is pushed to the main line via a pneumatic
push mechanism. As this operation is time consuming, 4 such machines are installed on-line
so that the process can be regulated.
These machines are:

Pic (11): SSB 2208

3. FSF Machine

They perform Honing operation for material removal and finishing and removing the
roughness. The honing operation is performed with the help of Honing Stone.

Pic (12): FSF 922 F&R, FSF 955 F&R

21
As this operation is time intensive and only one component is undergoing this operation in
one machine we have 2 sets of this unit, containing Roughing and Finishing Operation.
● Roughing Cycle time: 10 seconds
● Finishing Cycle time:10.3 seconds
We use different materials for finishing and roughing operations. Operation is done with the
help of an oscillating arm to which the stone is clamped. Similarly, the OR is also clamped via
a pneumatic mechanism.
4. Washing Machine

After all operations, for further removing the dirt and dust that may have been accumulated
in the OR, it is passed through the Washing Machine for the final for the final cleaning
process using Chemical STANSOL-80 MSDS No.9.
After washing operation, OR is passed through a Demag unit so that no magnetic properties
are present at the time of assembly.
ASSEMBLY
1. Ball Insertion Machine

After individual operations on IR and OR, they are brought together at the ball insertion
machine station. Both of their tolerances and measurements are recorded and accordingly
balls are inserted via a tubing mechanism in the between IR and OR rings. But these balls are
not inserted evenly, there is uneven space between them which needs to be rectified.

22
 Pic (13): R&S Ball Filling Unit (HMC)
2. Ball Dividing Unit

After balls are inserted, they need to be divided evenly. This is done via rotating the bearing
and insertion of a separation unit to evenly space-out the balls. After this process Female
Cage is placed on to the bearing and is then passed on a circular conveyor for pressing
operation
Before the bearing is placed on the circular conveyor, the Male Cage is placed on the clamp
so that the Female Cage is directly fitted onto the Male Cage. After this placement, the Male
Female Cages are not fixed, and for further operations, they need riveting operation-
attaching both cages with the help of rivets- so that they become fixed with each other.

23
 Pic (14): HIT
After Riveting, the bearing is gone under an RC Unit which checks if all fitments are
according to specifications and Male-Female Rings are pressed properly and if not pressed
properly, the bearing is rejected and sorted.
3. Chemical Washing Machine

After Riveting, the bearing is sent for washing operation. This occurs in 2 stages:
● Wet Washing: Washed with White Spirit
● Dry Washing: Washing with pressurized air so that the bearing is blown dry and
excess dirt which has become loose after wet washing is blown away and the bear
and the bearing is free of any dirt and also used for cooling.

Pic (15): Oiling M/C

24
4. Poka Yoke Machine

A quality inspection machine, Poka Yoke machine checks the following

● Is there a rivet missing?
● Is there braking?
● If there’s a ball missing?
● If more than one male/female cage is present?
Faulty Bearings are recognised and kept aside.
5.Vibration Monitoring Machine (MVM)
The most essential and important part of a bearing is its vibration. Bearing should have
optimum vibration which is specified by the company and standards and should not deviate
from them. If vibrations exceed the given parameters then:

Chart (iv): EXCESS VIBRATION CONSEQUENCES

25
Pic (16): MVM

26
6. Clearance Checking Machine

There should be optimum clearance in the bearing. Too much clearance and the bearing will
become too loose and too little clearance the bearing will become rigid after a certain time
and will fail.
The most common clearance types are:-
● N-Type (Normal)
● C3-Type

Pic (17): MYD

Customers specify how much clearance is required according to their needs and applications
and according to that, the machine is resetting and calibrated. Type C1, C2, C4 are rarely
used (Approximately 1 out of 100). That’s why these are not desirable in day-to-day
operations.

27
7. Laser Machine

After a bearing is cleared, it is required that the company marks their own bearings and give
them appropriate information so that it is easier for tracking, maintaining records and if
some defect is observed by the buyer, it can be easily identified and marked accordingly.
For the Marking process, it is sent to a laser machine where Company Name and Code are
printed.
For eg. SKF 6205 INDIA P 12 11 186U

SKF 6205 INDIA P 12 11 186U

Company Type Country City Channel Date & Year

Name

Table (3): Laser Machine Print Format for 6209

Pic (18): IGP Laser M/C

28
8. Washing Unit

To remove any excess dirt and debris from the marked bearing, washing and subsequent
drying is done in a washer unit before being passed for greasing. If washing is not done
before greasing, it is difficult to remove dirt and debris afterwards.

