WEL- COME
Fassler K-300
(Honing)
“I” LEVEL- Training Module.
Rev-02 Dated 08.05.2023
-
Vision & Mission
❑Values :
1. Respect for each other
2. Passion for excellence
3. Responsibility to our communities
4. Power of collaboration
5. Personal integrity
❑Vision :
To be recognized as a world-class Indian brand in automotive
drivetrain components & systems.
❑Mission :
To help our customers & peoples continually innovate & excel
in building world-class drivetrain components & systems
Divgi-TTS Policies
Customer Satisfaction
❑Quality Policy: Quality Product
Continual Improvement.
Safe Work Practices
▪ People Involvement
❑Safety & Environment
▪ Education & Training
▪ Continual Risk Reduction
Policy:
▪ Hazards Prevention
Energy Saving
Waste Reduction & Control
Divgi-TTS Production System
Quality System Basic
1. Fast Response Meeting (FRM)
2. Control of Non-Conforming part/product
3. Error Proofing Verification
4. Layered Process Audits (LPA)
5. Standardized operations (SOS-JES)
6. Standardized Operator Training / Operator Licensing
7. Contamination Control
8. RPN Risk Reduction
9. Supply Chain Management
10. Verifications Station
Contents for '' I " level Training Module
Introduction of Machine & working principle
How to start the machine
Daily preventive maintenance sheet & it’s importance.
Work standardization.
Process flow diagram.
Manufacturing process layout & it’s content.
Contents for '' I " level Training Module PPT
Special characteristics & it’s importance.
Standard operation sheet & it’s purpose.
Job element sheet & it’s purpose.
Dial least count & Geometrical symbols.
Documents maintained by an operating engineer.
NRFT handling & Unusual situation procedure.
PMC plotting, Set up approval, Quality alert , 5’S & QSB importance.
Definition Gear Honing
Definition of Honing
Honing is a machining process in which an abrasive cutting tool is
used to produce a very fine surface
How to Start the Machine
How to start the machine
1 2 3
PRESS STABILIZER ON MAIN SWITCH ON PRESS CYCLE
BUTTON START BUTTON
Part Loading & Unloading
1 2 3
Clean the fixture Take job from IN tray Clean the part and cartridge
Load the job & centering sector in cartridge
Part Loading & Unloading
5 6 7
Load the cartridge on DBB & PCD R/O
Load the DHG
machine fixture Inspection
Part Loading & Unloading
8 9
DBB & PCD R/O Roll test inspection to be
Inspection done on both side
Machine Indicator
Red Indicate machine at Emergency Stop.
Yellow Indicate machine at Optional Stop.
Green Indicate machine at Working Condition.
Daily Preventive Maintenance ?
• Performing preventive maintenance prolongs the life of your
equipment , reduce downtime , decrease reactive maintenance.
Daily Preventive Maintenance Check Sheet
Daily preventive maintenance
DPM DPM DPM
2 3 4
CHECK LUBRICATION OIL LUBRICATION OIL LEVEL OF HYDRAULIC
LEVEL PRESSURE TANK
Daily preventive maintenance
DPM DPM DPM
5 6 7
CHECK HYDRAULIC OIL PROPER WORKING OF CHECK THE LEVEL OF
PRESSURE MAGNETIC FILTER DRUM HONING OIL
Work Center Standardization.
Work Centre Standardization
Operator License MPL Control Plan And Reaction
Plan
Emergency Button SOS,JES Dpm
Process Documents
MPL ( Manufacturing Process Layout )
1
3
2
6
7
9
10
What to look in MPL
1) Component drawing : L – Location , C – Clamping.
2) Component drawing : R – Resting.
3) Previous operation Name & No. , Current operation Name & No. , Next
operation Name & No. and Machine Name & No.
4) Setup procedure.
5) Fixture Name & No.
6) Cutting tool specification, speed, feed & tool life frequency.
7) Process control plan.
8) Special characteristics, Cycle time & Shift quantity.
9) Part Name , Part Number & Revision level.
10) MPL Revision history card.
Special Characteristics
Def. : Special characteristics is a feature of material, process or part
(includes assemblies) whose variation within the specified tolerance has a
significant influence on product fit, performance, service life or
manufacturability.
Critical characteristics - User safety & Govt. regulations
Significant characteristics - Fit, Function, mounting or appearance
of the product.
