BE project

1. Fr. CONCEICAO RODRIGUES COLLEGE OF ENGINEERING
BANDRA, MUMBAI - 50
April - 2014
A presentation on
DESIGN & COSTING IMPROVEMENTS IN OPERATING SYSTEM OF INSPECTION TABLE BY
CONVERTING IT FROM PNEUMATIC TO HYDRAULIC SYSTEM
AT
CEAT TYRES LTD.
BY
ASHISH SANJAY MENKUDALE
(B.E. Production Engineering)
Under the guidance of
Prof. Zoya Rizvi (Faculty Guide)
Mr. Pradeep B. Gargote (Company guide)

2. PROJECT OBJECTIVE
• To overcome all the problems faced by operators handling inspection
table.
• To provide the alternative ergonomic solution for existing pneumatic
operated system.
• To design the components and the entire assembly of the new system
using CAD.
• To increase the operator efficiency by using work measurement.
• To prepare Inspection sheet to ensure working life of system by means
of proper maintenance.
• To assess the replacement analysis on the basis of
• Depreciation cost
• Work measurement
• Maintenance cost
• Electricity consumption
INSPECTION TABLE

3. START
Observing the problems occurring in the company and discussing them with the
field engineer.
Detecting the problem, discussing with the workers, field engineers.
Study of the existing system which involves analyzing actual site.
Drawing the layout & all views of the system in CAD for ease of work.
Systematic study of each part which includes its functions & efficiency.
Study on the proposed idea i.e. hydraulic system which includes its principles of
working, components included in it & its efficiency.
Costing of various engineering drawings.
Comparisons of the drawings whose costing is done analytically with its present
price sold by the vendor.
Study of the working of the new system (Hydraulic system)
Costing of the system
Finding vendors from the market who will manufacture these parts in minimum
price.
Fabrication or manufacturing of the system.
Installation of the system
Analysis of the system i.e. its’ working after its’ installation.
Annual performance analysis & its comparison with the pneumatic system.
Annual performance analysis & its comparison with the pneumatic system.
Conclusion from the comparison done.
END
Steps involved in project planning

4. PRACTICAL PROBLEMS - 1/2
• The table is not rotating properly due to jamming of
rollers & excessive wear of rollers.
• There is sudden drop in pressure - constant pressure
supply is not available due to air leakage.
• Compressor efficiency is less & consumption of
electricity is more than required for operation.
• It is not possible to hold the table at certain height for
long time due to air leakage. It comes down
automatically after some time.
• Due to improper functioning of the system it leads to
defects in the tyres.
• Operator fatigue comes into picture & therefore his
efficiency & productivity is reducing.
Actual site location

5. CAD - Area layout of site location
• System is not compact therefore more space is
required.
• If the table falls suddenly it may harm the worker as
well as the product.
• Range & capacity of pneumatic system is very less.
• Lubrication does not sustain for longer duration
therefore, it should be lubricated frequently.
• Operation is very noisy.
PRACTICAL PROBLEMS - 2/2

6. PROPOSED SOLUTION
Advantages of Hydraulic operating system over pneumatic:
• Less electricity consumption
• No need of lubricator
• Lower susceptibility towards leakages
• Lesser maintenance
• Lesser load on valves and actuators
• Longer working life of machines
• Ergonomic working conditions
• Compact system
• Most efficient in economic aspect
Hydraulic system overcomes the
existing problems in greater extent
than any other alternative solution.
Hence it was chosen.

7. DESIGN OF HYDRAULIC SYSTEM USING CAD
CAD model of hydraulic system assembly – side view CAD model of hydraulic system assembly – top view

8. STUDY OF PROPOSED SOLUTION
Basic principle of hydraulic system Working of hydraulic system
OIL TANKPUMP
MOTOR
Pressure relief
valve
Single acting
cylinder
Two way solenoid
valve
Pascal’s law
Force Multiplication

