MANUFACTURING SYSTEMS DESIGN FOR MASS

PRODUCTION OF DISC BRAKES

By

Kumanan A/L Raman

Dissertation submitted
in partial requirement for the
Bachelor of Engineering (Hons)
(Mechanical Engineering)

JANUARY 2010

UNIVERSITI TEKNOLOGI PETRONAS

Bandar Seri Iskandar,
31750 Tronoh,
Perak Darul Ridzuan

i
 CERTIFICATION OF APPROVAL

Manufacturing Systems Design for Mass Production of Disc Brakes

By

Kumanan A/L Raman

A project dissertation submitted to the

Mechanical Engineering Programme
Universiti Teknologi PETRONAS
In partial fulfilment of the requirement for the
BACHELOR OF ENGINEERING (Hons)
(MECHANICAL ENGINEERING)

Approved:

______________
Dr.Ir Setyamartana Parman
Project Supervisor

UNIVERSITI TEKNOLOGI PETRONAS

Tronoh, Perak Darul Ridzuan
January 2010

ii
 CERTIFICATION OF ORIGINALITY

This is to certify that I am responsible for the work submitted in this project, that the
original work is my own except as specified in the references and acknowledgement,
and that the original work contained herein have not been undertaken or done by
unspecified sources or person

______________________
KUMANAN A/L RAMAN

i
 ABSTRACT

Disc Brake is a commonly used component in vehicles. It is used as a braking

device to stop a moving vehicle. According to research, Malaysia being a car
manufacturing country does not have any major disc brake manufacturing plant.
Therefore, Malaysia is still depending on China and Taiwan to cater the spare part
market demand for disc brakes. This project aims to theoretically apply the concepts of
forecasting, process selection, modelling machining configurations, designing plant
operations and modelling a quality control inspection plan to build a manufacturing
system that is capable of producing certain amount of disc brakes. The manufacturing
system is designed in a best possible way to cater the demand of market where a few
cases of implementation have been considered. The operating systems proposed in the
report can be used on a long term provided that the assumptions made are still
applicable. The results of this project shows that the manufacturing systems design will
be able to handle huge demands of disc brake with very few improvements. This has
been proven by using the WITNESS Simulation. This project is a theoretical application
and there are a lot of room for a more robust and optimum upgrades.

ii
 ACKNOWLEDGMENTS

My appreciation to my project supervisor Dr Ir Setyamartana Parman, for taking me

under his wing and providing me all the necessary assets and resources, not only to
accomplish this project, but to enrich my character and knowledge further. My utmost
appreciation and gratitude is also extended to Dr. Ir. Mohd Amin Abd Majid, for the
dedication of his time and effort, relentlessly teaching and guiding me despite his many
other obligations. Many thanks to my family back home for their sacrifices coupled
with their continuous encouragement and support in heading me towards the stars.
Special thanks to all the members of the Mechanical Department, for establishing
continuous support and backing me up, my appreciation is also extended to my friends
and everyone who encouraged and supported me throughout the successful completion
of this project.

iii
 TABLE OF CONTENTS

ABSTRACT ...................................................................................................................... ii
ACKNOWLEDGMENTS ...................................................................... iii
LIST OF FIGURES...................................................................................................... vi

CHAPTER 1: INTRODUCTION ............................................................ 1

1.1 Background of Study ..................................................... 1
1.2 Problem Statement ......................................................... 1
1.3 Objectives ...................................................................... 2
1.4 Scope of Study ............................................................... 2

CHAPTER 2: LITREATURE REVIEW…............................................. 3

2.1 Disc Brake…….. .......................................................... 3
2.2 Mechanism of Disc Brake……………………………..4
2.3 Historical Data…………………………………………6
2.4 Forecasting……............................................................ 7
2.5 Design Selection ........................................................... 9
2.6 Machining Process...................................................... 10

CHAPTER 3: METHODOLOGY………. ............................................ 14

3.1 Procedure Identification .............................................. 14
3.2 Tools and Equipment......... ...................................... 15

CHAPTER4: RESULTS AND DISCUSSION..... ................................. 16

4.1 Forecasting .................................................................. 16
4.2 Process Selection ......................................................... 19
4.3 Configurations of Machining Parameters ..................... 21
4.4 Designing of Operation Systems .................................. 25
4.4.1 Theoretical Model ................................................ 25

iv
 4.4.2 Analytical Model.................................................... 27
4.4.2.1 Case 1.................................................................. 28
4.4.2.2 Case 2... .............................................................. 31
4.4.2.3 Process Flow ...................................................... 35
4.4.2.4 WITNESS Simulation for Case 1 ......................... 36
4.4.2.5 WITNESS Simulation for Case 2 ......................... 37
4.5 Modeling a Quality Control Inspection Plan ................. 40

CHAPTER 5:CONCLUSION AND RECOMMENDATIONS ............ 41

5.1 Recommendations ........................................................ 41
5.2 Conclusion.................................................................... 42