Pic (19): Washing M/C

9. Greasing Machine

After laser marking, the bearing is passed to the greasing machine. There are 7 types of
grease:
● MT-33
● MT-47
● LGHP-2
● GHU RETINEX, LX2
● GJN
● VLUT-189
● LHT-23

29
 Pic (20): Auto greasing M/C (HHM)
According to customer requirements different types of grease are used. When the bearing is
brought to the station, it is weighed and according to the weight, grease is filled in it so that
the ratio of grease weight to the total bearing weight remains constant. After filling, it is
passed through a sensing machine which senses if the grease amount is too less or too much
or optimum. Unsatisfactory bearings are then taken off the line and the optimum filled
bearings are carried on for further operations.
10. Filler Machine

After grease is filled into the bearing, we need a sealer which will make sure that the grease
won’t leak out and do its job without any difficulties.
We have 2 kinds of Filler plates namely:
● Rubber Filler
● Metal Filler
For some types there may be no any kind of filler like eg., BB1-0596 type.

30
 Pic (21): Z&R Seal Filling (HHE)
According to customer requirements, one of the above 2 fillers are used.
11. Visual Inspection & Oiling

A strict Visual Inspection is done on the bearings by a skilled operator and inspector who
identifies:
1. Face Damage
2. Unclear Face
3. Uneven OR radius
4. Cage un fill
5. Cage crack
6. Rivet Missing
7. Excess bore radius
8. Double etching etc.
After Visual Inspection, Washing with oiling is done so that the bearing is thoroughly cleaned
and no form of moisture remains on the bearing which may cause rusting after 30-40 hours.

31
 Pic (22): Visual Inspection Station
12. Final Checking and Stacking:

Then they are further detected and set aside and oiling is done and then the final product is
then stacked and sent for Auto Packing.

Pic (23): Autoloading Station

32
 DGBB CHANNEL 4
IR Operations
1. SPC

In IR ring operations, face and OD Grinding is done on the line itself. We get the heat-
treated product from the heat treatment dept according to order and then the first
operation is SPC Operation. This involves face grinding the IR. Before passing through the
SPC Machine we have to ensure that all material used has the desired hardness.

Pic (24): IR Buffer & NDT Master Ring PokaYoke M/C

Pic (25): SPC M/C

Therefore, before passing through the SPC, it is brought to a buffer station and then passed
through a Hardness Testing Machine. If the material is not up to the specified hardness, it
will get rejected.

33
There are many sensors present on line and at the buffer table which counts the number of
workpieces on the line and ensures that there is no overcrowding on the line.
In the SPC Machine, the face is grinded and polished. The critical parameters are:
i) Waviness
ii) Width
iii) Groove Parameter

2.SGB
After Facing operation, grooving operation is done. The machine used on line is SBG 1003.
This operation mainly fulfils 2 purposes, grooving operation in the middle section of the IR
and Land operation at the edges. Wheel and the workpiece are under rotary motion and in
contact with each other which causes removal of excess material. This excess material is
then thrown out in the form of slag and dirt which requires periodic clean-up.

Pic (26): SGB Troubleshooting & SGB M/C

UD Apparatus are present to periodically check the groove position and groove diameter of
the IR. The critical parameters are:
● Groove
● Face: ±14 micron
● Ovality: 2 microns

34
 Pic (27): Grinding Stone, SGB M/C inside
3.SHG
After OD Grooving, the component is brought to the bore station where grinding of internal
diameter is done to achieve required specifications. There are 4 types of grinding:
a) Air Grinding
b) Rough Grinding 1
c) Rough Grinding 2
d) Fine Grinding

