A Project Stage-I Report On
Setup Time Reduction for 2/3 Piece Valve Body
By
Mr. Abhishek Hargapur (B150940823)
Mr. Sagar Kharinar (B150940830)
Mr. Akshay Salvi (B150940846)
Internal Guide: [Link]
External Guide: [Link]
Department of Mechanical Engineering
[2018-19]
CERTIFICATE
This is certify that Mr. Abhishek Hargapur, Mr. Sagar Khairnar, Mr.
Akshay Salvi, has successfully completed the Project Stage-I entitled
―“Setup Time Reduction For 2/3 Piece Valve Body” under my supervision,
in the partial fulfilment of Bachelor of Engineering – Mechanical Engineering
of University of Pune.
Date:
Place:
Prof. [Link] Prof. [Link]
Project Guide ProjectCo- ordinator
Prof. [Link] Prof.
Head of Department External Examiner
Dr. [Link]
Principal
ACKNOWLEDGEMENT
It gives me a great pleasure to present this report, a written testimony of the most fruitful
training I have undergone. I sincerely acknowledge that whatever achievement I have made, was
through the efforts and sincere co-operation of the entire Emerson Process Management Pvt Ltd.
I whole-heartedly thank to my company guide Mr. V. Lambe and college guide Prof. S. V.
Campli & also thank to my Project Co-ordinator Prof. M.A. Mane, who had been an invaluable
source of encouragement & motivation for me during my project. I am immensely grateful to them for
all their help and support.
I also extend my gratitude towards Dr. [Link] (Principal) & Prof. [Link] (HOD)
for giving me opportunity to undergo project training at Emerson Process Management Pvt Ltd.
Lastly I want to thank whole ‘Emerson Process Management Pvt Ltd.’ for extending their
needed cooperation during my project & for enormous qualities & knowledge that I have gained
during project training period which will definitely help me in developing good career.
Name: Sign:
Abhishek Hargapur
Sagar Khairnar
Akshay Salvi
ABSTRACT
Lean manufacturing initiative is being followed by various organizations in the recent years
which mainly focus on improving the efficiency of operations by eliminating and reducing wastes.
Lean manufacturing system was selected to meet the company’s quality, cost and delivery targets.
After implementing lean manufacturing system, the manufacturing lead time reduced by forty per
cent, defects were reduced, higher process capability achieved, quick response to the customer
demand in small lots were achieved.
The introduced methodical approach connects Value Stream Mapping (VSM) and Methods-Time
Measurement (MTM) and offers new distinct advantages to reduce lead time and increase
productivity based on lean principles and standardized processes. The mutually aligned design and
improvement of assembly and (production) logistic processes takes the workplaces, their surroundings
and the supply areas as well as the overall value chain into account. The identification and
exploitation of productivity potentials is realized by the joint application of VSM and MTM focusing
the (work) methods, the performance and the utilization of the processes (the dimensions of
productivity).
Cycle time Should be cost based costumer response considered a viable option when an organization
is trying to improve efficiency, productivity and. Tools of lean manufacturing and line balancing are
used to reduce the cycle time in automobile assembly plant which contain many non-value added
activities and work. Assembly line balancing is process of assigning operation to work station along
an assembly line in such way that assignments is optimal in some sense
CONTENTS
[Link]. Description Page No.
About Company
Nomenclature
1. Introduction 1
2. Problem Statement 15
3. Literature Review 20
4. Procedure 21
5 Conclusion 50
6. Future Scope 51
References 52
List of Figures.
Figure 1: Emerson ........................................................................................................... 7
Figure 2: Production Department.................................................................................... 8
Figure 3: Assembly Department ..................................................................................... 9
Figure 4: Trevisan Machine. ......................................... Error! Bookmark not defined.
Figure 5: Two Piece Valve Body .................................. Error! Bookmark not defined.
Figure 6: Three Piece Valve Body ................................ Error! Bookmark not defined.
Figure 7: Components ................................................... Error! Bookmark not defined.
Figure 8: Disc ................................................................ Error! Bookmark not defined.
Figure 9: Seat ................................................................ Error! Bookmark not defined.
Figure 10: Valve Balls .................................................. Error! Bookmark not defined.
Figure 11: Work base .................................................... Error! Bookmark not defined.
Figure 12:Tool magazine .............................................. Error! Bookmark not defined.
Figure 13: Tool ............................................................. Error! Bookmark not defined.
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List of Tables.
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Table 10 ........................................................................ Error! Bookmark not defined.
