CERTIFICATE

To Whomsoever It May Concern

This is to certify that the report entitled Designing a poke yoke to overcome plunger mix-up embodies the original work done by Manish Tewani. He has completed his 45 days summer training/project from 14th May 2012 27th June 2012 under my guidance and supervision at Bosch Jaipur. Place: Jaipur Date: 27th June 2012

. Signature Mr. Seemant Arora Deputy Manager (JaP/MFD-A)

ACKNOWLEDGEMENT
EVERY GOOD WORK REQUIRES THE GUIDANCE OF SOME EXPERTS

I would like to express my deepest gratitude to all the people, who have helped me in the successful completion of project. I am highly obliged to Mr. Santosh Joseph (JaP/HRL) for giving me a golden opportunity to pursue my In-Plant Training with this prestigious organization (Bosch Limited).

It is indeed my pleasure and privilege to thank Mr. Suraj Dev Singh (JaP/MFD) & Mr. Vaibhav Sharma (JaP/MFD-E) as their guidance, help and encouragement was a big support and inspiration to me during my projects.

I owe my heartiest thanks to Mr. Seemant Arora (JaP/MFD-A), my guide during my project for their guidance and strong support, without which I would not have been able to accomplish the projects successfully.

Last but not the least; I extend my special thanks to Mr. Ashutosh Mudgil, Mr. Vikas Saxena, Mr. Utsav Yadav, and Mr. Amit Gupta for sharing valuable experience required for the completion of the project.

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PREFACE
After the completion of academic studies, most of the Mechanical Engineering students will serve in public or private sector industries. The students should have an exposure to the Industrial environment to get a better place in a company. The Industrial training develops understanding about tools, plants, machinery processes and organization. The industrial training serves to bridge the gap between theoretical and practical knowledge. Industrial training develops: Awareness of industrial environment and work culture. Understanding of engineering skills, practices and process involved. Understanding of social, economic and administrative consideration and their influence on the working of organization. Understanding about discipline, punctuality, teamwork, value of time and money, dignity of labor and sense of responsibility. Last, but not the least industrial exposure helps creating a professional attitude towards work. To get acquainted with the industrial environment and to minimize the gap between the theories and the practical, I completed my industrial training at, Bosch Limited JAIPUR. This plant manufactures rotary type fuel injection pumps for diesel engines. The plant started commercial production in March 1997.This unit is well equipped with modern machinery shops comprising many sophisticated and precision machines. This unit has got QS 9000 certification in March, 2001. Working at Bosch was an experience in itself that I will relish for the rest of my life. It was here that I learned about working in the corporate world, the entire scenario was new to me and was a great learning experience.
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As a multi-unit company in the Bosch Group, Bosch gives a unique opportunity to work on cutting edge technology. During this period of 45 days, I was exposed to the real working environment and working conditions of the industries, materials, processes, tools plant, machinery, organization, administration, quality, safety and many other aspects of industries. As a budding Mechanical Engineer, I was able to understand the responsibilities and competence required in a Mechanical Engineer. However the best part it was that I worked on projects related with Manufacturing as well as Industrial Management. Above all this training period helped me personally, to get an insight into the working environment and conditions prevailing in the engineering industry, which I will soon enter. In this period of training I maintained a training notebook, in which day to day observations were recorded. On the basis of these information collected and guidance provided, I have prepared a comprehensive training report. This report contains the history of Bosch, introduction to Robert Bosch GmbH, introduction to Bosch and things I have learnt I wish to thank Bosch Jaipur for providing the practical training and giving the best suggestions, information and help in completing this report.

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Contents: List of Figures List of Tables Abbreviations Chapters vii x xi

1. Introduction to BOSCH Group

2. Product Information
2.1 Introduction to fuel injection pump 2.2 Nomenclature of VE pump 2.3 BOSCH VE-Pump with Schematic Diagram 23 23 25
v

2.4 Working Principle & Constructional Features 2.5 Components

27 32

3. Key customers

37

4. Projects
4.1 Poke yoke for plunger mix up 4.2 Machine capability analysis 39 55

5. Conclusions

85

6. Learning gains

85

7. References

86

8. Bibliography

86

vi

LIST OF FIGURES

S.NO.
1 2 3 4 5 6 7 8 9 10 11

FIG. NO.
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11

CAPTION
Robert Bosch Bosch Headquarter at Germany Boschs sector wise sales BeQIK policy flow diagram Boschs presence worldwide Boschs Bangalore plant Boschs Nashik plant Boschs Nagnathpura plant Boschs Jaipur plant Boschs Goa plant Bosch Jaipur plants manufacturing building Boschs Product flow BPS process description BPS features VE Pumps VE-LDA Pump