REFERENCES ....................................................................................... 43

APPENDIX A.......................................................................................... 44

v
 LIST OF FIGURES
Figure 1 Common disc brake ........................................................................................... 3
Figure 2 Mechanism of disc brake (single piston floating calliper) ................................ 4
Figure 3 Types of disc brakes .......................................................................................... 5
Figure 4 The summary of total vehicles assembled in Malaysia (1981 -2009)................ 7
Figure 5 AUTOCAD design for the disc brake ................................................................ 9
Figure 6 Schematic illustration of the basic turning operation,..................................... 10
Figure 7 General recommendations for turning process .............................................. 11
Figure 8 General recommendations for drilling process .............................................. 12
Figure 9 Measurement parameters and suitable measuring devices for quality control
inspection . ....................................................................................................... 13
Figure 10 Flow chart for the project methodology ........................................................ 14
Figure 11 Historical data to be used in forecasting ....................................................... 16
Figure 12 Analysis of the historical data into trend projection forecasting .................. 17
Figure 13 Forecasted values for the year 2009-2022 .................................................... 18
Figure 14 Demand projection graph .............................................................................. 19
Figure 15 Process distribution for the top layer machining for disc brake ................... 20
Figure 16 Process distribution for the bottom layer of the disc brake........................... 20
Figure 17 Process involved in disc brake machining operations .................................. 21
Figure 18 Summary of calculation on the facing and turning operations ..................... 23
Figure 19 Summary of calculation on the drilling......................................................... 24
Figure 20 Time distribution for each work element in seconds .................................... 27
Figure 21 Summary of the analysis for case 1 .............................................................. 29
Figure 22 Production Rate versus Annual Demand graph ............................................ 29
Figure 23 Cycle Time versus Annual Demand graph ................................................... 30
Figure 24 Line Balancing Efficiency versus Annual Demand graph ............................ 30
Figure 25 Summary of the analysis for case 2 .............................................................. 32
Figure 26 Production Rate versus Annual Demand graph ............................................ 32
Figure 27 Cycle Time versus Annual Demand graph ................................................... 33
Figure 28 Line Balancing Efficiency versus Annual Demand graph ........................... 33
Figure 29 Specific Process Flow Chart for processing disc brake ................................ 35
Figure 30 WITNESS Simulation using Case 1 parameters ........................................... 36
Figure 31 WITNESS Analysis for Case 1 parameters .................................................. 36
Figure 32 WITNESS Simulation using Case 2 parameters ........................................... 37
Figure 33 WITNESS Analysis for Case 2 parameters .................................................. 37
Figure 34 Quality Control Plan for disc brake manufacturing. ..................................... 40

vi
vii
 CHAPTER 1
INTRODUCTION

This chapter is dedicated for the introduction and explanations of the project entitled
“Manufacturing Systems Design for Mass Production of Disc Brakes”. Also included
are the background study, problem statement, objectives, and finally the scope of study
for the project.

1.1 Background of Study

A disc brake is a device for slowing or stopping the rotation of a wheel. It is usually
made of cast iron or ceramic composite. Disc brakes was first developed and used in
England in 1890’s. Since then it has gone through many modifications and development
to fulfill the need of consumers. This FYP topic entitled “Manufacturing Systems
Design for Mass Production of Disc Brakes” was initiated by Ir. Dr. Amin B Abd Majid
and it will be carried out under the supervision of Dr. Satyamartana Parman from the
Mechanical Engineering Department and is to be funded by UTP. This project will be
fully concentrating on the manufacturing systems design for mass production of disc
brakes to cater the Malaysia’s spare market demand.

1.2 Problem Statement

Disc brakes were only used in racing cars like Jaguar C-Type and Citreon DS when it
was initially developed. But later on, disc brakes were also used on passenger vehicles.
At the current market, almost all the cars in the market are fitted with disc brakes
because it ensures a reliable and efficient braking system. Therefore, the demand for
disc brakes as spare parts has increased tremendously over the years. Research shows
that Malaysia is depending on China & Taiwan to fulfill more than 50% of its disc

1
brake spare part demand [4]. This is because Malaysia does not have any mass disc brake
producer. Therefore, putting up a disc brake producing plant in Malaysia could help to
cater all the local disc brake demand thus reducing the need to import disc brakes from
china and Taiwan. This could also indirectly reduce the currency outflow and develop
our country’s economy.

1.3 Objectives
The objectives of this project are:
• To do research and forecast on the disc brake demand for Malaysia’s spare part
market for the next 12 years.
• To model a reliable and efficient manufacturing system to produce disc brakes.

1.4 Scope of Study

The project will only focus on manufacturing 12’ solid type disc brakes and the
scope of study will be as follow:
• Forecasting the demand for disc brakes in Malaysia for the next 12 years.
• Selecting the manufacturing process to be used in the plant.
• Configuring the machining process for the disc brakes.
• Designing of operation systems for the manufacturing process.
• Modeling a quality control mechanism for the finished products.

2
 CHAPTER 2
LITERATURE REVIEW

This section reviews the critical points and theories covered in this project

2.1 Disc Brake

Disc brakes are now widely been used on vehicles. It is used not only on cars
but also on motorcycles, and also bicycles. The braking performance of disc brakes is
proven to be more efficient and reliable than the common drum brakes. Cars nowadays
are using disc brakes on all the four wheels. That provides a more confident driving.
The picture of a common disc brake is used in most vehicle is shown below.

Figure 1 Common disc brake

3
The main components of a disc brake are as below where every part can be replaced
individually.
i. Brake pads
ii. Brake caliper
iii. Disc (rotor)
2.2 Mechanism of Disc Brake
The working mechanism of a disc brake is a lot like the breaks on a
bicycle.Bicycle brakes have a caliper,which squeezes the brake pads against the wheels.
In a disc brake,the brake pads squeezes the rotor instead of the wheels and the force is
transmitted hydraulically instead of through a cable.Friction between pads and the disc
slows the disc down . A moving car has a certain amount of kinetic energy and the
brakes remove this energy from the car in order to stop it. Each time you stop the car,
the brakes convert the kinetic energy of the car to heat generated by the friction between
the pads and the disc.Some brakes are vented to be able to dissipate the heat faster. The
diagram below shows the mechanism of a common disc brake.

Figure 2 Mechanism of disc brake (single piston floating calliper)

4
 The disc brake also has a self-adjusting /self centering capability where caliper
is able to slide from side to side so it will move to the center each time the brakes are
applied. Also, since there is no spring to pull the pads away from the disc, the pads
always stay in light contact with the rotor (the rubber piston seal and any wobble in the
rotor may actually pull the pads a small distance away from the rotor). This is important
because the pistons in the brakes are much larger in diameter than the ones in the master
cylinder. If the brake pistons retracted into their cylinders, it might take several
applications of the brake pedal to pump enough fluid into the brake cylinder to engage
the brake pads. Older cars had dual or four-piston fixed-caliper designs. A piston (or
two) on each side of the rotor pushes the pad to that side [1]. This design has been
largely eliminated because single-piston designs are cheaper and more reliable.

There are a few types of disc brakes in the market. The types of disc brakes are shown
below.

