M.project Part2

Chapter 1
COMPANY PROFILE
1.1 INTRODUCTION
Tecumseh Products India Private Limited (TPIPL) is a wholly owned subsidiary of Tecumseh Products Company (TPC), USA. TPIPL has two plants in India, one at Ballabgarh near New Delhi and the other at Balanagar Industrial Estate in Hyderabad. Tecumseh Products Company (TPC) is a full line, independent global manufacturer of hermetic compressors for air conditioning and refrigeration products, gasoline engines and power train components for lawn and garden applications, industrial pumps, and small electric motors. The facility at Hyderabad has been setup through the acquisition of Siel Compressors Ltd. Hyderabad. TPIPL is now the largest independent manufacturer of compressors in India. The facility is both ISO 9001 and 14001 certified. One of the four global Technology Development Centers (TDC) of TPC is located in this facility. In-house Application Engineering Testing facility is well equipped to optimize and ensure performance improvement of the appliance. The facility at Hyderabad is engaged in the manufacture of the following series of compressors for different applications as mentioned below. 1. Reciprocating hermetic compressors

AW series (12000 42000 BTU/hr) - Air conditioning Application AK series (5500 1000BTU/hr) - Commercial refrigeration Application
2. Rotary compressors (18000 26500 BTU/hr)

RN Series - Air conditioning application RK Series Commercial Refrigeration& Low end Application Air Conditioning
The facility at Ballabgarh is engaged in the manufacture of the following series of compressors for different applications as mentioned below.
THK Series Reciprocating compressors Refrigeration application
1.2 GLOBAL PRESENCE

ARCELIK Turkey Tecumseh TPC, Canada Tecumseh, USA Canada Europe , Turkey
Vecomesa Venezuela , Venezuela
Tecumseh Do Brasil
Tecnamotor Italy , Italy
Tecumseh India , India
1.3 CERTIFICATIONS
Chapter 2
INTRODUCTION TO COMPRESSORS
2.1 DEFINITION OF COMPRESSOR
A compressor is a mechanical device that is used to increase the pressure or compress the fluid. In refrigeration and heating system it is the most essential component. It pressurizes a gas in order to turn it into a liquid, thereby allowing heat to be removed or added. The development of compressors began during the late 1800s and matured in early 1900s. There are various different kinds of compressors in the market today.
2.2 TYPES OF COMPRESSORS

The tree diagram shows the various types of compressors drawn below.
Fig: 2.1 Types of compressors As shown in Figure.2.1, there are two basic compressor types: positive-displacement and dynamic. In the positive-displacement type, a given quantity of air or gas is trapped in a compression chamber and the volume it occupies is mechanically reduced, causing a corresponding rise in pressure prior to discharge. At constant speed, the air flow remains essentially constant with variations in discharge pressure. Dynamic compressors impart velocity energy to continuously flowing air or gas by means of impellers rotating at very high speeds. The velocity energy is changed into pressure energy both by the impellers and the discharge volutes or diffusers. In the centrifugal-type dynamic.
2.3 DIFFERENT TYPES OF COMPRESSORS MANUFACTURE IN TECUMSEH, HYDERABAD

Capacity Series AW series AK series in BTU/hr (British Thermal Unit) 12000 42000 5500 10000 18000 26500 18000 26500 Application Air conditioning Application. Commercial refrigeration Application Air conditioning application RK series Commercial Refrigeration & Low end Air Conditioning Application Table 2.1 The company given different names based on their convenience . AW and AK are reciprocating compressors where as RN and RK are rotary compressors. Normally
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SI.No
Type of compressor Reciprocating compressors
1.
2.
Rotary compressors
RN series
reciprocating compressors pressurize more air than rotary and these compressors are used where we need more air.
2.4 COMPONENTS OF A COMPRESSOR

Physically it has 3 main sub-assemblies viz. the pump kit, motor and housing.
Motor Housing
Pump Kit
Fig: 2.2 Components of a compressor The manufacture of the compressor consists of three different processes which are done at three different locations which are called 1. Machine shop 2. Motor shop 3. Assembly shop There exists a different department which checks the accuracy of the components inspects the error level and keeps a tab on the quality of the products obtained. This department works very hard to maintain the quality level of the company and to satisfy their customers needs. This department is the Quality control department. They check whether the components are according to the required specifications or not after every process. The system followed by the Quality department is very systematic and it can be observed that they do the processes in a very meticulous manner. In the machine shop, the parts which are outsourced according to the specification provided by the Tecumseh Company are worked on according to the desired dimensions.
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Since the company has outsourced most of its components from casting plants located at different corners of the country, it saves time involving the gathering of raw materials and then casting the materials into the required moulds. Most of the work done is this company is done by machines which reduce the human error to a bare minimum. Due to the use of the machines, the efficiency of the company has increased and it has also increased the productivity of the company. Since the machines work continuously and mostly there is contact in between moving parts, lots of heat is generated. To reduce the damages caused due to the heat, coolants are used at every machine. The coolant which is used maximum in the manufacture of rotary compressor is Tech cool 3900 sometimes mixed along with water.
The main function of motor shop is to manufacture the rotor and stator. After the manufacture of rotor and stator, it is sent to the assembly shop. In comparison to the machine shop, this shop has less number of operations. Though the number of operations is very less, each operation has its own significance and without that operation, the working of compressor becomes faulty. The machines used in RN rotor motor shop are completely automated and hence we can find very few people working at the RN-motor shop. The equipment used at the motor shop does very meticulous tests which confirm the perfect working of the stator and it reduces the number of faulty pieces. If the components fail these tests, the components are rejected and sent back. The equipment used in this shop is considered the latest equipment in the world.
Assembly shop is the final stage in the compressor manufacture. This shop reflects the companys efficiency and productivity. In this shop as well, we can see that machines are used in every operation. Assembly shops activities are further divided into three sub lineskit line, terminal line, cylinder head and valve plate sub-assembly. In this shop, various kinds of operations can be observed from turning to painting, welding to cooling, etc. Testing is done at many stages. Testing is done at one stage which is called pre-testing which checks before the assembly of the final product. Then testing is also done before the kit is sent to the customers. The compressors are painted and done tests on to check leakage and then are packed according to the customers requirements.
Next chapter deals with the types of reciprocating compressors manufactured in Tecumseh and discuss about the main components of machine shop and their machining operations. Chapter 3
RECIPROCATING COMPRESSORS
3.1 INTRODUCTION
Reciprocating compressors can be classified into two types. They are single acting reciprocating compressors and double acting reciprocating compressors. Company divided these into AK series (Single acting) and AW series (Double acting).
3.2 MACHINE SHOP

The place where various operations such as finishing operations are done on the different components of compressor is called the Machine Shop. The AK or AW Reciprocating compressor consists of five main components. 1. Crank Case 2. Crank Shaft 3. Piston 4. Connecting Rod 5. Out Bore Bearing 3.2.1. CRANK CASE Crankcase is the main component of the compressor. It is made up of cast iron whose hardness value is 170-229 BHN. It houses cylinders, pistons, crankshaft, connecting rod, OBB and cylinder head. It may have a single or multi-cylinder depending on the output. The entire compression of gas (refrigerant) takes place in cylinder bore of crank case.
AK model Fig.3.1 Crank case 3.2.2 CRANK SHAFT
AW model
The crankshaft is made of either forged alloy steel or out of spheroid Grey Iron casting. The portions of shaft that work inside the bearings are called journals. The crankshaft should be strong enough to take the thrust of the piston during compression without getting distorted. The reciprocating motion of the piston is made possible by the crank of the crankshaft. The piston-end of the connecting rod is attached to the piston by the piston pin, which is tightly fitted in the position. In AK type one Portion of the shaft is provided with eccentricity to form throws to which the connecting rods are attached. As the crank shaft rotates, the pistons reciprocate forward and backward. In AW type there are two kinds of pins and journals called the short end pin, long end pin and the short end journal and the long end journal.
AK model Fig.3.2 Crank shaft 3.2.3 PISTON
AW model
Piston is a cylindrical metal plug that reciprocates in the cylinder. They are made of Cast Iron or Aluminum alloy. The clearance between the cylinder and the piston must be less so that it should not allow the flow back of discharge gas from the top of the piston to the crankcase. At the same time that gap must be filled with oil film to provide lubrication. For bigger compressors, pistons are fitted with piston rings, so that when they get worn out, only the rings have to be changed. It sucks in the low pressure gas through the suction valve, compresses it and pushes it out through the discharge valve.
AK model Fig.3.3 Piston 3.2.4 CONNECTING ROD
AW model
The connecting rod, as the name suggests connects the crank shaft and the piston and is an important component required to convert the rotation of crank shaft to the reciprocating motion of piston. It is made of Aluminum for it should add least possible inertia to the piston-crank shaft system.
AK model Fig.3.4 Connecting rod 3.2.5 OUT BOARD BEARING
AW model
This, as the name suggests is one of the bearings which support the crank shaft during its rotation. This is fitted to the crank case and supports the lower end of the crank shaft. This is a casting. A bronze bush is fitted in the shaft hole for friction free rotation. This is fitted to the crank case with three screws.
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AK model Fig.3.5 Out Board Bearing
AW model
3.3 VALVE PLATE SUB-ASSEMBLY

This is the most crucial component from the designing, manufacturing and functional point of view (in addition the project has lots to do with this). This is an assembly of many parts. The valve plate contains the valves, the discharge valve and the suction valve. Valve is an arrangement which allows the flow (of gas in case of a gas compressor) only in one direction. The suction valve allows gas to flow only from the suction muffler to the piston chamber (during suction stroke) and the discharge valve allows the compressed gas to flow only from the piston chamber to the discharge muffler (during the compression stroke). E.V.R & EV L Suction Valve
Rivet Discharge side of valve plate Fig.3.6 Valve Plate Suction side of valve plate
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3.4 GASKET
There are two gaskets installed in the pump kit to prevent leaks by sealing the metal to metal contact areas. One of them, a rubber gasket cut in suitable pattern is placed between the valve plate and the crank case. The second, a rubberized metal gasket (Buna N) cut in suitable pattern is placed between valve plate and the cylinder head.
Rubber Gasket Fig.3.7
Rubberized Metal Gasket
3.5 MUFFLERS
Mufflers are components attached to the compressor to reduce noise during its functioning by modifying the flow pattern of fluid. There are two mufflers in the pump kit. A discharge muffler which reduces noise of the discharge gases and the other is suction muffler which reduces noise of the suction gases. The discharge muffler is built within the crank case as two cylindrical chambers and the suction muffler is a rectangular chamber fixed to the cylinder head at the inlet hole.
3.6 CYLINDER HEAD

The cylinder head is a heavy metal casting. The cylinder bore containing the piston and the cylinder head lie on either side of the valve plate. This acts as a directing gateway for the incoming and outgoing gases.
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The molding has two pathways, one which leads the incoming low pressure gas from the suction muffler to the suction holes and the other which leads the high pressure output gases from the discharge holes to the discharge muffler.
3.7 MANUFACTURING OF COMPRESSOR COMPONENTS

