Date of Award

5-2012

Document Type

Thesis

Degree Name

Master of Science (MS)

Legacy Department

Mechanical Engineering

Advisor

Mears, Laine M

Committee Member

Mocko , Gregory M

Committee Member

Li , Gang

Abstract

The purpose of this thesis document is to describe a method developed for reducing setup time in machining processes and simultaneously improve the quality of production after setup. Bosch Rexroth at Fountain Inn is a semi-automated plant and is still in its initial stages of standardizing the setup process. Setup time at different machining centers includes: machining time, inspection time, loading and unloading times and deburring. The focus of the described method is in reducing setup times related to inspection time and loading and unloading times. To achieve success in these problems the following new tools were developed: first piece inspection charts, design inspection fixture and design of new handling tools. This work involved interaction with operators, collection of data, and analyzing and developing new plans based on the analysis. Tools like Failure Modes Effects Analysis (FMEA), 5S and Single-Minute Exchange of Die (SMED) techniques helped in making and implementing these changes on the production line. Implementation of first piece inspection charts and inspection reduced inspection time by almost 50%. Design of handling tools helped in reducing stress on the operator and also in reducing loading and unloading time by 40%. Also quality was improved through a related project. This subproject's aim is to reduce shaft alignment problems as reported by the customer. To achieve this goal I designed a fully automatic shaft alignment tool, which helps operator in installing the shaft into the pump without any difficulty. This shaft alignment tool is installed on the line and eliminated the shaft alignment problems completely. Also the quality improvement techniques and set up time reduction techniques used at BOSCH are discussed in this document

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