9. Sr. No Hydraulic lifter capacity 1 ton Weight Rate Total
1 Plate 3 Nos = Dia 1200 X Thk 8 mm = Weight 70 Kg X 3 Nos = 210 Kgs 210 50 10,500
2 Bottom Plate = Dia 1200 X Thk 25 mm = 220 Kgs 220 50 11,000
3 Bidding 8 mm Thk. X 40 Width = Wt. = 20 Kgs 20 50 1000
4 Cylinder Dia 200 X length 1500 mm = weight = 367 kgs 367 50 18,350
5 Piston Dia 150 X length 1200 = Weight = 165 Kgs 165 50 8,250
Total weight = 100 Kgs X 50 / Kg = Rs 50,000 982 49,100
Rate M.S. Conversion 1000 Kgs X 100 Rs = Rs 100,000 78,560
6 Dowty pump 3015 Type 6,500
7 Pressure relief valve 1,200
8 Oil Filter 500
9 Breather 200
10 Electric motor 7,500
11 Assembly 2,000
12 Delivery 1,000
13 Erection and commissioning 5,000
14 Training to end users / 3 days 1,500
15 Guarantee & free replacement of parts -
Total cost 1,03,960
COSTING OF HYDRAULIC SYSTEM

10. Sr. No. FACTORS
EXISTING EQUIPMENT
(PNEUMATIC STSYEM)
PROPOSED EQUIPMENT
(HYDRAULIC SYSTEM)
1 COST OF SYSTEM Rs. 1,00,000 (Approx.) Rs. 1,24,752.00
2 OPERATING EXPENSES Rs. 12,000 Rs. 9,600
3 SCRAP VALUE Rs. 1,000 Rs. 1,500
4 INTEREST 10% 10%
5 LIFE OF EQUIPMENT 10 YEAR 20 YEAR
6 DEPRACIATION
Rs. 1,00,000 − 1,000 = Rs.
99,000
Rs. 1,24,752 –1,500 = Rs.
123252
7 OPERATING EXPENSES (IN TOTAL SPAN OF LIFE) Rs. 12,000 × 10 = Rs. 1,20,000 Rs. 9,600 ×20 = Rs. 1,92,000
8 INTEREST @10% Rs. 11200 Rs. 13435.2
9 TOTAL LIFE COST OF EQUIPMENT Rs. 2,30,200 Rs. 328687.2
10 AVERAGE COST PER YEAR Rs. 2,30,200/10 = Rs. 23020 Rs. 328687.2/2 = Rs. 16434.36
ASSESSMENT FOR REPLACEMENT ANALYSIS

11. Sr. No.
CUMULATIVE INTEREST
CALCULATION
COST/YEAR
1 (99000 × 10/100) = Rs. 9900 Rs. 9900
2 (89100 × 10/100) = Rs. 8910 Rs. 8910
3 (80190 × 10/100) = Rs. 8019 Rs. 8019
4 (72171 × 10/100) = Rs. 7217.1 Rs. 7217.1
5 (64953.9 × 10/100) = Rs. 6495.39 Rs. 6495.39
6 (58458.51 × 10/100) = Rs. 5845.85 Rs. 5845.85
7 (52612.66 × 10/100) = Rs. 5261.26 Rs. 5261.26
8 (47351.39 × 10/100) = Rs. 4735.1 Rs. 4735.1
9 (42616.25 × 10/100) = Rs. 4261.625 Rs. 4261.625
10 (38354.63 × 10/100) = Rs.3835.463 Rs.3835.463
TOTAL CUMULATIVE COST OF
SYSTEM
Rs. 55,571.143
Sr. No.
CUMULATIVE INTEREST
CALCULATION
COST/YEAR
1 (123252 × 10/100) = Rs. 12325.2 Rs. 12325.2
2 (110925.8 × 10/100) = Rs. 11092.58 Rs. 11092.58
3 (99834.12 × 10/100) = Rs. 9983.412 Rs. 9983.412
4 (89850.708 × 10/100) = Rs. 8985.07 Rs. 8985.07
5 (80865.63 × 10/100) = Rs. 8086.563 Rs. 8086.563
6 ( 72779.07 × 10/100) = Rs. 7277.9 Rs. 7277.9
7 (65501.17× 10/100) = Rs.6550.117 Rs. 6550.117
8 (58951.05× 10/100) = Rs.5895.105 Rs. 5895.105
9 (53055.95× 10/100) = Rs.5305.595 Rs.5305.595
10 (47750.35× 10/100) = Rs.4775.035 Rs.4775.035
11 (42975.32× 10/100) = Rs.4297.523 Rs.4297.523
12 (38677.783× 10/100) = Rs.3867.77 Rs.3867.77
13 (34810.01× 10/100) = Rs.3481.001 Rs.3481.001
14 (31329.013× 10/100) = Rs.3132.9 Rs.3132.9
15 (28196.113× 10/100) = Rs.2819.61 Rs.2819.61
16 (25376.5× 10/100) = Rs.2537.65 Rs.2537.65
17 (22838.9× 10/100) = Rs.2283.89 Rs.2283.89
18 (25376.5× 10/100) = Rs.2537.65 2537.65
19 (18499 × 10/100) = Rs. 1849.9 Rs. 1849.9
COST ANALYSIS FOR DEPRICIATION