In Tecumseh input components are castings. Every component of compressors needs to undergo certain operations before going to assemble so the components of compressor undergo various operations at different machines. The following tables give the details about various operations of different component with cycle time also. COMPONENT: CONNECTING ROD Operation START (Receipt of connecting rod) Burnishing Jet washing END COMPONENT: PISTON Operation START (Receipt of pistons) Rough grinding Fine boring Pin bore ID chamfer, External chamfer/Deburr Grooving, Crown chamfer, Shirt chamfer Engraving and oil hole drilling Lock pin hole drilling and chamfering Diamond reaming Finish grinding MIP(magnesium iron phosphate) coating Buffing END COMPONENT: OBB
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Cycle time in sec 05 03 -
Cycle time in sec 06 21 20 13 18 17 12 06 06 04 -
Operation START (Receipt of OBB) Oil stone Fine boring / Demurring Burnishing Bullows cleaning COMPONENT: CRANK CASE Operation START (Receipt of crank cases) Stator side machining Rough boring Bush fitting OBB side machining Fine boring Slot milling Manual demurring ADA washing Air blow all tapped holes Crank bore burnishing Honing Bellows cleaning END COMPONENT: CRANK SHAFT
Operation
Cycle time in sec 15 40 08 20
Cycle time in sec 58 42 25 32 30 30 20 33 20 10 54 24 -
Cycle time in sec
START (Receipt of crank shaft) Jet cleaning of shafts Shot blasting Straightening Air cleaning and Jet cleaning Journal rough grinding Journal finish grinding Thrust face grinding Pin grinding SE Pin grinding LE Oil hole cleaning MIP Pin buffing Journal and hand buffing
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12 12 18 10 35 28 30 50 50 26 20 09 12
Jet and bullows cleaning END
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Next chapter deals with the manufacturing process of rotary compressors and working of compressors and discuss about the gauges used in the company. This chapter also discuss about the kit assembly, external parts of compressor, main assembly and tests performed for compressors. Chapter 4
ROTARY COMPRESSORS
4.1INTRODUCTION TO RN-ROTARY COMPRESSOR
RN compressor consists of five components. In this compressor, roller rotates and along with the roller the crankshaft moves up and down, in turn causing the rotator motion. Thus, it can be observed how the compressor got its name.
4.1.1 RN-MACHINE SHOP

The place where various operations such as finishing operations are done on the different components of the rotary compressor is called the Machine Shop. This part of the project describes all the processes in detail that are performed in the machine shop. The RN rotary compressor consists of five main components. 1. Crank shaft 2. Roller
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3. Out Board Bearing ( OBB) 4. Main Bearing (MB) 5. Cylindrical block. The five components are manufactured in the machine shop. 4.1.2 RN-MOTOR SHOP The place where the stator part of the compressor is made or manufactured is called Motor shop. It is so called because it deals with the electronics part of the compressor and it shows the specific details of the making of the stator component of the rotary compressor.
4.2 GAUGES
We use different gauges to measure different parameters of components after some operations to check whether the parameters are in specifications or not. In Tecumseh Company all gauges are air gauges in all machine shop. The following are some of the gauges using in company. 1. 2. 3. 4. Air gauge Deck height gauge Height gauge Vernier calipers
4.3 KIT ASSEMBLY

After successful completion of different operations on different components, all components send to assembly section where all components put together and made them a single component called kit. In this assembly they do not assemble external parts of compressor only kit assembly. Before going to assemble all components they check the specifications of components and from those specifications they provide one grading and according to they assemble.
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Fig. 4.1 pump kit Here grading plays major role in assembly because similar grading components only assemble together not different grading components. The grading to each component is given based on value came from the gauge used to check parameters of component. Grading will provide only to components which undergone different operations at machine shop.
4.4 EXTERNAL PARTS OF COMPRESSOR

Compressor has some external parts which are visible from outside. Some of these external parts protect internal parts of compressor. The name of external parts names given below and these parts are combined together by various operations at different machines. 1. 2. 3. 4. 5. 6. Housing Top cap Bottom cap Discharge adopter on top cap Suction adopter on housing Three phase terminal on top cap
4.5 MAIN ASSEMBLY Here we explain about the assembly of RN compressors only. The following gives the details about assembly of external parts and their operations before going to put together. Here every operation contains one respective code for convenience. It also explains about different tests through which a compressor will undergo. This process is up to final packing. 1310 Rough expand The housing is placed on a 9-finger expander machine and expanded to required dimensions. 1320 Finish ends The sharp corners on both the ends are broken and given a smooth finish. 1330 Pierce suction hole, punch witness mark
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The hole for suction is made at the bottom of the housing using a pierce machine. Then a witness mark is punched at 20 from the hole. 1340 Pierce weld holes Three weld holes are pierced by pierce machine at given distance from the suction hole. This distance is measured using hole position gauge. 1345 Housing degreasing The degreasing of housing, top cap and bottom cap are done in four stages. First they are cleaned with diver spray, then DM water and Grisiron 8517. Then they go through a hot air blow-off. 1350 Weld suction adapter The suction adapter is welded into the suction hole and the ID of the adapter is ball burnished. 1360 Weld accumulator bracket A bracket is welded to the housing for holding the accumulator in place after assembly.
1370 Final expand, stamp housing code The hosing is expanded once again finally using expander machine. Then the code of the housing is stamped on it. 1400 Housing finish wash This wash is done in a 3-stage washer using the chemical Grisiron 8517 and then 4th stage hot air blow-off is done. During this wash the conveyor speed should not exceed 1m/min. 4.5.1 HOUSING TOP CAP SUB-ASSEMBLY 1510 Braze discharge tube The discharge tube and silver braze ring (40% silver alloy) are loaded on top cap and brazed. 1520 Hanger bracket welding A bracket is welded opposite to the terminal hole for hanging purposes. 1530 Weld cover stud A stud is welded beside the terminal hole.
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1540 Wash The top cap is washed in Grisiron 8517 and degreased. 1550 Weld terminal The electric terminal is placed in the terminal hole and welded.
4.5.2 TERMINAL ASSEMBLY

2010 Rotor & Kit assembly Rotor is heated to 190oC (max.) and is placed on the crank shaft of the kit and is then cooled to room temperature. 2030 Stator & Housing assembly Housing is heated to 3700C (2570C to 3730C) and then stator is dropped into it. 2040 Cool down The statorhousing assembly is cooled for 45 min. to 280C. 2050 Electric parameters check of stator & bar code Three tests Continuity test, Hi-Pot test and Insulation Resistance test are done. In continuity test the compressor is run at normal voltage and resistance, common, start and run currents are checked. In Hi-Pot test, a high potential of 1865V is applied for 1 sec. Then the insulation resistance is verified at 500V D.C. This should not be less than 2 Mohm. 2060 Assemble Kit/Rotor to Housing/Stator The rotor-kit sub assembly is placed into the housing-stator assembly. 2065 Bottom cap assembly onto housing A magnet is attached to the bottom cap and is assembled by gentle malleting to the housing. The magnet is for attracting any rust or other magnetic particles present inside the compressor. 2070 Weld Main Bearing to Housing The main bearing in the kit is welded to housing at the suction adapter using welder machine. 2080 Check air gap After removing the air gap can, this was placed between stator and rotor, the air gap created by it is checked by Air Gap Feeler gauge. 2090 Install O-Ring and Plug suction hole Using insertion tool, install O-Ring in O-Ring groove in cylinder block. Install plug into suction hole using plug pusher.
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Note: O-Ring should not be punctured & inserted in correct position. Apply little Shell Tellus 68 oil on the O-Ring for easy entry. 2095 Connect stator to top cap terminal The cluster box of the stator is connected to the electric terminal in the top cap sub assembly. 2096 Continuity test Apply run voltage of 160V for 1 sec for main winding and say OK if compressor doesnt buzz. 2110 Press top & bottom caps into housing Both the caps just placed on the compressor are pressed tightly onto it. 2120 - Seam weld top & bottom caps to housing Both the caps are seam welded carefully by an automatic welder. Hydrostatic test of welder is to be done once in a week 2130 Remove plug from suction and assemble accumulator The plugs put earlier for avoiding moisture from entering the compressor are removed and the accumulator is inserted into the suction adapter, rotating as tube is inserted. It should be done gently; otherwise the O-Ring will be punctured. 2140 Braze accumulator to suction adapter The accumulator assembled to suction adapter is brazed (welding at lower flame) using solder wire and dual tipped torch. 2150 Assemble plugs to suction & discharge tubes Plugs are placed to the suction tube on the accumulator and the discharge tube on the main compressor. 2160 Weld base plate to compressor A triangular base plate is welded to the compressor. 2170 Bubble tank leak test The compressor is passed into water at high pressure and checked for any leakages. If one hole is leaking the compressor is sent for redoing the weld, but if two or three holes are leaking the compressor is rejected. 2180 Install paint shields
4.6 DIP PAINT AND VACUUM DEHYDRATION

2310 Compressor pre-treatment- Zinc Phosphate (before paint)
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The compressor is pre-treated with Zinc Phosphate as a protective layer. 2320 Dip paint process The compressors are dipped into a black epoxy/amino paint with 30-45% (V/V) thinner. 2330 Paint Baking The compressors dip painted are now baked at 1750C for 2.5 hrs. If done at lower temperatures yellow marks are formed. 2340 Vacuum Dehydrate compressor The compressor is dehydrated to remove any moisture remaining inside it. This process is done for 20 min. Then a Residual Moisture Test is done which takes about 3 hrs. To pass this test the moisture should be less than 75 mg. If rejected it is heated to 1200C and dehydration is done.
4.7 OIL LINE AND PACKING FINAL TEST

2510 Remove all plugs The suction plugs and discharge plugs are removed by plug remover. 2520 Oil charge/ Oil processing 650 ml of oil (for 22K model) is filled into the compressor. 2525 Electric testing/Strap Tightening Three tests are done continuity test, high potential (Hi-Pot) test, insulation resistance. 2530 Performance test psi. Low Voltage start: Both suction and discharge at 175 +/- 5 psi and has to start at less Locked rotor test: At rated voltage when auxiliary winding is cut off, if compressor than 120 volts current. buzzes, indication of fail.
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High Voltage: Start at 250V for 3 sec Pump Up: Measure voltage, wattage, amperage after reaching 300 psi discharge Ground fault detection: Current leak during run has to be less than 6 mA. Leak back test: When discharge pressure is 225 +/- 5 psi. Pressure rise on suction is 5
pressure.
2540 Rubber plug and N2 charge Rubber plugs are put and Nitrogen is charged with 5-10 psig. Dry Nitrogen is used for this purpose. 2550 Assemble terminal parts per bill of material The components are installed with a protective cover as per bill of material. 2560 Single Packing For single packing cardboard cartons are used. 2570 Multiple Packing The compressors are packed in 2-3 layers. Polythene covers and rings are placed over the compressors and cardboard is placed between each layer. 2580 Wrap and Seal The conveyor will skid the packages into a stretch wrapper and it will be automatically wrapped. The use of Instapack foam for packing has been eliminated as an environmental initiative and has been replaced by paper and cardboard packing.
4.8 WORKING OF COMPRESSOR

4.8.1 RECIPROCATING COMPRESSOR A reciprocating compressor uses the reciprocating action of a piston inside a cylinder to compress refrigerant. As the piston moves downward, a vacuum is created inside the cylinder. Because the pressure above the intake valve is greater than the pressure below it, the intake valve is forced open and refrigerant is sucked into the cylinder. After the piston reaches its bottom position it begins to move upward.
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Fig: 4.2 working of reciprocating compressor The intake valve closes, trapping the refrigerant inside the cylinder. As the piston continues to move upward it compresses the refrigerant, increasing its pressure. At a certain point the pressure exerted by the refrigerant forces the exhaust valve to open and the compressed refrigerant flows out of the cylinder. Once the piston reaches it top-most position, it starts moving downward again and the cycle is repeated.
4.8.2 ROTARY COMPRESSORS In a rotary compressor the refrigerant is compressed by the rotating action of a roller inside a cylinder. The roller rotates eccentrically (off-centre) around a shaft so that part of the roller is always in contact with the inside wall of the cylinder. A spring-mounted blade is always rubbing against the roller. The two points of contact create two sealed areas of continuously variable volume inside the cylinder. At a certain point in the rotation of the roller, the intake port is exposed and a quantity of refrigerant is sucked into the cylinder, filling one of the sealed areas.
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Fig.4.3 working of rotary compressor As the roller continues to rotate the volume of the area the refrigerant occupies is reduced and the refrigerant is compressed. When the exhaust valve is exposed, the highpressure refrigerant forces the exhaust valve to open and the refrigerant is released. Rotary compressors are very efficient because the actions of taking in refrigerant and compressing refrigerant occur simultaneously. Next chapter deals with the role of quality control, 7 QC tools used in the statistical process control and discuss the gauge repeatability and reproducibility.
Chapter 5
QUALITY CONTROL
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5.1 INTRODUCTION
The managerial process during which actual process performance is evaluated and actions are taken on unusual performance. It is a process to ensure whether a product meets predefined standards and requisite action taken if the standards are not met.
5.2 ROLE OF QUALITY CONTROL