Figure 3 Types of disc brakes [2]

5
Most Malaysian cars use the solid type disc brakes. According to the Malaysian
Automotive Association, the number of cars in Malaysia is increasing tremendously.
The increase in the number of cars manufactured in Malaysia is growing very fast over
the years. Therefore, the needs for disc brakes as spare parts are almost increasing. The
table below shows the figure on the total vehicles manufactured in Malaysia

2.3 Historical Data on Number of Cars Assembled In Malaysia

There are many car assembling plants operating in Malaysia. There are both
continental car and local car assembling plant in Malaysia. Continental car assembling
plant includes Mercedes Benz and Honda while local cars assembling plant is Proton
and Perodua. The table below shows the number of cars been assembled in Malaysia
from year 1981 to 2008.
Year Passenger Vehicles
1981 87,822
1982 85,321
1983 100,226
1984 96,357
1985 69,769
1986 41,896
1987 33,878
1988 74,144
1989 86,148
1990 116,526
1991 135,479
1992 116,965
1993 120,864
1994 147,351
1995 231,280
1996 280,222
1997 337,717
1998 143,756
1999 257,607
2000 295,318
2001 355,863
2002 350,050
2003 355,450
2004 364,852
2005 372,225

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 2006 377,952
2007 403,245
2008 484,512
Figure 4 Summary of total vehicles assembled in Malaysia (1981 -2009) [4]

Research shows that 70% of the total passenger cars assembled in Malaysia are
Malaysian cars [4]. The life time for a disc brake is approximated to be maximum of 5
years under standard operating conditions (well maintained).

2.4 Forecasting
Forecasting is a process of predicting a future event. Forecasting is the
underlying basis of all business decisions. For example, production forecasting,
Inventory forecasting, personnel forecasting and also facilities forecasting. In the case
of modelling a manufacturing system to manufacture disc brakes, the disc brake
demand for the future must be forecasted to determine the production volume of the
plant. The forecasting can be done by using the historical data of the number of
passenger vehicles assembled in Malaysia [6].
Before forecasting is done, we have to be aware that there are a few types of
forecasting models available. Forecasting can be broke in to 2 major groups,
Quantitative and Qualitative method. Qualitative method is a method which uses
expertise’s intuition to predict the future. The most famous method is the Delphi
method. A group of expertise will discuss the factors and all related methods before
concluding their predictions. Usually no calculations or analysis is involved [6].
Meanwhile, Quantitative method is more analytical. This method has 2 sub
groups, Time Series Model and Associative Model. Associative Model includes Trend
Projection .It takes into account the variables or factors that might influence the quantity
being forecasted. However, the Time Series Model predicts on the assumption that the
future is a function of the past. In other words, they look at what has happened over a
period of time and use a series of past data to make a forecast. Time Series Model can
be expanded into few other models like, Naïve Approach, Moving Averages and
Exponential Smoothing.

7
 Naïve approach is assumed as the demand in the next period will be equal to the
demand in the most recent period. This model is the most cost-effective
cost effective and efficient
objective forecasting model [6].
Moving Averages model uses a number of historical data values to generate a
forecast. Moving averages are useful if we can assume that market demands will stay
fairly steady over time. When a detectable trend or pattern is present, weights can be
b
used to place emphasis on recent values. This makes the forecasting technique more
responsive to changes because more recent periods may be more heavily weighted.
Below is a example of the moving average and weighted moving average calculations.

Trend projection fits a trend

tren line to a series of historical data points and then
projects the line into the future for medium to long range forecasts. Least
Least-square
method can be used to develop a linear trend line by a precise statistical method. This
approach results in a straight line that minimises the sum of the squares of the vertical
differences from the line to each of the actual observations. A least-square
least line is
described in terms of its yy-intercept. If y-intercept
intercept and slope can be computed,
compu the line
can be expressed with equation:

   
The slope b is found by:    ∑
//∑2 2

8
There are seven important steps that need to be taken in account before a forecast is
done. The steps are shown below [6].
1. Determine the use of the forecast
2. Select the items to be forecasted
3. Determine the time horizon of the forecast
4. Select forecasting models
5. Gather data
6. Make the forecast
7. Validate & implement results

2.5 Design Selection

Product design is a crucial matter in manufacturing industry. Every product that
is to be manufactured must have a design. Design can be created by using software like
AutoCAD or Solid Works. Product design specifies the measurement and shape of the
actual product to be manufactured. It is a guide for the operators on how a completed
product will look like after going through the machining process. Below is the design of
the disc brake that will be manufactured. The final dimensions and shape is shown in
detail.

Figure 5 AUTOCAD design for the disc brake

9
2.6 Machining Process
Common machining process used in producing round shapes is turning. Turning
is defined as the part is being rotated while it is being machined. The starting material is
generally a work piece that has been made by other process such as casting, forging,
extrusion or drawing. Turning process is typically carried out on a lathe machine. A
lathe machine can be manual handled or automatically operated. A lathe machine can be
used to produce a wide variety of shapes [7].
Turning: produce straight, conical, curved, grooved work piece.
Facing: produce flat surface at the end of the part and perpendicular to its axis.
Drilling: produce a hole

Figure 6 Schematic illustration of the basic turning operation

The material removal rate (MRR) in turning is the volume of material removed
per unit time .For each revolution of the work piece, a ring-shaped layer of material is
removed, which has a cross-sectional area that equals the product of the distance the
tool travels in one revolution (feed,f) and the depth of cut,(d).The volume of this ring is
the product of e cross sectional area (f)(d) and the average circumference of the ring
,given below as,
•     /2
•    where V= cutting speed
•    where l=distance travelled
•   /

10
 Figure 7 General recommendations for turning process [7]

Drilling is also an important process in making disc brakes. Drilling can be done
on a lathe machine but the parameters and tools used are different. Drills typically have
high length-to-diameter
diameter ratios. The material-removal-rate (MRR)
MRR) is the volume of
material removed by drill per unit time. For a drill with
with a diameter D, the cross sectional
'(%
area of the drilled hole is . The velocity of the drill perpendicular to the work piece
&

is the product of the feed, f and the rotational speed is N, where


•  .
!

