Study of cycle time reduction and assembly process improvement for various electric stackers

Material handling is a system or combination of methods, facilities, labour, and equipment for moving, packaging and storing of materials to meet specific objectives. A stacker is a machine used in material handling unit. In the present study among the different stackers which are manufactured in maini material movement private limited, electric stackers are considered. These electric stackers can move in horizontal and vertical directions. The vertical movement is controlled by hydraulic actuators and the travelling or horizontal movement is carried out with the help of motor drives. The main objective of this study is assembly process improvement by various methods and cycle time reduction for assembly and welding process. In order to achieve the objective, assembly and welding process flow chart, time line study for present manufacturing process are to be noted and critical path method is applied to find out critical path and cycle time. By studying the assembly process sheet, various sub-assemblies are suggested to directly import from outside so that the cycle time will be reduced. Then hydraulic steel pipe fitting dimension are noted in order to change pipe end fitting from bsp to standard jic. Then studying the fixtures and tooling, quality management and testing for revised manufacturing process. Finally, standardization of stackers is carried out. That is standardization of 1.5 kw ac vertical drive motor along all stackers and standardization of lifting height of stackers. The key area of concern is that equipments are being manufactured using old methods and needs to be enhanced to the current industry standards with various changes suggested to reduce cycle time. Creo 3.1 software is used for modeling and drafting purpose.