SUMMER

INTERNSHIP
2017

Submitted by:
RAVI CHOUDHARY

IIT DEHI
 CONTENTS
1. Introduction

2. Products made in the plant

3. How JCB machine works

4. To study different sections of manufacturing unit

• Ram Paint Shop

• Fabrication Shop

• Main Frame Assembly Line

• Backhoe Assembly Line

• Twin Slat Line

• PDI AND Hot Test Zone

5. Project Works

• Time for study motion

• Line Balancing

• Standard Operation Procedure

• Temperature Study of the whole plant

• Work Combination Table

 CONTENTS
1. Introduction

2. Products made in the plant

3. How JCB machine works

4. To study different sections of manufacturing unit

• Ram Paint Shop

• Fabrication Shop

• Main Frame Assembly Line

• Backhoe Assembly Line

• Twin Slat Line

• PDI AND Hot Test Zone

5. Project Works

• Time for study motion

• Line Balancing

• Standard Operation Procedure

• Temperature Study of the whole plant

• Work Combination Table

 INTRODUCTION

The company is JCB (Joseph Cyril Bamford Excavators Limited).It’s founder is

Joseph Cyril Bamford (1916-2001).
(1916-2001).

Who always followed the motto :

“You know my motto from my initials J.C.-Jamals

J.C.-Jamals Content-that’s
Content-that’s very very much
me.I am never content.”

JCB Heritage :
What begin in a garage of 12 feet by 15 feet back in
i n 1945,today manufacturers
over 220 models of construction & agricultural equipments on four different
continents with bases in U.K.,the U.S.,India & South Amrica.

JCB world headquarters is one of the finest engineering factories in Europe and
sells a full range of equipments in over 150 countries.

Today,JCB is one of the world’s largest construction equipment manufacturer.

It follows policy of E=MC 2

Where E = Energy to
to infuse “sense of
of urgency”

M = Motivation to win

C = Challenge

C = Care & Commitment

 Joseph Cyril Bamford
---Founder 1916-2001---

I was once asked as a founder of JCB ,what it took to succed.’The same thing it
took to get started.’

I said, “a sense of urgency about getting things done .”

The people who makes things move in this world share this same sense of
urgency.

No matter how intelligent

intelligent or able you are,if you don’t
don’t have the same sense of
urgency,now is the time to start developing it.The world is full of very competent
people,who honestly intend to do things tomorrow,or as soon as they can get
around it.Their accomplishments however seldom match those of less talented
who are blessed with a sense of importance of getting started now.

(Joseph Cyril Bamford)

Founder 1916-2001
 PRODUCTS MADE IN THE PLANT

1. JCB 3DX BACKHOE LOADER :

It is the machine which comes under the category of earth movers in which
their

Is a bucket fitted in the front portion of the machine & an excavator fitted

Backwards which are used to dig earth or transfer it from one position to other.

This machine does 3-dimensional movement during its working that’s why ,it is

Called 3DX Backhoe Loader.Its functioning is totally based on hydraulics.

Features :

Engine

 76 horsepower fuel efficient KOEL engine with increased size of coolers

for better performance in hot and dusty working conditions.
 New transmission designed to provide high traction forces and long life
for continuous loading duties.
 Low Fuel Consumption.
 76 horsepower fuel efficient KOEL engine with increased size of coolers
for better performance in hot and dusty working conditions.
 New transmission designed to provide high traction forces and long life
for continuous loading duties.
 Low Fuel Consumption.

Performance

 Increased shovel capacity of I.I cu.m. with high breakout forces give
extraordinary loader productivity.
  Improved performance. Increased diesel tank capacity, protection on
excavator, hoses and improved excavator valve block feature, ensure
even better excavation economics.
 Highest Productivity in Class.
 Increased shovel capacity of I.I cu.m. with high breakout forces give
extraordinary loader productivity.
 Improved performance. Increased diesel tank capacity, protection on
excavator, hoses and improved excavator valve block feature, ensure
even better excavation economics.
 Highest Productivity in Class.

Design

 D section loader arm and chassis design gives lifelong structural

durability.
 Pannier design diesel and hydraulic tanks greatly add to the operator .
 High Versatility.
 Strong Excavator End.
 D section loader arm and chassis design gives lifelong structural
durability.
 Pannier design diesel and hydraulic tanks greatly add to the operator .
 High Versatility.
 Strong Excavator End.

3DX Backhoe Loader

2. JCB 3DX Super :
Its construction,functioning,working as well as area of applicability is very

Much similar to that of the 3DX Backhoe apart from the only difference

That, it is a 4-wheel drive machine giving it more power & edge over the 3DX

Backhoe Loader.

3DX Super

3. 4DX Bachoe Loader :

This machine is also quite similar to 3DX Backhoe Loader apart from the
difference that it’s forward bucket area as well as volume can be increased or
decreased according to the need of the user thus making it a 4-dimensional
working machine as it called so as 4DX Backhoe Loader.

