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Process Strategy

Process Strategy

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Published by Ba Tien Nguyen

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Published by: Ba Tien Nguyen on Jun 20, 2012
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09/17/2012

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PROCESS STRATEGY
ĐÔNG Á
 I.
 
General
The production line is WETLUX technology. The factory has prepared to build a new productionline with NOF technology. Productivity: 5000-6000 ton/month (the ratio is 80% Zinc plated Steelplate, 50% Color plated steel plate. Recently, the ratio is changed to 50% plated Steel plate and50% Color plated steel plate. And last month, the ratio of production is that the percentage of color plated steel plate is more that one of zinc plated steel plate. ) Effective output is 30% or40% of design capacity. Instruction includes 4 independent production lines. Maybe the productof this production line becomes raw material for another one (internal traffic)
II.
 
DetailA.
 
Galvanized Iron
There are 8 sections in Zinc plated Steel plate production line
Step 1
: Checking input Materials:From production schedule, checking the specification of materials and define quantity.Weighing the Black Sheet bundle, writing and recording the data such as: standard weight,actual weight, suttle, specification and mode into the quality logbook of Black Sheet.Checking the quality:Round check: specification, place of originUnpacking the bag, checking inside materials. To some bundles which are not enough equalitysuch as : distorted, exothermic, iron-mould
….they will be carried out without producing.
In the production process, workers often monitor the quality of Black Sheet (level of fertile,
exothermic, rupture…) then record in the quality logbook of Black Sheet.
 
Step 2
: Direct feed material continuously:If the materials are enough quality to produce, they are inflow exhaust system and hood upwith the first bundle to provide continuously for production line.
Step 3
: Deoiling and Pickling:Before Steel plates was entering to plate, they had had to through the deoling and picklingsection, this section has 4 parts :
 
First, the Sheet band must go through the cistern concentration from 23 to 40, the temperatureis 600C
 –
800C here with steam, then next to two flushing chambers. Those flushing chambersis including : pump high
 –
pressure team system and small detergent from the cistern. Itatomizes two faces of black sheet bundle; use the crane to cleanse deoiling parts.It continues going through the hot water flushing chamber (600C
 –
800C) to reclean some dirtyelements on Sheet.After that, sheets are gone into HCl bath with 10% - 20% strength. This is checked twice perturn ad record in the quality logbook.The last part is a water bath to make HCl out, and Sheets go through the hot water flushingchamber again. Then they are dried by a couple of rubber crane before come to next section.
Step 4
: Heating the sheet before coming Pan:This process makes the temperature of black sheet bundles go to 2000C.
Step 5
: The process of plating ZINC:With the temperature of 1800C
 –
2000C, sheets is entered soldering flux chamber (AmmoniumChloride, antimony, aluminum) to flush, increase the brightness and mechanical behavior of 
materials…
Then, sheets are gone through zinc chamber, second to radiator grouping to finish this process.
Step 6
: The process of Cooling:The air duct system and booster perform this process. But after cooling sheets with air ductsystem, the temperature of sheets still are high. So they is bathed with a water chamber, herethe temperature is slow down 600C-800C. And the water chamber makes sheets clear more.
Step 7 
: Surface Passivation:Here, sheets are dipped in chromium chamber with the 3
 –
7 strength and the temperature is550C-600C. Sheets are overlapped by a protective coating chromium against to pickling. Thenthey are dried by a couple of rubber crane before come to next section.
Step 8
: Packaging and Inventory:Steel plates are categorized with the level of A, B, C of management department. After makingsteel plates become bundles, they are weighed, labeled and move to inventory. Some bundleswhich are not quality enough, are taken out and recorded in the document.
B.
 
Pre-painted Galvanized Iron
Step 1
: Input areaRaw sheets feed consecutive into manufacturing process, choose good material to manufacturethe best quality product
 
Black sheet bundle or zinc plated sheet plate which was be warm up and checked carefully, willbe choose to be material for Color plated steel plate product.Material feed into input area by a couple of rubber crane and carry on carriageTo prepare for feeding raw sheets tin into manufacturing , material bring in drum todecompress raw sheets by carriageAfter bringing in drum to decompress raw sheets, hydraulic system decompress tang , brace thecore of raw sheets and move them into the center of route. Some devices is such as junctors,sheets reserves place by Korea technology to ensure route will be consecutive from input tooutput
Step 2
: Cleanse areaCleaning oil, dust on sheets to make higher adhesive strength of coat on tin interface.Cleanse area includes one clear oil bath with an injection blow molding system; inject hot Alkalisolution into both 2 surface of tin. Then sheets were reamed by crane system ( imported fromKorea) to clean oil and dust which adhere on tin interface ( Notes: if tin material still have oil or
dust on its surface, so coat will be appear easy….) oil in the clear oil bath will be recycle and
check carefully before exhaust outside. After clear oil bath are 2 hot and cold flushing waterbath, injection system, squeeze crane. To clear chemical drains from clear oil bath and squeezetin conveyor careful when it exit from clear baths.
Step 3
: Coating ,baking, coolingCoating, baking and cooling area or center area are some main parts of tin plate route in orderto output productsCenter area include 3 lacquering machine (imported from Korea) after lacquering machines aredrying ovens which laboratory heat could be more than 600oCa.
 
Lacquering machine: 2 coat axis technology, coating 2 surfaces in parallel. The axes aredriven by AC vector motor which purpose is to cover coat interface by a chromatesolution cover. This solution is a good protection from corrosion and it is also play a rolelike a bonding layer to adhesive other coatsb.
 
After lacquering machines are baking ovens; baking oven with the firing system importfrom German, using LGP to bake the chemical surface and help it adhere on base metalc.
 
After baking oven is air-blast system with high capacity to cool tin surface before feedinto other lacquering machinesd.
 
Rough lacquering machine: 2 coat axis technology, coating 2 surfaces in parallel. Theaxes are driven by AC vector to adjust the thickness of lacquer film by driving engine,infinitely variable control and modern load cell system. Lacquer using here is lacquerbase chromate, import from well know trade mark like Becker, KCC, Duracoat - help to

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