!%
• "##  $ &
) *

11
 Figure 8 General recommendations for drilling process [7]

Tapping is a process to make internal threads in a work piece. A tap is a chip-

producing threading tool with multiple cutting tools with multiple cutting teeth. Taps
generally are available with two, three or four flutes. The most common production tap
is the two-flute spiral-point tap. Tappered taps are designed to reduce the torque
required for the tapping of through holes. Tapping may be done by hand or a lathe
machine.
Honing is an abrasive machining process that produces a precision surface on a
metal work piece by scrubbing an abrasive stone against it along a controlled path.
Honing is primarily used to improve the geometric form of a surface, but may also
improve the surface texture [8].Typical applications are the finishing of cylinders for
internal combustion engines, air bearing spindles and gears. Types of hone are many
and various but all consist of one or more abrasive stones that are held under pressure
against the surface they are working on. Since honing is a high precision process, it is
also relatively expensive. Therefore it is only used in components that demand the
highest level of precision. It is typically the last manufacturing operation before the part
is shipped to a customer. The dimensional size of the object is established by preceding
operations, the last of which is usually grinding. Then the part is honed to improve a
form characteristic such as roundness and flatness. Since honing is a relatively

12
expensive manufacturing process, it can only be economically justified for applications
that require very good form accuracy. The improved shape after honing may result in a
quieter running or higher precision component [9].

Quality control is a compulsory procedure in every manufacturing industry.

Quality control is a process by which entities review the quality of all factors involved
in production [10]. Quality control inspection is a compulsory procedure in
manufacturing plants. Products produced by a plant must be inspected to ensure that the
product fulfills the design specifications. Poor quality control system can cause great
losses to the company. Consumers are liable to take legal actions against the company if
the marketed products are proven to be not within the specifications.

In the case of ensuring the quality of the disc brake manufactured, many types of
equipments can be used. Specific gadgets are used in measuring and quantifying the
specifications of the disc brake. The parameters and the suitable measuring device are
shown in the table below.

Parameters Devices

Lengths Vernier Caliper

Thickness Micrometer

Inside/outside dimensions Micrometer

Diameters Vernier Caliper, Micrometer

Angle Bevel Protractor, Sine Bar, Surface Plate

Straightness Autocollimator

Flatness Dial Indicator,Surface Plate, Optical

Flat(Interferometry Method)

Roundness V-Block

Figure 9 Measurement parameters and suitable measuring devices for quality

control inspection [7].

13
 CHAPTER 3
METHODOLOGY

This chapter discusses the project’s procedure identification as well as the tools and
equipments utilized throughout the course of completing this project

3.11 Procedure Identification

Procedures of a project are very important to guide us through the project.
Below are the procedures in sequence in order
der to complete the project.
project

Research & Forecasting

Process Selection

Configuration of Machining Parameters

Designing of Operation Systems

Modelling A Quality Control Inspection

System
Figure 10 Flow chart of project methodology
.

14
3.2 Tools and Equipments
The equipments and tools which are expected to be used in the project are bulleted
below.
1. AUTOCAD/SOLID WORKS
2. WITNESS Software

15
 CHAPTER 4

RESULTS AND DISCUSSION

This chapter discusses the outcomes of every stage and phase of the project.

4.1 Forecasting
Trend projection method is used to calculate the disc brake demand forecast for
the year 2009 to 2022.This method is used because the future demand of the disc brakes
can be determined based on the historical data gathered. The maximum capacity of the
plant will be ±20% of the maximum forecasted values. Research shows that 70% of
total cars assembled in Malaysia are local Malaysian cars. The assumption that we make
during forecasting is as below.
Assumption:
• 50% of total Malaysian cars assembled in a year use the solid type disc brake.

Year Total assembled No. of Malaysian No. of cars using

cars ,A cars, B(70% of A) Solid type disc brakes
( 50% of B)
2005 372 225 260 558 130 279
2006 377 952 264 566 132 283
2007 403 245 282 272 141 136
2008 484 512 339 158 169 579
Figure 11 Historical data to be used in forecasting.

16
 2
Year Time period ,X Disc Brake X XY
Demand, Y
2005 1 130 279 1 130 279
2006 2 132 283 4 264 566
2007 3 141 136 9 423 408
2008 4 169 579 16 678 316
2
∑X = 10 ∑Y = 573 277 ∑ X =30 ∑XY=1 496 569

Figure 12 Analysis of the historical data into trend projection forecasting

+  ∑,/
= 10/4
- = 2.5

Ў  ∑//
= 573 277 / 4
Ў = 143 319

b = (∑XY - n + Ў) / (∑ X - n +2)
2

= [1 496 569– (4) (2.5) (143 319)] / [30 – (4) (2.5)2]

= (1 496 569– 1 433 190) / 5
b = 12 676

a=Ў-b+
= 143 319 – 12 676 (2.5)
a = 111 629

17
 Therefore, the least square trend equation is Y = 111 629 + 12 676x .To project
demand for the following years, we replace the denoted years into the equation thus
generating the future forecasted values.

Forecast for year 2009

Y = 111 629 + 12 676x
= 111 629 + 12 676 (5)
= 175 009 units

Time Period
Forecast year Forecasted Value
(X)
2009 5 175 009
2010 6 187 685
2011 7 200 361
2012 8 213 037
2013 9 225 713

2014 10 238 389

2015 11 251065

2016 12 263741

2017 13 276417

2018 14 289093

2019 15 301769

2020 16 315998

2021 17 315998

2022 18 315998
Figure 13 Forecasted values for the year 2009-2022

18
 350000
Disc Brake Demand 300000
250000
200000
150000
Historical Data
100000
Projected Demand
50000
0
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
2021
2022
Year

Figure 14 Demand projection graph

4.2 Process Selection

The processes identified to machine the disc brake are turning and facing
processes. Drilling and tapping will be done at the end of the machining process. CNC
lathe machine will be used to carry out the turning, facing, drilling and tapping process.
The drilling and tapping process will be incorporated in a single process called Draping.
During this process, the drilling process and tapping process will be done
simultaneously. The Draping tool has a drilling bit at the tip and followed by a tapping
section. Therefore, when the drill moves downwards, a hole will be drilled followed by
a tapping process. These can increase the production rate of the system. After the
machining process, a finishing process will be carried out. Superfinishing method has
been identified to be used in this system. Superfinishing, also known as micromachining
and short-stroke honing, is a metalworking process that improves surface finish and
work piece geometry. This is achieved by removing just the thin amorphous surface
layer left by the last process with an abrasive stone; this layer is usually about 1 µm in
magnitude and it creates a cross-hatch pattern on the work piece [11].
The disc brake must be machined in few different processes. The machining
process distribution of the top layer and bottom layer of the disc brake is shown below.