Pic (28): SHG-1, SHG-2

Critical Parameters are: Ovality, Bore Diameter and CLA. We use a 45 gauge spindle, i.e 45000
rpm is observed. In addition to that, it is very important to continuously motor the grinding
35
of the spinning wheel. If the wheel is worn out more than the specified range, grinding will
be uneven.
It is also important that dressing operation takes place after every 2 cycles so that the
grinding will be even. After 2 cycles, a 12-micron dressing is done with the help of a diamond
edged spindle. Wheel change is required after 1000-1200 cycles.
UD Apparatus are also present alongside the line for periodic dimensional verification, these
are:
a) Face and Groove Machine
b) Top and Bottom Machine
c) Bore Diameter
4.ABG
After the bore operation is complete, we need to check if the operation has been done
according to specifications. That’s where ABG Machine comes into play. ABG Machine ( Auto
Bore Gauge) is used to check the bore size. If the bearing is above specified size (Oversize),
and below the specified size (Undersize) it is rejected. Undersize Bearings can be sent to
rework again but Oversize Bearings are sent to scrap because the extra removed material
cannot be replenished.
Tolerances is set as 0 to -10 micron
5.FGM
After checking parameters, IR is sent for final cutting and polishing. This operation has a
higher cycle time than others, therefore a buffer unit is added so that the machining time
and production can be simultaneous.

Pic (29): FGM 35, 36, 95

Material removal up to 27 microns is done depending on the bearing model and
specification. Out of this first 25 micron is rough cutting operation and remaining 2 micron is
final finishing operation and hence we get the shine and polished finish on the bearing.

36
As we can operate on only one component at a time and cycle time being high, it is difficult
to maintain the speed of production. To compensate that, we use 3 FGM Machines namely:
a) FGM 65A
b) FGM 65B
c) FGM 65
The mean cycle time of an FGM Machine is 14 seconds. There are 3 pressure display dials
present on the machine for right arm clamping, left arm clamping and one for the clamping
unit for the honing stone.

Pic (30): FGM 35 inside

After Honing Operation, IR tends to pick up magnetic properties due to magnetic current
present in the boring machine. This is not desirable so all IR is passed through a damage unit
so as to remove any unwanted magnetic properties.
6.Washing
After passing through the damage unit, final washing of the components is done in order to
remove any dust and debris that may be present on the workpiece.

37
OR Operations
The outer rings are already mounted via a facing and hardness checking unit.
1.Poka Yoke
Here the OD of the ring and width is checked in this unit with the tolerance having -20 to -80
micron and is then passed for face grinding operation.

Pic (31): OR Buffer Line

2. SPD

Here face grinding is done with the help of two wheels where the ring is placed in between
two wheels and motion is given to the wheels so that they rotate and facing operation is
done. This is a Hydraulic process where oil is used for facing operation and coolant is used to
reduce the temperature which is increased due to wear and tear in between wheels and
ring.

38
 Pic (32): SPD M/C
And after a certain fixed number of cycles dressing is done in order to prevent the wheel.
3.Measuring unit
In this unit all tolerances are set at the same value of -20 to -80 micron except Inner Grinding,
which is set as 0 to -13 micron. Critical Parameters are:
a) Groove
b) Waviness
c) Ovality

4. OD GRINDING

In this process, the workpiece is placed between the Grinding wheel and Regulating wheel
via pneumatic clamping. Rotational motion is carried out on the wheel and also on the
workpiece in opposite directions so that maximum grinding may take place in limited time.
Critical Parameters are:
Ovality: <5 micron

39
5. Inner Groove Grinding

OR is fixed in the machine via chuck by means of pneumatic clamping and undergoes a
rotational motion and the grinding wheel is brought on the workpiece and operation is
taken place. After Inner groove grinding operation, OR undergoes washing process.