Features :

• Strong excavator ends

• 4 wheel Drive machine

• Two Did depth option

• Bigger coolers to work in hot and dusty conditions.

• 96hp powerful engine

4DX Backhoe loader

4. Liftall :
LIFTALL – Lift and Carry Mobile Crane.
The first model, JCB Liftall – 1253 is a 12T capacity mobile crane fitted with a
telescopically extendable 3-part boom and is very useful for the erection and
construction sites, container, steel and timber yards. This will be a highly useful
tool for equipment rental companies because of its versatility.

This is the only machine in its class presently in India with European standard (IP-
69) electrics, making the piece of equipment very reliable. It also has many
exclusive and superior features, best in class, like height of lift 12.5m under hook;
travel speed – 30 kmph; a very sturdy transmission for more reliability;
unrestricted visibility on full height and wider wheel track, altogether making it a
safe and highly useful machine for erection and container jobs.
Like all JCB products, the Liftall offers unparalleled operator comfort, with its
insulated ceiling, fan, long helper seat (adequate for overnight sleep on distant
sites) and large tool box. All controls are ergonomically designed for better
operation.
 Liftall

These are the four products which are manufactured at the JCB (Balabhgarh)
plant which is world’s largest plant for the manufacturing of backhoe loaders.

Here,at JCB 75 Backhoe Loaders are produced daily with it’s 5 working days in a
week out of which generally four days are of production & 1 day in a week is NPD
(Non-Production day).On NPD ,there is no production bu t the reworking of the
produced goods are done as well as plant’s inspection takes place.
 HOW JCB MACHINE WORKS

The Basic Idea of hydraulics :

The basic idea behind any hydraulic system is very simple: Force that is applied
at one point is transmitted to another point using an incompressible fluid.  The
fluid is almost always an oil of some sort. The force is almost always multiplied in
the process.

If two pistons fit into two glass cylinders filled with oil and connected to one
another with an oil-filled pipe. If you apply a downward force to one piston
(suppose the left one ), then the force is transmitted to the second piston through
the oil in the pipe. Since oil is incompressible, the efficiency is very good -- almost
all of the applied force appears at the second piston. The great thing about
hydraulic systems is that the pipe connecting the two cylinders can be any length
and shape, allowing it to snake through all sorts of things separating the two
 pistons. The pipe can also fork, so that one master cylinder can drive more than
one slave cylinder if desired.

The neat thing about hydraulic systems is that it is very easy to add force
multiplication (or division) to the system. In a hydraulic system, all you do is
change the size of one piston and cylinder relative to the other, as shown here:

Hydraulic multiplication :Suppose the piston on the right has a surface area nine
times greater than the piston on the left. When force is applied to the left piston, it
will move nine units for every one unit that the right piston moves, and the force is
multiplied by nine on the right-hand piston.

To determine the multiplication factor , start by looking at the size of the pistons.
Assume that the piston on the left is 2 inches in diameter (1-inch radius), while the
 piston on the right is 6 inches in diameter (3-inch radius). The area of the two
 pistons is Pi * r2. The area of the left piston is therefore 3.14, while the area of the
 piston on the right is 28.26. The piston on the right is 9 times larger than the piston
on the left. What that means is that any force applied to the left-hand piston will
appear 9 times greater on the right-hand piston. So if you apply a 100-pound
downward force to the left piston, a 900-pound upward force will appear on the
right. The only catch is that you will have to depress the left piston 9 inches to
raise the right piston 1 inch.

Air in the System

It is important that a hydraulic system contains no air bubbles. We may have heard
about the need to "bleed the air out of the brake lines" of our car. If there is an air
 bubble in the system, then the force applied to the first piston gets used
compressing the air in the bubble rather than moving the second piston, which has
a big effect on the efficiency of the system.

The brakes in our car are a good example of a basic piston-driven hydraulic
system. When we depress the brake pedal in our car, it is pushing on the piston in
the brake's master cylinder.Four slave pistons, one at each wheel, actuate to press
the brake pads against the brake rotor to stop the car. (Actually, in almost all cars
on the road today two master cylinders are driving two slave cylinders each. That
way if one of the master cylinders has a problem or springs a leak, we can still
stop the car.)

In most other hydraulic systems, hydraulic cylinders and pistons are connected
through valves to a pump supplying high-pressure oil.
Circulation of hydraulics in Backhoe Loaders :
(CYCLE OF MANUFACTURING UNIT

AT BALLABHGARH PLANT)
Cycle of manufacturing unit :

Logistics to fabrication :

• First of all,the machined sheets & pre-build parts (e.g., gear assy. Parts,rear axle
assy. Parts & engine etc.) are brought in the logistics area.These parts are given
by different vendors set by the company,(e.g., Engine by Kirloshkar etc.)

Then,according to the requirements :

• Metal sheets from which main frames,rear frames,Boomers/Dippers are to be

welded are moved to fabrication shop.

• Engines are moved to skid sub-assembly line and the gears & rear –axle parts
are moved to transmission line.

