PROJECT

GODREJ & BOYCE MFG. CO. LTD.

HARDIK SHAH D.J.S.C.O.E Page 1

1. INTRODUCTION TO THE

COMPANY



1.1 COMPANY PROFILE

GODREJ AT GLANCE: -

In the year 1997, Godrej & Boyce celebrated their century year. This dynamic

organization has progressed tremendously since its inception and has been gaining strength

consistently. Quality is the hallmark of all the Godrej products and any product with the

'Godrej' mark represent quality, dependability & satisfaction to its customers. What now is a

gainful industrial organization was a brainchild of Mr. Ardeshir Godrej, which - through the

help dedicated men with tremendous foresight and finely honed engineering and marketing

skills, has become one of the biggest houses in India.

His brother Mr. Phirojshah Godrej, under whose leadership the organization grew and

diversified, further carried on the founder's pioneering work. In 1905 Godrej built its first

safe thus vetting foot in to the security equipment business, which at eight years from its

century has become 100 cores turnover division with almost no competition in the Indian

market and global presence in this field. Former expansion came in 1923 with the

introduction of steel shelves with industrialization growing at a brisk space need for office

equipment like chairs, tables, filing cabinets and movable partition system, etc. was felt in

1937. In 1955, started the production of one item without which no office in India could be

complete' "The Typewriters". This indigenously built all Indian typewriters has made Godrej



one of the leading manufacturers of typewriters in India. Realizing today's need this branch

has also set foot in the field of electronics - typewriter, projectors, and basic models of word

processor.

The next Godrej product to sweep the Indian market was the steel cupboard in 1958.

This product became a regular sight in homes. This was then followed by another product,

which passed many a milestone since it's conception and which has become a household

name 'The Godrej Refrigerator' the manufacture of range of hospital furniture. The steel locks

for Libraries in 1936, designed to keep up with modern library methods, canteen's equipment

made to the latest design in 1951 and auditorium chairs in 1954, make contribution of

Godrej to national welfare.

In 1953, Godrej started manufacturing tools crib and cabinets for systematic

adaptable, fully accessible storage. In order to keep up with modern with growing needs of

industries, Godrej entered another progressive phase in 1957 with manufacture of ink tool

for internal as well as external use. The first Godrej Mechanical Press Breaks were made in

1942 and son almost every plant at Godrej was using this. The long life, quality and

performance at these miles are reflected in the excellence of Godrej products.

In 1960, in collaboration with M/s. Clark International, started the manufacturing of

Forklift trucks, both types that can be operated by fuel and electric with capacity ranging

from one ton to sixteen tones which have time and again proved their worth as a rugged and

versatile material handling equipment. With the field of welding technology gaining

importance and recognition Godrej has setup one of the most modernized units for the

fabrication of large pressure vessels and other equipment.

Godrej also made a significant contribution to self-reliance of the century by building

the engine for the PSLRU locker launched by India. In the year 1978 Godrej diversified in to

the field of chemicals by starting the manufacturing of soaps and further diversified into

production of chemicals for various industries like textile mills, pharmacies, confectioneries,

etc.



The most recent achievement by Godrej was made when it acquired “the ISO 9000,

ISO 9001 and ISO 14000 certificate which former reinforced the rest of not only the Indian

market but also the global market in the, product of Godrej.

Today Godrej employee over 15,000 people and has grown in to a multi-core

professionally managed group with far reaching service and distribution network: "Economy

and Services" are being the main motto of Godrej they have already diversified in to field of

Indian industry thus helping in the economic growth of the country.

Century old brand name, ' Godrej ', it now also provides electronic security systems

products and is angered with the supply and installation of the electronics safes, electronics

security alarm systems, access control systems, closed circuit television systems and very.

Highly sophisticated advanced electronic surveillance systems.



1.2 CURRENT CHAIRMAN

ADI GODREJ JAMSHYD GODREJ

BOARD OF DIRECTORS

Chairman & Managing Director: JAMSHYD N. GODREJ

Executive Directors: Non-executive Directors:

Phiroze D. Lam Adi B. Godrej

Kyamas A. Palia Nadir B. Godrej

Vijay M. Crishna Kavas N. Petigara

Anil G. Verma Fali P. Sarkari

Navroze J. Godrej Pradip P. Shah



2. Introduction to Security

Solutions Division



2.1 Overview

A hundred years ago, Ardeshir Godrej took up safe making. To this day, diverse as the

enterprise he founded has grown, most Indians associate GODREJ with Security Equipment.

For this is the name that still protects the wealth of the nation and personal belongings in

countless homes.

To find proof one need only walk into any bank in India. Here, GODREJ

STRONG ROOM DOORS and safe-deposit lockers can be seen in use-skillfully made, along

with a wide range of safes in different sizes, to resist every form of attack.

The oldest business in the group also manufactures a line of fire-resistant

filing cabinets and record-protecting equipment, used extensively in offices and institutions

around the country.

The recently introduced electronic alarm systems are just the beginning of

better things to come as the country's largest manufacturer of security equipment gears up to

meet newer challenges.



2.2 PLANT 17 - DEPARTMENTS IN BRIEF

Besides the assemblies, there are departments which provide support services to manufacture

the products. These departments are as follows:

DESIGN

PRESS SHOP

DRILL AND MACHINE SHOP

PRE-TREATMENT DEPARTMENT

PAINT SHOP

FINAL FITTING AND PACKING DEPARTMENT

QUALITY ASSURANCE DEPARTMENT

VENDOR DEVELOPMENT CELL

STORES

PURCHASE

MAINTENANCE DEPARTMENT



2.3 PRODUCTS MANUFACTURED AT SSD

DEFENDER SAFES

Defender safes can be treated against risks of fire, import due to fall and attacks of

power drill, oxyacetylene flame and arc cutting.

