jignesh

1. INTRODUCTION

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1.1 INTRODUCTION TO LARSEN & TOUBRO LIMITED

Larsen & Toubro Limited (L&T) is India's largest engineering and construction

conglomerate with additional interests in electrical, electronics and IT. A strong customer-

focus approach and constant quest for top-class quality has enabled L&T to attain and sustain

leadership position over 6 decades. L&T enjoys a premiere brand image in India and its

international presence is on the rise, with a global spread of over 30 offices and joint ventures

with world leaders. Its large technology base and pool of experienced personnel enable it to

offer integrated services in world markets.

Larsen & Toubro Limited (L&T) is a multi-dimensional, US$ 7 billion conglomerate

employing 45,000 people across its 130 offices and 30 factories all over the world. L&T

holds the distinction of being India's largest engineering conglomerate and having an

engineering resource pool of over 11000 engineers.

L&T was founded in 1938 by two Danish engineers- Mr. Henning Holck-Larsen and Mr.

Soren Kristian Toubro. L&T, with its headquarters in Mumbai, has an engineering legacy of

seven decades. Its commitment to quality and distinguished record in customer service has

enabled it to establish a leadership position in most of its business ventures viz. Engineering

& Construction, Heavy Engineering, Electrical and Electronics, Industrial Products and

Information Technology. Its large technology base and pool of experienced talent enables it

to offer integrated services in the world market.

L&T’s record of outstanding achievements coupled with its European name lead many to

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believe that it is the Indian arm of foreign corporation. The truth is that the genesis was very

much on Indian soil, in fact in a tiny room in south Mumbai just a few hundred meters from

where the corporate headquarters now stands. Two engineers set it up from distant Denmark

– Henning Holck Larsen (also former Chairman ‘Emeritus’) and Soren Keirsten Toubro, men

with the infallible prescience of visionaries and the daring of entrepreneurs. They also shared

an abiding infatuation with the country that was to become an adopted homeland–India. On

May 1, 1938, they set up a partnership firm named Larsen & Toubro to repair and market

Danish dairy equipments and… A LEGEND WAS BORN!

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1.2 INTRODUCTION TO ELECTRICAL & ELECTRONICS DIVISION (EBG)

Electrical & Electronics Division (EBG) is one of the core businesses of Larsen & Toubro

Limited (L&T). This division is engaged in the business of low voltage Switchgear products,

Electrical systems, Energy meters, Medical equipment, Petroleum dispensing pumps and

Automation solutions.

This division is the largest manufacturer of low voltage switchgear and control gear in India

and enjoys market leadership amidst competition from international players. A countrywide

network of Stockiest takes care of products’ distribution along with a widespread service

network. Offices of the L&T Group companies, located around the world, support the

requirements from export market.

Strategic Business Units (SBUs) of the division have operations at five locations in India:

Electrical Standard Products (Operations at Mumbai & Ahmednagar)

Electrical Systems & Equipment (Operations at Mumbai & Faridabad)

Petroleum Dispensing Pumps & Systems (Operations at Mumbai)

Medical Equipment & Systems (Operations at Mysore)

Metering & Protection Systems (Operations at Mysore)

L&T manufactures a range of custom-built boards to meet the power distribution & motor

control needs in various industrial sectors. L&T offers the widest range of low-tension

switchgear products in the country. It has resulted in the development of innovative & trend

setting solutions for increasing the safety, reliability as well as ease of operation &

maintenance of equipments.

L&T is leading supplier of petroleum dispensing pumps in India. The range includes

standard duty, heavy duty, single/dual nozzle, mechanical/electronic display dispensing

pumps and multi product dispensing (MPD) units for dispensing up to 5 grades of fuel. L&T

offers complete solution for design, engineering, installation and commissioning of Auto

LPG dispensing Systems.

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1.3 INTRODUCTION TO ENGINEERED TOOLING SOLUTIONS (ETS)

Established in 1964, ETS is an integral part of Electrical and Electronics Division of

Larsen & Toubro Limited. As one of the most modern Tool Rooms in India, it provides

Engineered Solutions for a wide spectrum of tooling requirements. Leveraging upon the

domain knowledge acquired over four decades along with a cutting edge lead in the latest

technology, L&T's ETS offers a one stop shop for tooling, serving a wide range of Plastic

Moulds, Press Tools, Pressure Die Casting Dies, Jigs & Fixtures, Gauges etc.

Today in 2007, having a solid foundation of over Four Decades of Experience and

equipped with World class Design and Manufacturing Facilities along with Six Sigma,

Value Engineering and “Six Thinking Hats Methodologies” ETS provides customers a

"TOTAL TOOLING SOLUTION " and above all.... “TOTAL DELIGHT”

L&T’s Tool Engineering and Design Department at Mumbai is equipped with CAD

systems, and is also linked to the integrated CAD facility. Tool manufacturing facilities at

Mumbai and Ahmednagar are equipped with Computer Aided Manufacturing facilities

(CAM), high-precision machines like jig boring, vertical machining centres, CNC jig

grinder, CNC wire erosion machine, CNC surface grinder and CNC spark erosion

machine. Set up over 40 years ago, the centre has over 300 trained engineers and

technicians, excellent networking of computers, and a high level of CAD-CAM

integration. With continuous investments to keep pace with world-class tool room

technology and its thrust on technical developments, L&T’s Tool Room facilitates

introduction of new products in the shortest possible time, enhancement of product

quality, and supply of complex and critical items for various projects.