12. TIME STUDY FORM
Product: Tyres Time Study Engineer :
Operation No: 1 No. of cycles: 1
Std. Time found: 5 minutes Operation Description: Analysis
Element Description
Observed Time (Stop
Watch Reading) (Minute)
Average Observed Time
(Minute)
Normal Time (Minute) Allowance (Minute) Standard Time (Minute)
Taking tyre to the work
space table
1 1.25 1.5 0.5 1
Inspection and repairing
of tyre
4.7 5 4.85 1 4
Keeping the repaired tyre
in the store room
1.25 1.625 2 1 1
TIME STUDY FORMAT

13. TIME DISTRIBUTION FORMAT
Sr. No Work Specification Time (Minute)
1 Taking tyre to the work space table 1
2 Inspection and repairing of tyre 4.7
3 Keeping the repaired tyre in the store room 1.25
Sr. No Work Specification Time (Minute)
1 Taking tyre to the work space table 1
2 Inspection and repairing of tyre 3
3 Keeping the repaired tyre in the store room 1.25
For pneumatic system:
Official working hours = 8 hrs/shift
Actual working hours = 7 hrs/shift
Actual working time (mins) = 7 × 60 = 420mins
Number of Tyres repaired per day = 50-60 tyres
Therefore, we cannot get the actual time spent for one
tyre. It depends on the number of defect the tyre is having. If
the tyre has many flaws, it will take time to repair, while the
one with less flaws will take less time. Therefore, we will
consider approximate time for 1 tyre.
Time required to complete one tyre =
420
60
= 7 mins
For Hydraulic system:
Official Working hours = 8 hours/shift
Actual working hours = 7 hours//shift
Actual working hours (mins) = 7 × 60 = 420 mins
Number of tyres required per day = 70-80 tyres
Therefore, we cannot get the actual time spent for one tyre.
It depends on the number of defect the tyre is having. If the tyre
has many flaws it will take long time to repair, while the one with
less flaws will take less time. Therefore, we will consider
approximate time for 1 tyre.
Time required to complete 1 tyre =
420
80
= 5.25 mins

14. Operation Performance
=
Units of work actually produced by worker
Units of work which could be produced at standard performance
× 100
Suppose 8 hour duty, 30 min required to complete job (standard),
But 7 hours. = 60 jobs possible
P. A. =
60
85
× 100
= 0.7051 × 100
= 70.51%
Operation Performance
=
Units of work actually produced by worker
Units of work which could be produced at standard performance
× 100
Suppose 8 hour duty, 30 min required to complete job (standard),
But 8 hours = 14 jobs possible
P. A. =
80
85
× 100
= 0.941 × 100
= 94.11%
COMPARISON OF PERFORMANCE ANALYSIS FOR WORKER

15. COMPANY: CEAT Tyres Ltd. NAME OF THE MACHINE:
RESPONSIBLE PERSON DATE OF INSPECTION:
LOCATION OF UNIT: SIGNATURE OF INSPECTOR:
TYPE OF INSPECTION:
DAILY/MONTHLY/YEARLY CHECK LIST:
SR. NO ITEM CHECK SATISFACTORY UNSATISFACTORY REMARK
1 Oil tank
2 Leak
3 Wear of table bearings
4 Electrical wire carrier
5 Oil filter
6 Dusty environment
7 Motor condition
8 Pump condition
9 Actuation switches
10 Noise level
11 Speed of the system
12 Hydraulic hoses
13
Lubrication and wear of moving
INSPECTION SHEET 1/2

16. SR.
NO.
ITEM CHECK SATISFACTORY UNSATISFACTORY REMARK
14
Operator remote control devices to check for proper
operation
15 All structure member for damage
16 Any leaks at fittings, seals and between sections
17
Hoses and tubes for leakages, abrasions, damage,
blistering
18 Cracking, deteriorating, fittings leakage
19 End limits of extension rods or bars
20 All values like pressure relief valve, non return valve
21 Direction of control valve
Note: all unsafe items shall be repaired or replaced before continuing the use
Is unit ready for use? Yes  No 
If no time shop notified
Operator/Inspector Signature:
Description on Repairs Performed
Signature: Time:
Operators/Inspectors are required to read and fully understand the operation manual.
This Check List is not intended to replace it.
INSPECTION SHEET 2/2