Fabrication Shop :

• In fabrication shop,welding of different parts of (3DX Backhoe

loader),the product which is made are done and then after their
machining,finishing,surface smoothening etc. are done.After
machining,the machine parts are moved to paint shop.

Paint Shop :

• In paint shop,all the components parts are moved and painted ,then the
painted parts are moved to main frame assembly line.
Main Frame Assembly Line (M-Line) :

The machine parts from paint shop are brought to the main assembly line with
the help of EMS (Electric Monorail System) & cranes.

• This line has 10 zones ,for each zone certain workload is divided.In this line all
the assembling of the main frame is done.Then,this assembled main frame is
moved to the backhoe assembly line with the help of cranes & EMS system.

Backhoe Assembly Line (A-Line)  :

• At the backhoe assembly line,skid is dropped from the skid sub assembly line.

Skid Sub-Assembly Line : Assembled gear box & rear axle from transmission
line are moved to skid sub-assy. Line.Here, the engine is connected to the gear
box & rear axle.Thus (skid=Engine + Rear axle + gear box).

• The main frame is then dropped on this skid and,then after the process to
process assy. of backhoe starts.

• The main assembly line (A-Line) has 22 zones for each zone certain workload is
divided , just likewise in the main frame assy. line.

• The assembled Backhoe is then moved over to twin-slat line.

Twin-Slat Line :

• At twin-slat line firstly the booms & dippers coming from the Boom/Dipper Sub-
assy. line is attached to the machine and then the different oil filling process in
the machine is done.
PDI AND TESTING ZONE  :

• The backhoe after being assembled in previous zones is moved to the

PDI and testing zone in which the full range of machine functioning (i.e.,
working of all the parts of the machine;missing of any part,bolts or
nuts;dismatching or defects in part of the machine ) is checked.

• Then after,the machine is greased,washed & again goes on for the 45

minutes trial run.

• After that,all the machines parts are checked and if any part is missing or
defected,then the list of those parts are made.Then after,the machine goes on for
the U.V.test by which the lower portion of the machine is checked ,wether any
leakage or defect in the hose and feed pipes are not.

• After making the list of all the defects and deformities ,the machine moves in
the reworking zone where all these remedies are solved.

• And,then after final washing,decal pastings & paint touch-ups ,the machine is
green signalled for dispatch.
 RAM PAINT SHOP
• It is the shop in which hydraulic rams as well as certain other components of the
machinery parts are painted.These components are :

KPC,LEG,SHAVAL,LIFT,BOOM,DIPPER,CROWD,ST-RAM

• The raw material is fed into the loading zone where they are moved over EMS
system which after then follows the cycle.

• The material which is pre-greased & oiled (to prevent corrosion) is passed
through WATER RINSE-1,where it is bathed with a mixture of water mixed with
chemical.

Chemical name : Deoxylite 54NC

• Then,the components are passed through activation zone and after that in the
phosphating zone where phosphate coating is done on the surface of the
components.The coating chemical is

Fixodiene 30-L

• Then,the components are moved in the reason water rinsing section-2 &

• Then,the component is moved to airblow-off zone in which the components are

air blown so that no water molecules should stick on the surface.

• The component is moved to dry-off zone where it is heated in the oven,heating

temperature maintained at 62 degree celcius and 1 atm. Pressure.In this zone the
components are fully dried.

• The component is moved to masking zone where masking of holes are done to
prevent the inflow of paint in the bores.
• Then,the component is moved to primer booth blower where the component is
coated with the primer.

• The components are then moved to top-coat booth blower where final coating
of the paint is done and then the components are moved in the baking zone
where the components are baked in the oven having temperature in the range of
(90-95) degree celcius.

Here,the paint on the components surface’s are baked.

• The components are then unloaded in the unloading zone and then prepared to
move to different sections of the manufacturing lines.
 FABRICATION SHOP

1.Boom Cell :

3DX Boom is assembled and welded in this zone.In this zone manual welding is

Done with the process used is gas welding.

2.Rear Frame Cell :

Rear frame parts are assembled,welded and machined to give smoothness &

Finishing.

3.Loader Tower Robotic Cell :

The parts of the loader tower are brought,assembled,tacked & then welded in
this zone with the help of robotic welding.After which manual welding &
machining of those parts are done which cann’t be done with the help of robo
welding.

4.Loader Tower Boring Cell :

In this zone, mounting holes of loader tower is machined & fabricated with the
help of CNC machine.
5.Press Shop :

Mainly in press shop, the various components parts are pressed with the help of
different machines fixed here such as

• Bevelling machines which cuts chamfers.

• Embossing machines

• Radial Drilling Machines

• Hydraulic Press 1

• Hydraulic Press 2

To make their surface leveled.

6. Main Frame Welding Process :

• Different parts of the main frame are assembled or arranged by tacking them
in main frame tacking fixture cell.

• Then,it is pre-welded in pre-welding zone where simple welding spots are done
on the main fame.

Then,the main frame is moved to

• Manual welding shop where those parts are welded which cann’t be welded in

Robotic cell.