Quality Control measures both products and processes for conformance to quality requirements (including both the specific requirements prescribed by the product specification, and the more general requirements prescribed by Quality Assurance); identifies acceptable limits for significant Quality Attributes; identifies whether products and processes fall within those limits (conform to requirements) or fall outside them (exhibit defects); and reports accordingly. Correction of product failures generally lies outside the ambit of Quality Control. The defects due to leaks in compressor pump kits is a Quality Control related problem. The recent advancements in Operations Management and Quality Control have brought revolutionary techniques to solve problems related to Quality Control. These are the 7QC tools and 6-Sigma tools, to name a few. These tools fall under the category of Statistical Process Control (SPC).
5.3 STATISTICAL PROCESS CONTROL

Statistical Process Control (SPC) is a collection of statistical techniques that are used to monitor critical parameters and reduce variations. We used SPC to achieve process stability and improve the capability through reduction of variability. Often the term "Statistical Quality Control" is used interchangeably with "Statistical Process Control." The objective of SPC is to get a process under control. This is done by identifying and eliminating any specific causes of variation not associated with the process itself. A process that is in control will constantly perform within its own natural limits. SPC can be broken into two components: process control and acceptance sampling. In process control, SPC involves these seven tools: 1. Histogram,
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2. Check Sheet, 3. Pareto Chart, 4. Cause and Effect Diagram, 5. Defect Concentration Diagram, 6. Scatter Diagram and 7. Control Chart These tools often called "The 7 QC tools." Most of the tools help us to identify a problem in the process. Acceptance sampling is used to reduce variation in the process by using statistical sampling techniques to select the proper sampling size and to interpret whether our whole product should be accepted or rejected.
5.4 7QC TOOLS

Seven QC tools are fundamental instruments to improve the quality of the product. They are used to analyze the production process, identify the major problems, control fluctuations of product quality, and provide solutions to avoid future defects. Statistical literacy is necessary to effectively use the seven QC tools. These tools use statistical techniques and knowledge to accumulate data and analyze them. Seven QC tools are utilized to organize the collected data in a way that is easy to understand and analyze. Moreover, from using the seven QC tools, any specific problems in a process are identified with 6 sigma Tools like process mapping & FMEA. 7QC tools always include
Check Sheet is used to easily collect data. Decision-making and actions are taken from the data. Pareto Chart is used to define problems, to set their priority, to illustrate the problems detected, and determine their frequency in the process. Cause-and-Effect Diagram (Fishbone Diagram) is used to figure out any possible causes of a problem. After the major causes are known, we can solve the problem accurately.
Histogram shows a bar chart of accumulated data and provides the easiest way to evaluate the distribution of data.
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Scatter Diagram is a graphical tool that plots many data points and shows a pattern of correlation between two variables. Flow Chart shows the process step by step and can sometimes identify an unnecessary procedure. Control Chart provides control limits which are generally three standard deviations above and below average, whether or not our process is in control. These tools help us identify the critical areas of defects and helps solve the problem
efficiently and effectively. The above tools proved to be highly efficient when effectively apply to the present problem in Quality Control of compressors pump kits.
5.5 GAUGE REPETABILITY AND REPRODUCIBILITY
Repeatability: It is the variability of measurements obtained by one person while measuring the same parameter repeatedly.
Reproducibility: It is the variability of measurement system caused by differences in operator behavior.
Next chapter deals with the process capability and machine capability and conditions for the process capability and machine capability.
. Chapter 6
PROCESS CAPABILITY & MACHINE CAPABILITY

6.1 PROCESS CAPABILITY
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Process capability is the long-term performance level of the process after it has been brought under statistical control. In other words, process capability is the range over which the natural variation of the process occurs as determined by the system of common causes. Process capability is also the ability of the combination of people, machine, methods, material, and measurements to produce a product that will consistently meet the design requirements or customer expectation.
6.1.1 PROCESS CAPABILITY STUDY

Process capability study is a scientific and a systematic procedure that uses control charts to detect and eliminate the unnatural causes of variation until a state of statistical control is reached. When the study is completed, you will identify the natural variability of the process.
6.1.2 NECESSITY OF KNOWING THE CAPABILITY OF OUR PROCESSES

Process capability measurements allow us to summarize process capability in terms of meaningful percentages and metrics. To predict the extent to which the process will be able to hold tolerance or customer requirements. Based on the law of probability, you can compute how often the process will meet the specification or the expectation of your customer.
It helps you choose from among competing processes, the most appropriate one for meeting customers' expectation. Knowing the capability of your processes, you can specify better the quality performance requirements for new machines, parts and processes.
6.1.3 NECESSITY OF KNOWING THE CAPABILITY OF OUR SUPPLIER'S

PROCESSES To understand hidden supplier costs. Suppliers may not know or hide their natural capability limits in an effort to keep business. This could mean that unnecessary costs could occur such as sorting to actually meet customer needs. To be pro-active, For example, Cpk estimation made using injection molding pressure measurements during a molding cycle may
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help reveal a faulty piston pressure valve ready to malfunction before the actual molded part measurements go out of specifications. 6.1.4 MEASURES OF PROCESS CAPABILITY - PROCESS CAPABILITY INDICES Cp, Cpl, Cpu and Cpk are the four most common and timed tested measures of process capability. Process capability indices measure the degree to which your process produces output that meets the customer's specification. Process capability indices can be used effectively to summarize process capability information in a convenient unit less system. Cp and Cpk are quantitative expressions that personify the variability of your process (its natural limits) relative to its specification limits (customer requirements). Following are the graphical details and equations quantifying process capability
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A minimum of four possible outcomes can arise when the natural process variability is compared with the design specifications or customer expectations: Case 1: Cpk > 1.33 (A Highly Capable Process) This process should produce less than 64 ppm. This process will produce conforming products as long as it remains in statistical control. The process owner can claim that the customer should experience least difficulty and greater reliability with this product. This should translate into higher profits.
Note: Cpk values of 1.33 or greater are considered to be industry benchmarks. This means that the process is contained within four standard deviations of the process specifications.
Case 2: Cpk = 1 to 1.33 (A Barely Capable Process) This process will produce greater than 64 ppm but less than 2700 non-conforming ppm. This process has a spread just about equal to specification width. It should be noted that if the process mean moves to the left or the right, a significant portion of product will start falling outside one of the specification limits. This process must be closely monitored.
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Case 3: Cpk < 1 (The Process is not Capable) This process will produce more than 2700 non-conforming ppm. It is impossible for the current process to meet specifications even when it is in statistical control. If the specifications are realistic, an effort must be immediately made to improve the process (i.e. reduce variation) to the point where it is capable of producing consistently within specifications.
Case 4: Cpk < 1 (The Process is not Capable) This process will also produce more than 2700 non-conforming ppm. The variability (s) and specification width is assumed to be the same as in case 2, but the process average is off-center. In such cases, adjustment is required to move the process mean back to target. If no action is taken, a substantial portion of the output will fall outside the specification limit even though the process might be in statistical control.
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6.2 MACHINE CAPABILITY

Machine capability is the ability of machine to produce a product that will consistently meet the design requirements or customer expectation.
6.2.1 MACHINE CAPABILITY INDEX (Cm)

Machine capability index which gives capability of the machine to meet the tolerance, is expressed in terms of a ratio as follows. Cm = (Tolerance) (6 sigma for machine) Since process capability index should be greater than 1.33, it may be preferable to achieve an index of 1.67 or even 2 for machine capability. However, if improvement in machine capability involves expensive modification, check overall process variation before making such modifications. If variation from other factors such as material, method, man is negligible, then machine capability index of 1.50 to 1.66 may be sufficient for the process. Next chapter deals with the results of gauge repeatability and reproducibility, machine capability and process capability reports in AW machine shop and RN assembly.
31
Chapter 7
PROCESS CAPABILITY REPORTS OF DIFFERENT SHOPS

7.1 AW MACHINE SHOP
The components of AW series compressors undergo different types of operations before going to kit assembly in the AW machine shop which already discussed in chapter 3. Among various operations only critical operations are considered for doing this project. Critical operations are defined as the operations which directly effect the quality of the product.
The quality of the product mainly depends on the machine capability and process capability, which are discussed in chapter 6. So, the quality is controlled by providing the better capable processes.
Before going to know about the process capability and machine capability, first check the gauge repeatability and reproducibility of the gauges used in those critical operations for measuring the specifications of the parameter.
7.1.1 GRR (GAUGE REPEATABILITY & REPRODUCIBILITY) REPORTS

For calculating the GRR there are some standard formulas provided. In this project Microsoft excel sheet is used to calculate the values of GRR. In this a Microsoft excel sheet is created such that it has the all formulas for calculating GRR and give final value of GRR just by entering the measured values of the parameters. 7.1.1.1 CONDITIONS FOR GRR TEST
1. GRR is less than 10 % and NDC (No. of Distinct Categories) is greater than 5 -
Measurement system can be used for SPC study.

2. GRR between 10% to 30% & NDC (No. of Distinct Categories) is greater than 5 -
Measurement system can be used for detection purpose only.

3. GRR above 30 % - Error - Measurement system stands rejected.
32
7.1.1.2
FORMULAS FOR GRR
Operators : A,B & C No. of Trails, r = 3 No. of Parts, n=10 Gauge Repeatability and Reproducibility, GRR =
o
Repeatability - Equipment variation, EV = Rbar * K

K = 0.5908 Rbar = (Ra + Rb +Rc)/3 Ra =

, Rb =
& Rc =
Range,Rai= Rbi = Rci = (Max. value during the trails

Min value during the trails) for part i.
Reproducibility - Appraiser Variation, AV =
Xdiff = Max(Xj) Min(Xj), where j stands for operator

where Xj = average of all values collected by operator j.
% GRR = 100 ( GRR/ TV)

o o o o o
Total Variation, TV = Part Variation, PV = Rp * K
K = 0.3146 Rp = Max(Ai) Min(Ai), where I stands for part Average, Ai = (Rai+ Rbi + Rci) / 3
No. of Distinct Categories, NDC = 1.41 (PV / GRR)
By using above formulas GRR can be calculated.
7.1.1.3 GRR TABLE

It contains following data
Parameter is to be measured Part name Specification of parameter

33
Collected data
GRR report of Crank case- cylinder bore diameter on Honing Machine 1 The following table 7.1 shows the GRR sheet for the gauge which is used at honing machine1. In this machine, honing operation is done for the crank case cylinder bore diameter. The specification of the cylinder bore diameter is 1.5494/1.5506, it means for honing operation the lower specification limit is 1.5494 and upper specification limit is 1.5506. Here Air gauge is used to measure the specifications. All the readings are in inches which are mentioned in the following tables. In which three operators say A, B & C are taken the readings in three trails for ten different parts or samples. The shaded area in the table represents the values generated by Microsoft excel. At the end of the table GRR (Gauge Repeatability and Reproducibility) and NDC (No. of Distinct Categories) values are provided. This Explanation is similar for all GRR tables but parameter and machine are changed.
GRR ( III EDITION) DATA COLLECTION SHEET Part Name: Crank Case Parameter: cylinder bore dia Operato r
Trial A1 A2 A3 Average Range B -1 B -2 B -3 Average Range C1 C2 C3 1 1.55070 1.55070 1.55070 1.5507 0.0000 1.55075 1.55075 1.55070 1.5507 0.0001 1.55075 1.55075 1.55070 2 1.55000 1.55000 1.55000 1.5500 0.0000 1.55000 1.55000 1.54995 1.5500 0.0001 1.55000 1.55000 1.55000 3 1.54965 1.54965 1.54965 1.5497 0.0000 1.54965 1.54965 1.54965 1.5497 0.0000 1.54965 1.54965 1.54965 4 1.54980 1.54980 1.54980 1.5498 0.0000 1.54980 1.54985 1.54980 1.5498 0.0000 1.54980 1.54985 1.54980 5 1.54995 1.54985 1.54985 1.5499 0.0001 1.54985 1.54985 1.54985 1.5499 0.0000 1.54985 1.54985 1.54980
Gauge name: Air gauge Spec: 1.5494/1.5506 PART