19
 Process 3
Process 1

Process 2

Process 5
Process 4

Figure 15 Process distribution for the top layer machining for disc brake

Drilling small Hole (2)

Process 6

Process 9
Process 7
Drilling Big Hole (4) Process 8

Figure 16 Process distribution for the bottom layer of the disc brake

20
 The disc brake must go through a set of process before it achieves its final
desired shape and dimensions. The process flow for the disc brake machining and the
equipments involved are shown below.
Station 1 Station 2
Casting product •Facing •Facing
• Turning
•Chamfering

Station 5 Station 4 Station 3

•Drilling
Drilling •Facing •Facing
•Drapping
Drapping • Turning •Turning
•Chamfering

Station 6 Station 7
• Superfinishing •QC inspection Finished product

Figure 17 Process involved in disc brake machining operations

4.3 Configurations of Machining Parameters

In this section, the
the machining parameters for the turning, facing and drilling
process are calculated. Machining parameters su
such
ch as, cutting speed, feed and drilling
spindle speed are chosen from the general recommendation given in the book. The
parameters are chosen while considering the work piece material and the design
requirements. Design requirement includes the surface quality
quality and dimensional
accuracy. While, other parameters such as, lathe spindle speed and cutting time are
calculated with the selected parameters. The formulas that are used in the calculations
have been elaborated in the chapter 2.
Below are the calculations
calculations involved in the process of calculating the cutting time
for each facing and turning process and followed by a summarised table which contains
all the parameters.

21
Process 1
Cut 1 (DOC =2.5mm)   
3
T=L/FN 300*10^ mm/min= (П) (36mm)(N)
= [36mm/ (0.32mm/rev) (2653RPM)] *60sec N =2653 RPM
= 2.4sec

Cut2 (DOC =1.0mm)   

T=L/FN 185*10^3 mm/min = (П) (36mm)(N)
= [36mm/ (0.25mm/rev) (1636RPM)] *60sec N =1636 RPM
= 5.28sec

Cut 3 (DOC =0.6mm)   

T=L/FN 75*10^3 mm/min = (П) (36 mm)(N)
= [36mm/ (0.10mm/rev) (663.15RPM)] *60sec N =663.15 RPM
= 32.57sec
Total time for process 1 = 40.25sec

22
 Length Variables: Total
of Depth of Feed,F=mm/rev, Spindle Cutting Cutting
Cut Cut(L)/ Cut(DOC)/ Cutting Speed(N)/ Time(T)/ Time(T)/
Process No. mm mm Speed,CS=mm/min RPM sec sec

1 1 36 2.5 F=0.32,CS=300*E3 2653 2.4

2 1 F=0.25, CS=185*E3 1636 5.28

3 0.6 F=0.25 ,CS=75*E3 663.15 32.57 40.25

2 1 26.64 3 F=0.25, CS=285*E3 3405.3 1.87

2 2 F=0.25 ,CS=185*E3 2210.5 2.89

3 1.21 F=0.10 ,CS=75*E3 896.1 17.84 22.13

3 1 5.46 2.5 F=0.10, CS=75*E3 4372.4 0.7492

2 2 F=0.10, CS=75*E3 4372.4 0.7492 1.5

4 1 47 3 F=0.10, CS=185*E3 1252.9 22.51

2 2 F=0.10, CS=75*E3 1252.9 22.51

3 0.36 F=0.10, CS=75*E3 507.9 55.5 100.52

5 1 13 2.5 F=0.10 ,CS=75*E3 4897.1 1.593

2 2 F=0.10, CS=75*E3 4529.8 1.722

3 1.08 F=0.10 CS=75*E3 1836.4 4.247 7.562

6 1 47 1.5 F=0.25 ,CS=185*E3 1252.9 9

2 5 F=0.10 ,CS=75*E3 507.9 55.5 40.25

7 1 32 2 F=0.25 ,CS=185*E3 1840.9 4.17

2 2 F=0.25 ,CS=185*E3 1840.9 4.17

3 1 F=0.25 ,CS=185*E3 746.04 25.7 34.04

8 1 7.02 1.5 F=0.1 ,CS=75*E3 3400.7 1.24

2 0.5 F=0.1 ,CS=75*E3 3400.7 1.24 2.48

9 1 36 1 F=0.1 ,CS=75*E3 663.15 32.57

2 1 F=0.1 ,CS=75*E3 663.15 32.57 65.14

Figure 18 Summary of calculation on the facing and turning operations

23
 Below are the calculations involved in the process of calculating the cutting time
for each drilling process and followed by a summarised table which contains all the
parameters.

