Production, Optimization and Quality Control of Fuel Injectors Manufacturing

Production, Optimization and Quality Control of Fuel Injectors Manufacturing.

MMAE-557

Personal Consulting Project

Acknowledgement

Several people should be mentioned for their contributions to the paper. I am grateful to the following: Prof. J. Cesar one of the Illinois Institute of Technology, Chicago, USA, for his thoughtful reviews of Chapters 13 to 23 in Automation Production, Systems and Computer Integrated Manufacturing Book.

Abstract

The project gives an outline for Fuel Injector production, its Manning Level estimation and quality aspects to be improved to achieve better production. Fuel Injectors are the main components of Diesel Engines. DSLA is a convential type injector. It has two main components- body and needle. In our project we discussed about the soft stage of injector body. The production line is semi automated, with raw material coming from the vendor, and the production starts with inscription rolling, where batch number is assigned to Kanban batch. Then onwards the production in every machine is done on the according to batches. Process control is done using SPC charts. And one worker is engaged for control and quality supervision of final product.

Table of Contents

Section No Description Page No

1 Client Description 5

2 Analysis of production line 13

3 Cycle time Calculations 14

4 Optimization 18

5 Automation 24

6 Quality Assurance 25

7 Results 26

8 Literature Sited

27

9 List of Figures 28

Section 1

Client Description

CLIENT: MICO BOSCH (FUEL INJECTOR MANUFACTURERS)

Soft stage of DSLA nozzle body is taken.

Low Productivity, Manning Level is high, Automation is required.

Production Line: Containing 9 stations.

Production rate required is 12000 parts/day.

Number of Workers: 9 or more

Work Schedule: 3, 8hr shifts per day, 7 days per week, 52 weeks per year.

Classification: III H, S

Process Description:

This is semi automated production line with nine station and each station operates separately. The operations done on the line are Inscription rolling, Guide bore drilling, operation on spinner, collar grinding, Inlet and dowel hole drilling, high pressure cleaning, ECM, piscal cleaning, ball turning. All the operations are independently. All the machines can have multiple machines except for ECM, because it is costly and machine takes a large place with all its storage tanks. So the ECM becomes bottleneck for the line.

Workstation 1(Inscription rolling):

Kanban production system is followed on the line, so the parts are divided in to batch of fifty number each. Every batch has batch number, which would be same for all the fifty parts in a batch. The batch number is in scripted on the part at this station. The machine consists of eccentric wheel, with numbers embossed on it.

Fig 1: Inscription Rolling

Workstation 2(Guide bore drilling)

This is done Widma Gun drilling machine. The guide bore is the hole in which the needle vibrates. The length of the drill would be around 35mm. Four parts are loaded at a time on the machine and four different gun drilling spindles drill the four parts simultaneously. The worker has to load the the parts on the holders and start the cycle, the