17. Sr.
No.
Month
Frequency of
maintenance
Detected problem Description of the problem
Repair
cost
Remark
1 Aug 2012 4 Filter, leakage, valve, wear
Filter-Filter cleans the air supplied which contains
lots of dust therefore it is necessary to clean and
replace the filter periodically,
Leakage-due to the great time elapsed since
installation there is leakage problem in the cylinder
that has to be solved,
Valves- Different valves like pressure relief valve,
non returning valve are not functioning properly.
1000
Satisfactorily problem is
solved
2 Sept 2012 3 Filter, Leakage, Noise As explained above 800
Satisfactorily problem is
solved
3 Oct 2012 3
Filter, Leakage, Electrical connection
problem
Electrical connection problem- there might be same
electrical connection problem
800
Satisfactorily problem is
solved
4 Nov 2012 2 Filter, Leakage As explained above 300
Satisfactorily problem is
solved
5 Dec 2012 4 Filter, Leakage, Valve, Noise
Noise- Due to the moving parts and decrease in
lubrication there is noise while the system is in
work.
1000
Satisfactorily problem is
solved
MAINTENANCE SHEET FOR PNEUMATIC SYSTEM 1/2

18. Sr.
No.
Month
Frequency of
maintenance
Detected problem Description of the problem
Repair
cost
Remark
6 Jan 2013 3 Filter, Leakage, Wear
Wear- Due to the moving parts and decrease in
lubrication wear occurs between the moving parts
in touch with each other
800
Satisfactorily problem is
solved
7 Feb 2013 2 Filter, Leakage As explained above 300
Satisfactorily problem is
solved
8 Mar 2013 3
Filter, Leakage, Electrical connection
Problem
As explained above 800
Satisfactorily problem is
solved
9 Apr 2013 4 Filter, Leakage, Valve, Noise As explained above 1000
Satisfactorily problem is
solved
10 May 2013 2 Filter, Leakage As explained above 300
Satisfactorily problem is
solved
11 Jun 2013 3 Filter, Leakage, Wear As explained above 800
Satisfactorily problem is
solved
12 Jul 2013 3 Filter, Leakage, Noise As explained above 800
Satisfactorily problem is
solved
TOTAL 36 8700
MAINTENANCE SHEET FOR PNEUMATIC SYSTEM 2/2

19. Sr.
No.
Month
Frequency of
maintenance
Detected problem Description of the problem
Repair
cost
Remark
1
DEC
2013
2 Lubrication, Filter
Lubrication- since the Hydraulic system works on
oil, it serves the purpose of lubrication as well as
oil supply therefore periodically lubrication is
very much necessary.
Filter- Since the oil might contain dust filtering is
very important and therefore filter should be also
cleaned properly.
200 Satisfactorily problem is solved
2
JAN
2014
2 Lubrication, Filter As explained above 200 Satisfactorily problem is solved
3
FEB
2014
2 Lubrication, Filter As explained above 200 Satisfactorily problem is solved
4
MAR
2014
3
Lubrication, Filter, Oil
Supply
Oil supply- Because of the moving parts moving
continuously some heat is generated and
temperature increases due to this the viscosity of
the oil is decreased therefore it is essential to
400 Satisfactorily problem is solved
MAINTENANCE SHEET FOR HYDRAULIC SYSTEM 1/2

20. Sr.
No.
Month
Frequency of
maintenance
Detected problem Description of the problem
Repair
cost
Remark
5
APR
2014
2 Lubrication, Filter As explained above 1000 Satisfactorily problem is solved
6
MAY
2014
3
Lubrication, Filter, Dusty
Environment
Dusty Environment- since oil is the working fluid in this
system, dust from the surrounding might settle down on
the oil and may enter the system therefore it is required
to take preventive action for it
800 Satisfactorily problem is solved
7
JUNE
2014
2 Lubrication, Filter As explained above 200 Satisfactorily problem is solved
8 Jul 2014 3
Lubrication, Filter, Oil
supply
As explained above 400 Satisfactorily problem is solved
9
AUG
2014
4 Lubrication, Filter As explained above 200 Satisfactorily problem is solved
10 SEP 2014 2 Lubrication, Filter As explained above 200 Satisfactorily problem is solved
11
OCT
2014
3 Lubrication, Filter As explained above 200 Satisfactorily problem is solved
12
NOV
2014
3
Lubrication, Filter, Oil
supply, Dusty Environment
As explained above 600 Satisfactorily problem is solved
TOTAL 30 3300
MAINTENANCE SHEET FOR HYDRAULIC SYSTEM 2/2