Drilling (012.5mm)

MRR drilling = ^2/4f N

= 12.5^2/40.3800
= 29452.4mm^3 /min

Volume of the hole

= j^2t
=  6.25: 7.74
=9.49 mm^3

Time required to remove the amount of material for 1 hole is:

= (9.49 mm) / (29452.4 mm^3/min) *60sec
= 1.93sec

For 4 holes, 1.93 * 4 = 7.72sec

Process Diameter(D) Feed(f)=mm/rev Rotational Drilling T*4/sec T*2/sec

/mm Speed(N)/rpm Time(T)/sec
1 12.5 0.30 800 1.93 7.72
2 6.64 0.0225 700 29.5 59.0
Figure 19 Summary of calculation on drilling

24
4.4 Designing of Operation Systems

4.4.1 Theoretical Model

In the previous section, the machining time for facing, turning and drilling was
configured. The cutting time is now used to design the processing line in the plant. A
set of machines must be arranged in a sequence to machine every part of the disc brake.
The arrangement must be done in the best possible way to achieve the optimum
production output. Analysis of the assembly line must be made before the modelling is
done. There are a few formulas used in this analysis.
The assembly line must be designed to achieve a production rate Rp, sufficient
to satisfy demand for the product. Product demand is often expressed as an annual
quantity which can be reduced to an hourly rate. Management must decide on the
number of shifts per week that the line will operate, and the number of hours per shift.
Required hourly production rate is given by:

<  /=>? Where: Rp= Hourly production rate

D= Annual demand for the product
S=Number of shifts/week
H=Number of hours/shift

Production rate must be converted to a cycle time Tc, which is the time interval
at which the line will be operated. The cycle time must take into consideration the
reality that some production time will be lost due to occasional equipment failures,
power outages and labour problems. As a consequences of these losses, the line will be
up and operating only a certain portion of time out of the total shift time available. This
uptime proportion is referred as line efficiency. The cycle time is determined as:

@A  60B/< Where: E=line efficiency

25
 A machined product requires a certain total amount of time to complete its
process. It is called Work Content Time, Twc. This is the total time of all the work
elements that must be performed on the line to make one unit of the product. The
formula is:

@CA  <DAEFF1  <DAEFF2  <DAEFF3, , , , , , , , , <DAEFF9

Repositioning losses, Tr is the amount of time lost at each station for

repositioning of the work unit. The repositioning time must be subtracted from the cycle
time, Tc to obtain the available time remaining to perform the actual machining task at
each station.

Owing to the difference in minimum rational work element and the precedence
constraints among the elements, it is virtually impossible to obtain a perfect line
balance. Measures must be defined to indicate how good a given line balancing solution
is. One possible measure is balance efficiency which is the work content time divided
by the total available service time in the line. Balance efficiency is given by:

B  @CA/C@F Where: Eb=balance efficiency

Twc= Work content time
Ts=Maximum available service time
W=number of workers

26
4.4.2 Analytical Model

No. Work Element Description Tek (sec)

1 Process 1 40.25

2 Process 2 22.13

3 Process 3 1.5

4 Process 4 100.52

5 Process 5 7.562

6 Process 6 40.25

7 Process 7 34.04

8 Process 8 2.48

9 Process 9 65.14

10 Drilling (12.5mm) 7.72

Draping(Drilling+Tapping)
11 (6.64mm) 59

12 Superfinishing 100

13 Quality Control 100

Figure 20 Time distribution for each work element in seconds

27
4.4.2.1 Case 1 (Assuming 50 weeks/year, 21 shifts/week, 7.5 hours/shift)

Assumptions
1. Production running for 50 weeks, 21 shifts per week, with 7.5 hours per shift.
2. Applying semi-automated processing system.1 machine has 1 operator
3. Assuming annual demand 178 692 units
4. Uptime efficiency is 95%
5. Repositioning time lost per cycle is 0.5 min
6. Defect rate is 5%

Total Work Content time

Twc =
(40.25 +22.13+1.5+100.52+7.56+40.25+34.04+2.48+65.14+7.72+59.0+100+100) sec
= 580.6sec
= 9.68 min

Required hourly production rate

Rp = 178692/ [(50) (21) (7.5)]
= 22.69 units /hour

Corresponding cycle time

Tc = 60(.95) / 22.69
= 2.51 min

Available service time with which the line must be balanced

Ts = 2.51-0.5
= 2.01 min

Line balance Efficiency

Eb = 9.68/ 7(2.01)
= 0.6880 ≈ 68.8 %

28
Annual Rp Line Balancing
demand Twc(sec) Twc(min) (units/hr) Tc(min) Ts(min) Efficiency,Eb

178692 580.6 9.68 22.69 2.51 2.01 68.80%

187056 580.6 9.68 23.75 2.4 1.9 72.78%

195421 580.6 9.68 24.82 2.29 1.79 77.25%

203785 580.6 9.68 25.87 2.203 1.703 81.20%

212150 580.6 9.68 26.94 2.11 1.62 85.00%

238770 580.6 9.68 30.32 1.88 1.38 100.00%

250000 580.6 9.68 31.75 1.79 1.29 107%

Figure 21 Summary of the analysis for case 1

35

30

25
Production/hr,Rp

20

15
Production/hour
10

0
178692 187056 195421 203785 212150 238770 250000
Annual Demand

Figure 22 Production Rate versus Annual Demand graph

29
 2.5

2
Cyclt Time,Tc

1.5

1 Cycle Time, Tc

0.5

0
178692 187056 195421 203785 212150 238770 250000
Annual Demand

Figure 23 Cycle Time versus Annual Demand graph

120.00%
Line Balancing Efficiency,Eb

100.00%
80.00%
60.00%
40.00%
Line balancing Efficiency
20.00%
0.00%

Annual Demand

Figure 24 Line Balancing Efficiency versus Annual Demand graph

30
4.4.2.2 Case 2 (Assuming 50 weeks/year, 15 shifts/week, 7.5 hours/shift)

Assumptions
1. Production running for 50 weeks, 15 shifts per week, with 7.5 hours per shift.
2. Applying semi-automated processing system.1 machine has 1 operator
3. Assuming annual demand 120 000 units
4. Uptime efficiency is 95%
5. Repositioning time lost per cycle is 0.5 min
6. Defect rate is 5%
7. Using two similar processing lines

Total Work Content time

Twc =
(40.25 +22.13+1.5+100.52+7.56+40.25+34.04+2.48+65.14+7.72+59.0+100+100) sec
= 580.6sec
= 9.68 min