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1.3.1 DEPARTMENTS IN ETS

Powai tool room is composed of

Tool Engineering and Design (TED)

Tool Management Group (TMG)

General machine shop

Special machine shop

Fitting shop

Heat treatment shop

Inspection department

Plant maintenance department

Raw material stores

Tool Administration Cell (TAC)

TOOL ENGINEERING AND DESIGN (TED)

This department is mainly involved in the design of various productions tooling such as:

Jigs

Fixtures

Press Tools

Moulds

Inspection Gauges, etc.

All the tools designed in this department are manufactured in the tool room shop. TED

can be basically said as the centralized system since all the design of the tools for the

various tool rooms are made at Powai only.

TOOL MANAGEMENT GROUP (TMG)

Planning activities include

Process planning of the tooling

Design of electrodes for manufacturing of the tooling

Production planning and control

Follow up of the jobs

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CAM &Machine Shop

ETS has a Computer aided Manufacturing Dept. where the programs for the machining of

items in the Computer Numerically Controlled machines are extracted from the 3D models of

the items which they receive from TED.

General machine shop has lathe, shaper, milling grinding machines etc. Parts that are possible

to machine on general purpose machines are manufactured in the general machine shop e.g.

rough machining of the base plates, top plates etc. Intricate parts such as cavities in the

moulds, press tools are not made in the general machine shop.

Special machine shop is equipped with all special purpose machines such as CNC jig

grinding machines, jig-boring machines, vertical machining centers, CNC wire erosion and

spark erosion machines etc. Intricate and accurate shapes in press tools, moulds, jigs, fixtures

that require high accuracy and which are not possible to machine in the general machine shop

are manufactured in the special machine shop.

HEAT TREATMENT SHOP

Various types of heat treatments such as hardening, tempering, and case hardening which are

required for the tool components are carried out in this department.

FITTING SHOP

Fitting shop is mainly involved in the assembly work of the entire tool. It is the responsibility

of the fitting shop to maintain the different types of fits mentioned on the tool drawing.

Fitting shop also issues various machining instructions for the individual parts of the tools.

INSPECTION DEPARTMENT

Inspection activities related with various tool components are carried in the inspection

department.

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TOOL ADMINISTRATION CELL (TAC)

Tool administrative cell is responsible for arranging and conducting trials of all tools and

during trial any defects faced has to be rectified by tool administrative cell.

PLANT MAINTENANCE DEPARTMENT

Plant maintenance department is responsible for carrying out the maintenance work related

with all types of machines in the tool room shop.

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1.3.2 OPERATIONAL RESPONSIBILITIES OF VARIOUS

DEPARTMENTS

Tool Engineering and Design (TED)

Register the tool request.

Prepare the tool designs.

Design Discussion meeting with manufacturing shop and initiator.

Prepare job ticket for each tool.

Refine the product designs for the ease of the tooling and manufacturing.

Trial, Trouble shooting and Rectifications (if required)

Tool Management Group (TMG)

Estimation of Tool Cost

Material Planning and Procurements

Process Planning

Scheduling of activities

Monitoring and control of Inventory and Work- in Process

Logistic Support for movement of Tools and material

After completion of tool receive the job ticket from inspection & forward to cost account

department.

Also, maintaining proper relations with the customers and fulfilling the commitments

with them.

Stores

Cut raw material as per the Material Requisition

Issue raw material for further machining

Issue standard components and hardware to the die maker

Receive material from suppliers and issue the same

Enter material issue in the card.

Material planning and inventory control.

General Machine Shop

Initial rough machining as per the process cards

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Send the job to fitting shop.

Fitting Shop

Allocation of jobs to toolmakers

Toolmaker to send the job for further machining with proper inSTRuctions

Assembling of the tool once all items (machined as per requirements) are received.

Special Machine Shop

Allocation of the job to the operator

Carry out the machining as per the instructions from the fitting shop and sending items

back to fitting shop through inspection.

Heat Treatment Shop

Carry out the heat treatment as per the hardness required and the material specification.

Inspection

Inspection of items

Send for the final assembly to the fitting shop.

Inspection of the product

Fitting Shop

Cleaning the job and getting sizes for the mating members.

Get sizes for the mating members.

Send the parts for the post heat treatment operations like grinding spark erosion, wire cut

jig-grinding etc.

Send for inspection.

Final assembly of the tool

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2. PRODUCTS MANUFACTURED IN ETS

Press tools

Moulds

Die casting die

Jigs & Fixtures

Special purpose Tools

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2.1 PRESS TOOL

Press tools are used for manufacturing stamped components from various materials like steel,

stainless steel, brass, copper, glass epoxy laminates etc. Press tools are classified on the basis

of the operation being performed by them. Some of the classifications are

Blanking die

Piercing, flaring and embossing die

Bending die

Compound die

Shaving die

Progressive die

Ribbing die

Fine blanking die

Draw die

Riveting die

Chamfering die

2.2 MOULDS

WHAT IS MOLD?

Molds are used for manufacturing plastic components in large quantity with

consistent quality and reliability. Molded component are generally used in as molded

condition without need for any further processing. Therefore molds have to produce

components of very good quality, reliability, robustness and interchangeability. Mold is an

accessory mounted on a machine to produce components in large quantity. It gives large no.

of components small or big of any shapes that are identical to one another.

