International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395 -0056
Volume: 04 Issue: 3 | Mar -2017
p-ISSN: 2395-0072
www.irjet.net
PRODUCTIVITY ENHANCEMENT OF CLIPPING MACHINE Pranali Burungale1, Jagdish Dubey2, Gaurav Handoo3, Sailee Raul4, Dipak Chaudhari5 1,2,3,4 Students,
, Department of Mechanical Engineering, Vidyavardhini’s College of Engineering and Technology, Vasai (W), Pin- 401201, INDIA. 5Asstistant Professor, Head of Department of Civil Engineering, Vidyavardhini’s College of Engineering and Technology, Vasai (W), Pin- 401201, INDIA. ---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - Kokuyo Camlin is manufacturer and designer of
writing and stationary products for customer application. Quality with quantity is a main characteristics that helps a company stay on competition. At Kokuyo Camlin plant in Vasai pencils are manufactured using machines which are partially automatic. The paper presents the modifications in process and machine to increase the productivity. Our work is totally dedicated to design, manufacturing and on machine testing. Paper covers design, manufacturing and installation of hopper and feeder bowl. Detail study is done at shop floor level to find out root cause of rejections using various quality tools. Along with improvement in quality and productivity, reduction in manpower is done. Key Words: Productivity, Design, manufacturing.
1.INTRODUCTION In Kokuyo Camlin plant of Vasai, 0.5mm of mechanical pencils are produced. Major operations are done by using pneumatic actuator. But for placing and moving clips on barrels still done manually. Numbers of labour working on this machine at present are 4 in 2 shifts and they are paid ₹370/day. Clips are placed by 2 labours in liner and 1 labour is allotted for placing barrel in jigs and remaining 1 is used for removing all the rejection material. Further the clipping operation is done by pneumatic actuator in which clips are inserted in barrel. Our main objective is to make this whole system automatic. So after doing survey for few days and by performing various analysis we concluded that we have to place a part feeder system for clips and storage cum placing system for barrels. From our industrial visits, we had seen that feeder bowl of various types can be used as part feeder system. Similarly for storage of barrels we concluded that conical hopper will serve our purpose. Thus we are designing a feeder bowl , hopper , pick and place and various liners for increasing the productivity of the machine. Also we are doing WHY-WHY analysis, ROUTE CAUSE analysis, NET PRESENT VALUE analysis and SIMPLE PAY BACK PERIOD analysis. By doing this all analysis we are able to know the exact reasons for rejections, its root cause and financial analysis for the machine. © 2017, IRJET
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Impact Factor value: 5.181
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Hence by doing all this design changes we are able to remove labour cost and the rejection rates of the machine. Richard Silversides et[1] investigated the vibratory bowl feeder for automatic assembly, presented a geometric model of the feeder, and developed force analysis, leading to dynamical modeling of the vibratory feeder. Based on the leaf-spring modeling of the three legs of the symmetrically arranged bowl of the feeder, and equating the vibratory feeder to a three-legged parallel mechanism, the paper reveals the geometric property of the feeder. The effects of the leaf-spring legs are transformed to forces and moments acting on the base and bowl of the feeder. Resultant forces are obtained based upon the coordinate transformation, and the moment analysis is produced based upon the orthogonality of the orientation matrix. This reveals the characteristics of the feeder, that the resultant force is along the z-axis and the resultant moment is about the z direction and further generates the closed-form motion equation. The analysis presents a dynamic model that integrates the angular displacement of the bowl with the displacement of the leaf-spring legs. Both Newtonian and Lagrangian approaches are used to verify the model, and an industrial case-based simulation is used to demonstrate the results. Development of a model for part reorientation in vibratory bowl feeders with active air jet tooling done by Nebojsa I. Jaksic and Gary P. Maul[2] stated that Vibratory bowl feeders (VBFs) are widely used in industry for feeding and reorienting small parts in high volume production. Standard VBF tooling consists of various mechanical barriers inserted in the bowl path which are prone to jamming and limit the feeder to only one type of part. Programmable feeders have been developed to improve the exibility of these devices, however feed rates are often low. This research describes the development of a model of part behavior required for reorienting a part with an air-jet-based computer controlled orienting system. This system can be used to eliminate jamming and improve feed rates in VBFs. The control algorithm accepts the part's weight, geometry, and its orientation. Sensors then compare the present with the desired orientation and the algorithm determines the appropriate pulse of air to produce the desired orientation. Feeders are devices that orient parts for production operations. They can be divided into two major groups: vibratory and non-vibratory. A typical vibratory bowl feeder (VBF) is comprised of a shallow cylindrical bowl supported by several leaf springs attached to a cylindrical base containing an electromagnet. Inside the bowl is an inclined
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