Required hourly production rate

Rp = 120000/ [(50) (15) (7.5)]
= 21.33 units /hour

Corresponding cycle time

Tc = 60(.95) / 21.33
= 2.67 min

Available service time with which the line must be balanced

Ts = 2.67-0.5
= 2.17 min

Line balance Efficiency

Eb = 9.68/ 7(2.17)
= 0.6372 ≈ 63.72 %

31
Annual Rp Line Balancing
demand Twc(sec) Twc(min) (units/hr) Tc(min) Ts(min) Efficiency,Eb

120000 580.6 9.68 21.33 2.67 2.17 63.72%

140000 580.6 9.68 24.89 2.318 1.818 76.06%

160000 580.6 9.68 28.44 2 1.5 92.00%

170550 580.6 9.68 30.32 1.88 1.38 100.00%

180000 580.6 9.68 32 1.78 1.28 108.00%

Figure 25 Summary of the analysis for case 2

35

30
Production/hr,Rp

25

20

15
Production/Hr, Rp
10

0
120000 140000 160000 170550 180000
Annual Demand

Figure 26 Production Rate versus Annual Demand graph

32
 3

2.5

2
Cycle Time,Tc

1.5

1 Cycle Time,Tc

0.5

0
120000 140000 160000 170550 180000
Annual Demand

Figure 27 Cycle Time versus Annual Demand graph

120.00%

100.00%
Line Efficiency,Eb

80.00%

60.00%

40.00% Line Balancing Efficiency

20.00%

0.00%
120000 140000 160000 170550 180000
Annual Demand

Figure 28 Line Balancing Efficiency versus Annual Demand graph

33
 Analysing Figure 21 to Figure 24, it can be seen that the Production Rate, Cycle
Time and Service Time and Line Balancing Efficiency varies depending on the Annual
Demand. In Case 1, it is assumed that the plant runs 50 weeks/year, 21 shifts/week and
7.5 hours/shift. As the Annual Demand increases, the Production Rate and the Line
Balancing Efficiency increases. However, the Cycle Time and Service Time decrease.
The Line Balancing Efficiency’s value is the critical parameter that decides the design
of the processing line. Analyzing Figure 21, shows that a processing plant that operates
as the parameter of Case 1 can produce up to 238 770 units/year. This is the maximum
annual output that can be gained with the given cutting parameters and available time.

Referring to Figure25 to Figure 28, it can be interpreted that the Production

Rate, Cycle Time, Service Time and Line Balancing Efficiency varies against the
Annual Demand. In the analysis of Case 2, it is assumed that the plant runs 50
weeks/year, 15 shifts/week and 7.5 hours/shift. The Production Rate and the Line
Balancing Efficiency increases while Cycle Time and Service Time decreases as the
Annual Demand increases. The Line Balancing Efficiency reaches 100% at a lower
Annual Demand compared to Case 1. This is because of the limitations on the available
time. The operating time available for Case 2 is lesser than in Case1 as there are only 15
operating shifts in Case 2 but 21 shifts in Case 1. Implementing Case 2 as the
operations system can only produce a maximum of 170 550 units/year.

Based on the analysis above, there are two types of potential operating systems
that can be adapted to the processing line of the disc brake manufacturing systems.
Taking into account the forecasted values in the previous sections, both the operating
systems can be adopted at a different time line. Referring to Figure 13, the forecast on
the annual demand up to year 2014 is only 238 389 units which is lesser than the
maximum output capability of Case 1.While the forecast till year 2022 which is also the
ultimate maximum value of the disc brake annual demand is 315 998 units.

34
 Therefore, it is proposed that a single processing line is used up to year 2014
while adapting the parameters of Case 1 and for the consequence years, another
processing line is added and both the processing lines adopt the parameters of Case 2 up
to year 2022.This is because up to year 2014, one processing line could cater all the
annual demands and after year 2014, each of the lines can produce 170 550 units
amounting to 341 100 units of disc brakes. This can certainly cater the ultimate
maximum value preset by this project
p which is 315 998 units. Applying Case 1 will
require the plant to operate 7 days a week. But however, when another processing line
is added and parameters of Case 2 are implemented, the operating hours can be reduced
from seven to five days. Even though
though the initial investments are high, but it can be
justified as the maximum market demand can be satisfied as well as the savings on
utilities and salary.

4.4.2.3 Process Flow of the Disc Brake Processing Line

The parameters of the processing line have
have been determined in the previous
section. Applying the parameters into the real case scenario is another task. The
processes are arranged in groups in which the machining will be done. The process
chart below shows the processes that are allocated in their
their respective stations.

Figure 29 Specific Process Flow Chart for processing disc brake

35
4.4.2.4 WITNESS Simulation for Case 1

WITNESS Simulation is used to check the feasibility of the processing parameters in

real time scenario. Below is the simulation for the processing line per shift when Case 1
parameters are used.

Figure 30 WITNESS Simulation using Case 1 parameters

Name Station_1 Station_2 Station_3 Station_4 Station_5 Station_6 Station_7

% Idle 7.59 8.06 8.53 9.00 9.47 9.97 18.55
% Busy 80.44 80.04 79.64 79.23 78.83 78.40 77.57
% Setup 11.97 11.90 11.83 11.77 11.70 11.63 3.88

Name No. Entered No. Shipped No. Scrapped W.I.P.

Units 181 170 8 3
Figure 31 WITNESS Analysis for Case 1 parameters

36
4.4.2.5 WITNESS Simulation for Case 2

Below is the simulation of the processing line when parameters of Case 2 are
used. The processing line must have 2 similar lines. Since the WITNESS simulation is
unable to cater more elements, the simulation is done on one processing line and
multiplied into two.

Figure 32 WITNESS Simulation using Case 2 parameters

Name Station_1 Station_2 Station_3 Station_4 Station_5 Station_6

% Idle 2.90 3.44 3.98 4.52 5.08 5.63
% Busy 78.99 78.56 78.12 77.68 77.23 76.77
% Setup 18.11 18.00 17.90 17.79 17.69 17.60

Name No. Entered No. Shipped No. Scrapped W.I.P.