ADVANTAGES OF MOULDING:-

Dimensional consistency

High production rate of molded components

Tooling life is very high.

Skill required for operation is low

Raw material is easy to handle

Intricate shapes can be made.

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LIMITATIONS OF MOULDING:-

Lead times of manufacturing moulds are very high.

Each component needs a special tool.

Initial investment is very high.

Tool design and manufacturing required high skill and experience.

Not suitable for low production volume.

2.2.1 INJECTION MOULD

Injection moulding is a manufacturing technique for making parts from both

thermoplastic and thermosetting plastic material in production. Molten plastic is injected at

high pressure into a mould which is the inverse of the product’s shape. After product is

designed by an Industrial designer or an engineer, moulds are made by mould maker (or

toolmaker) from metal, usually steel or aluminum, and precision machine to form the features

of the part. .Injection molding is used for manufacturing a variety of parts, from the smallest

component to entire body panels of cars.

ASSEMBLE VIEW OF INJECTION MOULD

DESCRIPTION OF VARIOUS COMPONENTS OF INJECTION MOULD

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1 Frame:

It consist of the base plate, punch holder, spacer, die housing, punch housing, ejector

plate, holder plate etc. The basic function of frame to hold and support die punch and all

moving item e.g. moving core etc. Basically expect die housing and punch housing full frame

is made up of M.S. die and punch housing are made up of EN8 for better properties.

2 Punch:

Punch it is made up of (H13) OS material. Its hardness is between RC 52-54.This is

responsible to create internal shape of article, so it’s machining should be very accurate. This

should be highly polished, shrinkage allowance and machining allowance is kept on it.

3 Die:

Die is also made up of (H13) OS material. Its hardness is between RC 52-54. This is

responsible to create external shape of article, so it’s machining should be highly polished.

Sometimes to increase its aesthetic value etching or sand blasting is done on it.

4 Hot Runner system or Spur Bush:

It consist of spur bush and Arco sheet the main function of it is to inject the material

from machine i.e. nozzle to tool. By providing a hot runner system addition feature of

wasting material in runner and spur is been eliminated thus lead to saving in material

5 Insert:

In some case it is impossible or very difficult to machine the whole die or punch in

one piece. So it’s necessary to slit the punch or die in number of part and manufactured

independently. Slitting of punch or die must be so chosen that relationship is been maintained

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Fig. 5.2 Flat Ejector pin

and becomes ease for manufacturing. Due care must be taken at manufacturing for avoidance

of tolerance stack. As there is no overall tolerance possible at time of manufacturing.

6 Moving slide:

In some case there is window on side of component this can’t be obtained even by

splitting as it will obstruct the ejection of component out of mould. Hence moving core with

help of dog leg or angle pin is used for movement of moving slide at time of closing or

opening mould. At time of closing angle pin or dog leg pushes core attached to slide to make

cut bearing with insert to form window in component as soon mould retract a spring is

attached to slide and is forced backed to close the component for ejection.

7 Ejection systems:

For every injection mould there is an ejection system for ejecting component out of

the mould. Most of the part forming elements is been provided with draft for ease in ejection

these drafts also take care of warpage in component. But a force is been needed for ejection

of component. This force is been applied by means of ejector pin or blade ejector. Pin ejector

is normally used to provide more area for better ejection. But in case of small rib this mostly

get stuck up in thin walls of insert so blade ejector is been used this ejector pin have rec. cross

section at start and circular at end for sliding. Force for ejection (forward) is provided by the

machine of injection mould by means ejector pin provided and is returned back by means of

spring force after ejection. Level of all ejector pin is so adjusted so that component rest

perfectly otherwise component will toggle with respect to ejection burr in component

8 Holding, Locating & Supporting:

For holding and location of various plate and sub assembly Allen screw and dowel

pin of various size are used this all are consider as standard item of hardware.

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2.2.2 COMPRESSION MOULD

A method of molding in which the molding material, generally preheated, is first

placed in an open, heated mold cavity. The mold is closed with a top force or plug member,

pressure is applied to force the material into contact with all mold areas, and heat and

pressure are maintained until the molding material has cured. The process employs

thermosetting resins in a partially cured stage, either in the form of granules, or preforms.

Compression molding is a high-volume, high-pressure method suitable for molding complex,

high-strength fiberglass reinforcements.

As a process for mass-producing intricate and accurate parts at relatively low cost,

compression molding is the oldest method of mass production in the plastics industry.

Initially it was limited by lack of understanding of materials, particularly under stress, lack of

product design ability and lack of experience in processing. With today’s technology it

represents one of the shortest routes for producing parts from raw material to the finished

product, and is a very important part of today’s industrial scene. The waste that is formed

from thermo set materials can be recycled as fillers.

ASSEMBLY OF COMPRESSION MOULD

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TERMINOLOGY USED IN COMPRESSION MOULD:

1. Base plate: Base plate is the bottom most part of the mould assembly. It is used for

clamping the stationary mold parts of the bottom assembly to the machine platen.

2. Top plate: Top plate is the top most plate. The top position of the mold parts are clamped

by means of screw and also used for clamping the top assembly to the machine platen.

