Weld groove

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LT-MHPS Turbine Generators Pvt. Ltd.
Quality Circle
UNIQUE
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Introduction of Quality Circle
UNIQUE
Facilitator Mr. Vimal Awasthi
Leader Mr. Nikunj Khatri
CHIRAG
AJAY
JAYDIP
VIPUL
JIGAR
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Details of Quality Circle
Summary of Quality Circle progress Summary of Quality Circle progress
Name of Quality Circle UNIQUE
Date of Inauguration 23/12/2012
Meeting time 1st Shift (130 pm To 230 pm) 2nd Shift (500 pm To 600 pm) 3rd Shift (215 am To 315 am)
Meeting day FRIDAY
No. of problems identified 85
No. of problems solved (total) 49
Month Jun 13 July 13 Aug 13 Sep 13 Oct 13 Nov 13 Dec 13 Jan 14 Feb 14 Mar14
No. of Meeting  4  4  4  3  3  4  4 4 3 4
No. of Meeting (Scheduled) 4 4 4 4 4 4 4 4 4 4
Attendance in  100 100  84  84  84  100  84  84 100 100
No. Problems Solved  2 1  2  2 2  1  1  2 1 1
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Zero Accident
Zero Rejection
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Problem of A-category
NO. Problem Identified Status
1 Tool offset Solved
2 Work offset Solved
3 Body width variation in blade solved
4 Outer ring and inner ring variation in blade In-process
5 Pitch variation in blade In-process
6 Weld groove variation in blade In-process
7 Jig groove variation in blade solved
8 Total length variation in blade Solved
9 Fixture problem for end machining the diaphragm blade solved
10 Tool breakage problem Solved
11 Drawing study of workmen  
12 Blade traceability Solved
13 HSK63 Tool boy is to be modify  
14 wastage oil drum place has to be fixed Solved
15 s-blade outer ring height variation to be control Solved
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Problem of A-category
NO. Problem Identified Status
16 hard roller is to be replaced Solved
17 Dent mark on fir tree blade to be eliminate  
18 machine identification sticker on all machine Solved
19 Halogen light numbering to be standardized solved
20 R-blade end cutting fixture to be develop in band saw solved
21 R-blade end machining fixture to be modify for butting solved
22 Washing room liquid tank problem solved
23 profile dimension variation after 5-axis machining.  
24 standard size to be prepare for marking the blade traceability number on laser machine solved
25 SOP Training on blade traceability to bladeshop workman solved
26 No crane is available from material storage to robot loading station solved
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Problem of B-category
NO. Problem Identified Status
1 Regrind tool problem solved
2 Telescopic cover guard damaged in BM304 solved
3 Pocket no 16 not working in BM306 solved
4 Jig and fixture accessories to be available solved
5 L-0-C profile machining problem solved
6 X-axis telescopic cover guard having abnormal noise solved
7 Air not coming through spindle in BM318 solved
8 Tool data error coming in all Mazak machine solved
9 Only 2 air grinder working out of 6 air grinder solved
10 Z-axis not working in auto mode in BFW-2 m/c. solved
11 Air pressure not coming properly in polishing area solved
12 1 no's scientific calculator required solved
13 coolant filling system leakage is to be solved solved
14 Nozzle end cutting to be standardized solved
15 Dia 06 Shrinkage adaptor problem  
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Problem of B-category
NO. Problem Identified Status
16 Dia 08 Shrinkage adaptor problem  
17 Dia 12 Shrinkage adaptor problem  
18 Tool ID has to be standardized solved
19 serration machine has to be fixed solved
20 Mazak machine Operator stand is not proper  
21 coolant to be change in shrinking induction machine  
22 shrinking induction machine handle is not working solved
23 spring is not available in zoller machine for locking the adaptor  
24 robot connection to be separate while switch on and switch off.  