Customer Touch Point - Customer Assembly Parameters
Process Key Parameters- These parameter related to manufacturing
& assembly such as speed ,feed & hydraulic pressure
◑ Key instruction-Important for subsequent operations (Ex: Resting,
Clamping dimensions for next operation)
Process Flow Diagram - PFD
Control Plan ( CP )
Process
No & Specification
Name
Machine ,
Fixture &
Tools Inspection
Freq.
Product
Characteristic
Control
Method
Understanding Control Plan and its Content
1. Part name, no. & Date ,Rev. level
2. Process name ,No & Description.
3. Product &Process characteristics
4. Tolerance, Evaluation & control method
5. Inspection size & Frequency
6. Responsibility & Reaction plan
Standard Operation Sheet (SOS)
What to Look in SOS
1. Sequence of operation or steps to complete the operation
2. Takt time
3. Quality checks
4. Safety equipment’s (PPE’s) to be used on the machine
Job Element Sheet (JES)
What to see in JES
1) What to do.
2) How to do.
3) Why to do.
4) Major and Critical Steps to do.
Gauge least Count & Calibration
Identifying the Least Count of Dials
Ensure Setup & Setup Approval
Setup Approval Check Sheet for Process Approval
Protocol for Setup Approval, When?
1) Part change.
2) Cutter Change .
3) After Preventive maintenance.
4) Machine Idle more than 3 days.
Setup Approval by QA
Documents to be maintained by Operating Engineer
Basic Calculation to select scale on PMC
Ex. DBB= 134. 80 ±0.04
1) Upper limit :- Base value + Upper tolerance
UL :- 134.80 + 0.04 = 134.84
2) Lower limit :- Base value - Lower tolerance
LL :- 134.80 - 0.04 = 134.76
3) Mean = (Upper limit + Lower limit) / 2
Mean = ( 134.84+ 134.76 ) / 2 = 134.80
4) Total Tolerance = Upper limit - Lower limit
Total Tolerance = 134.84 – 134.76 = 0.08mm
5) Scale = Total tolerance / No of line
Scale = 0.08 / 20 = 0.004mm
Basic Calculation
Profilator
Ring gear
45-54-162-001-E
(Reg)
DBB (134.84 /134.76
) shift
06/5/2023 /1st 1
div-0.004mm Upper Specification Limit
US
134.84
L
25% Tolerance Yellow zone USL
LP
134.8 Total
Mean Size Tolerance
FP 0
T1 50% Tolerance Green zone
25% Tolerance Yellow zone LSL US
134.76 L
Lower Specification Limit
Tool History card & In process check sheet maintained at station
Set up approval before starting production
Set up approval
❑ Set up is done by supervisor /
Setter
❑ Operator should ensure set
up approval before start of
machine.
❑ If the set up is not approved
inform to supervisor do not
start the machine until setup
approval.
Documents maintain by operating engineer- DPR
Honing
NRFT Handling Procedure
Different NRFT Tags
NRFT ( Not Right Frist Time ) Procedure
Re
Ap Paint
d
ply
INFORM TO
SUPERVISOR
Fill U
p
rejec the
t Tag
W hy,
rit
W y on
W ck
e
h
Ba de
si
NRFT ( Not Right Frist Time ) Procedure
Tag with
job Keep in
Red Tray
At Shift end
Keep job in
NRFT Area
Rejection OR Rework are also
to be Shown in PMC , Check
sheet , DPR.
Unusual Situation Handling
Unusual situation handling
Power failure / Air
Reaction plan Tool dash/damage/ POKA YOKE
Drop part policy Drop gauge policy leak, oil leak
accident failure
Breakdown
Impact on
N.A Yes Yes Yes Yes
process
Impact on
Yes Yes Yes Yes Yes
product
1.I/L level operators -
1. Stop the
Inform to supervisor
1. Inform to supervisor production.
2. U/O level operators -
2. If supervisor not 2. Inform to
Reaction by take actions as per defined Inform to
available - kept in red bin supervisor Inform to supervisor
operator power failure policy supervisor
with red paint along with 3. If supervisor not
3. Enter the event in
red tag. available inform to
process monitoring check
QA supervisor
sheet or chart.
1. Verify the tool/insert 1. Fill the GEMBA
Hand over the
condition / Inform to 1. Fill the GEMBA sheet sheet & analyze
instrument/gauge to
maintenance technician. & analyze the root cause the root cause
Verify the all dimensions QA personnel.
Reaction by 2. If not OK replace the thru 8D report. thru 8D report.
as per MPL including Alternate
supervisor tool/insert. 2. Take the corrective 2. Take the
visual defects. gauge/gauging
3. Ensure the last piece & actions in line with the corrective actions
method/issue new
first piece product 8D report. in line with the 8D
gauge
parameter after the event. report.