Pic (33): SHG M/C

6. Honing Operation

They perform Honing operation for material removal and finishing and removing the
roughness. The honing operation is performed with the help of Honing Stone. As this
operation is time intensive and only one component is undergoing this operation in one
machine we have 2 sets of this unit, containing Roughing and Finishing Operation.
● Roughing Cycle time: 8.2 seconds
● Finishing Cycle time: 8.3 seconds

40
 Pic (34): FSF M/C
We use different materials for finishing and roughing operations. Operation is done with the
help of an oscillating arm to which the stone is clamped. Similarly, the OR is also clamped via
a pneumatic mechanism. The oscillatory motion is at 700-800 rpm. There are 2 pressure
gauges present, i.e clamping pressure gauge and stone pressure gauge which is set at the
limited pressure of 1.5-2 bar and depending on the quality we can increase or decrease the
pressure.
After honing the OR components are subjected to demagnetization operation so any
unwanted magnetic properties acquired by them are lost.
7. Poka Yoke Machine

After all operations it is essential to check the parameters like tolerances, width, OD so that
the unfit components are segregated and can be sent to rework or scrap. After passing
through the poka yoke machine, the OR is sent to the assembly line.

Assembly
1. Ball Insertion Machine

After individual operations on IR and OR, they are brought together at the ball insertion
machine station. Both of their tolerances and measurements are recorded and accordingly
balls are inserted via a tubing mechanism in the between IR and OR rings. But these balls are
not inserted evenly, there is uneven space between them which needs to be rectified.

41
 Pic (35): Auto ball Fill M/C
2. Ball Dividing Unit

After balls are inserted, they need to be divided evenly. This is done via rotating the bearing
and insertion of a separation unit to evenly space-out the balls. After this process Female
Cage is placed on to the bearing and is then passed on a circular conveyor for pressing
operation.
Before the bearing is placed on the circular conveyor, the Male Cage is placed on the clamp
so that the Female Cage is directly fitted onto the Male Cage. After this placement, the Male
Female Cages are not fixed, and for further operations, they need riveting operation-
attaching both cages with the help of rivets- so that they become fixed with each other.

42
 Pic (36): HIT
In addition to metal male and female cages, different types are available according to
requirements and different models. For eg Bearing BB13673 uses a Single Nylon Cage
instead of Metallic Male and Female Cage.
After Riveting, the bearing is gone under a RC Unit which checks if all fitments are according
to specifications and Male-Female Rings are pressed properly and if not pressed properly,
the bearing is rejected and sorted.
3. Chemical Washing Machine

After Riveting, the bearing is sent for washing operation. This occurs in 2 stages:
● Wet Washing: Washed with White Spirit
● Dry Washing: Washing with pressurized air so that the bearing is blown dry and
excess dirt which has become loose after wet washing is blown away and the bearing
is free of any dirt and also used for cooling.

43
 Pic (37): Oiling M/C
Machine used for this operation is the MTO System.
4. Poka Yoke Machine

A quality inspection machine, Poka Yoke machine checks the following

● Is there a rivet missing?
● Is there braking?
● If there’s a ball missing?
● If more than one male/female cage is present?
● If some rings are pressed more than others?
For operator’s ease, there are various samples of unfit bearings so that it is easier for the
operator to understand the various defects and set aside accordingly. Faulty Bearings are
recognised and kept aside.

44
 Pic (38): Assembly PokaYoke
5.Vibration Monitoring Machine
The most essential and important part of a bearing is its vibration. Bearings should have
optimum vibration which is specified by the company and standards and should not deviate
from them. If vibrations exceed the given parameters, Excess vibrations will occur which
results in Heat and Noise dissipation because of which bearing failure may take place which
is very harmful for the machine.

6. Clearance Checking Machine

There should be optimum clearance in the bearing. Too much clearance and the bearing will
become too loose and too little clearance the bearing will become rigid after a certain time
and will fail. The most common clearance types are:-

● N-Type (Normal)
● C3-Type

45
Customers specify how much clearance is required according to their needs and applications
and according to that, the machine is resetted and calibrated. Type C1, C2, C4 are rarely
used (Approximately 1 out of 100). That’s why these are not desirable in day-to-day
operations.
7. Laser Machine

After a bearing is cleared, it is required that the company marks their own bearings and give
them appropriate information so that it is easier for tracking, maintaining records and if
some defect is observed by the buyer, it can be easily identified and marked accordingly.