Godrej offers range of ‘Defender safes 26, 31, 41, 49, 61- SD, 61- DD, 81 and

84. A fully welded multi-corner bends construction without a single rivet makes the body an

integral whole. Defender Safes have all their five sides and doors armored with a specially

formulated double duty barrier material which provides massive resistance to attacks with

sledge hammer, power drill, oxyacetylene flame arc cutting. The body thickness on all five

sides 100 mm including double duty barrier material. The total thickness of various barrier

materials in door is 135 mm to 145 mm. The defender range of products is fitted with Godrej

superior quality, dual control, and high- protection 8-lever lock bolt mechanism to the door.

Safes are given of high quality expensive nitrocellulose paint to render smooth, scratch free,

lasting and attractive finish. The body is finished in dark gray and the door in light gray.



FIRE RESISTING RECORD CABINET AND FILING CABINET

FRRC FRFC

FRRC:- Recognizing the need for valuable fire protection, coupled with the need for

easy accessibility of records and office aesthetics, Godrej has designed its Fire Resistance

Record Cabinet. The Godrej FRRC has a sturdy double walled body and door of multi-bend

construction fabricated from good steel. This is reinforced at some points to enable the

cabinet to withstand severe fall of debris.

FRFC:- Only prime quality steel from SAIL is used. FRFC is developed to provide as

much resistance to flame and to gases as a 550 mm concentrate wall.

Moreover, this compound having very low thermal Conductivity, which keeps the contents of

the cabinet relatively, cools.



SAFE DEPOSIT LOCKER CABINET

Assembly II produces 'Safe deposit Locker Cabinets' (SDLC). Godrej Safe deposits

locker cabinets are use in Banks for storing valuables of the people. These cabinets are

fabricated from steel and have a number of lockers of different sizes in varying configuration.

Safe-deposit locker cabinet is available with containing lockers till 90. These cabinets are use

in banks for storing their valuables.



STRONG ROOM DOORS

The main product of this line is Defender Strong room doors are classified into two types:

Class- I Doors are recommended for small to medium size deposit Locker. Class-II Doors

are recommended for large vaults.

Defender Class -I Door Slab: -

The 12 mm thick plate is fortified over the entire lock-case area measuring

1.75 sq.m with an oxyacetylene arc, drill and hammer resisting layer. The total thickness

over the locker and vital parts is 65 mm.

Defender Class - II Door Slab: -

1. The 32 mm thick door plate is fortified over the entire lock case area

measuring 1.75 sq. m with a oxyacetylene, arc, drill and hammer resisting layer.



MARINE DOORS

Our sliding electro-hydraulic operated watertight door combines decades of experience and

today's technology. Controls are now supplied pre-mounted on the door frame. Where space

constraints exist, operating equipment can be mounted separately on the bulkhead. These

doors can be supplied to all classification society regulations, and are available in various

sizes.



3. Introduction to Safe

Assembly Department



3.1 Overview of Department

The safe Assembly department deals with the manufacturing of safes used in residences and

banks. The safes come in different sizes from 26” to 84”. There are various classes of safes

for the different sized safes. The department also manufactures special safes which are

ordered by customers as per their requirements.

The department is spread over 3 plants, i.e. Plant 17, Plant 18 and Plant 1.

Plant 17 is where the bulk of the safes are manufactured and are dispatched to the customers.

The department in plant 17 has 2 lines, one is the Single Piece Flow line(SPF Line) on which

the double bodies (inner body welded on the outer body) for the safes are manufactured, and

the other is the post RMC Filling line where the doors are manufactured and fitted on the

double bodies and the locking mechanism is fitted on the doors. The capacity of the

department is 36 safes per day.

Plant 1 is where the automated SPF line of the department is situated. The

outer bodies are manufactured at plant 1 and then transferred to plant 17 for further work.

The SPF line at plant 1 is an automated line with welding robots and automated grinding

machines. The planned capacity of the line is 70 outer bodies per shift.

Plant 18 is where the new Z+BB safes are manufactured. The new Z+ BB

safes are a new type of safes where the door is mounted on the sides of the safes instead of

the top and bottom surface. The Class A and Class AA type of safes are also manufactured at

plant 18.



3.2 Product Range of Safe Assembly Department



3.3 Features of Defender Safes

What makes Defender Safes the best?

Underwriters Laboratory, USA and BIS have approved Defender plus Safes. It has unique

features like two-step door design, higher thickness of barrier material such as Double Duty

Barrier Material (DDB), Torch & Drill Resistant Barrier (TDR), and Drill

Defeat Shield that offers more protection against burglary and fire.

Double Duty Barrier:

DDB (Double Duty Barrier) is provided in the door and the body. It has a unique formulation

that uses ultra hard particles in binders. It bestows excellent fire and burglary resistance to the

safe.

TDR matrix:

TDR (Torch and Drill resistant) is used in safes of higher-class i.e. Class BB, A, AA

The strong seamless body:

Fully welded multi corners bend construction without a single rivet makes the body and

integral whole. All five sides and the door of the Godrej Defender Plus Safes (Class C) are

armoured with a specially formulated Double Duty Barrier material that is encased between

strong outer and inner steel bodies. This provides massive resistance to attacks of sledge

hammers, power drills and chisels, and also helps withstand the impact of a fall from upper

floors. The overall body thickness on all five sides is 100 mm (approx.), which offers as

much resistance as 25-mm solid steel. The special outer body thickness of 5 mm plate offers

extra protection, thus making the Godrej Defender Plus Safe unique.