6 1.55000 1.55000 1.54995 1.5500 0.0001 1.54995 1.55000 1.54995 1.5500 0.0001 1.54995 1.55000 1.54995 7
Date: 28/02/2010
Machine : Honing 1
Performed by: JNTU students
8 1.55000 1.55000 1.55000 1.5500 0.0000 1.55000 1.55000 1.55000 1.5500 0.0000 1.55000 1.55000 1.55000
9 1.54985 1.54980 1.54980 1.5498 0.0000 1.54985 1.54985 1.54980 1.5498 0.0000 1.54980 1.54985 1.54980
10 1.54945 1.54945 1.54945 1.5495 0.0000 1.54950 1.54950 1.54945 1.5495 0.0001 1.54950 1.54950 1.54945 Avg. Avg. Avg. Xa Ra= Avg. Avg. Avg. Xb= Rb= Avg. Avg. Avg. 1.5501 1.5501 1.5501 1.5501 0.00002 1.5501 1.5501 1.5501 1.5501 0.00004 1.5501 1.5501 1.5501
1.55165 1.55165 1.55160 1.5516 0.0000 1.55165 1.55165 1.55160 1.5516 0.0000 1.55165 1.55165 1.55160
34
Average Range Part
1.5507 0.0001
1.5500 0.0000
1.5497 0.0000
1.5498 0.0000
1.5498 0.0000
1.5500 0.0001
1.5516 0.0000
1.5500 0.0000
1.5498 0.0000
1.5495 0.0001
Xc = Rc =
1.5501 0.00003
1.5507 Average
1.5500
1.5497
1.5498
1.5499
1.5500
1.5516
1.5500
1.5498
1.5495
% GRR 2.86 Table 7.1
NDC- 51
From the above table 7.1 GRR is less than 10% and NDC is greater than 5. So, from the conditions of GRR test, it is found that the Measurement system can be used for SPC (statistical process control) study.
GRR report of Crank case- cylinder bore diameter on Honing Machine 2

GRR ( III EDITION) DATA COLLECTION SHEET Part Name: Crank Case Parameter: cylinder bore dia
Operator Trial A1 A2 A3 Average Range B -1 B -2 B -3 Average Range C1 C2 C3 Average Range Part Average PART 1 1.55170 1.55170 1.55170 1.5517 0.0000 1.55160 1.55175 1.55175 1.5517 0.0001 1.55165 1.55175 1.55170 1.5517 0.0001 2 1.55030 1.55030 1.55030 1.5503 0.0000 1.55030 1.55030 1.55030 1.5503 0.0000 1.55030 1.55030 1.55030 1.5503 0.0000 3 1.55025 1.55025 1.55025 1.5503 0.0000 1.55025 1.55030 1.55025 1.5503 0.0001 1.55030 1.55030 1.55030 1.5503 0.0000 4 1.55010 1.55010 1.55010 1.5501 0.0000 1.55010 1.55010 1.55010 1.5501 0.0000 1.55015 1.55010 1.55015 1.5501 0.0000 5 1.54995 1.55000 1.54990 1.5500 0.0001 1.54990 1.54995 1.54995 1.5499 0.0000 1.54995 1.54995 1.54995 1.5500 0.0000 6 1.54985 1.54990 1.54990 1.5499 0.0001 1.54990 1.54990 1.54990 1.5499 0.0000 1.54990 1.54990 1.54990 1.5499 0.0000 7 1.55010 1.55010 1.55010 1.5501 0.0000 1.55010 1.55010 1.55010 1.5501 0.0000 1.55015 1.55010 1.55010 1.5501 0.0000 8 1.55015 1.55015 1.55015 1.5502 0.0000 1.55015 1.55015 1.55015 1.5502 0.0000 1.55015 1.55015 1.55015 1.5502 0.0000 9 1.54950 1.55000 1.55000 1.5498 0.0005 1.54995 1.55000 1.55000 1.5500 0.0001 1.55000 1.55000 1.55000 1.5500 0.0000 10 1.55018 1.54950 1.54950 1.5497 0.0007 1.54950 1.54950 1.54950 1.5495 0.0000 1.54950 1.54950 1.54950 1.5495 0.0000 Avg. Avg. Avg. Xa Ra= Avg. Avg. Avg. Xb= Rb= Avg. Avg. Avg. Xc = Rc = 1.5502 1.5502 1.5502 1.5502 0.00013 1.5502 1.5502 1.5502 1.5502 0.00003 1.5502 1.5502 1.5502 1.5502 0.00002
Gauge name: Air gauge Spec: 1.5494/1.5506
Date: 28/02/2010
Machine : Honing 2
1.5517
1.5503
1.5503
1.5501
1.5499
1.5499
1.5501
1.5502
1.5499
1.5496
% GRR 5.46
35
NDC- 26
Table 7.2
C2 C3 Averag e
GRR report of Crank Shaft- S.E pin diameter on Parishudh S.E Machine
1.43740 1.43730 1.43740 1.43730 1.43785 1.43780 1.43740 1.43730 1.43740 1.43730 1.43745 1.43745 1.43720 1.43725 1.43655 1.43655 1.43740 1.43730
1.43725 1.43715
Avg. Avg. Xc =
1.4373 1.4373
1.4374
1.4373
1.4378
1.4374
1.4374
1.4374
1.4373
1.4366
1.4374
1.4372 Rc =
1.4373 0.0000 8
Range Part Averag e
0.0001
0.0001
0.0001
0.0001
0.0001
0.0000
0.0001
0.0000
0.0001
0.0001
1.4374
1.4373
1.4378
1.4374
1.4373
1.4374
1.4372
1.4366
1.4372
1.4372
% GRR 15.97
NDC- 9
36
Table 7.3
From the above table 7.3 GRR is between10- 30% and NDC is greater than 5. So, from the conditions of GRR test, it is found that Measurement system can be used for detection purpose only.
GRR report of Crank Shaft- L.E pin diameter on Parishudh L.E Machine
GRR ( III EDITION) DATA COLLECTION SHEET Part Name: Crank Shaft Gauge name: Air gauge Date: 28/02/2010 Machine L.E Parameter: L.E pin diameter Operat or
Trial A1 A2 A3 Average 1 1.43750 1.43745 1.43740 1.4375 2 1.43785 1.43780 1.43780 1.4378 3 1.43745 1.43740 1.43740 1.4374 4 1.43750 1.43745 1.43745 1.4375 5 1.43735 1.43730 1.43735 1.4373
Parishudh
Spec: 1.4371/1.4376 PART

6 1.43750 1.43740 1.43750 1.4375 7
8 1.43660 1.43655 1.43665 1.4366
9 1.43745 1.43745 1.43745 1.4375
10 1.43750 1.43745 1.43745 1.4375 Avg. Avg. Avg. Xa R a = Avg. Avg. Avg. X b = R b = Avg. Avg. Avg. Xc = Rc = 1.4373 1.4373 1.4373 1.4373
1.43745 1.43740 1.43745 1.4374
Range B -1 B -2 B -3
0.0001 1.43745 1.43750 1.43740
0.0001 1.43780 1.43780 1.43780
0.0000 1.43745 1.43740 1.43740
0.0001 1.43750 1.43750 1.43750
0.0000 1.43740 1.43740 1.43735
0.0001 1.43745 1.43740 1.43740
0.0000 1.43745 1.43745 1.43745
0.0001 1.43660 1.43665 1.43655
0.0000 1.43750 1.43745 1.43745
0.0001 1.43750 1.43750 1.43750
0.00007 1.4373 1.4373 1.4373
Average
1.4375
1.4378
1.4374
1.4375
1.4374
1.4374
1.4375
1.4366
1.4375
1.4375
1.4373
Range C1 C2 C3
0.0001 1.43735 1.43735 1.43740
0.0000 1.43780 1.43780 1.43780
0.0000 1.43740 1.43730 1.43740
0.0000 1.43745 1.43745 1.43745
0.0001 1.43730 1.43735 1.43740
0.0000 1.43740 1.43735 1.43740
0.0000 1.1.4373 1.43740 1.43740
1.4375 1.43660 1.43665 1.43660
0.0001 1.43740 1.43740 1.43745
0.0000 1.43740 1.43745 1.43745
0.00014 1.4373 1.4373 1.4374
Average Range
1.4374 0.0001
1.4378 0.0000
1.4374 0.0001
1.4375 0.0000
1.4374 0.0001
1.4374 0.0001
1.4374 0.0000
1.4366 0.0000
1.4374 0.0000
1.4374 0.0000
1.4374 0.00004
Part Average 1.4374 1.4378 1.4374 1.4375 1.4374 1.4374 1.4374 1.4366 1.4374 1.4375
NDC- 15
37
GRR report of Piston OD grinding on Micron Machine

GRR ( III EDITION) DATA COLLECTION SHEET Part Name: Piston Parameter: Piston OD grinding Operator Trial 1 1.5489 5 1.5490 0 1.5490 0 1.5490 0.0000 1.5489 5 1.5490 0 1.5490 0 1.5490 0.0000 1.5490 0 1.5490 0 1.5490 0 1.5490 0.0000 2 1.54935 3 1.54955 4 1.54945 5 1.54920 Gauge name: Air gauge Spec: 1.5490/1.5500 PART 6 1.54940 7 1.54970 8 1.54865 9 1.54975 10 1.54905 Avg . Avg . Avg . Xa R a = Avg . Avg . Avg . X b = R b = Avg . Avg . Avg . Xc = Rc = Date: 02/03/2010 Machine : Micron
A1
1.5493
A2
1.54935
1.54955
1.54950
1.54925
1.54940
1.54975
1.54870
1.54975
1.54910
1.5493
A3 Average Range
1.54940 1.5494 0.0001 1.54935
1.54955 1.5496 0.0000 1.54955
1.54950 1.5495 0.0001 1.54950
1.54925 1.5492 0.0001 1.54915
1.54945 1.5494 0.0000 1.54935
1.54975 1.5497 0.0000 1.54975
1.54865 1.5487 0.0000 1.54870
1.54975 1.5498 0.0000 1.54975
1.54905 1.5491 0.0000 1.54905
1.5493 1.5493 0.00004
B -1
1.5493
B -2
1.54940
1.54955
1.54950
1.54925
1.54945
1.54975
1.54870
1.54975
1.54910
1.5493
B -3 Average Range
1.54940
1.54955
1.54950
1.54925
1.54945
1.54975
1.54870
1.54975
1.54905
1.5493 1.5493 0.00003
1.5494 0.0001 1.54940
1.5496 0.0000 1.54955
1.5495 0.0000 1.54945
1.5492 0.0001 1.54920
1.5494 0.0001 1.54940
1.5498 0.0000 1.54975
1.5487 0.0000 1.54870
1.5498 0.0000 1.54975
1.5491 0.0000 1.54905
C1
1.5493
C2
1.54940
1.54955
1.54950
1.54925
1.54945
1.54975
1.54870
1.54975
1.54910
1.5493
C3 Average Range
1.54935
1.54955
1.54950
1.54920
1.54940
1.54975
1.54870
1.54975
1.54905
1.5493 1.5493 0.00003
1.5494 0.0001
1.5496 0.0000
1.5495 0.0001
1.5492 0.0001
1.5494 0.0000
1.5498 0.0000
1.5487 0.0000
1.5498 0.0000
1.5491 0.0000
38
Part Average 1.5490 1.5494 1.5496 1.5495 1.5492 1.5494 1.5497 1.5487 1.5498 1.5491
NDC- 24
GRR report of Connecting Rod crank bore on XLO - 732 Machine