3. Die Housing: Die Housing is used for locating the Die and powder chamber, holding

cartridge heaters.

4. Die: Die is the hollow shape of the mould, where the plastic is formed to shape and also

determines the outer shape of the molding

5. Powder Chamber: Powder chamber is used to locate the raw material on to the mould. The

selection of the powder chamber size must be accurate because it dictates the component

shape. The profile on the topside of the powder chamber will be similar to the profile of the

cavity i.e., length and breadth are same as on cavity.

6. Cavity plate: Cavity plate is a block of steel, which contains the cavity in position, where it

sunk directly into the block.

7. Core: Core is the solid part of the mould, which gives the inside shape to the molding.

8. Core plate: Core plate is the plate where the core is fixed in position and in alignment with

the cavity.

9. Spacers: Spacers are parallels to be used in the mould to facilitate the seating of ejector

assembly, which is used for the removal of the molding and also minimizes the heat loss form

holder plates to bottom and top plate.

10. Cartridge Heaters: Heating elements are required for thermoset material polymerization

reaction i.e. the process of permanent set takes place at a temperature range of 145 to 1750

Celsius. So the tool has to be heated to that and maintained at that temperature

11. Ejector plate: Ejector plate houses the ejector pins.

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12. Ejector back plate: Ejector back plate supports the ejector pins and together with the

ejector plate, ejector guides and forms an ejector assembly.

13. Ejector pin: Ejector pin is a moving pin used for the removal of components, which are

fitted in the ejector assembly.

14. Flash: Flash is extra plastic attached to a mold; must be removed for the part to be

considered complete.

2.2.3 TRANSFER MOULD

Transfer molding is a process in which articles are formed from thermosetting

materials in a closed mould. In the process, hot and soft molding material is passed under

pressure from an auxiliary chamber into the closed mould. Transfer molding is an old process

developed to overcome some of the design limitations on compression molded parts.

Compression molding does not readily permit the forming of articles having intricate

sections, thin walls and inserts, but this difficulty can more readily be coped with in a transfer

molded part.

Cycle times are typically shorter for transfer molding operation than for

compression molding operation. In transfer molding, considerable work is done on the

molding material during the transfer process. Good conductive heat transfer is also

encouraged, leading to faster heating, curing and cycle times than are usually the case with

compression molding. Because the articles are molded in closed condition, which are usually

subjected to less mechanical wear and erosion than open moulds, closer tolerance are possible

with transfer molded parts. Transfer mould cost will be higher than compression mould, and

the waste of the material of sprue and runner system in transfer molding present an added

production cost.

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ASSEMBLY OF TRANSFER MOULD

TERMINOLOGY USED IN TRANSFER MOULD:

1. Base plate: Base plate is the bottom most part of he mould assembly. It is used for

clamping the stationary mold parts of the bottom assembly to the machine platen.

2. Top plate: Top plate is the top most plate. The top position of the mold parts are clamped

by means of screw and also used for clamping the top assembly to the machine platen.

3. Die housing: Die Housing is used for locating the Die and cartridge heater.

4. Copper Rod: It is used for transferring the heat. So that entire mould gets equal heat at all

section of mould.

5. Transfer Cylinder: It is used for keeping the material, from where the material can flow

into the different cavities.

6. Transfer Piston: It pushes the material from transfer cylinder to upwards. It is placed inside

the transfer cylinder. All other parts are similar to compression mould only.

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2.3 Die Casting Die

Pressure die-casting dies are used to produce die cast components of non-ferrous

metal alloys. Non-ferrous metals are classified as light metal alloys like Aluminium &

Magnesium alloys and heavy metal alloys like Zinc & Copper based alloys.

Aluminium & Zinc are the most commonly used die casting alloys.

Tool Division is the pioneer in design and manufacturing of Die casting dies in India.

They have manufactured dies for various industries like automotive, electrical,

medical, electronic, computer industries, etc.

2.4 Jigs & Fixtures

Jigs & Fixtures are made for various processes like milling, drilling, welding,

checking, etc. The various types of Jigs & Fixtures made are:

o Milling fixture

o Drill Jig

o Welding fixture

o Checking fixture

o Riveting fixture

o Assembly fixture

Gauges are also manufactured for the purpose of Inspection.

2.5 Special Purpose Tools

Special tools manufactured by Tool Room are:

o Cold Extrusion Die

o Compaction Dies for powder metallurgy process.

o Fine Blanking Tools

o Tapping Attachment

o Tools for Multi-Slide Press

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3. FACTORS WHICH IS TO BE CONSIDERED FOR DESIGNING OF MOULD

COMPRESSION MOULD:-

Compression moulding process is selected when:-

Material used for product is Thermosetting plastic - Sheet Moulding Compound (SMC), Dough Moulding Compound (DMC).

Size of the component is large. Less production is required which reduces tooling cost of the mould. Component requires high wall thickness. Component possesses a hole, metal inserts, bosses, ribs etc. High strength of the component is required.

INJECTION MOULD:-

Injection moulding process is selected when:-

Material which is to be used for product is Thermoplastic material which cannot be processed by any other moulding technique.

Tight tolerance is required. Consistent flow of material is required for component. Part size is small and medium. Some time injection moulding process is selected for thermosetting material when

component requirement to with stand high temperature.

TRANSFER MOULD:-

Transfer moulding process is selected when:-

Component is very small and cannot be manufactured by Compression and Injection Moulding Processes.