Pic (39): Han’s Laser M/C

For the Marking process it is sent to a laser machine where Company Name and Code are
printed.
For eg. SKF 6208-2RS1/C3 INDIA P 06 11 186U

SKF 6209-2RS1/C3 INDIA P 06 11 186U

Company Type Country City Channel Date & Year

Name (Pune)

Table (4): Laser Machine Print Format for 6208

8. Washing Unit

To remove any excess dirt and debris from the marked bearing, washing and subsequent
drying is done in a washer unit before being passed for greasing. If washing is not done
before greasing, it is difficult to remove dirt and debris afterwards.

46
9. Greasing Machine

After laser marking, the bearing is passed to the greasing machine. There are 7 types of
grease:
● MT-33
● MT-47
● LGHP-2
● GHU RETINEX, LX2
● GJN
● VLUT-189
● LHT-23
According to customer requirements different types of grease are used. When the bearing is
brought to the station, it is weighed and according to the weight, grease is filled in it so that
the ratio of grease weight to the total bearing weight remains constant. After filling, it is
passed through a sensing machine which senses if the grease amount is too less or too much
or optimum. Unsatisfactory bearings are then taken off the line and the optimum filled
bearings are carried on for further operations.
10. Filler Machine

After grease is filled into the bearing, we need a sealer which will make sure that the grease
won’t leak out and do its job without any difficulties.
We have 2 kinds of Filler plates namely:
● Rubber Filler
● Metal Filler
11. Visual Inspection & Oiling

A strict Visual Inspection is done on the bearings by a skilled operator and inspector who
identifies:
● Face Damage
● Unclear Face
● Uneven OR radius
● Cage unfill
● Cage crack
● Rivet Missing
● Excess bore radius
● Double etching etc.
After Visual Inspection, washing with oiling is done so that the bearing is thoroughly cleaned
and no form of moisture remains on the bearing which may cause rusting after 30-40 hours.
12. Final Checking and Stacking: If any minute faults go unnoticed by naked eye, they are
further detected and set aside. Then oiling is done and then the final product is then stacked
and sent for Auto Packing.
47
PRESETTING OPERATION
There are 89 different types of bearings which are manufactured in the DGBB Lineup and
only a finite number of manufacturing channels available. For each type, we have common
machines but there are some specific parts which need to be replaced for a specific type of
bearing. This is where the presetting operation comes into picture. After completing a given
order, in order to manufacture another type of bearing, key components of machinery are
changed so as to accommodate the new workload.
As we know, we accept orders of different types and according to type there is setting on
line for that particular type. Presetting plays a very important role when we change one type
to another type.
Before the actual setting on the channel is done, we assemble all different parts on the
chuck for each machine on the channel approximately three days before it takes place.
We try to implement FTR i.e. First Time Right
Presetting means we assemble all required parts for a particular type on chuck and we test
that chuck is working or not and then we set that chuck on machine and after that for next
24 hrs by ramp up walk until line starts running smoothly.

48
5S Methodology

5S is a method aimed at providing a safe, well organized and clean workplace to do our job
first time right easily

This term was coined in the 1990s in Japan. The terminology is as follows:

1. Seiri (Sorting)
2. Seiton (Set in Order)
3. Seiso (Shine)
4. Seiketsu (Standardize)
5. Shitsuke (Sustain)

5S is a method to help ourselves to do our job first time right easily through:-

Improved workplace safety

Clutter free, organized & clean workplace

Improved ergonomics & ability to do our task with ease & minimal effort

1. Right Item
2. Right Place
3. Right Time
4. Right Quantity

This process required to achieve ZERO BAD, where BAD stands for Breakdown, Accident and
Defect.

Breakdown:

The state of machine and equipment when it stops fully on performing at desired level or
changes in behaviour observed like:

1. Frequent Stops
2. Malfunction
3. Slowing the speed
4. Wrong Indication or Output value
5. Excess Vibration, noise, heat, leak etc.