• Then,the main frame fixture is moved to Robotic cell where there are two
stations.

Station 1

Station 2 for robotic welding to take place.Thus,the final main frame fixture is
obtained.
7.Boom/Dipper Robotic Welding :

In this zone,robotic welding of boom/dipper is done in which those parts are

welded which was left after manual welding.

After this ,boom/dipper are moved in boom/dipper machining area where they
are machined and then collected in the storage area.

Each & every component after fabrication are stored in fabrication business
unit(Fixture storage) after which all components with main frame,boom/dipper is
moved in the paint shop where they are painted and then moved to main frame
assembly line.
TWO WAY CNC HORIZONTAL BORING MACHINE :

Designed for : Boom/Dipper

Output : 25 sets/shift

Payback Period : 1 year

• The machine has automatic computer numerical control (CNC) operation except
component load/unload.

• The two components are loaded in dedicated fixtures fitted on two linear
travelling tables which are alternately taken for machining.

• Two concentric tools fitted in rotating spindles machine each bore

simultaneously from either side half way down the length.Each bore is finished in
two stages –Rough and finish.

• One after the other bore is presented to spindles by movement of machine

tools.

Salient Specifications :
• Two way horizontal boring machines fixed columns.

• CNC Controller : Siemens 840D

• Taper Spindle : HSK 100A

• No. of Spindles :2

• Spindle Speed : 40-4000 RPM

• No. of tables/pallets :2
• No. of ATC/No. of tools in each ATC : 2/24

• Bed Size : 19 metres

• Cycle Time (set) : 18-25 minutes

• Components machine/Shift : 25 sets

• CP (booms) achieved in trials : 1.7-2.25

• CP (dippers) achieved in trials : 1.8-4.16

Function of this machine :

Precision machining of mounting holes of fabricated booms and dippers.

ASSEMBLY LINES :

Main Frame Assembly Line (M-Line ) :

ZONE M1 : Main Frame Drop

• Pick main frame

• Drop main frame on M-line

• Pick adjuster plugs from bins & Place on mai frame

• Pick pads & legs from bins & place it on main frame

• Pick pneumatic gun & fix adjuster plug

• Pick rivet gun from stand & fasten rivets with rivet guns of M8 &M10 size

ZONE M2 : Leg Fitment Zone

• Pick leg ram from trolley & place it on outer leg.

• Pick pivot pin from trolley

• Place in aligned hole in outer leg & inner leg

• Pick leg ram from trolley & palce it on rear frame

• Pick pivot pins from trolley & fix leg in place with pivot pins

• Pick circlip from bin,pick circlip plier & lock pivot pin in place with the circlip.
ZONE M3 : FRONT AXLE FITMENT

• Pick front axle from trolley & place it on main frame

• Pick pivot pins & shims from trolley

• Align hole of front axle & axle yoke,insert pivot pin in the hole

• Pick bolt & nut from the bin,lock pivot pin in place with bolt & lock nut.

• Pick battery gun,socket & nut runner.Tighten the bolt

• Pick cover plate from bin,Pick screws,battery gun & socket.Tighten the screws

• Pick loader feed pipe from trolley.Place it on main frame

• Pick hoses from trolley,join the hoses to loader feed pipe on each side

• Pick torque wrench.Tighten the adaptor to main frame from usig torque wrench

• Pick grease nipple from bin

• Fasten grease nipple to adaptor using nut runner.

ZONE 4 : STONE GUARD FITMENT

• Pick left & right hand stone guards from trolley.Place it on main frame

• Pick bolts,nuts & washers from bins.Pick battery gun,socket & nut ru nner

• Fasten stone guards in place with the help of bolts & nuts

ZONE 5 : VALVE BLOCKS

Loader hoses fitment :

• Pick hoses from trolley.Place it on main frame

• Pick hoses clamp from bin.Place it on main frame

• Pick battery gun,socket,nut runner.tighten hoses in place using battery gun

LVB FITMENT :

• Pick resilient mount from bin.Place it on main frame

• Pick LVB from trolley.Place on resilient mounts

• Pick lock nuts from bins.Pick battery gun,socket.Tighten the LVB with lock nuts
using battery gun

• Pick torque wrench.Join hoses of LVB to loader feed hoses.

EVB FITMENT :

• Pick EVB from trolley.Place it on main frame

• Pick bolts,nuts & washers from bins.Place it on EVB

• Pick battery gun,socket & nut runner.Tighten the EVB using battery gun

ZONE 6 : HOSES/PIPES

• Pick hoses from trolley.Place it on main frame

• Fasten two hoses on EVB to pipe rear return

• Fasten hose from LVB to EVB.Fasten hose to leg ram on both sides

• Fasten 4 hoses to EVB.Place it in retainer via right house guide

• Fasten 5 hoses to LVB.Place it in retainer via right house guide

• Place both retainers.Fasten hoses from front axle to orbital standing ram
• Remove cap from hoses & fasten it to loader feed pipes.Fasten hose from EVB
to tank.Place cab mountings on main frame.