The Door of Defender Plus safe: tough to the core. The most frequently attacked portion of

a safe, the door is given superior protection with a series of barriers. The two-step door and

frame construction gives higher fire and burglary resistance. The door has DDB as the barrier

material as per Underwriters laboratories, USA and Bureau of Indian Standards (BIS), India.



Locking System:The Godrej Defender Plus range of safes are fitted with Godrej s superior

quality, dual control, high precision 8 lever locks which are unpick able and only the original

keys will open them. Stainless steel keys are supplied in duplicate. The locks are of brass

body, unlike most other brands Dual control locks. Additional dual control locks can be fitted

in large models (size 41 to 81) Highly sensitive re-locking device on both locks prevents

burglary by instantly deadlocking the Door if the locks are tampered with either mechanically

or by using liquid explosives Unique Drill defeat shields protect vital parts of the lock and

dead locking device Optionally, a 3-wheel combination lock can also be fitted in addition to

the 2 key locks Option for fitting Time Lock available Combination lock can also be

retrofitted on existing safes does not have a combination lock


4. Time Study


4.1 Purpose of doing the Time Study

Time Study at Plant 18

The first Time Study was done of the Door fabrication workstation at plant 18 where

the new Z+ BB safes are made. The purpose was to identify the value adding, non

value adding and essential non value adding activities, and then by changing the

procedure and eliminating all the possible non value adding activities and reducing

the cycle time for making a Z+BB door, whose cycle time currently is 120.59

minutes.

Time Study at Plant 17

The time study performed at plant 17 was done for the three major work-stations of

SPF line.

The purpose was to help in setting up an automated line.

By referring to the time study, the time required at each workstation will be compared

with the time required for the proposed automated line and then the most feasible

method (Manual or Automated) based on the financial and productivity aspects will

be selected.


