ABSTRACT

A Broaching machine is a gear boring machine that makes hubs for clutches.
The efficiency improvement of Broaching Machine cell is focussed upon
here. Efficiency improvement is done by employing TPM tools such as
OEE, TPM’s 16 Major Losses. OEE is used to determine the current
working efficiency of the machine. OEE is calculated by using 3 factors
which are Availability, Performance and Quality. OEE was calculated for
Vertical Broaching and Horizontal Broaching machines. The various losses
that occur during the production process are classified under the 16 Major
TPM losses. Some of the major Losses pertaining to our study that affect the
performance of the machine cell are Equipment Failure, Setup and
Adjustment, Tool change and adjustment, Start-up loss, Idling and Minor
Stops, Speed Loss, Defect/ Rework Sub loss, Management Loss. The losses
are further sub-grouped into their respective categories. The major losses
that slowed down production were determined, and methods to eliminate
these losses were suggested. Setting Time Reduction: The various steps
involved in setting up a broach tool for production is identified and methods
to eliminate the unnecessary steps, methods to combine the simpler steps and
methods to simplify the complex steps were suggested. Tool life was
improved by using a different coating to the conventional one. The
conventional method uses TiN (Titanium Nitride) which is a gold coloured
coat. It improves abrasion resistance and increases tool life. TiAN (Titanium
Aluminium Nitride) coating is a black coloured coating. It is used for high
speed and high productivity especially in steels. It is also suitable for micro-
lubrication or dry machining. It also increases the tool life by 25%.