ZONE 7 : FUEL TANK FITMENT

• Pick fuel tank from trolley.Place it on main frame

• Pick srews,washers from bins.Place on fuel tank.Pick pneumatic gun,socket

• Tighten the tank into place

ZONE 8 : HYDRAULIC TANK FITMENT

• Pick hydraulic tank from trolley.Place it on main frame

• Pick screws ,washers from bins.Place it on the hydraulic tank

• Pick pneumatic gun ,socket & tighten the tank into place

ZONE 9 : KPC FITMENT

• Lift KPC sub assy.Place it on main frame

• Pick upper & lower lock washers from bins.Tighten the locks to KPC

• Align one hose from EVB to right hand hydraulic clamp T-joint

• Pick torque wrench.Tighten hose using wrench

• Align hose both sides from hose retainers through KPC slew ram pipe to join
with slew ram pipe in KPC

• Fasten hose from EVB to right hand upper hydra clamp adaptor
• Fasten hose from right hand upper hydra clamp to left hand lower hydra clamp

• Connect slew ram hoses in KPC from small hoses in hose retainer.

ZONE 10 :

• Main frame loading to move it on main assembly line through EMS

& cranes.

MAIN ASSEMBLY LINE (A-Line ) :

ZONE 1 & 2 : SKID DROP

• Pick skid from fixture & place it on conveyor

• Pick parking brakes from trolley

• Pick pneumatic gun,nuts,bolts & shuns from bin.

• Fix parking brake to rear axle.

ZONE 3 & 4 : MAIN FRAME DROP

• Unload main frame from hoist & place it on conveyor.

• Pick bolts,nuts & washers from bins.Place it on main frame.

• Bring auto shut off tool to position.Fasten the rear axle to m/f using bolts & nuts

• Pick yoke plate from trolley.Place on gear box.

• Pick bolts,nuts,washers from bins.Pick pneumatic gun,nut runner.

• Fasten yoke plate to gear box using the bolts,nuts.

• Pick bolts,nuts & washers from bin.Fasten yoke plate to m/f using bolts,nuts.

ZONE 5 : DRESS UP

• Pick hose from trolley.Pick torque wrench.

• Attach one end of hose to return feed pipe and another to hydraulic cooler
using wrench

• Connect retur hose from EVB to hyd. Tank already placed on m/f using torque
wrench.

• Fasten the hose from transmission to cooler.Pick hydraulic section hose from
trolley.Pick jubilee clip and worm drive clips from bin.

• Attach one end of hose to hyd. Tank and other to pump using the clips

Connect pressure sensor.

ZONE 6 : AFTER DROPPING ELECTRICAL FITMENT

• Fasten hoses from m/f to transmission.

• Fasten hoses from hydraulic tank to check valve

• Fasten hoses from return feed pipe rear side to exc. Return pipe.

• Lift hose to connect loader valve back to hydraulic pump

• Place cable tie from yoke late to conveyor to engine

• Pick battery gun & socket.Open the nuts of starter & alternator.

• Connect harness with starter & alternator

• Pick battery gun & socket.Connect +ve cable with starter on one side and the
other end on the battery side.Tighten the  –ve harness.

• Connect m/f harness with alternator connector

• Connect m/f harness with oil pressure switch connector

• Connect m/f harness with transmission switches for reverse & forward &
connect with transmission switch and one with speedometer switch.

ZONE 6 & 7 : ELECTRICAL FITMENT & RADIATOR/T. COOLER

• Pick horns from bins.Pick on main frame.

• Pick setpins,std nts,washers & spring washers from bin.Pick battery gun &
socket

• Fix horns using washers & nuts.Pick jubilee clip & gun.

• Fasten the hose from tank to engine using the clip & the gun

• Route the hose through diesel tank bend to engine over flow pipe.

• Pick gear lever.Place on transmission keeping angle on R/H side.

• Pick battery gun,socket.Tighten the lever using the gun

• Pick hose from trolley.Assemble with clip on water temperature switch

connector

• Tighten one end.Pick jubilee clip,battery gun.Fasten the hose using clip & gun

• Place hose b/w engine & radiator .Pick rubber,grommet.Make dipstick assy.

• Mount rubber grommet & dipstick assy on gearbox.Assemble dipstick on

transmission using clamp & bolt.

• Pick mounting bracket.Fasten the bracket on the engine

• Pick air cleaner.Fasten the air –cleaner on engine using bolts.

ZONE 7 : COOLING PACKAGE 1 & 2

• Pick mud filter & sediment from trolley.Place it on main frame.

• Pick bolts from bins.Attach both filters using bolts.

• • Pick torque wrench.Fasten the hose from engine to filter using the wrench.

• Fasten the hose from sediment filter to mud filter using the wrench.

• Fasten the hose from mud filter to diesel tank using the wrench.

• Lift cooling package assy.Place it on m/f.

• Pick bolts,washers & lock nuts from bin.Pick batrey gun ,socket &
spanner.Fasten the assembly using bolts & nuts.

