M/S AMTEK

CAPACITY ESTIMATION TRANSPORTATION

SYSTEMS LTD

Efficiency Production
FORK ROD ASSLY.- 200 NOS / MONTH Shift Hrs. %
BATCH
Target
AMTEK TRANSPORTATION SYSTEMS LTD. GURGAON 11.5 80 80
Load,unload, Tool Prod. In
Deburing Change, Prod. In 11.5 hrs.
Cycle
S.NO OPN. Machining before loading Inspection Prod. / Shift NAME OF
M/C NAME OPERATION DESCRIPTION time 11.5 hrs. on 1 shift M/C STATUS Remarks
. NO. Time(Min.) to work on M/c &
(Min.)
hr. Reqd. OPERATOR
station,part Tool shift basis@80
clean & dialing Cleaning %eff.

EMD FORK ROD

1 VERTICAL MILLING 10&20 Facing both side 22 2 0 24 2.5 28.8 23.0 3.5 M/C READY

2 VERTICAL MILLING 30&40 Side milling both side 22 2 0 24 2.5 28.8 23.0 3.5 M/C READY

Reference face finish milling & other side

3 VMC 50&60 ( upto half width )
52 2 1 55 1.1 12.5 10.0 8.0 M/C READY

4 HMC 65 Rough U slot milling & R 127.0 machining 32 3 2 37 1.6 18.6 14.9 5.4

Boring Crank end & Pin end , U- slot

5 HMC 70
machining,R5 milling end face milling
42 0 1 43 1.4 16.0 12.8 6.2

6 SURFACE GRINDER 80 Dimn 22.22 & 142.87 mm 7 3 3 13 4.6 53.1 42.5 1.9

7 HMC 90 Slab milling , drilling ,tapping & reaming 18 0 2 20 3.0 34.5 27.6 2.9

8 SHOT BLASTING 100 Shot Peening in U- slot area & R5. radius area. 5 10 0 15 4.0 46.0 36.8 2.2

9 MANUAL …… Final deburing 10 0 0 10 6.0 69.0 55.2 1.4

Total machining time / fork 210 22 9 241 0.0 0.0 34.93

EMD. CAP

1 VERTICAL MILLING 10 Rough U slot milling 10 10 2 22 2.7 42.3 33.8 2.4

Top face ,bottom face,Drilling,Reaming , counter

2 VMC 20,30&40
boring & pocket milling
73 4 3 80 0.8 11.6 9.3 8.6

3 HMC 50 Finish side milling & rough boring 18 2 0 20 3.0 46.5 37.2 2.2

4 HMC ……. Dimn 73.55 Face grinding 4 5 0 9 6.7 103.3 82.7 1.0

5 MANUAL …… Final deburing 10 0 0 10 6.0 93.0 74.4 1.1

Total machining time / fork 115 21 5 141 15.16

 EMD. ASSLY.

1 Marking m/c 10 Number punching_Fork rod & cap 10 4 4 18 3.3 51.7 41.3 1.9

2 Creep feed grinder 110&60 Fork & Cap Assembly. 46 12 0 58 1.0 16.0 12.8 6.2

3 MANUAL 20 Fork & Cap Assembly. 15 13 0 28 2.1 33.2 26.6 3.0

4 HMC 30 Crank end finish boring 30 0 8 38 1.6 24.5 19.6 4.1

5 MANUAL 40 Disassembly 0 8 0 8 7.5 116.3 93.0 0.9

6 INTERNAL GRINDER 50 Pin end grinding- Fork rod 14 6 2 22 2.7 42.3 33.8 2.4

7 HMC 60 Both dowel hole machining 7 2 2 11 5.5 84.5 67.6 1.2

8 MANUAL FIXTURE 70 Both dowel fitment 0 12 3 15 4.0 62.0 49.6 1.6

9 MPI 80 M.C.D 5 4 5 14 4.3 66.4 53.1 1.5

10 Manual 90 Final inspection 15 0 0 15 4.0 62.0 49.6 1.6

11 WASHING 100 Washing & packing 6 6 5 17 3.5 54.7 43.8 1.8

Total machining time / fork rod assly. 148 67 29 244 26.236559

 EMD BLADE ROD PERMONTH 200
START DATE 9/1/2022 September

S.NO. M/C NAME OPN. NO. OPERATION DESCRIPTION Prod. In 22 Start Date-Plan End Date-Plan 01 02 03 04 05 06 07 08
Days
Hrs.@80%e
Required Actual Start Date Actual End Date
fficiency Thursday Friday Saturday Sunday Monday Tuesday Wednesday Thursday