25 coolant leakage problem in makino machine  
26 BM319 Machine fan is required solved
27 belt joint problem  
28 Requirement of Customize M code for Mazak Machine solved
29 ac not working in Tool presetter room solved
30 4000220 belt required  
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Problem of B-category
NO. Problem Identified Status
31 Drinking water not coming from cooler in shop  
32 tail stock pressure release in makino machine solved
33 green light not working in BM318 machine  
34 Proved program to be update in DNC solved
35 Fan is required near surface table of BM305  
36 Light is required near surface table of BM303  
37 air pressure not coming smoothly in grinder master  
38 Lock pin is to replace in Robot loading station  
39 Table position to be changed near robot loading station  
40 Robot not running in auto mode in all four Liechti while loading cycle.  
41 Robot fault alarm in auto mode  
42 Chuck conformation not ok in robot loading station  
43 program position not ok wrt apc in BM304  
44 Robot loading Capacity to be define  
45 Clamping is not proper in robot gripper  
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Problem of C-category
NO. Problem Identified Status
1 blade movement problem due to step on floor solved
2 8 qty Lang chuck key to be required in Liechti machine. solved
3 Viewport window to be replace in BM305  
4 6 qty Pencil grinder tool required for transit radius polishing solved
5 Dia 25 mm roller not available.(solved) solved
6 Dia 75 mm SUMITOP wheel required for transit area cleaning. solved
7 Engraving machine required. solved
8 4 qty Machine vise required. Solved
9 Hydraulic pressure gauge is required in makino machine for hydraulic fixture. Solved
10 Exhaust fan system is required in makino machine
11 crane position to be change for heavy bar loading on bandsaw machine and bfw machine
12 coolant valve is required in BM 320 machine
13 noise pollution from dust collector
14 wire protection cover required for HCU of Robot
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Summary of problem List
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End-Machining Operation For Diaphragm Type Blades
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Milestone chart for End-Machining Process
Plan
Actual
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Problem Description
Three type of setup used for end machining
operation in diaphragm blades.
Root side weld groove operation Setup-2
Shroud side weld groove operation Setup-3
Diaphragm type blade
End machining operation Setup-1
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Setup sheet as per process established
Root weld groove
Total length
Shroud weld groove
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Past Data Analysis on
End machining operation
Operation list Tools used for operation Setup time for fixture setting/ stage Trial time for first blade prove out/ stage
1.End machining Dia50R6Dia50R0.8 5 Hrs. (as per pps.) 4.5 Hrs.
2.Root side weld groove machining Dia12endmill form cutter 5 Hrs. (as per pps.) 1.5 Hrs.
3.Shroud side weld groove operation Dia12endmill form cutter 5 Hrs. (as per pps) 1.5 Hrs.
Total time 5 diff tools used 15 Hrs. 7.5 Hrs.
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4W and 1H Analysis
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4W and 1H Analysis
Three setup used for end machining and weld
groove operation
WHAT
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4W and 1H Analysis
At 3-axis machines
During end machining and weld groove operation
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4W and 1H Analysis
VMC operator
As per the process established
HOW
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Cause and Effect Diagram
Man
Setting time is high for multiple fixture setup
Trial time increased in multiple setup
Blade loading and unloading time is increased
Machine
Blade setting time is increased
Blade measurement time more
Machine accident chance due to multiple trial in
different setup
Dent and scratch mark on blade
Three types of setup for end machining weld
groove operations
Risk of blade deviation and rejection
Tool changing time is high
Form cutter cost
Uses of fixture parts is more
Material
Regrinding time is high for form cutter
Sequence of operation is high
Numbers of cutting tool using is high
Method
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Cause validation
SR no. Man related Causes Valid
1 Setting time is high for multiple fixture setup Y
2 Trial time increased in multiple setup Y
3 Blade loading and unloading time is increased Y
4 Blade setting time is increased N
5 Blade measurement time increased N
6 Dent and scratch mark on blade increased N
7 Trial loss hours increased N
8 Risk of blade deviation and rejection N
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Cause validation
SR no. Machine related Causes Valid
1 Machine accident chance is high due to multiple trial in different setup N
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Cause validation
SR no. Method related Causes Valid
1 Uses of fixture parts is more Y
2 Tool changing time is high N
3 Regrinding time is high for form cutter Y
4 Sequence of operation is high Y
5 Numbers of cutting tool usage is high Y
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Cause validation
SR no. Material related Causes Valid
1 Form cutter cost is high N
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Rating for Valid causes(1-8)
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Sr Valid causes Chirag Ajay Vipul Jigar Jaydip Total
1 Setting time is high for multiple fixture setup 6 7 6 6 8 33
2 Trial time increased in multiple setup 8 8 8 8 6 38
3 Blade loading and unloading time is increased 7 5 7 7 3 29
4 Blade setting time is increased 5 2 1 1 5 14
5 Uses of fixture parts is more 1 1 2 2 4 10
6 Regrinding time is high for form cutter 3 3 3 3 1 13
7 Sequence of operation is high 4 6 5 5 7 27
8 Numbers of cutting tool usage is high 2 4 4 4 2 16
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Pareto analysis for Valid causes
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Why-Why analysis
1.Trial time increased in multiple setup
Why?-blade to be prove out in each
setup. Why?-no proper method.