GRR ( III EDITION) DATA COLLECTION SHEET Part Name: Piston Parameter: Piston OD grinding Operator Trial A1 A2 A3 Average Range B -1 B -2 B -3 Average Range C1 C2 C3 Average Range Part Average 1.5490 1.5494 1.5496 1.5495 1.5492 1.5494 1.5497 1.5487 1.5498 1.5491 1 1.43855 1.43860 1.43855 1.4386 0.0001 1.43860 1.43860 1.43860 1.4386 0.0000 1.43855 1.43855 1.43860 1.4386 0.0001 2 1.43875 1.43880 1.43880 1.4388 0.0001 1.43875 1.43880 1.43880 1.4388 0.0001 1.43880 1.43880 1.43875 1.4388 0.0001 3 1.43860 1.43865 1.43865 1.4386 0.0000 1.43865 1.43865 1.43865 1.4387 0.0000 1.43860 1.43865 1.43860 1.4386 0.0000 4 1.43840 1.43840 1.43845 1.4384 0.0001 1.43840 1.43845 1.43845 1.4384 0.0001 1.43840 1.43840 1.43845 1.4384 0.0001 5 1.43850 1.43850 1.43850 1.4385 0.0000 1.43850 1.43850 1.43850 1.4385 0.0000 1.43845 1.43850 1.43850 1.4385 0.0000 Gauge name: Air gauge Spec: 1.4382/1.4386 PART 6 1.43880 1.43875 1.43880 1.4388 0.0001 1.43880 1.43880 1.43880 1.4388 0.0000 1.43880 1.43880 1.43875 1.4388 0.0001 7 1.43880 1.43880 1.43880 1.4388 0.0000 1.43880 1.43880 1.43880 1.4388 0.0000 1.43885 1.43885 1.43880 1.4388 0.0000 8 1.43815 1.43815 1.43815 1.4382 0.0000 1.43820 1.43815 1.43815 1.4382 0.0000 1.43815 1.43815 1.43820 1.4382 0.0000 9 1.43880 1.43880 1.43880 1.4388 0.0000 1.43880 1.43880 1.43880 1.4388 0.0000 1.43880 1.43880 1.43880 1.4388 0.0000 10 1.43875 1.43875 1.43875 1.4388 0.0000 1.43875 1.43875 1.43875 1.4388 0.0000 1.43875 1.43875 1.43875 1.4388 0.0000 Avg. Avg. Avg. Xa Ra= Avg. Avg. Avg. Xb= Rb= Avg. Avg. Avg. Xc = Rc = 1.4386 1.4386 1.4386 1.4386 0.00003 1.4386 1.4386 1.4386 1.4386 0.00002 1.4386 1.4386 1.4386 1.4386 0.00004 Date: 02/03/2010 Performed by: JNTU students Machine : Micron
% GRR 8.09
39
NDC- 17
Table 7.6 From the above table 7.6 GRR is less than 10% and NDC is greater than 5. So, from the conditions of GRR test, it is found that the Measurement system can be used for SPC (statistical process control) study. 7.1.1.4 SUMMARY SHEET FOR GRR TEST
TEST S.NO COMPONENT MACHINE
HONING - 1 (OLD) HONING - 2(NEW) PARISHUDH S.E PARISHUDH L.E MICRON XLO 732
PARAMETER
CYL. BORE DIA CYL. BORE DIA S.E PIN DIA L.E PIN DIA OD GRINDING CRANK BORE DIA
GRR
2.76 5.46 15.97 9.49 5.98 8.09
NDC
51 26 9 15 24 17
(PASS/ FAIL)
P P F P P P
CRANK CASE
2 3 4
CRANK SHAFT PISTON CONNECTING ROD
Table 7.7 Summery sheet for GRR test From the above table 7.7
It is clear that the gauges available at the machines say Honing-1, Honing -2, Parishudh L.E, Micron and XLO 732 are satisfy the first condition (GRR % less than 10 % and NDC greater than 5) of GRR test. So, these gauges can be used for SPC study.
But the gauge at Parishudh S.E machine satisfies the second condition (GRR between 10% to 30% & NDC greater than 5) of GRR test. So, this gauge can be used for detection purpose only.
7.1.2 MACHINE CAPABILITY REPORTS

To know the capabilities of various machines, the machine capability test is performed. To perform this test some standard form of collection data table and formulas are used. This work is done on Microsoft excel by creating a excel sheet such that it contains the formulas for calculating machine capability.
7.1.2.1
CONDITION FOR MACHINE CAPABILITY TEST
40
The capability of the machine should be greater than 2, for the machine to be in good working condition. 7.1.2.2 FORMULAS FOR CALCULATING MACHINE CAPABILITY

No. of times readings are taken (by providing some interval between them), n = 10 Range , Ri = Max value Min value Average of all ranges, Rbar = Constant,
d = 2.326
Sigma = Rbar / d 6Sigma = 6 * Sigma Tolerance =USL LSL o USL Upper Specification Limit
o
LSL Lower Specification Limit
Machine Capability = Tolerance / 6Sigma
7.1.2.3 PROCEDURE FOR CALCULATING MACHINE CAPABILITY

Collect the data for different parameters from different machines in time intervals. Enter the data in the Microsoft excel sheet as shown in following table. The Microsoft excel sheet automatically generates the machine capability values, in which we provide the formulas for calculating machine capability.
Machine Capability Report of Honing1 Machine (CYLINDER BORE DIA) (Spec: 1.5494/1.5506) The following table 7.8 shows the machine capability sheet for Honing Machine1. In this machine, honing operation is done for the crank case cylinder bore diameter. In this table first column shows the serial number, second column shows the time at which readings are taken, next column shows the samples or work pieces readings taken during the time mentioned in the column2. The range column shows the difference in the maximum reading and minimum reading in the corresponding row. R bar is the average of all ranges. d is constant. Tolerance is the difference between the specification limits. For sigma, 6sigma and machine capability formulas are provided earlier. As mentioned in the procedure 7.1.2.3,
41
after entering all values in excel sheet it generates machine capability values. From these tables capability value is taken for the test. This explanation is similar for all AW and RN tables drawn in following pages, but machines are different.
S.N O 1 2 3 4 5 6 7 8 9 10 Samples Time 1 9:45 11:15 11:45 12:15 12:45 13:45 14:15 14:45 15:15 15:45 1.55000 1.55020 1.54990 1.55020 1.55020 1.54995 1.54990 1.54990 1.54980 1.54995 2 1.55005 1.55010 1.55025 1.55025 1.55015 1.55010 1.55015 1.54955 1.54980 1.54990 3 1.54995 1.55000 1.55015 1.55020 1.55000 1.55005 1.55005 1.54955 1.54970 1.54995 4 1.54995 1.54980 1.55000 1.55010 1.55015 1.55005 1.55025 1.54945 1.54955 1.54990 5 1.54990 1.54965 1.54990 1.55005 1.55010 1.54995 1.55020 1.54925 1.54960 1.54985 0.00015 0.00055 0.00035 0.00020 0.00020 0.00029 0.00015 0.00035 0.00065 0.00025 0.00010 2.326 0.00013 0.00076 0.0012 1.577 Range R bar d2 Sigma 6 Sigma Toleranc e capab ility
Table 7.8
From the table 7.8 it is found that machine capability is less than 2. So, the required condition for machine capability test is not satisfied.
Machine Capability Report of Honing2 Machine (CYLINDER BORE DIA) (Spec: 1.5494/1.5506)
S.N O 1 2 3 4 5 6 7 8 9 10 Samples Time 1 9:50 11:20 11:50 12:20 12:50 13:50 14:20 14:50 15:20 15:50 1.55015 1.55000 1.55000 1.54990 1.54995 1.55000 1.54995 1.54995 1.55005 1.55000 2 1.55005 1.54995 1.54995 1.55000 1.54995 1.54995 1.54990 1.54995 1.55000 1.54995 3 1.55005 1.54985 1.55005 1.55005 1.54995 1.54995 1.54995 1.55000 1.55005 1.54990 4 1.54995 1.54980 1.55000 1.54990 1.54990 1.54995 1.55000 1.54985 1.55000 1.54985 5 1.54995 1.54980 1.55015 1.54990 1.54995 1.54990 1.54990 1.54990 1.55015 1.54985 0.00020 0.00020 0.00020 0.00015 0.00005 0.00014 0.00010 0.00010 0.00015 0.00015 0.00015 2.326 0.00006 0.00037 0.0012 3.208 Range R bar d2 Sigma 6 Sigma Tolera nce Capabil ity
Table 7.9
From the table 7.9 it is found that machine capability is greater than 2. So, the required condition for machine capability test is satisfied.
42
Machine Capability Report of Parishudh S.E Machine (Crank Shaft) (Spec: 1.4371/1.4376)
S.N O 1 2 3 4 5 6 7 8 9 10 Samples Time 1 12:20 12:50 13:45 14:45 15:10 15:35 16:00 16:25 16:50 17:50 1.43730 1.43730 1.43730 1.43730 1.43730 1.43730 1.43735 1.43730 1.43730 1.43730 2 1.43735 1.43730 1.43725 1.43735 1.43730 1.43730 1.43735 1.43725 1.43735 1.43730 3 1.43735 1.43730 1.43735 1.43735 1.43725 1.43730 1.43735 1.43725 1.43735 1.43730 4 1.43735 1.43730 1.43725 1.43730 1.43730 1.43735 1.43730 1.43725 1.43735 1.43725 5 1.43730 1.43730 1.43730 1.43735 1.43725 1.43735 1.43730 1.43730 1.43730 1.43725 0.00005 0.00000 0.00010 0.00005 0.00005 0.00005 0.00005 0.00005 0.00005 0.00005 0.00005 2.326 0.00002 0.00013 0.0005 3.877 Range R bar d2 Sigma 6 Sigma Toleranc e capabili ty
Table 7.10
Machine Capability Report of Parishudh L.E Machine (Crank Shaft) (Spec: 1.4371/1.4376)
Table 7.11
43
Machine Capability Report of EMT Machine (Piston deck height) (Spec: 0.8403/0.8443)
S.N O 1 2 3 4 5 6 7 8 9 10 Samples Time 1 13:20 13:50 14:40 15:05 15:30 15:55 16:20 16:45 17:10 17:35 0.8468 0.8468 0.8468 0.8468 0.8463 0.8468 0.8468 0.8458 0.8468 0.8458 2 0.8443 0.8458 0.8463 0.8443 0.8443 0.8468 0.8468 0.8458 0.8458 0.8468 3 0.8458 0.8458 0.8453 0.8468 0.8438 0.8473 0.8443 0.8463 0.8473 0.8458 4 0.8453 0.8453 0.8448 0.8453 0.8463 0.8438 0.8453 0.8473 0.8453 0.8463 5 0.8443 0.8443 0.8443 0.8413 0.8463 0.8458 0.8463 0.8453 0.8458 0.8463 0.0025 0.0025 0.0025 0.0055 0.0025 0.00265 0.0035 0.0025 0.0020 0.0020 0.0010 2.326 0.00114 0.00684 0.004 0.585 Range R bar d2 Sigma 6 Sigma Toleran ce capabil ity
Table 7.12
Machine Capability Report of TU-2065 Machine (Piston deck height) (Spec: 0.7938/0.7958)
Table 7.13
44
7.1.2.4 SUMMARY SHEET FOR MACHINE CAPABILITY TEST
S.NO
1
COMPONENT
CRANK CASE
MACHINE
HONING - 1 (OLD) HONING - 2(NEW) PARISHUDH S.E PARISHUDH L.E EMT TUPELO 2065
PARAMETER
CYL. BORE DIA CYL. BORE DIA S.E PIN DIA L.E PIN DIA DECK HEIGHT DECK HEIGHT
MACHINE CAPABILITY
1.57 3.21 3.87 3.23 0.59 0.30
CRANK SHAFT
PISTON
Table 7.14: Summary sheet for Machine Capability test From the above table 7.14
It is clear that the machine capabilities of Honing2, Parishudh SE and Parishudh LE machines are greater than the required capability 2. Therefore they satisfies the condition for the for machine capability test.
But the machine capabilities of Honing1, EMT and TUPELO2065 are less than 2. So, the required condition for machine capability test is not satisfied.
7.1.3 PROCESS CAPABILITY REPORTS To know the capabilities of various processes, process capability test is performed. In this test first readings are collected and process capability charts for the collected data are drawn. The readings are nothing but process specification for example diameter of the cylinder bore. For drawing the process capability charts MTAB software is used. This software automatically generates the process capability charts for the given set of values.
45
This software needs the following information for drawing the process capability charts. Collected data Lower specification limit Upper specification limit Title for the graph
So that the MTAB software generates the process capability charts. Through this chart values of process capability (Cp) and process capability index (Cpk) are found. 7.1.3.1 CONDITIONS FOR THE PROCESS CAPABILITY TEST
1. Process capability index (Cpk) is greater than 1.33 - A Highly Capable Process. 2. Process capability index (Cpk) is between 1 to 1.33 - A Barely Capable Process. 3. Process capability index (Cpk) is less than 1 - The Process is not capable.
7.1.3.2 PROCEDURE FOR CALCULATING PROCESS CAPABILITY