4.2 Time Study of Door Fabrication of Z+BB Doors at Plant 18

Sr. No ACTION TAKEN TIME in

Seconds

1 Take the door 6

2 Take the pivot and place it below the door 8

3 Remove the gloves 3

4 Take the screws that are placed besides the door 5

5 Fix the pivot by fixing all the 4 screws 20

6 Take a pivot for placing it on another side 28

7 Fix the pivot by fixing all the 4 screws 45

8 Wear the gloves again 12

9 Take the Allen key from the pocket and tighten the

screws that were used to fix the pivot 27

10 Move on the other side 3

11 Tighten all 4 screws on the other side 45

12 Now lift the door and push the door ahead 6

13 Now tilt the door so that the pivot part comes up 13

14 Take gloves and hammer from the rack behind and

wear safety glasses 17

15 Talking to another worker, getting the required

material 41

16 Take the hammer and hammer on the pivot to adjust

the position of pivot according to the gauge 28

17 Take a right angle and hammer on the pivot to get its

position according to right angle 12

18

Take another right angle and place the right angle on

the door plate positioned flat and measure the position

of pivot from another side and hammer the pivot to get

it exactly at right angle

14

19 Take the hammer and right angle gauge and move on

the other side 5


20

Now place the right angle on the 2nd pivot and

hammer on the pivot to get it to the position of the

gauge

38

21

Take another right angle and place it on the other side

perpendicular to the door plate and hammer on the

pivot to adjust it to the position of the gauge

21

22 Take another right angle gauge and place it on the door

plate and hammer on the pivot 12

23

Take a measuring tape and measure the position of the

pivot from one end of the pivot to another end of 2nd

pivot

16

24

Again take the right angles and hammer on both the

pivots to adjust its position according to the

measurement

12

25 Again measure the distance between one end of pivot

to another end of another pivot 14

26 Hammer the pivot again 10

27 Get a wooden block 33

28 Lift the door and keep the wooden block(lafa) below

the door 15

29 Take a helmet , welding torch, and shield 7

30 weld the pivot with the door on the front side 17

31 Move to another side of the door 4

32 Weld the pivot on another side of the door 14

33 Keep the shield and welding torch aside 5

34 Remove the wooden block from below the door and

keep it back on the floor 6

35 Tilt the door again by keeping its pivot on the

downward side 7

36 Take the shooting bolt guide plates 18

37 wearing gloves properly and a break 32

38 Take the rod to support the shooting bolt guide plate 13


39 Take one guide plate and place it on a hole on the with

the support rod 10

40 Hold the support rod with hand and weld the shooting

bolt guide plate to the Door flat 26

41 Take another shooting bolt guide plate for next hole

and adjust its position according to the hole 16

42 Weld the guide plate to the hole by stitch welding on

two corners 7

43 Take another guide plate, adjust its position and weld it

to next hole 21

44

Take another guide plate, adjust its position, use a

support rod to support the shooting bolt guide plate and

weld it to the next hole

28

45 Collect some more guide plates and place one guide

plate on the hole on the door plate below 9

46 The worker is holding the support rod for guide plate

support and talking to some other worker 24

47 Weld the guide plate to hole 13

48 Clean the welding fumes and inspect the welding done

to the hole 7

49 Take another shooting bolt guide plate for next hole

and adjust its position and weld it from two corners 21

50 Then take another guide plate and weld it to next hole 17

51 Now take the allen key and tighten all the bolts for

door pivots 33

52 Explain the welder as where to weld the pivots 26

53 Take the helmet, and shield for protection 4

54 Start full welding at the corners of shooting bolt guide

plate 35

55 Full weld the next guide plate 16

56 Now full weld the next two guide plates 37

57 Weld the pivot support plate to the door plate 48


58 Weld another pivot support plate to the door plate 51

59 Then full weld the shooting bolt guide plates that were

welded to the holes on the door plate 58


61 Take 4 shooting bolt guide plates 4

62

Take the supporting rod and place it on 1st hole on

another side of door for supporting the guide plate and

weld the guide plate

28

63 Take another guide plate and fix its position with the

supporting rod and weld it the door flat 19

64 Break 102

65 Take another guide plate and fix its position with the

supporting rod and weld it the door flat 17

66 Take another guide plate and fix it to next position

with the supporting rod and weld it the door flat 18

67 Full weld the shooting bolt guide plates that were

corner welded earlier 93

68 Get the angles which are to be welded inside the door

on the door flats 33

69 Take the clamping fixtures for clamping the angles for

door flats 17

70 Clamp the angle with door fixture clamp on one side of

the door 39

71

Now clamp another clamping fixture at the centre of

the same door flat by rotating the screw of clamping

device and fixing it on door flat

17

72 Hammer on the angle frame 6

73 Take the helmet and shield for welding 4

74 Weld the angle at the spot where it is clamped with the

fixture at the start of the door 9

75 Now remove the clamping fixture from the place

where welding is done 13


76 Clamp the fixture at the other end of the door flat to

support the angle 17

77 Now take the welding torch and shield and move to

another side 27

78 Full Weld at the spot where welding was done earlier 12

79 Now weld the angle with the door flat at different spots 28

80 Take a hammer and hammer on the door to fix the door

angle 4

81 Remove the clamps and keep it aside 19

82 Now take another smaller angle and place it on the

other side with shorter door flat 6

83 Place the angle on the door flat and clamp it with the

clamping fixture 95

84 Now take the helmet and the welding torch 8

85 Weld the angle to the door flat 35

86 Unclamp the clamping fixture 18


88

Take another angle for the longer door flat of the door

and place it on the door and fix it with the clamping

fixture

26

89 Hammer on the angle frame 10

90 Weld the angle frame to the door flat by stitch welding

at specific intervals 29

91 Unclamp the clamping fixture and inspect the angle

welded 66

92 Clean the welding spatters 88

93 Get the jib crane near the roller table where door is

kept 32

94 The hooks in the safety latch is put at the holes in door

flats by adjusting the position of the crane 40

95 Move the crane upwards so that the door is moved up

and move the door on the ahead 22


96

Now move the crane to the side along with the door

and rotate the door so that the bottom side without door

flat faces in front

18

97

Now move the crane down and shift the door down

with the crane and adjust the door on the wooden

plank(laafa)

