Design & Development of Automated production line and SPM for the new product MCCB

Abstract

Moulded Case Circuit Breakers (MCCB) are electromechanical devices which protect the circuit from overload and short circuit. The rated current varies from 16 Amps to 1250 Amps. MCCB is a modular product, which consists of pole, mechanism, release & final integration of all the three modules or components. The release has also two variants i.e. Thermal Magnetic Release (TMR) & Micro-Processer Release (MPR). For the effective production of MCCB the production line is required to be developed, which includes different fixtures, automation setups, conveyors, pallets, feeders, mounting plates etc. In MCCB, the upper mechanism checking or testing is necessary because mechanism gives us operating on, off and trip facility. So for that the MCCB production required some special purpose machine for the testing of mechanism, which ensures the proper working of mechanism used in MCCB. In this project, a production line is designed, developed and installed to produce the new variety of MCCB. The production line is to be automated so that the production rate of the MCCB is increased. The production line consists of several equipment. All the equipment’s are designed to maintain or minimize the cycle time at each station. Production line is designed such that the customers should get the product delivery at right time of right quality and at less cost. The new production line of MCCB has to meet Key performance Index (KPI), production capacity of 15000 MCCB per month with cycle time of 60 seconds. While designing the production line, the concept of lean manufacturing is used for higher productivity and also the concept of poka-yoke for fixture design to avoid missing of parts.