49
Accident:

The state of being change of physical status of human or equipment with long term/ forever
reduction or elimination of original efficiency

1. Minor injury
2. Minor accident
3. Major accident
4. Disease
5. Loss of natural efficiency
6. Scrap (Out of specification)
7. Reworkable
8. Inferior quality (Deviational)
9. Sub standard

Effect of Abnormalities:

Types of Abnormalities:

1. Minor Flaws
2. Unfulfilled Basic Conditions
3. Inaccessible Places
4. Contamination Sources
5. Quality Defect Sources
6. Unnecessary and Non-Urgent Items
7. Unsafe Places

1) Minor Flaws

Contamination Dust, dirt, powder, oil, grease, rust, paint

Damage Cracking, crushing, deformation, chipping, bending

Play Shaking, falling out, tilting, eccentricity, wear, distortion, corrosion

Slackness Belts, Chain

Abnormal Unusual noise, overheating, vibration, strange smells, discoloration,

Phenomenon incorrect pressure or current

50
 Adhesion Blocking, hardening, accumulation of debris, peeling, malfunction

Table (5): Minor Flaws

2) Unfulfilled Basic Conditions

Lubrication Insufficient, Dirty, Unidentified, unsuitable, leaking

Lubrication supply Dirty, damaged or deformed lubricant inlets, faculty lubricant pipes

Oil level gauges Dirty, Damaged, leaking, No indication of correct level

Tightening Nuts and bolts slackness, Missing, Cross-threaded, Too long,

Crushed, Corroded, Unsuitable washers, wing nuts on backward

Table (6): Unfulfilled Basic Conditions

3)Inaccessible Places

Cleaning Machine construction, Covers, Layout, footholds, Spaces

Checking Construction, Covers, Layout, footholds, Instrument position and

Orientation, Operating-range Display

Lubricating Position of lubricant inlet, construction, height, footholds, Lubricant

outlets, spaces

Tightening Covers, Construction, Layout size,space

Operation Machine Layout, Position of valves, Switches and levers, Footholds

Adjustment Position of pressure gauges, thermometers, flow meters, moisture

gauges, vacuum gauges, etc.

Table (7): Inaccessible Places

51
4) Contamination Sources

Product Leaks, Spills, Spurts, Scattering, Overflow

Raw Material Leaks, Spills, Spurts, Scattering, Overflow

Lubricants Leaking, Spills, Seeping oils, Hydraulic fluids, Fuel oils, etc.

Gasses Leaking compressed air, gasses, steam, vapors, exhaust fumes, etc.

Liquids Leaking water, Hot, Cold, half finished products, waste water, Leaking
supply lines, etc.

Scrap Flashes, cuttings, packing materials, and non conforming products.

Others Contaminants by people & Forklifts, Infiltration through cracked walls,

broken windows etc.

Table (8): Laser Machine Print Format for 6208

5)Quality Defect Sources

Foreign Matter Dust, Rust, powder, chips, moisture, wire scraps, wood pieces, paper
pieces, stones, etc.

Shock Dropping, Jolting, Collision, Vibration

Moisture Too little or too much, Infiltration

Gain Size Abnormalities in Screens, Compressed air separators, centrifugal

separators

Concentration Inadequate warming, heating, compounding, mixing, evaporation, string,

etc.

Viscosity Inadequate warming, heating, compounding, mixing, evaporation, string,

etc.

Table (9): Quality Defect Sources

52
6)Unnecessary and Non-Urgent Items

Machinery Pumps, fans, compressors, columns, tanks, etc.

Piping equipment Pipes, hoses, ducts, valves, dampers etc

Measuring Temperatures, pressure gauges, vacuum gauges, ammeters, etc.

Instruments

Electrical Instruments Wiring, piping, power leads, switches, plugs, etc.

Jigs and Tools General tools, cutting tools, jigs, moulds, dies, frames, etc.

Spare parts Standby equipment, spares, permanent stocks, auxiliary materials,

etc.

Makeshift repairs Tape, String, wire, metal plates etc.

Table (10): Unnecessary and Non-Urgent Items

7)Unsafe Places

Floors Unevenness, cracked, holes, projections, peeling, wear of steel checker

plates, slipping

Steps Too steep, irregular, slipping, missing handrails, etc.

Lights Dim, out of position, dirty or broken covers, no explosion proofing, etc.

Rotating machinery Displaced, fallen oil or broken covers, not safe for emergency, missing
emergency stop devices.

Lifting Device Wires, hooks, brakes and other parts of cranes and hoists etc.

Others Special substances, solvents, toxic gasses, insulating materials, danger

signs, protective clothing, etc.