50

98 Now remove the hooks and take the jib crane on the

side 13

99

Now move to another side where slabs are placed and

place the hooks on the slab and lift it with the jib crane

and put the slab down on besides the stack of slabs

65

100

Now remove the hooks from earlier slab and put it on

the new slab and lift the new slab by placing the hooks

of the jib crane on the hooks fitted on the slab

117

101

Now take the door slab near the door assuring safety

and place it on the side of the door where door flat is

not welded

85

102 Maintaining accuracy insert the door slab into the door

making certain adjustments 154

103 Now remove the hooks from the door slab and move

the jib crane to the side 39

104 Take the hammer and clamping fixture to join to door

flats so that they can be welded properly 64

105 After clamping the fixture hammer at the corner of the

two door flats where the fixture is welded 32

106

Take the earthing wire of welding machine and fix it

on one side of door to give earthing to the welding

machine

24

107 Listen to the instructions where welding is to be done

and take the welding rod and the helmet 41

108 Now weld at the joint of two door flats where fixture is

fixed 78


109 Fix the fixture at the other end where two door flats are

joined 58

110

now again remove the fixture and Fix the door flats

and hammer on the door flats so that they are joined

properly

40

111 Now again fix the fixture and hammer at the joint of

two door flats 43

112 Weld at the joint of the two door flats starting from

lower part of the door flat to the upper portion 57

113 Put a hook on the Locksole at the space provided for

mounting the hooks 21

114 Get a jib crane and put the latch of the crane in the

hook 14

115

Put two gauges between the front and rear door flats

for keeping the distance between the door flats

constant

13

116

Now the lift the door with the jib crane and hammer on

the front and rear door flats to adjust the position

according to the gauges

72

117 Weld at the joint of the top and front door flat from

inside the door 42

118

Take a hammer and put it inside the shooting bolt hole

and move the hammer in the front part so that the door

flat is attached to the locksole properly

6

119 Take the welding torch and shield and weld the door

flat to the locksole 13

120 Again hammer on the rear door flat 15

121 Now weld the front door flat to the locksole keeping

specific intervals 46

122

Remove the two gauges that were put earlier to

maintain a specific distance between the front and rear

door flats and also remove the hooks that were tied

earlier to pick the door

44


123 Now hammer on the door flats 13

124 Take the stiffener from behind and place it on the front

and rear door flats 14

125 Weld the stiffener to the front door flat

126

Now insert the hammer in the shooting bolt hole of

front door flat and push it upwards and weld the

stiffener to the front door flat

65

127 Now weld the door flat to the locksole by 10 mm stitch

welding at fixed intervals 45

128 Now again hammer on the rear door flat from outside 30

129 now stitch weld at the same door flat to the locksole 259

130 Weld the other door flat to the locksole 214

131 Stitch Weld the top door flat to the locksole to the door

flat 73

132 Take the spray to clean the welding torch 133

133 Clean the welding torch and take the shield and helmet

and listen to the instructions for welding 57

134 weld at the corner joint of bottom door flat 123

135 Weld on the other side of the corner joint 256

136 Weld the buttons for lock fitting to the locksole by

stitch welding on all the sides 179

137 Get the jib crane near the door 83

138 Lift the door with the jib crane and tilt it by 180 degree 74

139 Rotate the cello-tape around the LC Bolt to ensure it

gets inserted properly 62

140 Searching for a chalk and the work station is left idle 173

141 Mark the centre to centre distance for all the holes with

a scale to insert the key spacer in the door 134

142 Get the door handle and instrument for inserting key

spacer in the hole 46

143 Pick the first key spacer with the instrument and insert

it in the hole 26


144 Inspect whether the spacer fits in properly 109

145 reworking by Making the holes proper 223

146 Place the key spacer in the hole 39

147

Take the welding instruments and tack weld the key

spacer on two sides and remove the instrument for

inserting the key spacer

16

148 Adjust the position of the key spacer by hammering

and by using spacer inserting instrument 42

149 Take another key spacer and insert it inside another

hole and adjust its position 44

150 Tack weld the key spacer on the two sides 13

151 Adjust the position of the key spacer by hammering

and by using spacer inserting instrument 54

152 Take another key spacer and insert it inside another

hole and adjust its position 46

153 Tack weld the spacer on one side and adjust its

position according to requirement 57

154 Full weld all the key spacers 237

155 Weld a stiffener at the front part of the door 39

156 Get the jib to flip the door 92

157 Flip the door and place it on the wooden plank 124

158 The work station is left idle 121

159 Get a hammer and hammer it on the locksole 56

160 Take the welding torch and the shield 28

161 Weld the key spacers from the loscksole side 32

162 Fill the hole for inserting the hook to pick the door on

the top side with the welding 172

163 Now fill the hole on the other side i.e. the bottom side 72

164 Remove the earthing wire of welding torch and get the

jib crane 47

165 Now pick up the door with the jib crane place it on the

cement filling rack 113


TOTAL 7259

NON VALUE ADDED ACTIVITIES 2024

Changes made to reduce time

A Fixture is being made for Door Fabrication of Z+BB doors.

Referring activity 141-144, 148,151,152, the total time for all these activities is 8.47

minutes. For these activities the cycle time was reduced from 8.47 minutes to 2.15

minutes. This was done by making a gauge for measuring the Distance Between door

plate edge & centre of the hole of key spacer for Z+ BB doors which is shown in the

later part of the report.


4.3 Time Study of Plug Welding work station at Plant 17

Plug welding

Sr.

No.

Time

recorded Action taken

Time

taken for

the

activity Action Plan

1

Get the body from previous

work station 4

2 0

Adjust the body below the

pressing plate with hands 8

3 0.13

Down the pressing plate in

outer body to rest on innrer

body edge and adjusting its

position by rod 13

Location of Outer

Body & Inner Body

not in line. Proper

Locators required.

4 0.15 Put the rod on place 2

Location of Outer

Body & Inner Body

not in line. Proper

Locators required.

5 0.28

Take the hammer and hammer

on holes 13

Modification required

in Pressing Plate which

will have the

arrangement to clamp

the Inner Body against

the Outer Body from

inside.

6 0.4

Take the welding torch placed

0n front side of the machine

from hook placed and keep it

on the body 12

7 0.48

Take the 'C' clamp and clamp

inner body with outer body on 10


the first hole to be welded

8 1.1

Take the chisel and hammer

and hammer on all the holes

again 28

Deviations in Inner

Body assembly to be

controlled

9 1.12

Take the welding torch and

start welding at the corner of

the body 5

10 2.33 Cleaning of welding torch 74

11 2.52 Grinding of welding rod 19

12 3.39

Again fitting the welding torch

and welding rod 47

13 3.41

Take the shield, place it in front

of your face and Start welding

on the holes on the smaller side

and den move ahead on the

bigger side 35

14 4.35

move ahead and Take the 'C'