• Pick jubilee clip.Fasten the hose bend to radiator using the clip & the gun.

• Pick bolts,washers & nuts from bin.Pick battery ,socket & spanner.

• Fasten the transmission & hyadraulic cooler using the bolts & nuts.

ZONE 8 : FRONT END

• Pick battery & mat from material feed conveyor.Place it on main frame.

• Pick battery from trolley.Place on all the levers

• Pick knobs from bins.Place it on lever & tighten the knobs with nuts.

• Join all the knob cable with harness connectors.Pick brake fluid reservoir.

• Open cap,put splash guard & tighten the cap.

• Pick bracket & place it on reservoir.Pick bolts,washers & nuts from bins.

• Assemble brackets to reservoir using nuts ,bolts.

• Pick assembly from tray & place it on main frame.Pick bolts,nuts & washers
from bin.Pick battery gun,socket & nut runner.Mount the reservoir using
bolts,nuts.

• Pick bumper from mat conveyor.Place it on main frame.

• Pick hack screws from bin.Pick battery gun,extension socket.

• Fix bumper in place using the screws.Pick yellow plugs from bin & place on the
bumper.

• Pick grill housing from mat conveyor.Place it on main frame.

• Pick bolts,nuts & washers from bin.Pick battery gun,socket.

• Pick housing in place using the nuts,bolts.Pick grommets & maxifuse from
bin.Place grommet on top of housing manually.

• Fix maxifuse to harness above R/H clamp.

• Pick bonnet stay,springs & split pins from bin.Assemble the parts into grill
housing.

ZONE 9 : LIFT RAM FITMENT

• Pick lift ram from trolley.Place it on loader tower

• Pick retaining collars,nuts & bolts from bin.Place on pivot pin

• Fix in place using nut & bolt.Pick torque wrench.

• Connect the hoses from lift ram to m/f using the wrench.
• Pick hose,jubilee clip from bin.Assemble with pre-cleaner pipe in main frame &
air pre-cleaner using battery gun.

• Pick silencer from mat feed conveyor.Remove masking from engine exhaust
manifold & keep yhe hardware for the assembly.

• Assemble the silencer on manifold one side & other side on fuel sedimentation
filter bracket.

• Tighten silencer on engine with engine manifold by tightening 2 bolts first &
then top 2 bolts using battery gun.

ZONE 9 : LEVEL LINK FITMENT

• Pick level link from trolley.Mount on pivot pin already placed on trolley.

• Pick safety strut & T-bolt.

• Mount the strut on the link using the T-bolt.

• Pick collar & bolt from the bin.Place the collar on the pivot pin using bolt,lock
nut.

ZONE 10 : CHASIS NUMBER

• Bring punching machine to the main frame.

• Fix it & engrave the chasis no. on it

ZONE 11 & 12 : LOADER ARM

• Bring down loader arm from EMS loop.Allign its rear end with loader tower
upper hole.
• Pick pins & shims from bin.Fasten the loader arm to loader tower using the
pivot pin,shim

• Insert collar & bolt in pin.Pick bolts & nuts from bin.Fix pin in place using nuts &
bolts.Align hole of level link & loader arm.

• Pick pin & insert in hole b/w level link & arm

• Fix pin in place by inserting collar,nut & bolt.

• Down the crane & remove the tackle for ram rod end both sides

• Insert lift ram b/w links of loader arm on both sides by using special rods for
alignment.

• Pick bolts & nuts from bins.Pick pivot pin from bin.

• Place pins in the aligned hole.Fix pin in place using the nuts & bolts.

• Tighten all the nuts & bolts with battery gun,nut runner .

• Release the tackle & front side after making loader arm fully down and send for
EMS loop.

ZONE 13 : BONNET FITMENT

• Pick bonnet from material feed conveyor.Place it on table.

• Pick bonnet hinge, washers ,bolts & nuts from bins.Place on table.

• Assemble all the parts to the bonnet .Pick battery gun, nut runner .

• Tighten the nuts,bolts using the gun.Lift the bonnet.

• Place it over shroud on one side & grill housing on the other.

• Pick bolts,washers & nuts from bin.Assemble the bonnet in place using the
bolts, nuts.
• Pick battery gun ,socket & nut runner.Tighten the nut,bolts using the gun.

Hold bonnet with stay.

ZONE 13 : PRE-CLEANER SUB-ASSEMBLY

• Pick pre-cleaner stud body from bin.

• Fix the body pre-cleaner to stud by pressing tightly.

• Pick top pre-cleaner. Place on body pre-cleaner.

• Pick base pre-cleaner from bin. Attach it to stud manually.

• Pick jubilee clip from bin. Place on bottom of the stud.

• Pick jubilee clips. Fasten it using the gun.

ZONE 14 & 15 : CAB FITMENT

• Lift cab from mat feed conveyor .Place it on main frame.

• Pick nuts,bolts & washers from bin. Fix them in their aligned holes.

• Tighten the nuts ,bolts using the nut runners.

• Pick side panels from trolley. Place it on main frame.

