Enhancing the productivity implementing triz method

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Enhancing the productivity implementing triz method

Rajit Singhal, Sanjay Mohite, Sanjay Goyal

Mechanical Engineering Department, Maharana Pratap College of Technology, Gwalior, Madhya Pradesh, India.

E-mail: [email protected], [email protected],

Abstract: This work is to increase the productivity of Drum Back Plate by minimizing the rejection rework in production of Drum Back Plate in Admach Auto India Ltd. Faridabad (Haryana).

Author has opt out various operation of work which is performed during the production work in plant. These operations are Inspection, Shaping, Punching, Knurling, Trimming, Angular Punching. Author first observed the rejection of Drum Back Plate due to Denting, Burr, Height of Bose and Cracking. Aiming at the mitigation in rejection rate of plate author used TRIZ Methodology. In this methodology a matrix of 39 feature is used to find the most suitable solution of identified problem. This solution is one solution among the 40 principle of TRIZ implementing the observed solution, author found that the rejection rate of drum plate and rework has reduced. In this way author save 78% rejection. Using more option of optimism tool one can achieve the target of zero percent rejection.

Keyword: Triz, Angular Punching, Trimming, Knurling, Denting, Shaping, Burr, Cracking

INTRODUCTION

Today many big organizations involved in producing products with high degree of customer satisfaction keeping maximum productivity. The success of a product or service largely depends on how they meet the customer‟s demand. More

efforts are employed in getting the information necessary for determining what the customer truly wants. A continuous improvement is required to catch up with rapidly changing development throughout the world understanding of customer

needs leads to successful product and shorter development time. A poor product definition commonly leads to either failure of that product in market or extended product development time.

Cost reduction and continuous improvement are becoming increasingly crucial to the future industry and also for existing ones. The new competition is in terms of reduced cost, improved quality, higher product performance with good service and wider range of products in large scale industries. Work is distributed among the trained employees according to their efficiency which improves the productivity.

Also these industries use huge capital with latest technologies which resulted in raised productivity and reduced cost per head.

TRIZ METHOD

History of TRIZ

1. TRIZ is a Russian acronym meaning

“theory of inventive problem solving”. In 1946, Generich Altshuller, the founder of TRIZ.

2. TRIZ has 6 classical ways to resolve

“physical contradiction” and these are known as “separation principles for “physical contradiction”.

a. Separation in space b. Separation in time

c. Separation at micro level; transition to

sub

system

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d. Separation at macro level; transition to

super system

e. Separation in condition

f. Convert to technical contradiction

3. He defined 39 basic properties and 40 principles for solving problems containing contradiction in any two of 39 properties. This he gave in the form of a contradiction table of size 39*39 with each cell giving up to 4 principles. That may be used to eliminate the contradiction.

LIST OF THE 40 PRINCIPLES

LIST OF THE 39 FEATURES

CASE STUDY

The main purpose of this study is to find out the

factors which will be fruitful in achieving leanness in manufacturing under all kinds of small scale industries. Effective managementof a small scale industry is viewed as, manufacturing, reducelead time, customer response and improving product quality, so our work is focused to fulfill following objectives.

• To make lean manufacturing

• To reduce the cost of product

•

To Increase the production

OPERATION ON PLATE

• Inspection :Measuring

• First Draw : Shaping

• Second Draw :Punching

• Third Draw : Knurling

• Forth Draw: Trimming

• Final Draw :Angular Punching

Fig. 1st Draw Shaping

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2nd Draw Punching

3rd Draw Knurling

4th Draw Trimming

Final Draw Angular Punching

CAUSE OF REJECTION

Denting 40% of Total Rejection Burr 35% of Total Rejection Height of Bose 20% of Total Rejection Cracking 05% of Total Rejection

1.Denting

Que 1 :- Who has the problem ? Ans :- Manufacturer

Que 2:- What does the prob. To be seem? What are the resources ?

Ans :- Denting on plate, Resources of problem may be vendor, operator, machine tool.

Que 3 :-When does the problem occur ? Under what circumstances ?

Ans :- After punching process, the surface finish of either plate or punching tool is not good.

Que 4:- Where does the prob. Occur ? Ans :- During punching.

Que 5:- Why does the problem occur ? What is root causes ?

Ans :- Hardness of material of plate and surface finish of tool may not appropriate.

Que 6 :-How does the problem occur ? How can be solve ?

Ans :- Gap between the surface of plate and punching tool is not uniform. We can solve this problem By

• Improving the surface finish of punching

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tool and plate.

• Improving the hardness of material.

Maintaining uniform the gap between tool and plate ,removing foreign particle.

FINAL PROB.:- Surface of either tool or plate is not finished properly as per requirement.

PHYSICAL CONTRADICTION:- There is no physical contradiction in Denting process.

Convert it to a technical contradiction.

.Refer to the contradiction matrix.