clamp and clamp the inner body

with outer body 16

Deviations in Inner

Body assembly to be

controlled

15 4.4 Start welding on the hole 21

16 5.2

Take a c clamp and clamp the

inner body with the outer body 4

Deviations in Inner

Body assembly to be

controlled

17 5.24 Weld the hole 14

18 5.44

Put down torch and remove c

clamp 10

Deviations in Inner

Body assembly to be

controlled

19 5.54

Clamp the c clamp to next

position 7

Deviations in Inner

Body assembly to be

controlled

20 6.1

Take the torch and plug weld

the hole 25


21 6.26

Remove the c clamp and clamp

it to next position 12

22 6.38

Take the torch and plug weld

the hole 7

23 6.45

Remove c clamp and weld the

next spot on the corner side 16

24 7.03

Clamp the c clamp to next

position 10

Deviations in Inner

Body assembly to be

controlled

25 7.11

Take the torch and start

welding 5

26 7.16

Stop welding and remove the c

clamp 20

27 7.36

Shift the c clamp to next

position and start welding 27

Deviations in Inner

Body assembly to be

controlled

28 8.03

Remove the c clamp and clamp

it to next position and start

welding 15

Deviations in Inner

Body assembly to be

controlled

29 8.18 Weld the next spot on corner 10

Deviations in Inner

Body assembly to be

controlled

30 8.28

put the torch back on the hook

placed on the front side of the

press machine 15

31 8.43

move the pressing plate above

with the pneumatic lever given

on the machine 7

32 8.5

Shift the body to the next work

station 5

TOTAL 516

NON VALUE ADDED

ACTIVITIES 155


4.4 Time study of Izonic Fixture on SPF line at Plant 17

Sr. No. Action taken Time

1 Clean the fixture with the help of a cleaning brush 15

2

Get the L/H and R/H C shell to the fixture by hands from

the previous work stations 16

3

Lower the fixture to its original position with the

pneumatic lever given 7

4

Match both L/H and R/H C shells by pushing them close

together 6

5 Take the clamps from behind the fixture 5

6

Put two clamps on the upper side and clamp with the jib

crane from the upper side so that body remains intact in

position 12

7 Inspect the fixture for proper position of both the shells 33

8

Take a hammer and Hammer inside for both the sides i.e

top and bottom to adjust the final postion of both shells 35

9

Take a wooden bamboo and joining strip. Insert the the

joining strip and wooden bamboos from inside the body to

support the joining strip and hammer the bamboo for

perfect position of the joining strip. 37

10 Take the CO2 welding torch and inspect the welding torch 17

11

Take the shield keep it in front of your face and wear a

helmet 5

12 Tack the shells from outside to join two C shells 18

13 Weld the joining strip from inside the body 14

14

Remove the clamp on the jib crane by taking the crane

above and tilt the body on one side with the izonic fixture 10


15

Remove the clamp which was set for adjusting the width

by hammering it on the side of the clamp and remove the

bamboo from the body 22

16 Keep the bamboo and clamp back on the rack 18

17

Take the bottom stiffner and clamp it with C clamp on the

respective side 11

18

Weld the bottom stiffner and the joining where tacking

was done earlier to the two C shells 46

19

Place the weld torch and shield on the other side where

welding is to be done 7

20

Tilt the izonic fixture on the other side with the help of a

switch at the sides of the fixture 15

21

The station is now left idle since the other worker is

working on the previous station 119

22

Remove the clamp which was set for adjusting the width

by hammering it on the side of the clamp and remove the

bamboo from that side of the body. Hammer is placed on

the cover near by. 10

23 Break 30

24

Take the top stiffner, inspect it and hammer it to straighten

the stiffner 11

25

Clamp the stiffner with a C clamp on the top front side of

the body from inside the body 24

26

Take the shield keep it in front of your face, weld the

stiffner and remove the C clamp which was placed earlier

to clamp the stiffner 14

27 Weld the joining strip to the C shells 21

28

Adjust the izonic fixture to the same level as other roller

conveyor tables with the help of the switch provided on

sides 62


29

Adjust the roller conveyors with the pneumatic lever to

move the body ahead 5

30 Push the body to next station on the roller table 10

TOTAL 655

NON VLAUE ADDED ACTIVITIES 171


4.5 Time study of SPM Grinding on SPF line at Plant 17

SPM Grinding

Sr.

No.

Time

Recorded Action Taken

Time

taken for

the activity Action Plan

1 0

Bring the body from previous

work station by pushing it

with hands on the roller

conveyor table 10

2 0.3

Adjust the body near the

grinding wheel 29

Pneumatic

Clampling/Declamping

to be provided to

eliminate these

activities

3 0.32

Clamp the body with a jib

crane from inside for ease of

lifting the body 10

4 0.42

Start clamping the body

between the clamps with the

help of handle by rotating it

so that it remains intact in

position 23

5 1.05

Check body is now clamped

properly and switch on the

SPM machine 2

6 1.07

Start vertical grinding at the

joint of two C shells. The

grinding wheel is first moved

up and then down by the

wheel which is to be

controlled by the operator 420

7 5.28

Stop grinding and Remove the

body from the clamps by

rotating the handle 30

Pneumatic


to be provided to


8 5.58

Rotate the body on the other

side with the help of the jib

crane clamped earlier. Move

the crane up and rotate the

body with hands and place it

again on the roller table by

moving the body down. The

body is rotated for vertical

grinding on the other side at

the joint of two C shells. 3

eliminate these

activities

9 6.01

Clamp the body by the two

clamps provided on the roller

table by rotating the handle

given below near the roller

table 35

10 6.36

Switch on the SPM machine

and move back to the wheel

and Grind at the joint of two

C shells by moving grinding

wheel up and down 512

11 11.5

Check the grind finish with

hands 2

12 11.52 Switch off the SPM machine 5

13 11.57

Unclamp the body by rotating

the handle given below near

the roller table 8

Pneumatic


to be provided to

eliminate these

activities

14 12.08

Move the body a little above

with the jib crane clamp and

rotate it and bring it down on

the roller table. Remove the

jib crane clamp by pushing it 23

Pneumatic


to be provided to

eliminate these

activities


with hands and rotating it.

Move up the jib crane with

the help of the switch so that

the body is now free.

15 12.33

Push the body to the next

work station on the roller

conveyor 8

TOTAL 1120

NON VALUE ADDED

ACTIVITIES 163


5. PROCESS IMPROVEMENT ON

SPF LINE


5.1 Introduction

While performing the time study for the above workstations there were some changes that

were necessary for reducing the cycle time for the above workstations.

An inspection gauge was made for inspecting the distance between the door flats and the door

plate edge. Earlier this distance was measured using a Vernier calliper which did not give

accurate results. Hence a gauge was made for inspecting a distance of 20mm from door flats

to door plate edge.

Another gauge was made for marking the distance between door flat edge and centre of the

hole of key spacer in Z+BB doors. This reduced the cycle time for Z+BB door fabrication.

Another gauge was made to inspect the lug position in the outer body for CLC safes. This is

done to avoid rework due to misplacing of lug position on the outer body and reduce the

cycle time at further workstations.

Many small kaizens were also proposed in order to reduce manpower and to decrease the

cycle time at various other workstations. Some of these kaizens are mentioned in the later

part of this report.


5.2 Gauge for Inspecting the Distance between Door flats & Door

Plate Edge

Basic Components of a Safe Door

To first understand the need of an inspection gauge for measuring distance between door flat

and door plate edge, let us understand the different parts that make up the frame of the door.

These are:-

1) Door plate

This is a mild steel plate of 10 mm thickness. It is the plate on which the door flats are

welded. The outer edges of the door plate mesh with the inner edges of the body with a gap of

maximum 1 mm. on each side.