• Pick bolts,nuts & washers from bin.Pick battery gun , nut runner.Fix panels in
place using battery gun & nut runner .

• Connect hoses from master cylinder to brake oil cup.

• Pick up gun to tighten the hoses. Push button to start cycle

• Remove gun after completion of the cycle.Place gun bolt on t he machine.

ZONE 16 & 17 : CAB INTERNAL

• Pick floor mat from trolley.Place on L/H & R/H side on the cab.

• Check electrical in the cab .Check lights from head lamp, indicators.

• Pick cab side cover from trolley.Pick battery gun socket.

• Pick bolts,washers from bin. Pick panels in place using bolts,nut & washers.

• Pick cab side covers from trolley. Pick battery gun socket.

• Pick bolts,washers from bin. Fix the panels in place using bolts & washers.

• Put the battery cable on the battery. Pick battery cover from trolley.

• Pick bolts, washers & flynut from bin. Place the cover on the battery using the
fly nuts etc.

• Pick grills from trolley. Place on the front end.

ZONE 18 : BRAKE BLEEDING

• Remove gun & press cycle abort PB. Flush cycle. Press cycle start.

• Evacuation, Excess vacuum, Leak test ,Revacuum.

• Fitting operation & leveling.

ZONE 19 & 20 : TYRE FITMENT

• Pick rear tyre sub –assy. Place them on rear axle.

• Pick front tyre sub-assy. Place them on rear axle.

• Pick nuts from bin.Place on rear & front axle. Fasten tyres to both the axles
using nuts & bolts & pneumatic gun.

TWIN-SLAT LINE :
•Pick trolley having boom & dipper.Place the boom & dipper on dedicated stand.

Join hoses of boom & dipper.

•Pick bolts, collars, shims & pivot pin from stand & bin.

• Connect boom & dipper using the pins. Fix them using a hammer. Join ram of
boom using to dipper using the pivot pin.

• Connect the remaining hoses to KPC assembly.

• Fill the oil in five respective oil tanks

DIESEL, ENGINE, COOLANT, TRANSMISSION, HYDRAULICS.

PDI AND HOT TEST ZONE :

BAY – 1 :

BUCKET FITMENT ZONE

Loader buckets as well as excavators buckets are brought in this zone to be

attached to the 3DX backhoe loader.

Excavator buckets :

These are first attached to rear portion through pivot pins.

Loader buckets :

These are attached to the front portion through pivot pins.

Then,the working of the buckets are tasted in this zone.The nuts of the king post
carriage are adjusted in such a way that the KPC arrangement could easily slide
along the line of the machine.

PRE-RECTIFICATION ZONE :

In this zone,all the fastenings of the machines are checked wether some
fastenings are missing,tightly fitted or loosely fitted,then all the errors are
rectified.

Further on, all the oil canters are kept here such as :

COOLANT ENGINE OIL TRANSMISSION OIL DIESEL HYDRAULIC OIL

If in any tank ,the oil is less then the required oil is filled according to the need.
Then the machine goes in the greasing zone where different portion are greased
using CASTROL grease.

* Hydraulic dye is filled in the hydraulic tank to inspect any leakage in the tank.

WASHING BAY :

Washing chemical : HENKEL-P3T768

With the help of this chemical the washing of the hole machine is done.

After that, the machine goes for a 45 minutes trial run in which it is used harshly
to check all the functioning s of the machine.

BAY – 2 :

DYNAMIC AND HUMPTEST ZONE :

• Locate the machine on roller testing bench. Move the hydraulic platform (b/w
the rollers ) downwards by pressing PB on electrical panel.

•Operate the machine in first gear & then in second & so on. Observe any
abnormal noises.

•Apply sudden brakes & observe the status on electrical panel.

TOTAL CYCLE TIME OF THE PROCESS : 10 MINUTES

BAY – 3 :

INSPECTION ZONE :
Quality inspection is done according to the parameters set up by the company or
quality control department.

* UV testing as well done here in this zone.

BAY – 4 :

INSPECTION ZONE :

Reworking o f machine of all the faults detected by the inspection zone at BAY –
3.

is done here in this zone.

BAY – 5 :

FINAL TOUCH-UP :

After reworking the machine goes in for the final touchs in different sections :

Washing BAY

PDI BAY – 1

PDI BAY – 2

DECAL PASTING

PAINT TOUCH UP BAY – 1

PAINT TOUCH UP BAY – 2

Major Rework BAY

PROJECT
REPORT
TIME FOR STUDY MOTION :

This is the project based on time - to – time study of each and every worker
working on the main frame line & assembly line for the manufacturing of a single
machine.

In this project, a simultaneous time was to be taken based on the work load of a
single worker working on the line.

For which , we have to take the individual time for a single worker depending
upon the time he devotes in doing his work

Manually (by hand ) .

With the help of machine like crane as well as different torques

& the time he devotes in walking which comes under NVA (Non-value added )
work.