NOMENCLATURE
Abbreviation/Symbol Meaning
VSM Value Stream Mapping
PMT Predetermined Motion Time
MOST Maynard Operation Sequence Technique
SSBV Soft Seated Ball Valve
STMBV Small Trunnion Mounted Ball Valve
LTMBV Large Trunnion Mounted Ball Valve
RB Reduced Bore
FB Full Bore
TPM Total Productive Maintenance
COMPANY PROFILE:
Figure 1: Emerson
In 1986, Emerson Group was incorporated by a group of technocrats with years of experience in
Industrial valves. Starting as a system house for Automated Valves, Emerson has now become one of
the world's fastest growing valve manufacturing companies, with product lines of Ball valves up to
60”, Triple Offset Valve (TOV) up to 56” and automated valves. Emerson has grown rapidly in global
markets with orders of over US$200 million in 2011. To service its international clients, Emerson has
created a strong Sales and Service Infrastructure through network of offices, distributors and
representatives across the world.
Today Emerson is a true multinational company with manufacturing plants in 3 countries (Italy, USA,
and India), warehouse/sales offices in 6 countries (USA, Italy, UAE, India, Malaysia, South Korea)
and customers in over 75 countries. Each location is staffed and equipped to provide application
engineering assistance. Presently, Emerson employs over 1000 people worldwide. Apart from
manufacturing standard API range of floating and Trunnion mounted Ball Valves and TOVs,
Emerson also manufactures specialties like cryogenic valves, metal seated valves, valves in higher
alloys such as duplex/super duplex stainless steel, Inconel etc. Emerson specializes in automated
valves with gas or gas over oil actuators, line break system, fireproof actuators, motor actuators,
hydraulic/ electro hydraulic actuators, digital partial stroking, etc. Emerson has in-house customized
test rigs for cryogenic, fugitive emission, high pressure gas and fire-safe testing.
Emerson is mark owned by one of the companies in Emerson Process Management business
unit of Emerson India, a leading manufacturer of ball valves and automation systems based in
Pune India. All Emerson valves are produced in conformance with API and BS requirements.
Figure 2: Production Department
Figure 3: Assembly Department
PROCESS MANAGEMENT
The Process Management segment offers customers products and technology, and engineering,
project management and consulting services for precision measurement, control, monitoring, asset
optimization, and safety and reliability of oil and gas reservoirs and plants that process or treat various
items. The Company’s array of products and services helps customers optimize their plant capabilities
in the areas of plant safety and reliability, product quality and output efficiency. Significant end
markets served include oil and gas, refining, chemicals and power generation, as well as
pharmaceuticals, food and beverages, pulp and paper, metals and mining, and municipal water
supplies. Sales by geographic destination in 2016 for Process Management were: the United States
and Canada, 42 percent; Asia, 23 percent; Europe, 19 percent; Latin America, 6 percent; and Middle
East/Africa, 10 percent.
PROCESS MANAGEMENT SYSTEMS AND SOFTWARE
Software Process Management systems and software control plant processes by collecting and
analyzing information from measurement devices in the plant, and then uses that information to adjust
valves, pumps, motors, drives and other control hardware for maximum product quality and process
efficiency and safety. Software capabilities also include upstream oil and gas reservoir simulation and
modeling for production optimization. The Company’s process control systems can be extended
wirelessly to support a mobile workforce with handheld tools/communicators, provide sitewide
location tracking of people and assets, and enable video monitoring and communication with wireless
field devices, thereby increasing the information available to operators.
VALVES, ACTUATORS AND REGULATORS
Control valves respond to commands from a control system to continuously and precisely modulate
the flow of process fluids to provide maximum process efficiency and product quality. Engineered
on/off valves are typically used to achieve tight shutoff, even in high pressure and temperature
processes. The Company designs, engineers and manufactures ball valves, sliding stem valves, rotary
valves, high performance butterfly valves and severe service valves for critical applications, and
related valve actuators and controllers. The Company provides a line of industrial and residential
regulators, whose function is to reduce the pressure of fluids moving from high-pressure supply lines
into lower pressure systems, and also manufactures tank and terminal safety equipment, including
hatches, vent pressure and vacuum relief valves, and flame arrestors for storage tanks in the oil and
gas, petrochemical, refining and other process industries
FLUID POWER AND CONTROL
These products control and power the flow of fluids (liquids and gases) in manufacturing operations
such as automobile assembly, food processing, textile manufacturing and petrochemical processing.
Products include solenoid and pneumatic valves, valve position indicators, pneumatic cylinders, air
preparation equipment, and pressure, vacuum and temperature switches.
