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Vinodh S.,National Institute of Technology Tiruchirappalli | Gautham S.G.,Purdue University | Ramiya R. A.,John Deere India Private Ltd
Production Planning and Control

The manufacturing organisations have been witnessing a key transition to lean manufacturing paradigm so as to eliminate waste. Concurrently, six sigma methodology has been widely used for reducing the defects. In order to attain the combined benefits of these two approaches, the amalgamated lean sigma framework has originated. Lean sigma framework proves drawbacks, such as lack of systematic and scientific management and feeble lean anchorage. In order to overcome these deficiencies, this article contributes a refined lean sigma framework, and its effectiveness has been test implemented in an Indian automotive valves manufacturing organisation. The implementation benefits are described in this article. © 2011 Taylor & Francis. Source

Maisenbacher S.,TU Munich | Yassine A.,American University of Beirut | El-Zein M.,Moline Technology Innovation Center | Goyal R.,John Deere India Private Ltd | Maurer M.,TU Munich
Gain Competitive Advantage by Managing Complexity - Proceedings of the 14th International Dependency and Structure Modelling Conference, DSM 2012

Changes in welding sequence have high effects on welding distortion and production time. As the effects on cycle time are simply due to the distance travelled by the Heat Source, the influences of welding sequence on distortion are still not clearly defined. The goal of this paper is to build a model of the entire welding process to get deeper insights on the physics of welding and especially on the influence of welding sequence on distortion. DSM and MDM models are used to map and analyse these correlations. Source

Malik M.,VJTI Mumbai | Kshirsagar S.,John Deere India Private Ltd | Barve S.,VJTI Mumbai
SAE Technical Papers

Rollover Protective Structures (ROPSs) are used in off-highway vehicles to protect operator in case of accidents involving overturning of vehicle. The role of a ROPS is to absorb the energy of Rollover without violating the protected operator zone. The performance of a ROPS is determined by its ability to absorb energy under prescribed loading conditions. The performance depends upon design parameters, such as tube thicknesses, material grades, ROPS tube cross-sections, etc., that define the structure. In this paper, we describe a method that uses Design of Experiments (DOE) to determine the correlation between the performance of a ROPS for a small tractor and its critical design parameters. The correlation results are discussed for two types of loading conditions, namely "front push loading" and "side push loading". The correlation obtained is further used to identify the optimal design parameters for maximum energy absorption under constraints on allowable deflections. Copyright © 2012 SAE International. Source

Dhokey N.B.,College of Engineering, Pune | Raskar A.,College of Engineering, Pune | Hake A.R.,College of Engineering, Pune | Mohapatra G.,John Deere India Private Ltd
Tribology - Materials, Surfaces and Interfaces

Wear by sand abrasion occurs in cutter blades of sugarcane cutting machine. The wear life of components used under sand abrasion conditions is governed by process parameters, properties of abrasive particles in the soil and material properties. In this article, the wear performance of conventionally and cryotreated specimens was tested in the soil containing 20% silica at different blade speeds such as 300, 400, 600 and 750 rev min−1 at the varied cutting times of 8, 16, 24 and 32h respectively using simulated test rig fixture of sugarcane cutting machine. In addition, treated specimens were characterised for the microstructural features, hardness and surface roughness. Microstructural study indicated fine structure of tempered martensite with addition of segregation of silicon and carbon spots in the cryotreated specimen. The surface roughness of cryotreated material was decreased by 50% with respect to conventionally treated one. The mass loss of cryotreated cutting blades was reduced by 28% over conventional treatment at 750rev min−1. The wornout surface and subsurface of conventionally treated specimens showed predominant dislodgment of wear particles. © 2015 Institute of Materials, Minerals and Mining and W. S. Maney & Son Ltd. Source

In the automobile industry finite element analysis is extensively used to simulate a structures response to external loads. Inadvertently the simulation typically captures the primary failure mode which is applicable when there is no redundancy - i.e. the structure being 100% complaint with the design. In spite of the advances in the manufacturing systems used in the automobile industry across the world it is observed that it is not possible to have zero redundancy products especially when it is a mass production and there are non-automated manufacturing phases. In the automobile industry the most prominent contributor to redundancy are manual welds. This paper is about incorporation of weld redundancy in the simulation for pre-identified critical welds using design of experiments. Copyright © 2011 SAE International. Source

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