Controlled flow of material is required in mould cavity. Tight tolerance is required with low shrink material.

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4. VALUE STREAM MAPPING (VSM)

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4.1 DIFFERENT TECHNIQUES FOR IDENTIFYING AND ELEMENATING

WASTE AND UNNECESSARY OPERATION FROM THE PROCESSES WHICH

INCREASE PROCESS LEADTIME:-

4.1.1 Operation Process Chart :-

Operation process chart record only major activities and inspections involved in the

processes. It uses only two symbol operation and inspection.

SYMBOLS:

OPERATION:- INSPECTION:-

4.1.2 Flow Process Chart:-

It is a amplification of flow process chart in which operation, Inspection, storage, delay and

transportation are represented

STORAGE:- DELAY:- TRANSPORTATION:-

4.1.3 Multiple Activity Chart:-

It is a chart where activity of more than one subject i.e. worker and equipment are each

recorded on a common timescale to show their inter relationship.

4.1.4 Flow Diagram And String Diagram:-

Flow diagram is used to show the flow or path of the material from one department to

another. String diagram is used to identify the actual distance travelled by a material during

whole process.

4.1.5 Value Stream Mapping:-

Value stream mapping is a tool commonly used in lean continuous improvement program to

help understand and improve the material and information flow within the organization.

Value Stream Mapping borne out of lean ideology captures and presents the whole process

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from end to end in a method that is easy to understand by those working in the process - it

captures the current issues and presents a realistic picture.

WHY VALUE STREAM MAPPING?

4.2 INTRODUCTION TO VSM :-

BASIC PRINCIPLE OF LEAN CONVERSION

Value Stream Mapping is a method of visually mapping the flow of materials and

information from the time products come in the back door as raw material, through all

manufacturing process steps, and off the loading dock as finished products. This is the Value

Stream. Mapping is a critical initial step in lean conversions.

Mapping out the activities in current production process with cycle times, down times, in-

process inventory, material moves and information flow paths, will help in visualizing the

current state of the process activities and guide the analyst towards the future desired state.

Value Stream Mapping can be a communication tool, a business planning tool, and a tool to

manage a process incorporating continuous changes.

The process includes physically mapping the "current state" while also focusing on where

you want to be, or your "future state" map, which can serve as the foundation for other Lean

improvement strategies. VSM can serve as a starting point to help management, engineers,

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production associates, schedulers, suppliers, and customers recognize waste and identify its

causes.

The goal is to identify and eliminate waste in the process. Waste being any activity that does

not add value to the final product.

4.2.1 Benefits of Value Stream Mapping

1. Helps visualize the production process at the plant level, not just at the single process

level.

2. Helps to see the sources of waste in value stream.

3. Shows the linkage between the information flow and the material flow

4. Makes decisions about the flow apparent

5. Forms the basis of an implementation plan

6. Ties together lean concepts and techniques to enable improvements that show up in

an organization's bottom line.

4.2.2 Waste, or non-value added activity can be broadly classified into 7 categories-

1. Overproduction

2. Waiting

3. Unnecessary Transport

4. Over-processing/Incorrect Processing

5. Excess Inventory

6. Defects

7. Unused Employee Time/Creativity

4.2.3 Definition of Value Added and Non Value Added

Value Added

Any activity that increases the market form or function of the product or service. (These are

things the customer is willing to pay for.)

Non-Value Added

Any activity that does not add market form or function or is not necessary. (These activities

should be eliminated, simplified, reduced, or integrated.)

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4.3 STEPS IN VALUE STREAM MAPPING

1. Selecting a product or product family:

Before starting the value stream mapping process one product or product family is to be

selected which will be mapped. Value stream mapping means walking and drawing the

processing steps (material and information) for one product family (group of products that

pass through similar processing steps and over common equipment in downstream processes)

from door to door in the plant.

2. Create a current state map:

The Current State Map represents the “as is”condition of the Value Stream observed today.

Define the scope of the value stream map.

Walk the process from end to end.

Agree upon the symbol,icon and data to use.

Brainstorm the initial map.

Determine the missing information VSM requires.

Collect as much information about causes of waste as possible.

Build the CURRENT STATE VALUE STREAM MAP.

3. Create the future state map:

The purpose of value stream mapping is to highlight sources of waste and eliminate them by

implementing the future state within a short period of time. The purpose is to build a chain of

production where every process is linked to their customer(s) either by continuous flow or

pull and each process gets as close as possible to produce only what its customer need and

only when they need it.

4. Achieving the future state map:

Value stream mapping is just a tool. Unless one implements the future state that he has

drawn, the value stream mapping is useless. In implementing the future state map the map is

broken into steps and the implantation sequence is developed.

4.4 SYMBOLS USED IN VALUE STREAM MAPPING

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VSM Process Symbols

VSM General Symbols

VSM Material Symbols

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VSM Information Symbols

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5. VALUE STREAM MAPPING (VSM) FOR REDUCING TOOL APROVAL TIME

SCOPE OF THE PROJECT:-

Tools such as Compression mould, Transfer mould and Injection mould are

manufactured in house and some parts are procured from vendors. The department namely

Tool Administration Cell of L&T-EBG (GATE NO.2) performs trial on the output product

of the respective mould. The present project is focused on the flow of information and the

flow of operation of the finished product after manufacturing. Basically time taken for

manufacturing of respective mould is quite less than the time taken for trial and approval of

mould.