USE CONTRADICTION MATRIX

ACCORDING TO TRIZ SOLUTION:-

13: (a) Invert the action used to solve the problem.

(b) Make movable part fixed and fixed part movable.

(C) Turn the object upside down.

02 : (a) Separate an interfering part from object using fiber optics.

28: (a) Replace a mechanical means with sensory means.

(b) Use electric ,electromagnetic, magnetic field to interact with object.

(c) Change from static to movable field.

(d) Use field in conjunction with field activated particles.

MORE SUITABLE ANSWER IS:-

(i) Separate the Interfering parts using fiber object.

CONCLUSION : Using a thin polythene between the tool and the plate during the stamping process

in first draw we can mitigate the denting in work piece.

BURR FORMATION Que 1 :- Who has the problem?

Ans :- Manufacturer

Que 2:- What does the prob. To be seem ? What are the resources?

Ans :- Cutting Edges are not smooth. It has uneven level .Resources may be the material machinability or the cutting ability of cutting tool Que 3 :- When does the problem occur ? Under what circumstances?

Ans :- During Trimming process, cutting chip of material is not being cutoff properly

Que 4:- Where does the prob. Occur?

Ans :- At trimming Edges

Que 5:- Why does the problem occur ? What is root causes?

Ans :- Quality of cutting tool may not appropriate. Material property of work piece and cutting ability of trimming tool.

Que 6 :How does the problem occur? How can be solve ?

Ans :- Shearing of material is not good. Multi shearing action can remove the burr

FINAL PROB.:-

Shearing action material is not taking place properly, It causes the burr at the cutting edges of work piece.

Convert it to a technical contradiction .Refer to the contradiction matrix.

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05 (a) Bring closer together identical or similar object

(b) Make operation contiguous or parallel 34 (a) Make portions of an object that have fulfilled their function go away or modify

these directly during operation

(b) conversely, Restore consumable part of an object directly in operation

04. (a) change the shape of object and increase the symmetry of object

(b) If an object is asymmetrical ,Increase its degree of asymmetry

10 (a) Perform before it needed the required change of object

(b) Pre arrange objects such that they can come into action without loosing time

MORE SUITABLE ANSWER IS:-

(a) Bring closer together identical or similar object

(b) Make operation contiguous or parallel CONCLUSION:-Both punching tool and the plate should close without any gap .Fixture part is consist of female part of punch tool.

4. Cracking in Plate

Que 1 :- Who has the problem?

Ans :- Manufacturer

Que 2:- What does the prob. To be seem? What are the resources?

Ans :- Crake generate the plate during punching .Resources may be the material of plate or the

non uniform force of punch

Que 3 :- When does the problem occur ? Under what circumstances?

Ans :- During punching process ,Because non uniform distribution of forces .

Que 4:- Where does the prob. Occur?

Ans :- In week section of plate.

Que 5:- Why does the problem occur ? What is root causes?

Ans :- Ductility of material of plate or applied force of tool is not appropriate.

Que 6 :- How does the problem occur? How can be solve ?

Ans :- Due to non uniform of stress on plate

thickness , failure in plate occur. Mitigating the stress ductility of plate may be increase

FINAL PROB.:- Material property is not appropriate as per the operation

Convert it to a technical contradiction .Refer to the contradiction matrix.

02 Separate an interfering part or property from an object

35. parameter change

a. change an object‟s physical state (e.g to a gas ,liquid or solid)

b. change the concentration or consistency c. change the degree of flexibility

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d. change the temperature

40. composite material

a. change from uniform to composite (multiple) material.

MORE SUITABLE ANSWER IS:- (i) change the concentration or consistency (ii) change the degree of flexibility

CONCLUSION:- Cracks is depend on toughness and ductility of plate. We can change the ductility of plate to avoid the crack

Result

 For Dent removal we can use the separator between the mating surface it may be a thin Polythene or Ranform Mazan oil between the tool and the plate.

 For Burr removal we can Set Punch Frequency.

 For mitigating uneven Height of Boss, Solid & Hard Sim provide in bottom segment in place of soft Sim, It reduces dimension variation.

 To avoid Cracking, Hardness of Raw Material Grade may change and supplier should be instructed to supply same grade of material.

CONCLUSION:- After application of TRIZ to increase the productivity of Drum Back Plate following result have been come out.

1. Rejection of Drum Back Plate due to Denting can be reduced by using a Polythene in between the punching tool and blank of Drum Back Plate.

2. Rejection of Drum Back Plate due to Burr can be reduced by applying Multiplied cutting tool in Trimming operation.

3. Rejection of Drum Back Plate due to Height of Boss can be reduce by controlling movement of punch and

using a fixture to constraint movement of punch.

4. Rejection of Drum Back Plate due to Cracking can be reduce by modification of material property of drum back plate using the above said solution company has mitigate 78 % of rejection has been saved .

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