Thus , keeping in view all the above working parameters , we noted down each
individuals time dividing everyone’s time in the three categories mentioned

above . Thus, we came on the conclusion that

there are 38 workers on the assembly line which are casual & 37 workers on the
assembly line which are permanent with each one’s individual time, which will be
compared with the tact time of the machine & whatever methods to be adopted
will be done to increase their efficiency as well as to increase the production line.
STANDARD OPERATION PROCEDURE :

This is the operation which is the base of any manufacturing unit because it is the
working parameter based on which the workers have to do their work to produce
a single machine.

Standard operation procedure is a wholesome process in which the total

processing of a manufacturing line comes under the scanner like picking up a
single pin , to walking of the man to his designated platform , to movement of
cranes from one position to another.

Thus , in standard operation procedure or so called (SOP) ,

Firstly, we had to study the whole processing of the JCB machine manufacturing
from main frame line to main assembly line and then to twin-slat line.

And after that , studying the SOP of each & every sub-assemblies.

BOOM/DIPPER , LOADER ARM , SKID , KPC , HYDRAULICS.

Thus , after studying the each & every motion of the process , we have to modify
& update the sop of the whole assembly line in which we have to see that

Wether , any operation or operator is left out or any operator is extra which can
be sorted out or can be indulged into any extra work.

Thus , this was our project based on the STANDARD OPERATION PROCEDURE.
TEMPERATURE STUDY OF THE WHOLE

MANUFACTURING UNIT

In this project , we have to take the temperature of some specified zone of the
whole plant on the daily basis with the help of a digital thermometer.

By taking the temperature of each & every zone , we came under the conclusion
of the fatigue level under which different workers of the whole plants are
working.

Thus , making a conclusion of the areas which are to be concerned in which the
worker’s fatigue level could be decreased.

The different areas in which temperature was to be measured were :

Main Frame Zone Z21 & Z22 32.4

M1 31.1 TWIN-SLAT LINE
M2 31.0 T1 32.5
M3 31.1 T2 32.5
M4 31.2 T3 32.8
M5 31.3 T4 32.6
M6 31.5 T5 32.8
M7 31.2 T6 32.8
M8 31.0 T7 32.7
M9 31.0 B/D Sub-assy. 32.2
M10 30.8 Loader arm sub-assy. 33.2
Assy. Line Skid assy. 32.3
Z1 & Z2 30.9 KPC Sub-assy. 30.9
Z3 32.0 Gear box trans. line 32.9
Z4 32.0 Rear axle line 33.2
Z5 31.8 CNC 32.3
Z6 31.9 Fabrication Shop
Z7 32.0 M/F Robo 33.2
Z8 32.1 B/D Robo 32.2
Z9 31.8 Loader Tower Cell 31.9
Z10 31.9 SIP 32.7
Z11& Z12 31.8 Machining Area 33.2
Z13 31.6 Old Power House 31.1
Z14 & Z15 31.7
Z16 & Z17 32.1
Z18 32.2 LDC 30.9
Z19 & Z20 32.1 Ambient 40.1

Thus ,we came under conclusion that area such as machining area ,
some sub –assy., & transmission line are relatively hotter than other
zones . Thus , something is to be done there .
WORK COMBINATION TABLE :

Standard Work Combination Table - Definition

The Standard Work Combination Table combines human

movement and machine movement based on takt time and is
used as a tool to determine the range of work and work.

Sequence for Human work and Machine work

The key notion for the elimination of waste and the effective combination of
work on the shopfloor is the separation of machine work and human work.
When we observe the work in which operators handle machinery, then that
work can be classified into machine or human work.
Understanding the separation of human and machine work is the basis for
understanding the interface between these two elements.
If operators are merely observing the machine working then this is the waste of
“Waiting” and should be eliminated.which a team member is responsible.

Human work

This refers to work that cannot be completed without human effort. For
Example ,
• picking up materials
• putting materials onto a machine
• operating the controls of a machine
• manual slaving
Machine work

This refers to work or incidental work that equipment, which has been started
by human hand, automatically performs operations.
• Milling
• Auto riveting / bolting
• Auto inspection (Hole probes) etc.

VA/NVA ANALYSIS – Perfect For Today’s

Economy

Just about everyone knows that the economy is bad. Organizations are laying off
employees by the tens of thousands, and realistically, most of the time this
becomes just a numbers game. If we get rid of X number of people, it will impact
the bottom line of the organization by Y amount.

Typically, this is not the case. Often organizations end up spending more or
incurring additional waste as a result of staff reductions. Processes can become
broken and often do not function properly because knowledgeable people have
been let go, and the people that remain, do not know what to do. Confusion is
rampant – with everyone wondering what needs to be done and how it will
happen with fewer people. The word “reorganize” is everywhere; to the point
where we are reorganizing so much, we never become organized.

This is where understanding the tools of  Lean & Lean Six Sigma becomes
invaluable. If companies want to reduce costs and waste in an organization, that
is the heart of Lean and Lean Six Sigma.

One of the best tools that can be used is the Value Added/Non Value Added flow
analysis. Upwards of 80% of most processes consist of non-value added activities.