It is needed to reduce this time as it increases the work- in- process inventory and thus

increases the total cycle time

According to the guide lines given by the industrial and college mentor the project started

with the basic data collection of the tool i.e compression & injection mould.

The following are the basic steps which help in understanding and implementing the project

5.1 SELECTING A PRODUCT FAMILY

Currently the Total lead time for tool trial and approval cycle is about 90-100days. Hence to

reduce the Total lead time, Value Stream Mapping for tool trial and approval cycle was

undertaken. For this purpose process from Tool List Received to Sample Submission For

SIR is selected

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5.1.2 SELECTION OF THREE MOULDS FOR MANUFACTURING

METHOD STUDY & MAPPING

To understand the whole mould making process three tools were selected in which

there are 2 injection moulds and 1 compression mould.

Flow diagram of mould manufacturing:-

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Moulded part drawing is received

Design meeting

Drawing is released to TMG

Design is made

Process planning by TMG

Information is released to TMD ,

CAM , ASSEMBLY SHOP.

Manufacturing process

Assembly

Trial and Inspection

The items in the tool consists of three categories

A - this items are manufactured in-house

B - this items are manufactured at vendor

C- this items are standard part (hardware parts)

5.1.2.1 MANUFACTURING PROCESS OF TOOL NO. 1

Tool description :- Compression Mould

A category items in tool no.1 is PUNCH 1, PUNCH 2, DIE 1, DIE 2, POWDER CHAMBER

1, POWDER CHAMBER 2

Operations performed for manufacturing PUNCH 1 & PUNCH 2 are as follow:-

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10. PRE MACHINING

20. SURFACE GRINDING

30. ROUGH VMC

40. FITTING SHOP

50. HEAT TREATMENT


70. JIG GRINDING

OPERATIONS REASON

Shape to size

To make all sides at right angle

To remove excess material & drilling holes

For removing burr & stamping

For hardening the job


For grinding hole

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100. FITTING SHOP

90. FINISH VMC

110. SPARK EROSION

80. SPARK DRILL

120. POLISHING

160. INSPECTION

999. FITTING SHOP


150. FINISH VMC

130. WIRE EROSION

For wire erosion

For complicated shape

For removing burr and cleaning the job

Finish mill profile as per 3D model

To match required fits

For machining blind hole

For match to fitting size & thickness

For finishing all collars & holes

Inspection of items as per

drawing

For assembly

Operations performed for manufacturing DIE 1 & DIE 2 are as follow:-

35

10. PRE MACHINING


30. ROUGH VMC

40. FITTING SHOP

50. HEAT TREATMENT

90. SPARK EROSION

80. FINISH VMC


70. JIG GRINDING

Shape to size & stamping


To remove excess material & drilling

holes

For removing burr & inspection



For grinding hole

For finish mill profile as per

drawing


OPERATIONS REASONS

Operations performed for manufacturing POWDER CHAMBER 1 & POWDER CHAMBER

2 are as follow:-

36

100. FITTING SHOP

110. WIRE EROSION


140. INSPECTION

999. FITTING SHOP

130. FINISH VMC

For finish core & ejector pin hole

For polishing

For finishing fitting size &

thickness

For finishing collar as per

drawing

For inspecting item as per drawing

For assembly

10. PRE MACHINING


Shape to size & stamping


OPERATIONS REASONS

37

30. VMC

40. FITTING SHOP

50. HEAT TREATMENT


90. FITTING SHOP

110. INSPECTION

80. WIRE EROSION


70. JIG GRINDING

120. FITTING SHOP


holes

For removing burr & inspection



For grinding hole

Wire cut profile as per drawing

For inspection as per drawing

For finishing fitting size & thickness

For polishing

For final assembly


Tool description: - Injection Mould

A category items in tool no.2 is PUNCH & DIE

Operations performed for manufacturing PUNCH & DIE is same as performed in tool no.1


Tool description: - Injection Mould

A category items in tool no.2 is PUNCH, DIE & PUNCH INSERT

Operations performed for manufacturing PUNCH & DIE is same as performed in tool no.1

& tool no. 2

Operations performed for manufacturing PUNCH INSERT are as follow:-

38

10. PRE MACHINING


30.ROUGH VMC

40. FITTING SHOP

50. HEAT TREATMENT


Shape to size



holes

For removing burr ,stamping & inspection



OPERATIONS REASONS

39

100. SPARK EROSION

90. WIRE EROSION

110. POLISHING

80. FITTING SHOP

70. FINISH VMC


For finishing mill profile as per 3D model

For removing burr & cleaning the job

To match required fits


For wire cut holes & corner radius

For finishing fitting size, thickness

& slot for flat ejector

130. INSPECTION

999. FITTING SHOP

For inspection as per drawing

For final assembly

5.2 CREATE A CURRENT STATE MAP

Tool trial and approval cycle contain following activity:-

1) Tool list received

2) Tool detail gathering

3) Request for trial arrangement

4) Tool readiness conformation

5) Tool received

6) Request for tool dispatch

7) Tool sent to vendor

8) In-house or Outdoor trial

9) Sample received

10) Sample submission for Sample Inspection Report (SIR)

11) SIR received

12) SIR analysis

13) Rectification release

14) Tool certification

15) Tool delivery

From the above activity Activity 1 To Activity 10 is selected for mapping.

