Study and Analysis of Problem Related to Wheel Cylinder Assembly Line and its Solution

Analysis of problems means problem rises during the assembly of wheel cylinder. I completed various projects during training of 1 year. Some of the projects are included in this report such as, a) Concept of mechanical bleeder screw poka yoke, b) Time saving fixtures, c) Modification in design of rejection bin etc. In production assembly line, because of wrong bleeder size, many times the expensive tools will be breakdown. Because of this production will be stop for 1 to 2 hours. After the analysis of problem and implementation on line, problem gets solved and we achieved reduction in percentage of tool breakdown. When the model of wheel cylinder assembly is change for assembly process, fixtures of wheel cylinder also changes. For changing this type of fixtures, all nuts and bolts will be open and closed for all 8 stations. In this process the large time will be waste which is nearly equal to15 to 20 minutes. Therefore we will provide one design of fixture which automatically changes within two to three minutes. Due to this process and design we should save ten to fifteen minutes. We should also change the design of rejection bin. Previously the rejection bin used in industry is rectangular in shape, which contains the rejected wheel cylinder bodies. When the machine put this body in rejection bin, bodies will strike highly to the surface of rejection bin. The reason behind that, there would be fifteen cm distance between the rejection bin and rejection putting machine i.e. Gripper. After striking the job on the rejection bin, it will damage the surface of wheel cylinder. Also because of this sometime blow hole will appear on it. Due to this, the wheel cylinder jobs will repeatedly goes on rejection and it will damage completely. After the analysis of problem and implementation on modification of rejection bin we will definitely reduce the quantity of blow hole wheel cylinder jobs.