Description - process variations within supplier factory create dimensional variability in the produced parts as well as creates outliers. Standard SPC charts are unable to catch specially the outliers. Efforts to weed out these variations / outliers are manual, costly & time consuming + they are not foolproof. This affects manufacturing cycle time variations on SKF Channels thereby limiting the productive output. A solution can be developed to identify key variables in the supplier factory & monitor them on real time basis. All cases of dimensional variations will be separated online
Explanation - this automated solution is expected to give real time signals to correct the variations in order to center the process outcomes & improve process capability at suppliers. Eventually this should help SKF to reduce the cycle time on channel to increase the output further.
Component suppliers plan raw material procurement and their internal manufacturing processes as per the 'forecast' from SKF. Any delay due to manufacturing / dispatch of raw material due to machine breakdown, workmen absenteeism, over booking by customers wrt capacity etc, can delay deliveries to customers in turn affecting final customers. A system to be developed to know real time status of all vital activities/ actions to customer & advance warning alarm should go off in case of any delays
In case of excess supply, wrong/damaged deliveries to end customers, SKF customer service team returns the product back to regional warehouse irrespective of condition of material. Hence, sometimes we (India Distribution Centre) end up receiving damaged stocks even after an ok Proof of Delivery which results in blocked stocks and we end up scrapping them leading to loss. A solution can be developed that a proper justification for return is mentioned and right decision on return of goods is taken
The Face & OD Centerless grinders for Bearing Rings with asymmetric cross section requires rings to be fed in the m/c in right orientation at high speed (ring OD size ~ 30 mm - 180 mm, width ~ 12mm - 60 mm). Conventional mechanical loaders have limitations, there are frequent interruptions during loading & rings get stuck. Whole system is very noisy & requires constant human intervention which is unsafe. A solution is required for feeding rings into m/c's at required speed and right orientation
The Bearings Rings & assembled Bearings need to be free from visual defects such as Surface Defects, Nicks, Dents, Black Patches, Uncleaned or Un-honed Surfaces, Laser Marking Missing, Character or faint marking etc. This needs to be prevented from being passed on. An automated visual inspection sys is required to detect these defects under actual production environment & oily conditions. Robot system with correct algorithms & intelligence built-in(for self-learning) also need to be built in.