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At the end of the first time study it was observed that the machine was stopped 180 times to complete the pocket operation. Each time the machine is stopped due to an insert failure there is a delay of about 3-4 minutes which includes checking the insert condition to flip or change the insert. On the whole the delay is about 4 hours in one particular shift when there is a pocket operation. To complete the entire pocket the machine was stopped 180 times due to the same problem which leads to a 12 hour delay and when added with the other delays in the operation such as waiting for paper work, and other unnecessary movement around the shop floor makes the total delay very worse for each and every part. Whenever this operation is performed there is usually confusion among the workers as the process does not follow the procedure or the standard program.

Whenever there is an insert failure the operator used to take his decision based on his experience to re run at the same depth of cut until the insert performs well till the end. As the skill set of the operators working in 2 such machines and on different shifts vary, each arguing their method to be superior and correct, lead to inconsistency or lack of standardized work procedure in the cell.

Based on the time study observation for this operation it is understood that the pocket is having an interrupted cut on a high strength inconel material which is causing this potential instability and delay in the process. Based on the input from the shop floor it was understood that the problem existed for a long time and most of the solutions which were tried either did not work or worked initially and the same problem started over again in a different way. This bottleneck process in the cell is very important for improving the cell throughput which eventually satisfies the product demand. To have a brief idea about the work piece, it has two holes running all along the part for a length of about 40 inches over the sides which are first drilled in the earlier operation and then a pocket is made in the middle of the 40 inch long part which cuts these two holes leading to an interrupted cut which is solely responsible for the delay and inconsistency.

As the time delay for every part in the system is more than 2 extra days an immediate solution was required for this problem. The tool insert company was contacted to get their potential views and solutions for the problem and to solve it faster with better grade inserts to prevent insert failure. The tool insert representative who came to have a look on this issue in the shop floor quoted that the insert which is currently used for the interrupted cut pocket operation was one of the best grade of inserts and he even quoted that if a different grade or type of insert could be used it could even worsen the problem, and there was no guarantee that it may improve the situation. With these inputs from the tool insert company it was decided to use the same tool insert.

As the first contact with the tool Insert Company did not help much in the work to reduce the cycle time to 本论文由英语论文网提供整理，提供论文代写，英语论文代写，代写论文，代写英语论文，代写留学生论文，代写英文论文，留学生论文代写相关核心关键词搜索。