Table (11): Unsafe Places

53
1 S:

The purpose of Sorting is to distinguish between necessary things and unnecessary things
and systematically dispose of what you do not need. Sorting is not a one-time activity rather
it should become a regular practice.

What are the findings in 1S?

1.Obsolete: Parts not required as the design has become obsolete.

2.Defective: Parts cannot be used as it is which needs some correction

3.scrap: Scrap items not thrown out.

4.Not in place: Kept at wrong place

5.Unnecessary: Extra / not useful.

6.Mix-up: Mixed parts which needs attention

7.Un-identified: Nobody’s baby

8. Items not used for last six months

9. Obsolete documents, not used but still stored for a long time.

10.Others: Even what is this part?

Search Here Look at

● Floors ● Tools
● Halls & Stairways ● Jigs
● Closets ● Fittings
● Around Machines ● Paperwork
● Inside cabinets ● Books/Manuals
● Back rooms ● Chairs/Benches/Desks
● Work areas ● Excess materials
● Bulletin Boards ● Scrap or defective products
● Desks ● Shipping materials
● Toolboxes ● Chemicals
● Shelves ● Stationary/office supplies
● Up/Down & Around ● Wall hangings/Posters

Table (12): Search-Location Table

54
2S:

It is the way of eliminating search

The main objective of Seiton is Place for Every Useful Thing & Every Useful Thing in its Place.

Arranging things in a systematic manner results in reducing Search time.

It is a creative process.

Set in Order- Place for everything and Everything in its Position (PEEP)

For PEEP one must ensure that it must be-

● Search free
● Bend free
● Climb free
● Count free

Also insure that-

1. Point of use
2. Fixed Location
3. One Touch pick-up
4. Mistake proofing

4 R’s for implementing PEEP-

● Right item
● Right place
● Right time
● Right quantity

While implementing PEEP we need to follow some rules that are the things which I use
every day must be close to me, the things which I use sometimes must not be too far from
me and the things which I use sporadically must be at a specified place.

Some PEEP’S Implemented on DGBB CH.12

Inside the tooling trolley all tools are placed at its right place.

55
 Pic (40): Document Stand: PEEP Implementation

Pic (41): OR Buffer : Marking done

3S:

Objectives for 3S i.e. Seiso are safe Workplace, Hygienic Workplace and Environment
friendly Workplace. It works for-

● Wet to Dry
● Dark to Bright
● Nothing on Floor
● Leak to Fix
● Congested to Free Space
● Unsafe to safe
● Hard to Access to easy to Access

56
Shine is nothing but clean and maintains our workplace where we identify and eliminate the
source of contamination which includes no dirt, no leakage and no spillage of components
on the floors, walls and aisles. We need to implement cleaning routines and to implement
its frequency and responsibility we have created a system of housekeeping.

Where we have a housekeeping check sheet to maintain all things related to cleaning and
maintaining.

4S-Standardize:

Standardization is must to maintain the improvements made in above all 3S standards

The Standardize step is a bridge between the first three steps (Sort, Straighten, Shine) and
the last step (Sustain). In this step your goal is to capture best practices for 5S as
standardized work for your team. Standardize makes 5S repeatable. It transforms 5S from a
one-off project to a reproducible set of activities.

Examples of standardize:

● Write down your 5S practices.

● Create “implementation” checklists and “audit” checklists.

● Create “kits” that contain the materials needed to perform a specific task.

● Use photos and other simple visuals as part of your training materials.

● Build a schedule for tasks.

Depending on the workspace, a daily 5S checklist or a chart might be useful. A posted

schedule indicating how frequently certain cleaning tasks must occur and who is responsible
for them is another helpful tool.

Initially, people will probably need reminders about 5S. Small amounts of time may need to
be set aside daily for 5S tasks. But over time, tasks will become routine and 5S organizing
and cleaning will become a part of regular work.

5S-Sustain

Sustain is necessary to bring a cultural change in the organization which is achieved through
Total Employee Involvement. Ways of sustenance or Holding Gains:

57
 ● Progress monitoring through Audit Scores
● Visual communication through Fixed Point Photography
● Continuous Training to all levels
● Periodic Audits at all levels
● Encouraging house-keeping projects through Total Employee Involvement (TEI).