PPM ( Parts per million ) Calculation
Target : Internal PPM -
200 Customer PPM -
20
Rejection + Rework Qty
PPM = X 1000000
Total Production Qty
Example :- Reject qty – 1 , Rework qty – 2 and Total produce qty - 55000
1+2
PPM = X 1000000
55000
3
PPM = X 1000000
55000
PPM = 54.54
What are 5S’s
• Sort
Sort means to remove all items from the workplace that are not needed for current production.
• Set in order
• Set in order means arranging necessary items so they are easy to use and anyone can find them and put them away.
• Shine
Shine means removing dirt, grime and dust from the workplace by wiping, sweeping and mopping. It means cleaning machinery and
equipment as well as shelves, drawers and lockers too.
• Standardize
Standardize is the method used for maintaining the first three Ss: Sort, Set in Place and Shine. It means creating a system where everyone
knows exactly what they are responsible for doing and exactly when, where and how to do it.
• Sustain
Sustain is the glue that makes 5S stick. It is undoubtedly the hardest part of implementing 5S. When organizations fail, they claim that
it does because of problems with sustain.
Thank You
PRODUCT LEADERSHIP
LIKE NO OTHER
WEL- COME
Fassler K-300
(Honing)
“L” LEVEL- Training Module.
Rev-01 Dated 08.05.2023
-
Contents for ‘’ L " level Training Module
Machine technical specification
Honing Machine axis information
Operating panel details
Cutter Specification
Profile and Lead Correction
Pitch Report
Offset correction
Machine Technical specification
K-300 Fassler Honing machine technical specification.
Length * width *Height : 2410 * 2300* 2605 mm.
Required Floor space ( Length * width *Height ) : 4600 * 4600 mm
Height : From Ground – 1140 mm
From working table – 270 mm
Width : Max 1000 mm
Axis Crossing angle : A-Axis Max - +/- 30 ˚
Pivoting angle : B-Axis Max - +/- 10 ˚
Feed Travel : X-Axis Max – 160 mm
Longitudinal Travel : Z- axis max – 600 mm.
Honing Machine axis information
LIEBHERR SHAPING
MACHINE LS 180 E
• This below axis is belongs to Ring gear part
gear Honing process on K-300 honing
machine
Operating Panel
Operating Operating
Screen Keys
Axis OP. Keys
Emergency
Stop
Rapid Feed
Chuck
Open/Close
Feed Override
Cycle Start
Operating Panel details
1.)Reset
1 2.)Emergency Button
2
3.)Spindle CW
9 8
4.)Cycle Stop
5.)Cycle Start
6.)Chuck Open/Close
7.)Key Section
8.)Mode Selector
6
7 9.) Rapid Feed
1
11
0 10.)Feed Override
4 5 3
11.)Handwheel
Cutter specification
Sr. Cutter parameter details Specification
Honing Cutter No.
1 Make Kaizer
2 Material Dimond
3 Tool no. RG 2380
4 No. of teeth 86T
5 Normal Pressure angle 20⁰
6 Hand of helix RH
7 Normal module 1.4362
8 Pressure angle 20⁰
9 Helix angle 25.22⁰
10 Step sharpening angle 5.2⁰
Profile Report
1.fHα – Profile Angular error
2.Fα – From error
3.ffα – Profile form error
4.Cα – Crowning error
1
2
3
4
Lead Correction (fHβ)
RH Lead (- 0.01) RH Lead (+ 0.01)
Negative Positive
RH Lead correction RH Lead correction
Increase Decrease
LH Lead (+0.01) LH Lead (-0.01)
Positive Negative
LH Lead correction LH Lead correction
Increase Decrease
Pitch Report for Gear Ring
Offset correction flow chart
1 2 3 4 5
Re-Ensure DBB
Master Size if
found ok than
Calculate the Press the offset Take the cursor
ensure the job
Required DBB button on Press the Wear on W 001
DBB Size if
Size to mean Machine offset button. correction
found out of
reading. screen. block..
spec follow the
bellow
procedure..
10 9 8 7 6
Program will
show the
Confirm the
Load the job as calculated Type the
part quality Press the
per SOS & value, Ensure calculated
after cycles, if Machine
Operation to be the value if offset value &
found ok position
made as per found ok & press the +
Continue the Button.
procedure.. press the Input button..
production
EXCUTE
button.
Thank You
PRODUCT LEADERSHIP
LIKE NO OTHER