21. COMPARISON OF ELECTRICITY CONSUMPTION 1/2
• For Pneumatic System:
• 1kWh = 1 unit
• Out of this the only time where the electricity is
consumed is the table uplifting and towering. Since in
the existing Pneumatic system, whole inspection and
repairing time.
• Therefore, Actual Electricity Consumption = 2.2 kW × 5
hours = 11 kWhr/ day
• Electricity Consumption for one month (30 days) = 11 ×
30 = 330 kWh/ day = 330 units
• Electricity Tariff Charges = Rs. 9.16 per Kwhr
• Energy cost= 330 units × 9.16 = 3022.8 Rs./Month
• FOR Hydraulic system
• 1kWh = 1 Unit
• In the replaced system i.e. Hydraulic system since there is no
leakage of electricity consumption is low as compared to
pneumatic system
• Therefore, Actual Electricity Consumption= 2.2 kW × 2 hours
= 4.4 Kwhr/Day
• Electricity consumption for one month (30 days) =4.4 × 30 =
132 Kwhr/Day = 132 units
• Electricity Tariff chargers = Rs. 9.16 per Kwhr
• Energy Cost = 132 Units × 9.16 = 1209.12 rupees/month

22. Sr
No.
Month
No Of
Working
Days
Electricity
Consumption
in kWh/day
Electricity
Consumption
Per month
Energy Cost
In Rs(Units x
tariff
charges)
1 JAN 24 11 264 2418.24
2 FEB 23 11 253 2317.48
3 MAR 25 11 275 2519
4 APR 24 11 264 2418.24
5 MAY 25 11 275 2519
6 JUN 26 11 286 2619.76
7 JUL 26 11 286 2619.76
8 AUG 24 11 264 2418.24
9 SEPT 24 11 264 2418.24
10 OCT 23 11 253 2317.48
11 NOV 23 11 253 231.48
12 DEC 25 11 275 2519
TOTAL 292 132 3212 29421.92
Sr
No.
Month
No Of
Working
Days
Electricity
Consumption
in kWh/day
Electricity
Consumption
Per month
Energy Cost
In Rs(Units x
tariff
charges)
1 JAN 24 5 120 1099.2
2 FEB 23 5 115 1053.4
3 MAR 25 5 125 1145
4 APR 24 5 120 1099.2
5 MAY 25 5 125 1145
6 JUN 26 5 130 1190.8
7 JUL 26 5 130 1190.8
8 AUG 24 5 120 1099.2
9 SEPT 24 5 120 1099.2
10 OCT 23 5 115 1053.4
11 NOV 23 5 115 1053.4
12 DEC 25 5 125 1145
TOTAL 292 60 1460 13373.6
COMPARISON OF ELECTRICITY CONSUMPTION 2/2
PNEUMATIC SYSTEM HYDRAULIC SYSTEM

23. Pneumatic System(Existing System) Hydraulic System(Replaced System)
Installation Cost=1,00,000 Installation Cost=1,24,752
Life of System=10Years Life of System=20 Years
Average Cost per Year=Rs 23,020 Average Cost Per Year=Rs 16,434.36
No of Tyres repaired per Day=50-60 No of Tyres repaired per Day=70-80
Working time required = 5mins Working time required = 3mins
Performance analysis = 70.15% Performance analysis = 98.11%
Annual Maintenance cost = 8700 Annual Maintenance cost = 3300
Annual electricity consumption = 3213kW Annual Electricity consumption = 1460kW
Annual Expenditure on Electricity =
Rs 29,421.52
Annual Expenditure on Electricity =
Rs 13,373.6
OVERALL COMPARISON

24. CONCLUSION
The Operator fatigue is reduced as the operator is provided with more ergonomic conditions. Hence the operator
efficiency is increased.
Using CAD, the design of new system is drafted and analyzed.
Through work study, the average time required to inspect each tire is reduced to 3 minutes from 5 minutes.
No of tyres repaired per day is increased from 50 – 60 tyres to 70 – 80 tyres per day.
The maintenance sheet and inspection sheets were drafted for ensuring longer working life of hydraulic system.
Roughly calculated, by replacing pneumatic system by Hydraulic system the annual saving is Rs. 21,448.32 just in terms
of Electricity consumption and maintenance.

25. THANK YOU