Reference face finish milling & other side 9/1/2022 9/10/2022 x x x x x x x x

1 VMC 10&20 23.0 8.7
( upto half width )

Both end rough boring,one side shoulder 9/2/2022 9/11/2022 x x x x x x x

2 HMC 30 dia machining, angular milling & pin end 40.6 4.9
face milling

All side finish milling & back counter hole 9/3/2022 9/11/2022 x x x x x x
3 HMC 40 55.6 3.6
machining

SHOT 9/5/2022 9/12/2022 x x x x

4 50 Shot peening on I - section area 70.4 2.8
PEENING

9/5/2022 9/12/2022 x x x x
5 MANUAL 60 Marking for part Identification 264.0 0.8

INDUCTION 9/6/2022 9/12/2022 x x x

6 65 Hardening on slipper face 105.6 1.9
HARDENUNG

SURFACE Both side Surface grinding after induction 9/6/2022 9/13/2022 x x x

7 70A&B 24.0 8.3
GRINDER hardening

9/8/2022 9/14/2022 x
8 HMC 75 Big end bore hard machining 62.1 3.2

INTERNAL Crank end bore & one side shoulder dia 9/10/2022 9/17/2022
9 80 33.0 6.1
GRINDER grinding

INTERNAL 9/17/2022 9/20/2022

10 90 Second side shoulder dia grinding 88.0 2.3
GRINDER

INTERNAL 9/20/2022 9/25/2022

11 100 Pin end bore grinding 48.0 4.2
GRINDER

9/21/2022 9/25/2022
12 BUFFING 110 Buffing on crank end bore & entry chamfer 70.4 2.8

Magnetic particle inspection and 9/22/2022 9/25/2022

13 MPI 120 150.9 1.3
demegnetisation.

9/23/2022 9/25/2022
14 MANUAL 125 Final deburing 105.6 1.9
14 MANUAL 125 Final deburing 105.6 1.9

9/24/2022 9/26/2022
15 MANUAL 130 Final Inspection 105.6 1.9

9/24/2022 9/27/2022
16 WASHING 140 Washing &packing 124.2 1.6
 CAPACITY ESTIMATION
Alco rod assly.-100 nos/month Date 10.10.14
03.01.14 AMTEK TRANSPORTATION SYSTEMS LTD. GURGAON

Tool Prod. In
Load,unload,debur Prod. In
change, Prod. In Prod. In 22 hrs.
ing before loading Cycle 15.5 hrs.
S.N OPN. Machining inspection Prod. 15.5 hrs. 22 hrs. on on 3
M/C NAME OPERATION DESCRIPTION to work time on 2 shift Shift Reqd. Remarks
O. NO. Time(Min.) on m/c /hr. on 2 shift 3 shift shift
station,part clean (Min.) basis@80
&tool basis basis basis@
& dialing %eff.
cleaning 80% eff.

A . ALCO ROD

Tempoary number punching for opn wise

1 MANUAL 3 2 0 5 12.0 186.0 148.8 264.0 211.2 5.0
treacibility

1 VMC 10 Clean Cut 7 2 0 9 6.7 103.3 82.7 146.7 117.3 8.9

VERTICAL Facing First side & Maintain Dimn. 26.5 +/-

2 15 23 3 4 30 2.0 31.0 24.8 44.0 35.2 29.8
MILLING 0.50 mm
Facing second side , Small end rough
3 VMC 20 22 4 2 28 2.1 33.2 26.6 47.1 37.7 27.8
boring & Ref. side milling
VERTICAL
4 25 Semi finish thickness 7 2 0 9 6.7 103.3 82.7 146.7 117.3 8.9
MILLING
SURFACE
5 30 Face Grinding Both side 38 3 1 42 1.4 22.1 17.7 31.4 25.1 41.8
GRINDER

