To increase the productivity in engine cooling assembly line in a minimum cycle time, Crimping machine plays major role in the ECA, where production line area trying to improve manpower work. In this project my main motive is to produce the maximum number of product within the minimum man power. Indeed the machines are play the major roles to improve the product.

1. PRODUCTIVITY IMPROVEMENT THROUGH LEAN TOOLS ON
ENGINE COOLINGASSEMBLY
Presented and prepare
by
DIPRANJAN GUPTA
https://www.linkedin.com/in/dipranjan -gupta-012215180
dipranjangupta@gmail.com

2. CONTENT
• ABSTRACT
• INTRODUCTION
• LITRATURE REVIEW
• PROBLEM DEFINITION
• PROJECT METHODLOGY
• DESIGN AND MEASUREMENT
• COST OF PROJECT
• WORKING PROCESS
• CONCLUSION
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3. ABSTRACT
To increase the productivity in engine cooling assembly line in a minimum cycle
time, Crimping machine plays major role in the ECA, where production line area
trying to improve manpower work. In this project my main motive is to produce the
maximum number of product within the minimum man power. Indeed the machines
are play the major roles to improve the product. Hence by using the lean tools we can
modify the crimping machine and increase the production value with the less number
of man power. Therefore we can control the production cost.
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4. INTRODUCTION
Assembly is combining parts in a specific order in a system. Assembly process
begins with completely separated segments and ends with combining all those parts in
to a system. In engine cooling assembly line the crimping machine plays major role to
assemble the radiator cooling system. Crimping machine is machine of joining two or
more parts. Crimping machines are more reliable, accurate and flexible machines with
easy and fast set up times and multiple cost effective tooling options than any other
joining machines, The crimping process can be made more and more efficient by
automating the individual process steps involved in machining. Crimping machines is
equipped with a universally adjustable stripping mechanism and a user-friendly touch
screen. 4

5. The precision manufacturing parts together with the engineering and assembly
expertise, it should be combined with quality control. we are going to develop and
modifying the crimping tools and time reduction for setup change process by
using the lean tools. it reduces the time consuming for joining process, labor cost
and number of labors. Main advantage of this project is for cycle time reduction,
man power reduce. we can do more number of products. By using crimping
machine we can achieve more accuracy in joining process then manually.
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6. PROGRESS SECOND TO FINAL REVIEW
ACTIVITY START DATE DURATION END DATE STATUS
Observe the wheel cramping
machine
22 JAN 2 DAYS 25 JAN COMPLETED
Setup change wheel
cramping
26 JAN 3 DAYS 29 JAN COMPLETED
Dai change module 01 FEB 05 DAYS 5 FEB COMPLETED
Reading Cycle Time 07 FEB 05 DAYS 12 FEB COMPLETED
Measurement Module 15 FEB 07 DAYS 22 FEB COMPLETED
Setup change check
list wheel
25 FEB 10 DAYS 05 MARCH COMPLETED