Collect the data for different processes. Enter the values in MTAB soft ware. Enter the specification limits for the given parameters. Enter the title of the graph. Then MTAB automatically generates the process capability charts. From which the process capability (Cp) and process capability index (Cpk) are taken.
7.1.3.3 COLLECTION DATA AND PROCESS CAPABILITY GRAPHS Collected Data for Crank Case cylinder Bore
The following table 7.15 shows the collected values for drawing the process capability charts. In this table the parameter is crank case cylinder bore diameter. AW crank case has two cylinder bores, they are called top bore and bottom bore. In table first column shows the serial number, second and third columns show the readings of top and bottom bore
46
on Honing machine1 and next two columns show the readings of top and bottom bore on Honing machine2. All the readings are taken in inches and measured by using Air gauges. The specification of the parameter is 1.5494/1.5496. This explanation is similar for all AW and RN tables but the parameters and machines are different.
PARAMETER : CYLINDER BORE DIA
Specification : 1.5494/1.5506
MACHINE S.NO HONNING 1 TOP BOTTOM
Date : 03 / 03 / 10
HONNING 2 TOP BOTTOM MACHINE S.NO HONNING 1 TOP BOTTOM HONNING 2 TOP BOTTOM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1.54995 1.54990 1.54975 1.54975 1.55000 1.54985 1.54985 1.54990 1.54990 1.54980 1.54995 1.55025 1.54990 1.54995 1.54985 1.55005 1.54990 1.54995 1.54985 1.55005 1.55010 1.55005 1.54985 1.55015 1.54995
1.54995 1.54975 1.54950 1.54970 1.54990 1.54970 1.54975 1.54985 1.59800 1.54985 1.55000 1.55005 1.54985 1.55000 1.54985 1.55000 1.54975 1.55005 1.54985 1.54970 1.55010 1.55005 1.54985 1.54990 1.54995
1.54990 1.54980 1.54990 1.54985 1.54985 1.54990 1.54980 1.55000 1.54985 1.54980 1.54985 1.54995 1.54990 1.54980 1.54990 1.54995 1.54980 1.54995 1.54970 1.54995 1.54985 1.54990 1.54995 1.54990 1.54985
1.54990 1.54980 1.54985 1.54990 1.54985 1.54990 1.54985 1.54990 1.54990 1.54980 1.54990 1.54995 1.54990 1.54985 1.54985 1.54990 1.54975 1.54975 1.54960 1.54950 1.54985 1.54990 1.54990 1.54990 1.54980
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1.55020 1.55005 1.55020 1.54995 1.54990 1.54995 1.54995 1.54970 1.54995 1.54995 1.54965 1.54970 1.54975 1.54965 1.54975 1.54960 1.54950 1.54990 1.54965 1.54940 1.54970 1.54985 1.54940 1.55035 1.55015
1.55020 1.54950 1.55025 1.55000 1.54995 1.54995 1.54970 1.54965 1.54990 1.54960 1.54965 1.54975 1.54970 1.54950 1.54990 1.54960 1.54965 1.54990 1.54990 1.54965 1.54970 1.54995 1.54935 1.55035 1.54995
1.54990 1.54980 1.54980 1.54980 1.54990 1.54995 1.55000 1.54995 1.55005 1.55000 1.55005 1.54985 1.54990 1.54995 1.54990 1.54995 1.54985 1.54980 1.54980 1.54990 1.54985 1.54985 1.54990 1.55000 1.54980
1.54990 1.54980 1.54980 1.54985 1.54995 1.54995 1.55000 1.54995 1.55005 1.55000 1.55000 1.54985 1.54990 1.54995 1.54990 1.54995 1.54980 1.54985 1.54980 1.54990 1.54985 1.54980 1.54980 1.54995 1.54980
47
Table 7.15
Process Capability Graphs for Crank Case Cylinder Bore Diameter The process capability graph explains the following points and this is common to all process capability graphs drawn in following pages, but operation is different.

The LSL dotted vertical line shows the lower specification limit for the given parameter. Here the parameter is cylinder bore diameter. The USL dotted vertical line shows the upper specification limit for the given parameter. The rectangular bar in between the LSL and USL show the number of parts with in the limit or specification. The rectangular bars out side the LSL or USL show the number of parts out of the limits. If the rectangular bars show on left side of the LSL means the parts are in under size and if they show on right side of the USL means the parts are in over size. From this graph we obtain the process capability (Cp) and process capability index (Cpk). These values are circled in the graph.
Graph 7.1
48
The above graph 7.1 obtains by entering the input values such are specifications of cylinder bore diameter, upper specification limit and lower specification limit in MTAB.
From The above graph 7.1 Cp = 1.21 and Cpk = 0.84 of top bore diameter of crank case at honing machine1
The graphs drawn below are followed by their corresponding Cp and Cpk values.
Graph 7.2 From The above graph 7.2 Cp = 0.93 and Cpk = 0.58 of bottom bore diameter of crankcase at honing machine1
49
Graph 7.3
From The above graph 7.3 Cp = 2.53 and Cpk = 1.78 of top bore diameter of crankcase at honing machine2
Graph 7.4
From The above graph 7.4 Cp = 2.90 and Cpk = 1.98 78 of bottom bore diameter of crankcase at honing machine2
50
Collected Data for Piston Deck Height

PARAMETER :Deck Height SPECIFICATION :( Deck height : 0.8238 / 0.8258" ) Deck Height (0.8238/0.8 258) Fixtures 1 2 3 4 5 6 7 8 9 10 1LL 0.8240 0.8250 0.8250 0.8240 0.8250 0.8245 0.8245 0.8250 0.8250 0.8250 Deck Height (0.8238/0.82 58) 3LL 0.8265 0.8260 0.8265 0.8280 0.8265 0.8265 0.8250 0.8255 0.8260 0.8255 Deck Height (0.8238/0.82 58) 3RL 0.8240 0.8245 0.8240 0.8250 0.8255 0.8240 0.8245 0.8245 0.8240 0.8245 Deck Height (0.8238/0.825 8) 3RR 0.8250 0.8255 0.8250 0.8250 0.8240 0.8255 0.8255 0.8250 0.8240 0.8250 Deck Height (0.8238/0.8 258) 4LL 0.8255 0.8250 0.8245 0.8255 0.8250 0.8250 0.8260 0.8245 0.8250 0.8245 Deck Height (0.8238/0.82 58) 4LR 0.8260 0.8250 0.8245 0.8250 0.8260 0.8250 0.8250 0.8260 0.8255 0.8255 Deck Height (0.8238/0.82 58) 4RL 0.8260 0.8255 0.8265 0.8215 0.8250 0.8255 0.8250 0.8270 0.8260 0.8255 Deck Height (0.8238/0. 8258) 4RR 0.8250 0.8250 0.8250 0.8245 0.8245 0.8245 0.8245 0.8245 0.8250 0.8245 MACHINE : TUPELO 2065
51
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
0.8245 0.8250 0.8245 0.8245 0.8240 0.8240 0.8240 0.8245 0.8245 0.8245 0.8245 0.8240 0.8240 0.8240 0.8240 0.8245 0.8245 0.8245 0.8245 0.8240 0.8245 0.8245 0.8240 0.8245 0.8245 0.8240 0.8240 0.8240 0.8240 0.8245 0.8245 0.8245
0.8260 0.8260 0.8255 0.8260 0.8250 0.8265 0.8255 0.8260 0.8250 0.8260 0.8260 0.8260 0.8255 0.8260 0.8255 0.8255 0.8255 0.8255 0.8255 0.8260 0.8250 0.8255 0.8255 0.8265 0.8255 0.8250 0.8255 0.8250 0.8260 0.8255 0.8255 0.8260
0.8240 0.8245 0.8260 0.8245 0.8265 0.8250 0.8250 0.8255 0.8255 0.8250 0.8260 0.8255 0.8255 0.8250 0.8250 0.8255 0.8250 0.8255 0.8250 0.8245 0.8250 0.8250 0.8250 0.8250 0.8250 0.8250 0.8255 0.8250 0.8255 0.8250 0.8250 0.8255
0.8255 0.8250 0.8250 0.8240 0.8250 0.8255 0.8250 0.8265 0.8250 0.8265 0.8260 0.8250 0.8255 0.8260 0.8260 0.8260 0.8260 0.8260 0.8265 0.8265 0.8260 0.8255 0.8255 0.8260 0.8260 0.8255 0.8245 0.8260 0.8260 0.8260 0.8245 0.8200
0.8250 0.8250 0.8245 0.8250 0.8250 0.8240 0.8255 0.8250 0.8245 0.8255 0.8250 0.8245 0.8240 0.8240 0.8250 0.8250 0.8250 0.8250 0.8245 0.8250 0.8245 0.8250 0.8245 0.8245 0.8250 0.8240 0.8240 0.8240 0.8245 0.8245 0.8250 0.8250
0.8255 0.8250 0.8255 0.8255 0.8250 0.8255 0.8260 0.8255 0.8255 0.8260 0.8260 0.8255 0.8250 0.8250 0.8250 0.8255 0.8255 0.8255 0.8260 0.8250 0.8250 0.8250 0.8260 0.8245 0.8250 0.8250 0.8250 0.8245 0.8250 0.8245 0.8245 0.8250
0.8260 0.8260 0.8255 0.8260 0.8260 0.8260 0.8265 0.8260 0.8265 0.8260 0.8265 0.8265 0.8265 0.8260 0.8255 0.8260 0.8265 0.8260 0.8265 0.8260 0.8260 0.8260 0.8265 0.8265 0.8260 0.8260 0.8260 0.8265 0.8260 0.8265 0.8260 0.8260
0.8250 0.8245 0.8255 0.8245 0.8250 0.8260 0.8255 0.8255 0.8255 0.8260 0.8250 0.8255 0.8255 0.8245 0.8260 0.8255 0.8260 0.8250 0.8250 0.8250 0.8250 0.8255 0.8255 0.8245 0.8250 0.8245 0.8245 0.8245 0.8245 0.8245 0.8245 0.8240
52
43 44 45 46 47 48 49 50 51 52 53
0.8245 0.8235 0.8230 0.8230 0.8245 0.8255 0.8245 0.8245 0.8245 0.8245 0.8250
0.8255 0.8255 0.8240 0.8250 0.8260 0.8250 0.8250 0.8255 0.8250 0.8250 0.8255
0.8255 0.8250 0.8250 0.8245 0.8255 0.8250 0.8250 0.8255 0.8250 0.8250 0.8250
0.8240 0.8240 0.8255 0.8260 0.8250 0.8250 0.8250 0.8250 0.8250 0.8255 0.8250
0.8240 0.8240 0.8250 0.8240 0.8240 0.8245 0.8245 0.8240 0.8245 0.8245 0.8240
0.8240 0.8245 0.8250 0.8245 0.8245 0.8240 0.8245 0.8245 0.8245 0.8240 0.8245
0.8250 0.8260 0.8255 0.8255 0.8260 0.8260 0.8260 0.8260 0.8260 0.8255 0.8260
0.8240 0.8245 0.8250 0.8250 0.8250 0.8250 0.8250 0.8250 0.8250 0.8250 0.8250
Table 7.16
Process Capability Graphs for Piston Deck Height
Graph 7.5
From The above graph 7.5 Cp = 1.22 and Cpk = 0.71of Piston deck height at fixture 1LL of TU-2065 machine
53
Graph 7.6
From The above graph 7.6 Cp = 0.65 and Cpk = 0.09 of Piston deck height at fixture 3LL of TU-2065 machine.
Graph 7.7
From The above graph 7.7 Cp = 0.70 and Cpk = 0.61 of Piston deck height at fixture 3RL of TU-2065 machine
54
Graph 7.8
From The above graph 7.8 Cp = 0.54 and Cpk = 0.30 of Piston deck height at fixture 3RR of TU-2065 machine
Graph 7.9
From The above graph 7.9 Cp = 0.80 and Cpk = 0.70 of Piston deck height at fixture 4LL of TU-2065 machine
55
Graph 7.10
From The above graph 7.10 Cp = 1.21 and Cpk = 0.84 of Piston deck height at fixture 4LR of TU-2065 machine
Graph 7.11
56
From The above graph 7.11 Cp = 0.67 and Cpk = -0.08 of Piston deck height at fixture 4RL of TU-2065 machine
Graph 7.12
From The above graph 7.12 Cp = 1.15 and Cpk = 0.96 of Piston deck height at fixture 4RR of TU-2065 machine
Collected Data for Crank Shaft Pin Grinding