6 HMC 40 Big end rough boring , facing & centering 14 2 0 16 3.8 58.1 46.5 82.5 66.0 15.9

7 CNC TURNING 50 OD. Turning 24 3 2 29 2.1 32.1 25.7 45.5 36.4 28.8

8 HMC-KH80G 60 Through drill dai 12.7 mm 15 3 0 18 3.3 51.7 41.3 73.3 58.7 17.9

9 GUN DRILLING 70 Bolt Hole 19 2 1 22 2.7 42.3 33.8 60.0 48.0 21.9

Total machining time / Alco Rod 172 26 10 208

B. ALCO CAP

Tempoary number punching for opn wise

1 MANUAL ….. 3 2 0 5 12.0 186.0 148.8 264.0 211.2 5.0
treacibility
VERTICAL
1 …. Clean Cut 7 2 0 9 6.7 103.3 82.7 146.7 117.3 8.9
MILLING
VERTICAL Facing First Side & maintain Dimn. 8.35 +/-
2 10A 25 2 2 29 2.1 32.1 25.7 45.5 36.4 28.8
MILLING 0.50 mm
VERTICAL Facing second side & maintain Dimn.
3 10B 25 2 2 29 2.1 32.1 25.7 45.5 36.4 28.8
MILLING 77.1+/- 0.10 mm
SURFACE
4 20A&B Face Grinding Both side 22 2 0 24 2.5 38.8 31.0 55.0 44.0 23.9
GRINDER

5 CNC TURNING 30 Shoulder Facing & O.D. Turning 22 2 0 24 2.5 38.8 31.0 55.0 44.0 23.9

6 CNC TURNING 40A ID semi finish Turning ( Second set up ) 22 2 0 24 2.5 38.8 31.0 55.0 44.0 23.9

7 CNC TURNING 40B ID Finish Turning 10 2 1 13 4.6 71.5 57.2 101.5 81.2 12.9

8 HMC 50 Bolt Hole 27 3 0 30 2.0 31.0 24.8 44.0 35.2 29.8

Total machining time / Alco Cap 163 19 5 187

 C. ALCO ASSEMBLY

1 MANUAL 80 Alco rod &Cap Assembly 30 0 5 35 1.7 26.6 21.3 37.7 30.2 34.8

Rough boring Diameter 160.5 mm with

2 HMC 90 19 2 2 23 2.6 40.4 32.3 57.4 45.9 22.9
Cap

VMC 95 Weight Reduction 40 2 0 42 1.4 22.1 17.7 31.4 25.1 41.8

100
3 MANUAL Deburing no. punching &Diss-assly. 25 0 0 25 2.4 37.2 29.8 52.8 42.2 24.9
&105
110
5 HMC Notch Milling 25 3 2 30 2.0 31.0 24.8 44.0 35.2 29.8
A&B

6 MANUAL 120 Alco rod &Cap Re-Assembly 25 0 5 30 2.0 31.0 24.8 44.0 35.2 29.8

7 HMC 130 Finish Boring &Oil Grooving 35 4 5 44 1.4 21.1 16.9 30.0 24.0 43.8

8 HMC 140 Side Drilling & Boss machining 15 3 2 20 3.0 46.5 37.2 66.0 52.8 19.9

9 VMC/MILLING 150 Weight reduction by hand grinder 50 2 2 54 1.1 17.2 13.8 24.4 19.6 53.7

Ch. On gun drill, O & E22 Punch,dowel

160 &
11 MANUAL fitment,final deburingon oil groove ,Bore 30 0 0 30 2.0 31.0 24.8 44.0 35.2 29.8
170
inspection & Rework

12 MANUAL 180 Mpi 20 2 2 24 2.5 38.8 31.0 55.0 44.0 23.9

MANUAL 190 Final inspection 20 0 0 20 3.0 46.5 37.2 66.0 52.8 19.9

13 MANUAL 200 Packing 20 2 0 22 2.7 42.3 33.8 60.0 48.0 21.9

Total machining time / Alco assly. 354 20 25 399