7. LITERATURE SURWAY
Tenah K. A. et al. (2009): In this paper, they used subjective assessment through
questionnaire, direct observation method, and archival data to improve productivity,
quality, increasing revenue and reducing rejection cost of the manual component.
Mihir B Patel, et al. (2011): Work study techniques are expensive to implement in
small-scale industries. However, this method gives better results than any other
technique. These techniques not only help reduce the cycle time, but also have proved
useful in numerous other departments in industry such as inventory control,
productivity, quality, labor work, and at various machines in a machine shop to
develop process variation.
Flinchbangh W. J (2011): Found that plant size had a significant effect on the
implementation of lean practices. This shows that regardless of establishing what lean
is, it remains important to establish how best to become lean in varied contexts.
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8. Rishabh Mishra (2013): Rishabh Mishra explored “Productivity Improvement in
Automobile Industry by Using Method Study.” He established improvements on
the basis of the method study, work procedure, and proper utilization of machine
and material. His study advanced the prevailing process by reducing transportation
and worker’s fatigue.
Singh M.P (2014): His study was concerned with the battery manufacturing plant.
He observed that the battery plant was not using optimum layout, which had
potential for improvement. Various layout and method study tools were applied
and flow process charts, Flow diagrams and existing layouts were prepared. New
technologies were applied to lessen production cost, process, cost, and energy
consumption.
Ravikumar Kamble (2015): The unwanted motion involved in the operation of
assembly has been substantially reduced by designing assembly table, fasteners
tray, and design of proper work place layout.
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9. PROJECT OBJECTIVES
The objectives of the project are as follows:
• To analyse the time study of crimping process.
• To reduce the cycle time of crimping process.
• To reduce the tool setup change time of crimping machine.
• To reduce the man power and cost.
• To improve the productivity of the plant with minimum rejection rate.
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10. PROBLEM DEFINITION
During tool setup change this work deals with the end to end perspective of
reducing waste at an engine cooling assembly line.
• Take more time for production
• Require more manpower for during the process
• Earlier found more damages in the product
• Less profit
• More economic
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11. PROJECT METHODOLOGY
LITERATURE SURVEY
QUESTIONERY
LEAN TOOLS STUDY
BRAINSTORMING
ANALYSIS
RESEARCH AND DEVELOPMENT
CONCLUSION
RESULT
PROBLEM DEFINITION
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12. ACTIVITIES IN CRIMPING PROCESS
In Set up change process, the following activities are to be followed by the Machine
and Man.
External Activity
• Clean the fixture which is to be used after set up (Adaptors,Bolts,& Nuts).
• Lubricate the guide ways.
• Tools arrangement according to the model to changed.
• Arrange the materials
Internal Activity
• Take machine to manual mode
• Place existing model crimped job on the fixture bring that top die to work position
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13. • Remove the top die screws with 6mm Allen key place the key property to aviod
slippage
• Ensure all the 6 screws are loosen then move the ram to the home position.
• Remove the die, check for any damages clean and place it in proper place.
• Remove the existing model core from fixtures.
• Take front cylinder in forward position removable the front side crimping tool blot
by using 5mm Allen key.
• Remove and replace the front supporting tool from existing to new by sing 6mm
Allen key.
• Fix the required model front crimping tool by using 5mm Allen key.
• Take the front cylinder back to home position.
• Press emergency button and move to rare position.
• Loose the width adjustment Spicer rollers.
• Loose the side lock nut with 8mm Allen key.
• Replace the Spicer for as per required model. 12

14. CRIMPING MACHINE AND SETUP CHANGE TOOLS
13

15. READING CYCLE TIME PERIODS
S.NO. FAN WHEEL
MOTOR
SHROUND
ASSIMINILY
BALANCING
WEIGHT
CONDENSOR
LEAKING
TESTING
WHEEL
CRAMPING
RADIATOR
LEAK TEST
MODULE
ASSIMILY
MODULE
TESTING
FINAL
Inspection
1 31.5 Sec 24.06 Sec 38 Sec 38.53 Sec 58.54 Sec 32.57 Sec 28.59 Sec 33.57 Sec 14 Sec
2 32.5 Sec 18.32 Sec 36.6 Sec 34.54 Sec 110.52 Sec 44.58 Sec 29.57 Sec 34.58 Sec 13 Sec
3 29 Sec 28.62 Sec 37.57 Sec 33.56 Sec 54.56 Sec 45.57 Sec 28.57 Sec 35.52 Sec 14.5 Sec
4 31 Sec 29.89 Sec 40.76 Sec 38.54 Sec 114.52 Sec 54.57 Sec 30.5 Sec 37.57 Sec 15 Sec
5 31.5 Sec 34.14 Sec 103.61 Sec 30.77 Sec 59.57 Sec 54.53 Sec 31.57 Sec 39.56 Sec 14 Sec

16. Final product from the engine cooling assemble line
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17. CONCLUSION
In this project the following activities were carried out in order to improve the
productivity
• Cycle time of crimping process is reduced by analysing and modifying the tool
setup change. By implementing lean tools technique, time taken for various
operations involved in crimping process was analysed. By changing the tools of the
side supports, reducing the setup change time, cycle time was reduced from 8
minutes to 10 minutes. This results in gradual increase of productivity by 60%.
•Reduced the time consuming for joining process, cost and number of man power.
•Increased the productivity.
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20. THANK YOU
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