There are different types of deviations observed on channel such as:

i. 1S Deviation
ii. 2S Deviation
iii. 3S Deviation
iv. Air Leakage
v. Coolant Leakage
vi. Oil Leakage
vii. Product Leakage
viii. Unsafe Condition

5
DGBB CH12 5S Operations:

A total of 61 Deviations observed on DGBB Channel no.12 which were classified into the
above types-

Completed Pending Total

1s 4 2 6

2s 10 3 13

3s 28 9 37

Unsafe condition 1 0 1

Unwanted display 0 0 0

Product leakage 3 1 4

Table (13): Deviation Table for DGBB CH12

There were a total of 61 deviations observed out of which 46 are closed and 15 are open.
Some of the major/unsafe deviations are mentioned below:

56
 Pic (42): Before (L), After (R) FSF 2217

Machine name: FSF 2217

Deviation: Coolant leakage from outlet

Solution: Provided metal guard at outlet.

Pic (43): Before (L), After (R) Oiling A

Machine name: oiling A

Deviation: Oil over flow from table

Solution: Tray is place with some extra hight.

5
 Pic (44): Before (L), After (R) SSB 62(2207)

Machine name: SSB 62 (2207)

Deviation: Coolant leakage from outlet pipe.

Solution: Structure of plate is changed.

Pic (45): Before (L), After (R)

Location: Near OR Loader

Deviation: Tooling trolley is not on proper place.

Solution: Trolley is on proper place.

5
Customers & Applications:
Bearing Type Customers Applications

BB1-3191 [CH- 03] 1. Jhon Deer India Ltd  Transmission Tractor

(OD Range 59-72mm) 2. Dana India Ltd  Differential Gear Box
RE Tractor

6308 [CH-04] 1. Jhon Deer India Ltd.  Transmission Tractor

(OD Range 72-100mm) 2. Kerla Agro Machinery  Differential Gear Box
3.VST Tillers Tractors Ltd. Tractor
4. Escorts Ltd.  Motor
5.Exports
6.Vsm

6310 [CH-05] 1. Kerla Agro Machinery  Differential Gear Box

(OD Range 85-140mm) 2.Tractor & Farm Eqpt. Ltd. Tractor
3.Force Motor Ltd.  Differential Gear Box
Truck
 Conveyors

63006 [CH-01] 1. Dana India Ltd  Differential Gear Box

(OD Range 50-68mm) RE Tractor
2. Exports
3.Vsm

6206 [CH-02] 1. Tata Motors Ltd.  Transmission Two

(OD Range 60-62mm) 2. VST Tillers Tractors Wheeler
Ltd. 3.Sona Koyo  Differential Gear Box
Steering System Ltd. Truck
4.Maruti Suzuki India Ltd.  Radiator Fan
5.TVS Delphi Ltd.  Electric Motor
6.Laxmi Hydraulics Ltd.  Water Pump
7.Hero Motors Ltd.  Steering Car
8. Piaggiao Vehicles Ltd.
9. Exports
10.Vsm

59
Results:

After clearing out major and minor deviations including 5S deviations and deviations listed
by the SKF Business Excellence Team during routine 3S Audits, the channel has been
elevated to 3S level which includes leak free machines, cleaning, no excess material present,
zero BAD, implementation of safety standards and awareness among operators for 5S and
‘MY MACHINE’ concept.

Pic (47): 5S Score Trend for DGBB CH02

From the above image, the 5S score trend went from 65-70 to a stable above 90 score.

60
Conclusion:

3S implemented on DGBB CH02. From the 5S implementation on channel, it can be

concluded that for elevating channel status to 5S, co-operation from all departments from
Maintenance, Operators, Housekeeping, Supervisors, BE, Fabricators etc is crucial. Every
operator must know the importance of MY MACHINE, Problem Elimination, Mindful
Cleaning (Cleaning with Meaning) and awareness about 5S Methodology and AM.

Implementation of standards, self-discipline, elimination of deviations, abnormalities is

important to ‘Sustain’ the level of channel.

61