CHAPTER 4
WORKING AND PROCESSES
1. Raw Material Entry:
Forged parts (C70S6 material) are received in wooden boxes with unique stickers.
No direct inspection is performed at entry. Both workers and forklift drivers
handle unloading.
2. Material Handling:
Jobs are moved on roller rails using custom-made trolleys pushed manually from
one machine to another, following the machine layout.
3. Cycle Time and Precautions:
Cycle time ranges from 30 seconds to 1 minute. Each machine includes poka-yoke
systems and sensors for hand safety and enclosure locks to avoid mishandling.
4. Nature of Operations:
Most operations are performed using CNC machines. Manual operations include
assembly and a few handling steps. Machines vary from automatic with HMIs to
manually controlled systems.
5. Machines Used:
CNC, VMC, SPM and others by brands like Jyoti, ACE, HMT, and Haas. 4–5 of each
type exist per plant. Maintenance is done weekly in-house and yearly by OEM
technicians.
6. Fixtures:
Custom fixtures and air pressure or suction clamps are used depending on the job
type and connecting rod size.
7. Inspection and Gauging:
Quality supervisors check the job after a set number of parts at each stage.
Workers can also report faults, which may lead to rework or rejection.
8. Laser Marking:
A laser machine marks both the cap and the body of each connecting rod with
unique and linked numbers and barcodes for tracking.
9. Final Inspection:
Takes place in a restricted area with multi-gauges, weight checks, visual
inspections, and lubrication before boxing the final parts.
10. Output and Shift:
Each line produces around 1600 jobs per day. Ubai Trunkwala worked in the
morning shift from 7:00 AM to 3:30 PM.
11. Safety and Utilities:
The plant includes fire extinguishers and has generator backup for power
interruptions.