Root cause multiple setup
Action Reduce the prove out time with single
setup
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Why-Why analysis
2. Fixture setting time is high.
Why?-three types of setup used. Why?-no proper
method.
Root cause Multiple setup
Action Reduce the no. of setup
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Why-Why analysis
3.Blade loading and unloading time is high.
Why?-loading and unloading multiple
times. Why?-multiple fixture used.
Root cause multiple setup
Action Reduce the no. of setup
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Why-Why analysis
4. Sequence of operation is more.
Why?-multiple setup used. Why?-special form tool
used.
Root cause Multiple setups
Action change the process in single setup.
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Why-Why analysis
5. More numbers of tools.
Why?-multiple setup used Why?-form tool used for
weld groove.
Root cause special form cutter.
Action use standard tools.
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Problem-RCA-Action
Sr. Problems Root- Cause Action Plan
1 Trial time increased in multiple setup. Multiple setup Reduce no. of setups
2 Fixture setting time is high. Multiple setup Reduce no. of setups
3 Blade loading and unloading time is high. Multiple setup Reduce no. of setups
4 Sequence of operation is more. Multiple Setup change the process in single setup
5 Numbers of cutting tools is high. special form cutter Use standard tool
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REDUCE THE NO. OF SETUPS ???
ELIMINATE THE FORM CUTTER USAGE
BRAIN STORMING
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Action Plan
1.Eliminate the use of form cutter with Disc mill
cutter
Form cutter
Dia 160mm Disc mill cutter
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Cross checking tool weight
It is 12.25 kg
Tool weight measurement
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Cross checking tool weight and Diameter with
Machine specification
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Trial successfully done for ATC operation
M/c NoBM 319
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Dia 160 mm Disc mill cutter accepted for operation
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Action Plan
2.Reduce no. of setups with using disc mill
cutter in single setup
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New Process Implementation in single setup on VMC
Roughing cutter
Operation 1 Roughing
Finishing cutter
Operation 2 Length Finishing
Disc mill cutter
Operation 3 Weld Groove
Final Output
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Setup sheet as per new process established
Setup sheet for total length and weld groove
operation on VMC machine.
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Tool sheet as per new process established
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Production Planning Sheet (PPS) as per new
process established
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Single Setup Roughing operation
Roughing Operation Cutter 50R6 Bullnose
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Single Setup Finishing operation
Length Finishing Operation Cutter 50R0.8
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Single Setup Weld groove operation
Weld-Groove Machining Cutter Dia 160 mm Disc
mill cutter
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Before-After Comparison
Sr. Parameter Before After
1 No. of setups 03 01
2 No. of programs/trials 03 01
3 Loading/Unloading Times 03 01
4 No. of Cutter types 05 03
5 Form cutters 03-04 types(design) -NR-
6 Cycle time reductions -NR- 30-40 time reduction
7 No. of operations 6 3
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Tangible Benefits
1.Cost Savings
1 Elimination of Form Tool Rs 9.9 Lakh/Project
2 VMC (Cycle time Reduction) Rs 14.5Lakh/project
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Tangible Benefits
2. Process Improvement
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Intangible Benefits
1.OPERATOR SKILL LEVEL IMPROVEMENT. 2.MORALE
IMPROVEMENT 3.CUSTOMER SATISFACTION
4.PRODUCTIVITY IMPROVEMENT.
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QC tools
BRAIN STORMING
4W and 1H Analysis
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Way Forward
To Eliminate the error while job loading in APC
with Robot
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