REF. NO.
1 1 1 2 1 1 1 1 1 1 1

PAGE NO.
1 2 4 6 9 11 11 12 12 13 13

12 13 14 15 16

1.12 1.13 1.14 2.1 2.2

1 1 1 1 1

14 20 21 22 23 vii

17 18

2.3 2.4

VE Pumps detailed diagram Detailed diagram of head & other part Mounting components Inlet Components of VE Pump high pressure components of VE Pump Injection and Timer Components Governor of a VE Pump Working diagram of VE Pump Schematic Diagram of the Pump and FuelTank Engine Assembly Major Components of a VE Pump Drive Shaft Roller Ring Cam Plate Pump Housing Cross-Disc Support Ring Housing Supply Pump TD Piston Hydraulic Head Fulcrum Lever

1 1

24 25

19 20 21

2.5 2.6 2.7

1 1 1

26 27 27

22

2.8

28

23 24 25

2.9 2.10 2.11

4 1 1

28 29 30

26

2.12

30

27 28 29 30 31 32 33 34 35 36 37

2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23

1 1 3 3 3 4 4 4 1 1 1

31 31 31 32 32 32 33 33 34 34 35

viii

38 39 40 41 42 43 44 45 46 47 48

3.1 3.2 3.3(a) 3.3(b) 3.4 3.5 3.6 3.7 3.8 3.9 3.10

Main components of hydraulic head Valve spool Top view of Y-stage head Bottom view of Y-stage head Plunger Valve Bush Hydraulic Head Z-Stage process flow 6 and 3 cylinder plunger foot 4 cylinder plunger foot Outlet hole on RHS w.r.t. head slot Outlet hole on LHS w.r.t. head slot Hard stage Process flow for plunger Ishikawa diagram for plunger mix-up. Front view and top view of the entire fixture Headstock front and top view Tailstock (all 3 views) Headstock centre bit Tailstock centre bit SPC flowchart Normal distribution curve

1 1 1 1 1 1 1 1 1 1 n/a

39 40 40 40 41 42 43 43 44 44 45

49

3.11

n/a

45

50

3.12

n/a

47

51

3.13

n/a

48

52

3.14

n/a

51

53 54 55 56 57 58

3.15 3.16 3.17 3.18 3.19 3.20

n/a n/a n/a n/a n/a n/a

52 53 53 53 57 62 ix

LIST OF TABLES

S. NO.
1 2 3 4

TABLE NO.
2.1 3.1 3.2 3.3

CAPTION
Customers of BOSCH[1] List of plungers and their specifications Validations for plunger mix-up Machine capability readings for new shrink fitting (angle) Machine capability readings for new shrink fitting (height) Machine capability readings for S33 grinding machine (height) Machine capability readings for 59068 grinding machine (height) Machine capability readings for 26902 grinding machine (height) Machine capability readings for micromatic machine (collar dia.) Machine capability readings for machine (V.S. match O.D.) Machine capability readings for micromatic machine (head match O.D.)

PAGE NO.
36-37 46 49 69-70

3.4

71-72

3.5

72-74

3.6

74-76

3.7

76-78

3.8

78-79

10

3.9

80-81

11

3.10

82-83

ABBREVIATIONS
PM PT PC MFV TEF SPE QMM MFV-A MFV-BM MFV-BS MFV-C SAF/EPR PER ISY-1 ISY-2 CFA MVC PUR MED WSD BPS SPC :- Plant Management :- Plant Technical :- Plant Commercial :- Manufacturing VE Pumps :- Technical & Engineering Function :- Special Project Engineering :-Quality Management & Methods :- Manufacturing of Assembly Parts :- Manufacturing of Machinery :- Manufacturing- Surface Treatment :- Manufacturing of Components :- Safety & Environment Regulation :- Personnel Department :- Information System of Hardware :- Information System of Software :- Controlling Finance & Accounting :- MICO Vocational Centre {Training & Developing Centre} :- Purchase Department :- Medical Facility : - Security Facility. :- Bosch Production System :- Statistical Probability Control

xi