Study and Comparative Analysis of Relocation of Second Generation Common Rail Injector

Abstract

The Dissertation report mainly focuses on line matching in which assembly line and test line are transferred from Robert Bosch Turkey plant (RBTR) to Robert Bosch Nashik Plant (NaP). The importance behind this relocation is cost saving, extra business to accepting plant and local support to customer. For assembly line matching and test line matching in common rail injector various parameters such as armature lift, residual air gap, pulling current, holding current, magnet spring force, nozzle spring force, nozzle needle lift, over lift are to be compared. These obtained results from accepting plant are compared with releasing plant to eliminate the deviation of products and set the setting parameters for each station of assembly line. This approach is low volume investigation which saves time and cost of product. Cross check analysis is followed after assembly line and test line matching. Target of the cross check analysis is to compare the injected quantity and current characteristics with respect to time between the common rail injector produced at accepting plant and releasing plant. The analysis results which are obtained from Reference test bench (RSS Analyzer) and HDA test bench are compared between releasing plant and accepting plant. If the comparison is within the specified tolerance then common rail injector is released on relocated plant. A Simulation modeling and analysis has been done for analyzing the assembly line for the effect of product design change on production throughput.