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Cost Saving Report Month : Oct 2013

ZANVAR GROUP Tooling Department . SHRIRAM FOUNDRY LTD. MACHINE SHOP. Cost Saving Report Month : Oct 2013 . Zanvar group of industries. SHRIRAM FOUNDRY LTD. MACHINE SHOP. CO ORDINATOR :- Prashant Dhoolappanavar Tool Engineer :- . Mr.P.J.Reagde Mr.Atul Chalke Mr. Vijay Jagdale

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Cost Saving Report Month : Oct 2013

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  1. ZANVAR GROUPTooling Department SHRIRAM FOUNDRY LTD. MACHINE SHOP Cost Saving Report Month : Oct 2013 Zanvar group of industries

  2. SHRIRAM FOUNDRY LTD. MACHINE SHOP • CO ORDINATOR :- Prashant Dhoolappanavar • Tool Engineer:-. Mr.P.J.Reagde Mr.AtulChalke Mr. Vijay Jagdale Mr.Preetam Patil Zanvar group of industries

  3. SHRIRAM FOUNDRY LTD. MACHINE SHOP SELECTION OF PROJECT • Need for reduction in tooling cost as well as in machining cost. • Need for improvement in cutting tools/tooling. • Reduce cutting time & improve productivity Zanvar group of industries

  4. SHRIRAM FOUNDRY LTD. MACHINE SHOP PROJECT : 01 • Unit :AlkaEnginering Work • Component : Komastu Cover • Tool Engineer : AtulChalke Zanvar group of industries

  5. SHRIRAM FOUNDRY LTD. MACHINE SHOP SHRIRAM FOUNDRY LTD. MACHINE SHOP • Problem • Bonfiglioli finish machining on VTL 02 M • have Finishing operation of Ø190 /200/235/530 • required surface finish (0.2Ra) for turning is not achievable. If surface finish is achieved, it will unstable after each 3 to 4 jobs • Increased tool cost. • 2) Bonfiglioli Ø 17.1 Drilling on machining on AMS HMC 500 • 1st Use Carbide drill it not success tool breakage & tool life problem • Then use taegutec champ drill .tool life do not achievable • Tool brakeage problem • Increased tool cost. Zanvar group of industries

  6. SHRIRAM FOUNDRY LTD. MACHINE SHOP DATA COLLECTION Existing Tool Cost Per Component in Rs. & Tool Life Rough Milling Operation • Insert:-PNMU 1205 • Tool Cost/Component : - 10.00 Rs.. • TOOL LIFE/INSERT : - 30 JOB • Finish Milling Operation • Insert:-SNMU 1305 TT 8150 • Tool Cost/Component : -16.5 • TOOL LIFE/INSERT : - 30 JOB • FOR Rough To Finish • Insert:- HNHX 1006 TT6300 • Tool Cost/Component : -12.9 • TOOL LIFE/INSERT : - 50JOB Zanvar group of industries

  7. SHRIRAM FOUNDRY LTD. MACHINE SHOP Planning Of Tools For Trial • Finish machining on VTL 02 M/C • Plan for use suitable steel grade finish application insert use. • For high surface finish turning of steel stainless steel • Excellent wear resistance and low coefficient of friction • Long tool life • Taken PVD Coated insert trial .Sandvik TaeguTec • 2) Ø 17.1 Drilling on machining on AMS HMC 500 • Plan for use suitable steel grade application use • For high cutting force due to the dynamic inclined sharp cutting edge • Long tool life • Taken Taegutec , Kyocera , Iscar make tool trail for this application Zanvar group of industries

  8. SHRIRAM FOUNDRY LTD. MACHINE SHOP Existing Tool Costing Graph Zanvar group of industries

  9. SHRIRAM FOUNDRY LTD. MACHINE SHOP Trial Report Of HNHX Milling Cutter Zanvar group of industries

  10. SHRIRAM FOUNDRY LTD. MACHINE SHOP Final Result Graph Saved cost per component Rs:-121.3/- Zanvar group of industries

  11. SHRIRAM FOUNDRY LTD. MACHINE SHOP Results after implement in Trial Possibilities of cutting parameter for milling operation to optimum value by using high parameters tools. 2. Better Surface finish &Tool Cost reduced as per attached data sheet Zanvar group of industries

  12. SHRIRAM FOUNDRY LTD. MACHINE SHOP Thank - You Zanvar group of industries

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