Units 174 160 11 3

Name No. Entered*2 No. Shipped*2 No. Scrapped*2 W.I.P.*2

Units 348 320 22 6
Figure 33 WITNESS Analysis for Case 2 parameters

37
 Figure 30 shows the WITNESS Simulation model for the processing line if Case
1 parameters are used. Inputting the Cycle Time and Service Time calculated earlier in
to the model shows that the line is capable of producing the required output volume.
Figure 31 shows the analysis of the processing line .The stations are well balanced as
the idle time and busy time does not vary much between them even though the line
balancing efficiency is only 68.80%.
According to the calculations in the previous section, the line should be able to
produce 22.69units/hour for the given parameters. Therefore for a shift of 7.5 hours, the
line should be able to produce 170.75units/shift. Taking in to account the 5% defect
rate, the line must produce a total of 178units/shift. This is proven feasible by the
analysis done on the WITNESS model. Based on the analysis, applying the model can
produce 170 good units, 8 defect units while 3 more in the ‘Work In Progress” mode.
When the production rate need to be increased, The service time and cycle time
need to be reduced according to Figure 21.This can be done by doing continuous
improvement on the machining process. By doing this the Line Balancing Efficiency
can also be increased which results in a more efficient processing line. Therefore, Case
1 parameters are proven to be able to cater the total demand of the disc brake plant until
year 2014.

Figure 32 shows the WITNESS Simulation Model for the processing line when
Case 2 parameters are used .The model has been build using the cycle Time and Service
Time from the previous calculations .The processing line uses Case 2 parameters and
therefore it should have 2 sets of processing line .Due to some limitations on the
WITNESS Software, the second line could not be modelled. However, since both the
lines are similar and the parameters are identical, the volume could be multiplied into 2
to gain the final volume.
According to the calculations in previous section, the lines should be able to
produce 21.33units/hour for the given parameters. Since the plant operates for 7.5hours
/shift and there are 2 processing lines, it can produce a total of 320units/shift.

38
Considering the 5% defect rate, the line should be able to produce at least
336units/shift. By observing Figure 33, it can be proven that Case 2 parameters are
capable of meeting the annual demand as 320 units are shipped, 22 are scrapped and 6
still in progress. When the annual demand increases later, the Cycle time and Service
Time must be reduced according to Figure 25 to cater the annual demand. As the annual
demand increases, the line balancing Efficiency will increase thus making both the lines
more efficient. Therefore, Case 2 parameters are proven to be able to cater the annual
demand of the disc brake plant from year 2014 until 2022.

39
4.5 Modeling a Quality Control Inspection Plan

Operations Machine Production Control Measurement

Methods Equipment
Cast discs Inspection by third Properties –hardness, Tensile testing,
person strength, surface defect hardness testing,
visual magnetic
particle inspection
Turning, Facing, Lathe (CNC) Dimensions- length, Digital Vernier
Chamfering diameter, roundness, calliper, Dial
flatness Indicator, V-Block
Drilling Drilling machine (CNC) Dimensions – hole size, Depth calliper,
hole depth Digital Vernier
calliper
Tapping Drilling Machine (CNC) Dimensions- tap size Digital Vernier
calliper
Superfinishing Aluminium Oxide, Surface Quality- Dial indicator,
Silicon Carbide flatness, straightness, Surface Plate
Abrasives surface hatching
Figure 34 Quality Control Plan for disc brake manufacturing.

Quality Control Inspection is crucial in every manufacturing plant. The

manufactured products must be regularly inspected to ensure the products are meeting
the specifications. Above is the table on the measurement equipments that are used to
inspect the specific dimensions.

40
 CHAPTER 5
CONCLUSION AND RECOMMENDATIONS

This chapter concludes the entire project and proposes several recommendations which
could improve the outcomes of the project.

5.1 Recommendations

Despite achieving the objectives, there are several recommendations, which

would be considered in order to improve the outcomes.

• Use lower cutting speed and feed for configuration of machining system.
This can improve the surface quality of the machined disc brakes .However the
time required to machine the surface will increase.

• Reduce the number of machine used. Reducing the number of machine and
trying to incorporate all the processes into the machines available can reduce the
capital cost. The number of machines has been predetermined in this project.

• Use a complete version of WITNESS Software to simulate the model. The

WITNESS Software used to simulate the model is an educational version.
Therefore it is has some limitations and some elements could not be modeled.

• Use better technology for Quality Control Inspection Plan. The equipments
used in quality control inspection must be upgraded to a better technology to
enhance the quality of the products produced. High technology equipments can
produce higher tolerance in measuring the specifications.

41
5.2 Conclusion

A disc brake manufacturing system was successfully modelled. The historical data on
car manufacturing has been used to predict the spare part market. The disc brake
machining configuration was modelled thus used to design the operational system.
Finally before completing the manufacturing process, the completed disc brakes will go
through a simple quality control inspection to ensure that it meets the design
specifications. Simulation of the model using WITNESS proves that the design can be
successfully used to produce disc brakes at the specified rates.

In conclusion, with the proposed model, it can be said that this project is a
success.

42
 REFERENCES

[1] http://en.wikipedia.org/wiki/Disc_Breaks
[2] Lexus Technical Material-Disc Break
[3] HowStuffWorks- “How Disc Breaks Works”
[4] Malaysian Automotive Association, Summary of Sales & Production
Data (1980-2009).
[5] Mikell P Groover, Professor of industrial &Systems Engineering ,Lehigh
University,Automation &Production Systems 3rd Edition
[6] Jay Heizer ,Barry Render, Operations Management 9th Edition
[7] Kalpakjian Schmid , Manufacturing Engineering And Technology, 5th
Edition in SI unit.
[8] Mohd Amin Abd Majid, Othman Mamat , Process Development for Small
Batch Manufacturing of Disc Brakes, University Teknologi PETRONAS.
[9] http://en.wikipedia.org/wiki/Honing_(metalworking)
[10] http://en.wikipedia.org/wiki/Quality_control
[11] http://en.wikipedia.org/wiki/Superfinishing

43
APPENDIX A

44