Specification : 1.4371 / 1.4376" Machine : Parishudh S.E , Parishudh L.E PARISHUDH PARISHUDH S.NO S.E L.E
1 2 3 4 5 6 7 8 9 10 1.4374 1.43735 1.43735 1.4373 1.4374 1.43735 1.43735 1.43735 1.43735 1.4375 1.43745 1.43745 1.4374 1.4374 1.4374 1.4374 1.4374 1.4374 1.4374 1.43755
03/03/2010 S.NO
26 27 28 29 30 31 32 33 34 35
PARISHUDH S.E
1.4373 1.4374 1.43735 1.4374 1.43735 1.4373 1.4373 1.4373 1.4373 1.43735
PARISHUDH L.E
1.4374 1.4374 1.43745 1.4374 1.4374 1.4374 1.43735 1.4374 1.4374 1.4374
57
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1.43735 1.43735 1.4374 1.4374 1.4374 1.4374 1.43725 1.4374 1.4373 1.43735 1.43735 1.43735 1.43735 1.4374 1.43735
1.43745 1.43735 1.4374 1.4375 1.43735 1.43745 1.4373 1.43745 1.43735 1.43745 1.4373 1.43735 1.4374 1.43735 1.4374
36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1.43735 1.43735 1.43735 1.43735 1.43735 1.4373 1.43735 1.4373 1.43735 1.43735 1.43735 1.4373 1.4373 1.4373 1.4373
1.43745 1.43735 1.43745 1.43735 1.43735 1.4374 1.4374 1.4374 1.43745 1.4374 1.43735 1.43745 1.43745 1.43745 1.43745
Table 7.17
Process Capability Graphs for Crank Shaft Pin Grinding
58
Graph 7.13
From The above graph 7.13 Cp = 2.56 and Cpk = 2.54
Graph 7.14 From The above graph Cp = 1.21 and Cpk = 0.84 7.1.3.4 SUMMARY SHEET FOR PROCESS CAPABILITY TEST
S.NO
COMPONENT
MACHINE HONNING 1 ( OLD )
PARAMETER CYL .BORE DIA TOP BOTTOM TOP BOTTOM 1LL 3LL 3RL
Cp 1.21 0.93 2.53 2.9 1.22 0.65 0.7 0.54 0.8 0.91 0.67 1.15
Cpk 0.84 0.58 1.78 1.98 0.71 0.09 0.61 0.3 0.7 0.64 -0.08 0.96
CRANK CASE HONNING 2 ( NEW ) CYL .BORE DIA
PISTON
TUPELLO 2065
DECK HEIGHT
3RR 4LL 4LR 4RL 4RR
59
CRANK SHAFT
PARISHUDH S.E PARISHUDH L.E
S.E PIN DIA L.E PIN DIA
2.56 1.87
2.54 1.46
Table 7.18 Process Capability report From the above table 7.18
The process capabilities of the processes which are done on the Honing 2, Parishudh S.E and Parishudh L.E machines are satisfactory values that means these values are greater than 1.33 (which is the condition of process capability test). So, these are highly capable processes.
The process capabilities of the processes which are done on the Honing 1 and TUPELO 2065 machines are not satisfactory values. The Cpk of these processes are less than 1.33. So, these processes are not capable. Among the above all operations, the operations performed at fixtures 3LL (Cpk
is 0.08) and 4RL (Cpk is -0.09) in the TUPELO 2065 considered in this project, because these have very less process capabilities among all. 7.1.3.5 CAUSE AND EFFECT DIAGRAM: In this process the parameter is piston deck height. So, it is important to know what the causes are and how they effect on the piston deck height.
60
Fig.7.1 Cause and Effect Diagram
From the cause and effect diagram it is concludes that There are six variables to cause the problems in the process. They are Men, Machine, Material, Method, Environment and Measurement
Men: Because of improper training, motivation, lack of attention of operator while working causes the problems in the process.
Machine: Improper alignment of OBB (out board bearing), variations in clamping of the component (due to manual clamping) and variations in the spindle alignment causes the piston deck height variation.
61
Material: Hardness of the material and variation in the piston squareness causes the variations in the piston deck height
Method: Due to the improper chips cleaning and improper locking of end stopper piston deck may be vary.
Environment: Poor ventilation and model mix-up (when different types models are available) causes the variations in the piston deck height.
Measurement: Due to the improper calibration of gauges and dials, improper mastering (master piece is provided for basic adjustment), operator skills to measure the deck height causes the variations in the piston deck height.
7.1.3.6 ACTION PLANS FOR THE PROBLEM After knowing the causes for piston deck height variation, following action plans are applied. The action plans are
1. Alignment and geometrical parameters of all spindles: In this step the realignment
of all spindles is done.

2. Alignment of all Fixtures and V blocks: In this step the realignment of all fixtures
and V blocks is done.

3. Inspection of Top and Bottom guide bushes: In this step inspection of the top and
bottom guide bushes with respect to the parallelism, squareness is done.

4. To provide proper coolant: In this step sufficient coolant is provided to remove the
chips form fixtures and V blocks.

5. To change the clamping springs: In this step the clamping springs are changed (here
clamping of the component is done by spring force).

6. To change the cutting tools: In this step the cutting tools say Drill bit and Reamers
are changed.
7. Component trails and corrections: In this step data is collected for the components
which are out from the machine, then adjusted the parameters if any adjustment required during the starting of process.
62
7.1.3.7 AFTER APPLYING ACTION PLAN

PARAMETER :Deck Height SPECIFICATION :( Deck height : 0.8238 / 0.8258" ) MACHINE : TUPELO 2065
Fixtures S.NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Deck Height (0.8238/0.8258) 3LL
Deck Height (0.8238/0.8258) 4RL S.NO
Fixtures
Deck Height (0.8238/0.8258) 3LL
Deck Height (0.8238/0.8258) 4RL
0.8255 0.8250 0.8250 0.8250 0.8255 0.8255 0.8255 0.8250 0.8245 0.8250 0.8260 0.8245 0.8255 0.8255 0.8255 0.8260 0.8255 0.8250 0.8250
0.8240 0.8240 0.8240 0.8240 0.8245 0.8240 0.8240 0.8245 0.8245 0.8245 0.8240 0.8245 0.8245 0.8240 0.8240 0.8240 0.8240 0.8240 0.8245
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
0.8250 0.8255 0.8255 0.8250 0.8250 0.8250 0.8250 0.8255 0.8255 0.8250 0.8255 0.8255 0.8260 0.8255 0.8255 0.8255 0.8255 0.8250 0.8255
0.8245 0.8245 0.8240 0.8245 0.8240 0.8240 0.8245 0.8245 0.8240 0.8245 0.8245 0.8245 0.8245 0.8240 0.8240 0.8240 0.8240 0.8240 0.8240
Table 7.19
63
36 37 38
After applying action plans again the data has been collected to calculate the process capability by drawing process capability graphs which are shown below. These graphs are drawn using the procedure explained in 7.1.3.2 earlier. Process Capability Charts for Piston Deck Height After Applying Action Plan
Graph 7.15
Graph 7.16

64
7.1.3.7 COMPARISON OF PROCESS CAPABILITIES FOR TUPELO 2065

FIXTURE 3LL 4RL BEFORE ACTION PLAN Cp 0.65 0.67 Cpk 0.09 -0.08 AFTER ACTON PLAN Cp Cpk
1.06 1.31
0.59 0.54
Table 7.20 From the above table 7.20 it is concluded that
For the fixture 3LL the process capability (Cp) is increased from 0.65 to 1.06 and process capability index (Cpk) is increased from 0.09 to 0.59.
For the fixture 4RL the process capability (Cp) is increased from 0.67 to 1.31 and process capability index (Cpk) is increased from -0.08 to 0.54.
7.2 ROTARY ASSEMBLY (RN SERIES)

65
The components of RN series compressors undergo different types of operations in the RN assembly shop. Among them only the critical operations are considered for doing this project. Critical operations are defined as the operations which directly effect the quality of the product. The process capability for all critical operations calculated by using the procedure explained in 7.1.3.2. Data is collected as explained in the table 7.15. 7.2.1 COLLECTION DATA AND PROCESS CAPABILITY GRAPHS: For Initial Expansion Operation on Housing rough expansion Machine
HOUSING INNER DIAMETER (Spec:5.883/5.893) 1st 1st 1st SI.NO END SI.NO END SI.NO END 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5.865 5.856 5.886 5.874 5.8815 5.886 5.886 5.8825 5.8835 5.886 5.886 5.8875 5.8835 5.8815 5.8845 5.8845 5.8805 5.8865 5.886 5.888 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 5.888 5.888 5.8885 5.8875 5.884 5.8815 5.8865 5.8875 5.8805 5.883 5.8855 5.888 5.8865 5.8855 5.8865 5.888 5.886 5.8875 5.884 5.8855 41 42 43 44 45 46 47 48 49 50 5.886 5.888 5.8825 5.888 5.887 5.888 5.888 5.888 5.8865 5.8875
For Final Expansion Operation On Housing Final expander Machine

HOUSING INNER DIAMETER (Spec:5.898/5.903) 1st 1st 1st SI.NO END SI.NO END SI.NO END 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5.9015 5.9065 5.907 5.904 5.91 5.904 5.902 5.9035 5.912 5.904 5.908 5.904 5.907 5.9045 5.9045 5.904 5.9095 5.9095 5.901 5.904 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 5.9035 5.9035 5.905 5.901 5.902 5.901 5.9045 5.9065 5.9065 5.92 5.9045 5.904 5.9095 5.9045 5.9245 5.912 5.903 5.9045 5.907 5.9045 41 42 43 44 45 46 47 48 49 50 5.886 5.888 5.8825 5.888 5.887 5.888 5.888 5.888 5.8865 5.8875
Table 7.21
66
Graph 7.17
Graph 7.18
From The above graph 7.17 Cp = 0.17 and Cpk = -0.24

67
For Suction hole making Operation

SI.No
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
SUCTION HOLE ID (Spec: 0.88-0.883) ID SI.No ID SI.No

0.8805 0.8805 0.8825 0.8805 0.8805 0.8805 0.8825 0.8805 0.8805 0.8805 0.8805 0.881 0.8825 0.8825 0.8805 0.8825 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 0.8805 0.883 0.8805 0.882 0.8805 0.8805 0.8805 0.881 0.881 0.8815 0.8805 0.883 0.8805 0.882 0.882 0.8805 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47
ID
0.881 0.882 0.882 0.8805 0.8815 0.8805 0.8805 0.883 0.8805 0.8805 0.8825 0.8805 0.8805 0.8805 0.8805
Table 7.22
Graph 7.19
68
For Puddle hole making Operation On 3-hole piercing Machine:

PUDDLE HOLE ID (Spec: 0.88-0.883) ID SI.No ID SI.No
0.245 0.257 0.24885 0.245 0.2505 0.253 0.249 0.254 0.2485 0.2475 0.2455 0.2445 0.253 0.2575 0.2515 0.251 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 0.2525 0.2545 0.249 0.248 0.253 0.2485 0.247 0.251 0.252 0.249 0.247 0.246 0.247 0.2525 0.246 0.249 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47
SI.No
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
ID
0.2475 0.251 0.249 0.246 0.247 0.2505 0.253 0.2455 0.2485 0.2455 0.2445 0.2465 0.2445 0.2485 0.246
Table 7.23
Graph 7.20

69
7.2.2 SUMMARY SHEET FOR PROCESS CAPABILITY TEST OPERATIO SL.NO 1 2 3 4 N NO 1310 1330 1340 1370 OPERATION PARAMETER SPECIFICATION Cp Housing Expansion ID 5.893-5.883 0.6 Suction hole making ID 0.883-0.880 0.55 Puddle holes making ID 0.255-0.245 0.5 Final Expansion of Housing ID 5.903-5.899 0.2 Cpk 0.44 0.42 0.41 0.14
Table 7.24 Process Capability reports before action plan From above table 7.24 The process capabilities of all operations are not satisfactory because the values of Cpk are less than 1.33. So, from the conditions of process capability test these process are not capable for the future operations 7.2.3 ACTION PLANS From the above reports some problems are found and to avoid these problems the following action plans are applied. The action plans are Tools changed Spacers changed Dice punch changed Expansion mandrel changed Hole punch reference changed Reference taken at dual location Expansion dimension changed at both initial and final Inspection implemented at both side of housing
7.2.4 COLLECTION DATA AND PROCESS CAPABILITY GRAPHS AFTER ACTION PLAN
70
For Initial Expansion Operation on Housing rough expansion Machine

HOUSING INNER DIAMETER (Spec:5.883/5.893) 1st 1st 1st SI.NO END SI.NO END SI.NO END
For Final Expansion Operation On Housing Final expander Machine

HOUSING INNER DIAMETER (Spec:5.898/5.903) 1st 1st 1st SI.NO END SI.NO END SI.NO END
5.891
1 21
5.888
41
5.888
1
5.9010
21
5.9000
41
5.9010 5.9000
42
5.892
2 22
5.888
42
5.889
2
5.9010
22
5.9010 5.9010
23 43
5.89
3 23
5.888
43
5.889
3
5.9010 5.9010
4 24
5.9010 5.9010
44
5.89
4 24
5.888
44
5.8885 5.889
45 5
5.9010 5.9000
25 45
5.89
5 25
5.888 5.885
26 46
5.9010 5.9010
6 26
5.9010 5.9010
46
5.891
6
5.89 5.888
47 7
5.9010 5.9010
27 47
5.89
7 27
5.8885 5.888
28 48
5.9020 5.9010
8 28
5.9020 5.9010
48
5.886
8
5.8905 5.8905
49 9
5.8990 5.9000
29 49
5.886
9 29
5.888 5.888
30 50
5.9010 5.9000
10 30
5.9000 5.9000
50
5.887
10
5.891
11
5.9000 5.8990
31
5.888
11 31
5.884 5.8885
32 12
5.9010 5.9000
32
5.888
12
5.9000 5.8990
33
5.888
13 33
5.888
13
5.9000 5.9020
14 34
5.884
14 34
5.888 5.888
35 15
5.9010 5.9010
35
5.8865
15
5.9000 5.9000
16 36
5.886
16 36
5.8885 5.888
37 17
5.9010 5.9000
37
5.888
17
5.9000 5.9000
18 38
5.888
18 38
5.888 5.888
39 19
5.9020 5.9010
39
5.888
19
5.9010 5.9000
20 40
5.888
20 40
5.888
5.9000
Table 7.25
After applying action plans again the data has been collected to calculate the process capability by drawing process capability graphs which are shown below. These graphs are drawn using the procedure explained in 7.1.3.2.
71
Graph 7.21
Graph 7.22

SUCTION HOLE ID (Spec: 0.88-0.883) ID SI.No ID SI.No
0.8810 17 0.8820 33
For Suction hole making Operation On Suction hole piercing Machine

SI.No
1
ID
0.8815
72
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
0.8810 0.8815 0.8810 0.8815 0.8810 0.8820 0.8815 0.8815 0.8810 0.8815 0.8810 0.8820 0.8820 0.8815 0.8820
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
0.8815 0.8815 0.8820 0.8815 0.8815 0.8815 0.8815 0.8815 0.8815 0.8810 0.8820 0.8815 0.8820 0.8820 0.8810
34 35 36 37 38 39 40 41 42 43 44 45 46 47
0.8820 0.8820 0.8810 0.8815 0.8815 0.8815 0.8810 0.8815 0.8815 0.8820 0.8815 0.8810 0.8815 0.8810
Table 7.26
Graph 7.23

PUDDLE HOLE ID (Spec: 0.88-0.883) ID SI.No ID SI.No
0.250 17 0.250 33
For Puddle hole making Operation On 3-hole piercing Machine:

SI.No
1
ID
0.250
73
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
0.250 0.249 0.250 0.250 0.250 0.249 0.250 0.249 0.250 0.250 0.250 0.250 0.250 0.250 0.250
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
0.250 0.249 0.248 0.250 0.249 0.250 0.250 0.250 0.249 0.250 0.250 0.250 0.250 0.250 0.249
34 35 36 37 38 39 40 41 42 43 44 45 46 47
0.250 0.249 0.250 0.250 0.250 0.250 0.250 0.249 0.250 0.250 0.250 0.250 0.249 0.250
Table 7.27
Graph 7.24 PLAN From The above graph Cp = 0.50 and Cpk = 0.41 7.2.5 SUMMARY SHEET FOR PROCESS CAPABILITY TEST AFTER ACTION
74
OPERATION SL.NO 1 2 3 4 NO 1310 1330 1340 1370 OPERATION PARAMETER SPECIFICATION Housing Expansion ID 5.893-5.883 Suction hole making ID 0.883-0.8800 Puddle holes making ID 0.255-0.245 Final Expansion of Housing ID 5.903-5.899 Cp 1.26 1.44 2.79 1.16 Cpk 1.19 1.44 2.63 1.11
Table 7.28 Process Capability and Machine Capability reports after action plan
From the above table7.28 it is concluded that
For Housing Expansion the process capability (Cp) is increased from 0.60 to 1.26 and process capability index (Cpk) is increased from 0.44 to 1.19
For the Suction hole making the process capability (Cp) is increased from 0.55 to 1.44 and process capability index (Cpk) is increased from 0.42 to 1.44.
For Puddle holes making the process capability (Cp) is increased from 0.50 to 2.79 and process capability index (Cpk) is increased from 0.41 to 2.63
For the Final Expansion of Housing the process capability (Cp) is increased from 0.2 to 1.44 and process capability index (Cpk) is increased from 0.14 to 1.11.
CONCLUSION
In this project, the manufacture of the compressor has been studied in detail. It has been observed that the company inputs are castings. So, for these castings finishing operations are done on the respected machine shops and then the components are assembled
75
according to the requirement while performing various tests on them to check the quality, whether the parts have been machined according to the required specifications or not. Every operation has its own specifications which the component must meet. Quality of the product depends upon the process capability and machine capability. So, to improve the quality in the AW machine shop and RN assembly the process capability and machine capability are studied for critical operations of compressors during the manufacturing process. In the AW machine shop process capability for critical operations are calculated. Process capability of piston deck height is found to be low for fixtures 3LL and 4RL at tupelo-2065 machine. After applying action plans for the fixture 3LL the process capability (Cp) is increased from 0.65 to 1.06 and process capability index (Cpk) is increased from 0.09 to 0.59. Similarly for the fixture 4RL the process capability (Cp) is increased from 0.65 to 1.06 and process capability index (Cpk) is increased from 0.09 to 0.59. Similarly in the RN assembly, action plans are applied to the critical operations, by this the process capability(Cp) is increased for puddle hole making operation from 0.50 to 2.79 and process capability index (Cpk) is increased from 0.41 t0 2.63. Finally the process capabilities of these critical operations which are not in desirable limits are improved by applying the different actions plans for different operations in AW machine shop and RN assembly. So, the quality and performance of compressors are improved.
BIBLIOGRAPHY
www.tecumsehindia.com www.mastermachines.com www.intinidia.com www.4shared.com
76
Automation, Production Systems and Computer Integrated Manufacturing by
Mikell P.Groover, PHI.
77

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Chapter 1

2. Rotary compressors (18000 26500 BTU/hr)

THK Series Reciprocating compressors Refrigeration application

1.2 GLOBAL PRESENCE

Vecomesa Venezuela , Venezuela

Tecnamotor Italy , Italy

Tecumseh India , India

2.2 TYPES OF COMPRESSORS

2.3 DIFFERENT TYPES OF COMPRESSORS MANUFACTURE IN TECUMSEH, HYDERABAD

Type of compressor Reciprocating compressors

2.4 COMPONENTS OF A COMPRESSOR

3.2 MACHINE SHOP

AK model Fig.3.1 Crank case 3.2.2 CRANK SHAFT

AK model Fig.3.2 Crank shaft 3.2.3 PISTON

AK model Fig.3.3 Piston 3.2.4 CONNECTING ROD

AK model Fig.3.4 Connecting rod 3.2.5 OUT BOARD BEARING

AK model Fig.3.5 Out Board Bearing

3.3 VALVE PLATE SUB-ASSEMBLY

Rubber Gasket Fig.3.7

Rubberized Metal Gasket

3.6 CYLINDER HEAD

3.7 MANUFACTURING OF COMPRESSOR COMPONENTS

Cycle time in sec 05 03 -

Cycle time in sec 06 21 20 13 18 17 12 06 06 04 -

Cycle time in sec 15 40 08 20

Cycle time in sec 58 42 25 32 30 30 20 33 20 10 54 24 -

Cycle time in sec

Jet and bullows cleaning END

4.1.1 RN-MACHINE SHOP

4.3 KIT ASSEMBLY

4.4 EXTERNAL PARTS OF COMPRESSOR

4.5.2 TERMINAL ASSEMBLY

4.6 DIP PAINT AND VACUUM DEHYDRATION

4.7 OIL LINE AND PACKING FINAL TEST

4.8 WORKING OF COMPRESSOR

5.2 ROLE OF QUALITY CONTROL

5.3 STATISTICAL PROCESS CONTROL

5.4 7QC TOOLS

5.5 GAUGE REPETABILITY AND REPRODUCIBILITY

Reproducibility: It is the variability of measurement system caused by differences in operator behavior.

PROCESS CAPABILITY & MACHINE CAPABILITY

6.1.1 PROCESS CAPABILITY STUDY

6.1.2 NECESSITY OF KNOWING THE CAPABILITY OF OUR PROCESSES

6.1.3 NECESSITY OF KNOWING THE CAPABILITY OF OUR SUPPLIER'S

6.2 MACHINE CAPABILITY

6.2.1 MACHINE CAPABILITY INDEX (Cm)

PROCESS CAPABILITY REPORTS OF DIFFERENT SHOPS

7.1.1 GRR (GAUGE REPEATABILITY & REPRODUCIBILITY) REPORTS

Measurement system can be used for SPC study.

Measurement system can be used for detection purpose only.

FORMULAS FOR GRR

Repeatability - Equipment variation, EV = Rbar * K

K = 0.5908 Rbar = (Ra + Rb +Rc)/3 Ra =

Range,Rai= Rbi = Rci = (Max. value during the trails

Reproducibility - Appraiser Variation, AV =

Xdiff = Max(Xj) Min(Xj), where j stands for operator

% GRR = 100 ( GRR/ TV)

Total Variation, TV = Part Variation, PV = Rp * K

No. of Distinct Categories, NDC = 1.41 (PV / GRR)

By using above formulas GRR can be calculated.

7.1.1.3 GRR TABLE

Parameter is to be measured Part name Specification of parameter

Gauge name: Air gauge Spec: 1.5494/1.5506 PART