Improving the Slug Removal Method in Piercing Operation of Brake Components Manufacturing Process by the Introduction of Semi-Automation

This experimental study is to improve the throughput time of the backplate manufacturing process line of heavy-duty brake system components in a process line of a machine shop. The existing method of removal of the pierced slug is performed by the pneumatically supported ejection for every 5 cycles using a compressor. This process is a critical process that is a feeder for the other processes in the process line. The steps in this study include Work-study, time study, brainstorming, funneling to suggestions for improvement, failure mode effects analysis, implementation of the suggestion, and validation. The brainstorming has been conducted with the cross-function team members and the suggestions were prioritized with respect to the outcome on a scale of productivity, quality cost, safety, and handling. The obtained suggestion is: implementing a mechanical system operated by a series of linkages to eject the slug from the piercing cavity for every cycle. The time taken for the removal is found to be 5 seconds against the previous time consumed18 seconds for every cycle. This enabled a cycle time reduction of 75% from the existing level. This reduced the throughput to an optimal level. The validation of this improvement has been performed by monitoring the process for one full day which comprises of three shifts and the activities were recorded. The feedback from the concerned authorities was collected and analyzed. The report indicated that the implementation of the semi-automation in the removal process of the slug has eliminated the compressor and its accessories from the line. Also, this saved the power consumed by the compressor 1500 units (approximately) which cost rupees 15000 per annum per press of six. This works out to one lakh per annum