5.2.1 BRIEF DESCRIPTION OF TOOL TRIAL AND APPROVAL

CYCLE:-

Tool Administration Cell(TAC) receives a monthly forecast of tool from Tool Management

Group (TMG)-planning department during last week of the month. This tools are planned to

be completed in the next month. After receiving tool list from TMG, TAC carries out tool

detail gathering activity in which the following details are mentioned

1. number of cavity in the mould,

2. weight and material of the component,

3. color of the raw material,

4. size of the mould,

5. wheather the component contains inserts or not,

40

6. requirement of warpage prevention fixture etc..

After tool detail gathering activity TAC requests for trial arrangement to initiator through

mail ,when initiator receive mail they arrange trial in which raw material, inserts, trial

location-if trial is out door are arranged. During this activity, moulds are under manufacturing

stage. When TAC receives tool readiness conformation from the Fitting shop then they

conduct trial of the mould. Trial can be performed in-house or outdoor depending upon the

size and tonnage requirement of the mould. Trial of injection mould is carried out outdoor

only. During trial actual weight of the component, temperature of the machine is noted down.

Any problem occurred is also noted.

After trial TAC receives component of the mould which is submitted to initiator for making

Sample Inspection Report (SIR) and some samples are also submitted to designer for

rectification purpose if SIR is rejected. If SIR is accepted then TAC requests TMG for tool

certification. After tool certification tool delivery activity is carried out by TMG Tool

Material Department (TMD)-purchase department. If SIR is rejected than designer analyzes

the SIR and releases the Tool Rectification Instruction (TRI). TRI is then given to fitting shop

by TAC.

Tool rectification activity is carried out by fitting shop then whole activity from tool

readiness conformation is performed again.

After observing the whole process, various points were noted down. The waste such as

waiting time,

inventories,

unnecessary movement of items

non value added activities which tends to increase the lead time.

Current state map was mapped by tracking mould from design to trial and approval

activity. This activity is done to understand whole process of mould manufacturing.

41

RESULT OF CURRENT STATE FOR TOOL 1

PROCESSES VA (in hr.) NVA (in hr.) VA+NVA

TOOL DETAIL GATHERING 1 48 49

REQUEST FOR TRIAL ARRANGEMENT 0.083 48 48.083

TOOL RECEIVED FROM FITTING SHOP 0.083 0.17 0.253

IN-HOUSE TRIAL 16 456 472

SAMPLE SUBMISSION FOR SIR 0.5 24 24.5

TOTAL 17.67 576.17 593.84

CYCLE TIME=VA+NVA

=17.67+576.17

=593.84 hrs.

=24.74 DAYS

VA(in hr.) NVA(in hr.)0

100

200

300

400

500

600

700

CURRENT STATE

TIM

E in

hrs

.

42






REQUEST FOR TOOL DISPATCH 0.083 96 96.083

OUTDOOR TRIAL 8 24 32

SAMPLE RECEIVED 0.083 16 16.083

SAMPLE SUBMISSION FOR SIR 0.083 0.5 0.583

TOTAL 9.415 232.67 242.085

CYCLE TIME=VA+NVA

=9.415+232.67

=242.09 hrs.

=10.08 DAYS

43


50

100

150

200

250

CURRENT STATE

TIM

E in

hrs

.






REQUEST FOR TOOL DISPATCH 0.083 216 216.083

OUTDOOR TRIAL 8 24 32

SAMPLE RECEIVED 0.083 16 16.083


TOTAL 9.415 352.67 362.085

CYCLE TIME=VA+NVA

=9.417+352.67

=362.085 hrs.

=15.08 DAYS

44


50

100

150

200

250

300

350

400

CURRENT STATE

TIM

E in

hrs

.

REASONS FOR DELAY IN TRIAL

45

ALL INFORMATION REGARDING TOOL DETAIL GATHERING RE like

Number of cavity in the mould, Weight and material of the component, Color of the

raw material, Size of the mould, Whether the component contains inserts or not,

Requirement of warpage prevention fixture etc..are not provided in assembly drawing

of the mould.

UNNECESSARY TRANSPORTATION when tool was completely outsourced and

it’s trial is also outdoor. when tool is completely outsourced that time tool came to

ETS from vendor and then sent to trial location.

46

During in-house trial of compression mould OPERATOR WAS AVAILABLE in 1st

shift only. And when components requirement from initiator for SIR purpose is more

than 25 nos. than it is not possible to manufacture that much component in one shift.

TOOL WAIT ON INPUT RACK because of unavailability of row material. some

time mold assembly is completed at time but raw material is not available which

increase in delay of trial.

Delay in trial because of DELAY IN TOOL ASSEMBLY. Some time delay occurs

because of tool assembly was not completed at time.

6 CREATE A FUTURE STATE MAP :

47

Future State Mapping is undertaken to reduce the Waste (NVA areas) identified from the current state maps.

Based on the current state maps I have identified an NVA area and principles of Value Stream Mapping were applied to reduce the NVA’s.

RESULT OF FUTURE STATE FOR TOOL NO.1 IF IMPLEMENTED.