2) Door Flats

The 4 door flats are welded to the door plate and provide the door with the required

thickness. The 4 door flats are

Door flat front: Door flat rear:

Door flat top: Door flat bottom:


The assembly of the door plate and door flats is shown below

Door Flat Box Assembly


Problems:

The gap between door flats and the edge of the door plate is sometimes more or

less than the required size.

The required size is 20mm.

The door flats are also bent so the gap at one corner is more and the other side is

less.

Following is the list of distances measured from all the door flats to door plate edges

for CLC Doors:

Sr.

no.

Types

of

Door

(mm)

Front

Door

Flat

(mm)

Rear

Door

Flat

(mm)

Top

Door

Flat

(mm)

Bottom

Door

Flat

(mm)

1 CLC 18 18 19.5 20

2 CLC 18.5 17 19.5 17.5

3 CLC 17 16.5 19 18

4 CLC 15.5 16 18.5 19

A gauge was made to inspect the distance between the door flats and door plate edge. The


Gauge for measuring Gauge is positioned this way:

Advantages:

Can be used as an inspection gauge for inspecting distance between door flats and

door plate edge.

Degree of bend in door flats can be found.

20 mm


5.3 Gauge for marking Distance Between door plate edge &

centre of the hole of key spacer for Z+ BB doors

As shown earlier Door assembly is done using 4 door flats (Top door flat, bottom door flat,

front door flat and rear door flat), Locksole (attached with TDR slab only in case of Z+ BB

Doors), Door plate & FR Chambers.

Problems:

The problem was that earlier distance between door plate edge and centre of the hole

of key spacer was measured using a scale. But due to human error there was

deflection of 1-2mm.

The above procedure was time consuming and it took around 15-20 mins for marking

the centre of one hole. There are 2 holes on the door plate where key spacer is inserted

so it took 35-40 mins for measuring the centres of the hole.

OLD METHOD OF MEASURING THE CENTRE OF A HOLE

WITH A SCALE


Gauge:

A Gauge was made for marking the centre of the hole and then inserting the key

spacer.

The gauge is made taking reference of the door flat at the edge as shown in the

photograph.


Gauge is placed on the door flat first and then taking reference of the two undercuts

made on the gauge, key spacer is inserted in the hole so that it is placed exactly

perpendicular to the two undercuts on the door plates.

Gauge is placed on the door flat as Two undercuts are as shown in the

shown in the photograph above photograph

Then the key spacer is inserted in such a way that the hole of the key spacer is exactly in line

with the two undercuts in the gauge as shown in the photograph. Hence the hole of the spacer

will be exactly perpendicular to the two under cuts on the door plate. For getting the key

spacer hole perpendicular to the two undercuts of the door plate centre distance is measured.


Advantages:

Time for measuring the centre of the holes with a scale and marking lines

perpendicular to the two undercuts of the door plate is saved.

Earlier marking centres of the holes took 15-20 mins per hole and now it takes only 2-

3 mins per hole.

Key spacer can be inserted directly into the slot without marking any perpendicular

lines.

Cycle time for Door fabrication is reduced.


5.4 Gauge for Inspecting the Lug Position

LUG -

A lug is a component in defender safe which is welded at the top and bottom profile of the

defender plus safe.

There are two types of lugs:

1) Top Lug 2) Bottom Lug


PIVOT -

Door pivot is the component of a defender plus safe which enables the door to swing in and

out. It is hinged to the door and it is attached to the body.

Pivot is screwed to the door and then the smaller end of the pivot is inserted in the lug and

door fitting is completed after both top and bottom pivot are fitted in the top and bottom lugs

respectively.

A gauge was made to check the position of the lug whether it is welded in position or no.


Gauge is made by welding a small square bar and the front part of the pivot which enters the

lug of the door by maintaining a vertical distance of 35.5mm from the bottom of the plate to

the centre of the spherical part of the gauge. This distance is the distance which is measured

from top part of the lancing on the stiffener to the centre of the hole of the lug. The horizontal

distance is maintained by 25mm which is the distance from the centre of the hole of lug to the

adjacent profile of the body.

Thickness

of the

plate is

5mm.


Length

of the

square

bar is

30.5mm.

Distance

from

centre of

the hole of

lug to the

adjacent

profile of

the body

is 25 mm.


5.5 Jig for Drilling a hole in Comb Lock Extension

Combination Lock is a type lock used in the locking mechanism of a safe’s door. This type of

lock is a lock that will open only when its dial is turned through a predetermined sequence of

positions identified on the dial face by numbers or letters.

A hole is to be drilled on the lock extension as shown in the photograph. Earlier this was

done by punching first and then drilling a hole directly on the punched portion of the lock

extension. The procedure was as shown in the photographs below.


A small jig was made for drilling a hole on the comb lock extension.

The lock extension cap is to be screwed on the comb lock extension so a hole is drilled for

that purpose. Now the lock extension cap is first fitted in the jig it is adjusted on the comb

lock extension and then drilling is done so that there is no deflection in the drill and no

tapered hole is obtained. If a tapered hole is obtained in the extension then the lock was

disposed. Now disposing the lock due to this defect was eliminated, which saves cost.


6. KAIZENS


Kaizen No. 1

Kaizen Theme: To improve the safety and to improve the morale of the operators.

Problem: At the 90 degree tilters on SPF line, when CLA/AA bodies are to be tilted there

was a stopper between the rollers and ball bearing table. That stopper was welded in an

inclined position and it was a square bar. Hence, after tilting since in CLA/AA double bodies

the outer edge is sharp and due to its heavy weight the stopper used to break. It was also an

unsafe act.

