Professional Documents
Culture Documents
INTRODUCTION
We have obtained the Sponsorship on Industrial Project in the SHARADA
MOTORS by Manager Mr.Dikshit Sir. Sharada Motors is the Manufacturer of suspension,
Exhaust System, Automotive Seat Timsand assembly of front and rear axle for cars. Last
year company turnover was 1156 Cr.
Company has Two Plants in Nashik, Plant 1 and Plant 2.We got project at the
plant1 of company at Satpur. In Plant 1 Assembly, Welding Work and Inspections of
product is done. There are many Machines, Cranes and Conveyors used in this plant.
Machines like CNC, Welding Robots are used for production. Hydraulic Cranes are used for
better Material handling andconveyors are used on assembly line. Welding robots also used
for welding purpose of product.
In plant 1 of Sharda Motors already have three automatic welding robots in
working condition. But these 3 robots can not complete company requirement of products in
given time. More time was wasted for welding purpose of product. Hence management team
of company decided to increase quantity of automatic welding robots in plant. Therefore
they bought 3 new automatic welding robots PANASONIC TM 1400 in disassembles
condition. In plant 1 some space is useless. Company worker used this space to put material
trolly and other useless material.
Plant 1 manager Mr. Dikshit sir gave us a chance or task to prepare a layout for
these three new automatic welding robots. Mr. Dikshit sir told us to use our theoretical as
well as practical knowledge and gave us a layout for new robots. Mr. Dikshit told Mr.
Abhijit to help our work.
We all are met Mr. Abhijit sir and discussed with him about our project details
.Mr. Abhijit sir gave us some requirements to make a better layout. Then we meet the other
working condition welding robot operator and try to get his requirements for layout. Then
we Study the working robots already exist in company. How it works? What is it cycle time
for 1 product? How they are give input to welding robot and how get output of final product.
We discus other workers work in plant to know about his working style, his safety
precautions take for working on automatic machines, his cloths and other important factors
related to automatic machines.
Then we study our space availability. We measured the available space by
using meter tap. The available space is 17m long and 7.6m width. Then we take the robots
dimensions. Two robots having same dimensions, but 1 robot having different dimensions.
We study the all over dimensions of space available and robots, trolleys of input and output,
worker and other parts of robot and make some possibility or primary layouts of new robots.
Page | 1
2.COMPANY INTRODUCTION
This Unit has been set up with clear objective of catering to the growing
demands of automobile giant M/s. Mahindra & Mahindra Ltd. We manufacture Independent
Front Suspension Systems and Exhaust for Tata Motors and Mahindra & Mahindra
The Unit is ISO 9002 & TS-16949 certified and planned to achieve 100 ppm
certification by end of financial year 2005-2006. Ours is a well equipped unit with latest
machinery and modern processing techniques such as CNC 3- axis pipe bending, PLC
controlled ROLL 'N' Spot, PLC controlled SPM for Welding, PLC controlled flange-up,
Page | 2
Baffle plate and bottle pipe insertion, Stuffing with PLC Control, Seam welding and
Covering press for Catalytic Converter.
Page | 4
3.LAYOUT PREPARATION STUDY
Page | 5
8) The principle of minimum handling :-
All movement and handling should be kept at optimum level.
Page | 6
4. OBJECTIVES OF LAYOUT
10. Better working condition like light, ventilation, noise control, smoke control etc.
Page | 7
5.GENERAL FACTORS AFFECTING LAYOUT
Page | 8
6.IMPORTANCE OF LAYOUT
1.Economics Of Handling:-
Layout should be cost effective. There should not be much time consumed
for movement of product or material.
Page | 9
7.PLANT LAYOUT
Plant layout is a mechanism which involves knowledge of the space requirements for
the facilities and also involves their proper arrangement so that continuous and steady
movement of the production cycle takes place.
Moore, a very well known name in the business world, explained plant layout as,”
The plan of or the act of planning, an optimum arrangement of facilities, including
personnel, operating equipment, storage space, materials handling equipment and all other
supporting services along with the design of the best structure to accommodate these
facilities”.
The problems related to plant layout are generally observed because of the various
developments that occur. These developments generally include adoption of the new
standards of safety, changes in the design of the product, decision to set up a new plant,
introducing a new product, withdrawing the various obsolete facilities etc.
Page | 10
The basic flow pattern types that are employed in designing the layouts are I-Flow, L-Flow,
U-Flow, O-Flow, S-Flow.
Page | 11
8.TYPES OF PLANT LAYOUT
1. Process layout :-
These layouts are also called the functional layouts and are very suitable in the
conditions, when the products being prepared are non – standard or involve wide variations
in times of processing of the individual operations.
Such layouts are able to make better utilization of the equipment that is
available, with greater flexibility in allocation of work to the equipment and also to the
workers. Imbalance caused in one section is not allowed to affect the working of the other
sections.
2. Product layout:-
These layouts are also known as the line layouts or the layout by sequence. In
such layouts, the manufacturing cycle is small with minimum material handling. The space
required is small and quality control is easy to exercise.
3. Project layout:-
Such layouts are also referred to as the fixed position layouts. In these
layouts, the components, heavy materials, sub assemblies – all remain fixed at one place and
the job is completed by movement of machines, men and tools to the location of the
operations.