TRIAL ARRANGEMENT 0.17 48 48.17TOOL RECEIVED FROM

FITTING SHOP 0.083 0.17 0.253

IN-HOUSE TRIAL 8 360 368


TOTAL 8.336 408.67 417.006

CYCLE TIME=VA+NVA

=8.336+408.67

=417.006 hrs.

=17.38 DAYS


50

100

150

200

250

300

350

400

450

FUTURE STATE

TIM

E in

hrs

.


48


TRIAL ARRANGEMENT 0.17 48 48.17


IN-HOUSE TRIAL 8 0.17 8.17


total 8.336 48.84 57.176

CYCLE TIME=VA+NVA

=8.336+48.84

=57.176 hrs.

=2.38 DAYS


10

20

30

40

50

60

FUTURE STATE

TIM

E in

hrs

.


49


TRIAL ARRANGEMENT 0.17 48 48.17


IN-HOUSE TRIAL 8 0.17 8.17


total 8.336 48.84 57.176

CYCLE TIME=VA+NVA

=8.336+48.84

=57.176 hrs.

=2.38 DAYS


10

20

30

40

50

60

FUTURE STATE

TIM

E in

hrs

.

50

COMPARISSION BETWEEN CURRENT STATE MAP &

FUTURE STATE MAP

TOOL NO. 1:-


100

200

300

400

500

600

700

Comparission Of VA & NVA

TIM

E

CURRENT STATE FUTURE STATE DIFFERENCE in hrs.

DIFFERENCE in days.

VA 17.67 8.336 9.334 0.39

NVA 576.17 408.67 167.5 6.98

TOTAL 593.84 417.006

TOTAL CYCLE TIME REDUCTION = TOTAL CYCLE TIME OF CURRENT STATE -

TOTAL CYCLE TIME OF FUTURE STATE

= 593.84 – 417.006

= 176.83 hrs

= 7.37 days

51

TOOL NO. 2 :-


50

100

150

200

250

Comparision Of VA & NVATI

ME

CURRENT STATE

FUTURE STATE

DIFFERENCE in hrs.

DIFFERENCE in days.

VA 9.415 8.336 1.08 0.04

NVA 232.67 48.84 183.83 7.66

TOTAL 242.09 57.176



= 242.09 – 57.176

= 184.91 hrs

= 7.7 days

52

TOOL NO. 3 :-


50

100

150

200

250

300

350

400

Chart Title

Axis Title

CURRENT STATE

FUTURE STATE

DIFFERENCE in hrs.

DIFFERENCE in days.

VA 9.415 8.336 1.08 0.04

NVA 352.67 48.84 303.83 12.66

TOTAL 362.09 57.176



= 362.09 – 57.176

= 304.91 hrs

= 12.7 days

53

7 RECOMMENDATIONS FOR IMPLEMENTING THE PLAN:-

All information regarding tool detail gathering should be provide by TMG.

It helps reducing waiting time.

Eliminate unnecessary work.

Trial arrangement responsibility should be handover to ETS & for this purpose

select one person who only handle this responsibility.

Reduce delay in material arrangement.

Eliminate communication between TAC and initiator.

If tool is completely outsourced and it’s trial is also outdoor than transfer tool

directly from vendor to trial location.

It helps reducing the waiting time.

Eliminates the Unnecessary movement/ transportation.

Eliminates the unnecessary documentation work for tool dispatch from ETS to trial

location.

Improve communication between TAC,TMG & FITTING SHOP.

This helps to reduce the time of delay in mould availability.

Assign an operator for in-house mould trial who work in general shift.

It helps in reduce the time of in house trial.

54

CONCLUSION

It has been an outright delectation for getting a chance to work in one of the most illustrious

companies existing in India. At the end of my training tenure, which I refer to as the most

exciting, enriching and challenging experience ever in the engineering curriculum, I wish to

epitomize the benefits accrued over a period of six months. The training has certainly helped me

in bridging the gap between theory and practical knowledge. It has empowered me to see how

knowledge gained through textbooks is implemented in practice.

The inplant training at M/S LARSEN AND TOUBRO LTD. offered an exposure to

industrial environment, which cannot be simulated in the engineering institute. The

training gave me a chance to carry out projects on various topics such as communication

testing and other many tests, which I have conducted in my six-month training . I gained

an insight into the psychology of the workers and their habits and attitude and the deal

with which they work for the company. I learnt the real value and thus the constraints of

time and costs within which goods are produced and services are rendered.

The report I am herewith presenting contains a detailed part of these projects and

will thus vouch for my prolific and invaluable training. Thus I can confidently

Conclude that this training was the most beneficial and enlightening experience that is

Bound to help me when I will be exposed to real life experience.

55

REFERENCES

a. “MAPPING THE TOTAL VALUE STREAM” - BY MARK A. NASH AND

SHEILA R. POLING.

b. DIE DESIGN FUNDAMENTALS - BY J.R.PAQUIN

c. TOOL AND MANUFACTURING ENGINEERS HAND BOOK.

d. INJECTION MOULD DESIGN - BY R.C.W. PYE

WEBSITES:

1. www.lntebg.com

2. www.wikipedia.com

3. www.google.com

4. www.livesearch.com

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http://WWW.LIVESEARCH.COM/

http://WWW.GOOGLE.COM/

http://WWW.WIKIPEDIA.COM/

http://WWW.LNTEBG.COM/

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jignesh