Why-Why Analysis:

1. There were chances of an accident occurring and it was an unsafe act.

2. Body could fall from the table and it could also go in the gap between the roller tables

and the ball bearing tables.

3. The stopper used was welded in an inclined position & it was square bar so it could

not bear the heavy weight and due to sharp edges of CLA/AA bodies.

Counter Measure: Welded a scrap plate functioning as a stopper at the gap between roller

table and roller bearing table in flat position.

Results: The stopper ensures that there are no accidents and that the operators can work with

a free mind. The safety at the workstation has been improved and the morale of the operators

has also been improved. CLA/AA bodies have no chances of falling in the gap between roller

table and roller bearing table.


BEFORE AFTER


Kaizen No. 2

Kaizen Theme: To improve safety and eliminate unsafe working conditions.

Problem: The grinder machine was kept in a stand at the side of roller tables, but wire was

an obstruction while passing through the door fabrication work station. The wire lying on the

floor can prove to be fatal as any workmen can fall down due to wire lying in between.

Why-Why Analysis:

1. Unsafe working conditions.

2. Grinder wire was lying in between the way of walking.

3. The wire stand was at the side of roller table so it was an obstruction while walking.

Counter Measure: To weld two L plate at the side of armor plates storage rack so that the

wire can be at a side of the roller table and it is not an obstruction any more for any workmen.

Results: Safety has been maintained and grinder is no more an obstruction in the nway of

walking for any workmen.


BEFORE AFTER


7. Conclusion

My project deals with time study and analysis on SPF line. After time study at all

workstations the non value added activities were eliminated. The non value added activities

accounted for 2024 seconds during time study of Z+BB Door fabrication. Referring the

activities 141-144, 148,151,152, the total time for all these activities is 8.47 minutes. For

these activities the cycle time was reduced from 8.47 minutes to 2.15 minutes by making a

gauge for measuring the Distance Between door plate edge & centre of the hole of key spacer

for Z+ BB doors. A fixture is being made for time Z+BB Door fabrication. At plant 17 time

study analysis at three major workstations was done to help in setting up an automated line.

By referring to the time study, the time required at each workstation will be compared with

the time required for the proposed automated line and then the most feasible method (Manual

or Automated) based on the financial and productivity aspects will be selected.

For plug welding workstation the cycle time is 516 secs out of which 155 secs were

non value added activities.

For izonic fixture the cycle time obtained is 655 secs out of which 171 secs were non

value added activities.

For SPM Grinding cycle time obtained is 1120 secs out if which 163 secs were non

value added activities.

All the above non value added activities will be eliminated during setting up of an automated

line for O/B assembly.

During the analysis of the time study chart 3 guages were made in order to decrease the cycle

time of different workstations on SPF Line.

1st gauge was made to inspect the distance between the door flats and the door plate

edge. It was used to find the degree of bend in the door flats.


2nd

gauge was made for marking Distance Between door plate edge & centre of the hole of

key spacer for Z+ BB doors. Earlier marking centres of the holes took 15-20 mins per

hole and now it takes only 2-3 mins per hole using this gauge.

3rd

gauge was made for Inspecting the Lug Position. After using this gauge, rework on outer

bodies at further workstations was eliminated.

Another jig was made for drilling a hole on the combination lock extension so that no more tapered

holes are obtained on the extension. After drilling a hole using the jig rejection of combination locks

has almost eliminated.


8. Training Experience

It has been my good fortune to get an opportunity to undergo training at a prestigious

company like Godrej & Boyce. It has been a very enriching journey, helping me realize my

hidden potential to work under tiring circumstances. The application of theoretical learning to

practical experiences, cannot be taught in a classroom but can be learnt only through actual

work, and Godrej & Boyce has provided an ideal platform for the best practical experience

one can get. The motive of making processes technologically advanced and a highly talented

management team coupled with skilled workforce makes it a lucrative environment fit for a

trainee such as me to gain industrial experience.

Working with various CAD software’s like PRO-E and Auto Cad, observing practices

in the department, noting down every detail, to handle various situations, to deal with people

on a day-to-day basis and to meet deadlines without excuses, completely changes your

perspective of thinking, moulding you into a responsible person. Working under a group of

seniors who don’t give the solution directly but rather leading you to it, thereby assisting you

in finding your way through the obstacles, helped develop my thinking. Analyzing every

solution to a problem, zeroing in on one, taught me how to make decisions, come to a

conclusion.

The period of 6 months In-plant training at Godrej & Boyce not only proved to be

educative but also extremely fruitful as it enriched my knowledge in various aspects of the

industrial environment. It is beyond doubt that this would make one stand in good stead

throughout my future endeavours. In-plant training has made an invaluable contribution to

starting my career.


9. References

Godrej & Boyce Intranet

Standards Available at Godrej & Boyce

Websites:

http://www.godrejsecure.com/godrej/SecuritySolutions/productsoverview

http://www.godrejandboyce.com/godrej/godrejandboyce/aboutgodrejandboyce.aspx?i

d=16&menuid=929

http://en.wikipedia.org/wiki/Continuous-flow_manufacturing

Research Papers:

One-piece flow manufacturing on U-shaped production lines

John Miltenburg, McMaster University, Ontario Canada, April 2001, Volume

33, Issue 4, Page numbers-303-321

http://www.godrejsecure.com/godrej/SecuritySolutions/productsoverview

http://www.godrejandboyce.com/godrej/godrejandboyce/aboutgodrejandboyce.aspx?id=16&menuid=929

http://www.godrejandboyce.com/godrej/godrejandboyce/aboutgodrejandboyce.aspx?id=16&menuid=929

http://en.wikipedia.org/wiki/Continuous-flow_manufacturing

http://link.springer.com/journal/10756/33/4/page/1

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