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Small and medium companies have few dedicated employees for process planning and analyzing. They have many defects in their operational processes which result in less productivity. This research analyze a process of small company, which makes a hole and a round for gear parts. We found that the drilling operation is a bootle-neck operation and propose a revised general machine for drilling operation.
The legacy drilling operation is performed as follows. First, a operator drills a half hole of a part and turns the part upside down. Then he drills a rest hole of the part. The operation needs more efforts than other operations. Therefore a productivity of the factory depends on that of the drilling operation. We developed a horizontal multi-drilling machine for the drilling operation. The machine has the drilling tool heads and takes three parts and makes a hole at the same time. It eliminates human operation in the middle of drilling, We also developed clamping jig for holding parts tightly. The proposed machine reduces the total operation time and enhances the productivity of the factory. The process capability index also increased from 6.8 to 9.6.