Page | 12
9.PRODUCT LAYOUT
Page | 13
10. WORKING STEPS
Phase I : Location
Phase II : General Overall Layout
Phase III : Detailed layout
Phase IV : Implementation
j. Modifying consideration
k. Practical Limitations
m. Evaluation of alternative
Page | 14
11. COMPANY PLANT LAYOUT
Page | 15
12. POSSIBILITY OF LAYOUTS
Advantages:-
Disadvantages:-
Page | 16
Fig. no 12.2 Layout 2
Advanteges:-
Good space saving.
Comfort material handling
Disadvanteges:-
Difficulty in supervision.
Working space is less.
Page | 17
Fig. no. 12.3 Layout 3
Advanteges:-
Better working space.
Better flexibility.
Disadvanteges:-
Difficulty in supervision.
Unuse space is more.
Page | 18
Fig. no. 12.4 Layout 4
Advanteges:-
More working space.
Disadvanteges:-
Unused space is more.
Difficulty in material handling.
Page | 19
Fig. no. 12.5 Layout 5
Advanteges:-
More space saving.
Well raw material handling.
Disadvanteges:-
Less flexibility.
Accident chances is more.
Page | 20
Fig. no. 12.6 Layout 6
Advanteges:-
Good space for working.
Disadvanteges:-
Space utilization is less.
Supervision is difficult.
Unused space is more.
Page | 21
Fig. no. 12.7 Layout 7
Advanteges:-
More space available.
Good supervision.
Disadvanteges:-
Some space get unused.
Worker Safety is less.
Flexibility is less.
Page | 22
Fig. no. 12.8 Layout 8
Advanteges:-
Worker safety is more.
Good Space saving.
Disadvanteges:-
Less flexibility.
Accident chances is more.
Complicated material handling.
Page | 23
12.1 Marking Chart For Possibility Layouts:-
2.Material Handling
4.Flexibility
5.Worker Safty
7.Unuse Space
8.Accident Chances
Layouts 1 2 3 4 5 6 7 8
Parameters
1 9 7 6 6 5 5 7 8
2 8 8 7 5 7 4 8 7
3 8 8 8 5 8 6 5 7
4 9 6 5 7 6 5 7 8
5 9 7 7 8 5 4 6 6
6 10 8 8 6 6 8 7 5
7 9 5 8 6 7 7 4 5
8 8 4 5 4 6 5 6 7
Page | 24
13. AUTOMETIC WELDING ROBOT
PANASONIC TM 1400 :-
TECHNICAL SPECIFICATIONS
Structure 6 Axis
RT 225°/s
UA 225°/s
FA 225°/s
Axis Speed
RW 425°/s
BW 425°/s
TW 629º/s
Page | 25
14. MATERIAL HNDLING
For better materil handling need good material handling devices. Sharda motors
use trolleys for material handling ,but new robot workpiece is change in its dimensions.
Hence we need design new trolleys for new robots raw material and finish products.
Page | 26
Fig. no. 13.2 Trolley for raw material
This is the final layout for automatic welding robots. it is selected by the
company management. its the more space utilizing, give more working space for worker and
more worker safety.In this layout material handling Is very good and easy. Inpection and
supervision on working is simple. Chances of accidents is reduces by using pneumatic
operating doors for robots cells.
Page | 27
15.1 After placing the robots with cell :-
This is the photo of automatic welding robot Panasonic TM1400 placed at the
company on the basis of selected layout
Page | 28
16. ADVANTAGES
Page | 29
17.DIFFICULTIES IN PROJECTS SOLUTIONS ON IT
Difficulty in measurement:-
Company use given space for put raw material and trolley hence we .
Difficulty to getting company requirements:-
We want communicates with the worker for desccus the problems facing
on working condition.but they are besy in its work.
Layout generation:-
For drawing the possibility layouts more time is required.
Required more numbers of possibility layout making:-
We found Many Drawbacks in layouts. So it is very difficult to reducing
the drawback and make new layout.
Lack of information:-
Less knowledge about layout preparation.
Material handling:-
The finish products of new layout is change in its dimensions hence we
facing the material handling problem.
Page | 30
18. ANALYSIS OF PROJECT
Company Requirements:-
company required good space utilization, no waste of space, easy movement for
operator, good layout for high productivity
Space Availability:-
space for layout is 17M x 7.6M. This was the available space for adjusting three
welding robots
Page | 31
19.GUIDELINE
Prof. P.P.Bhirud,
HOD,
Mechanical engineering department
K.V.N.Naik Polytechni,Nashik
Mr.SachinDikshit,
Sinear Production Manager,
Sharda Motors. Pvt.Ltd.
Mr. Pawar
Assistance Maintainance Manager ,
Sharda Motors. Pvt.Ltd.
Page | 32
20.CONCLUSION
Our project was to prepare a layot for automatic welding robots in SHARDA
MOTORS company. We had to prepare different possibilities of layout. For that we studied
diferent layouts possible to prepare. We considered different parameters like space available,
material handling, worker safety.
We studied different types of layouts and their disadvantages. And discussed those
with the company manager. Then we discussed about the best layout and chose it for the
establishment of the robots.
We learnt in this about the robots, layouts, time management, different processes
used in company for production.
Page | 33
21.REFERENCES
Page | 34