1

PROJECT REPORT
(Project Semester January-May 2014)



ANALYSIS OF MANUFACTURING PROCESSES IN SMALL
AND MEDIUM SIZE ENTERPRISE OF STEEL PRODUCTS
SUCH AS STRUCTURE ANGLES, FLAT BARS, PLAIN RODS
ETC. WITH THEIR APPLICATIONS AND MARKET
DEMAND



Submitted by
Deepankar Jain
Registration No- 11008858




Under the Guidance of
Faculty coordinator: Mr. Prashant Bagde Industry coordinator: Mr. Samir Paul
Designation: Internal Training Supervisor, Designation: HOD of Training,
LPU, Jalandhar, Punjab Assam Tubes Limited,
Guwahati, Assam



Department of Mechanical Engineering
School of Mechanical Engineering
Lovely Professional University, Phagwara
Jan-May 2014
2

CONTENTS
1. COMPANY PROFILE 9
a. OVERVIEW 9
b. COMPANY VISION 9
c. COMPANYS QUALITY 10
d. PRODUCTS 10
2. INTRODUCTION 11
a. STRUCTURAL STEEL 11
b. ADVANTAGES OF STRUCTURE STEEL 11
c. DISADVANTAGES OF STRUCTURE STEEL 12
3. COMPANYS MANUFACTURING DEPARTMENT 13
a. INTRODUCTION 13
b. FURNACE 13
i. INDUCTION FURNACE 14
ii. REHEAT FURNACE 14
c. MACHINERY 14
i. ROLLING MILLS 14
ii. LATHE MACHINES 14
iii. ARC WELDING MACHINES 14
iv. METAL SHEARING UNIT 14
d. MATERIAL HANDLING SYSTEM 14
i. ROLLERS 15
ii. EOT CRANES 15
iii. INGOTS MOULDS 16
4. MANUFACTURING PROCESSES 16
a. RAW MATERIALS REQUIRED 16
i. SCRAPS 16
ii. SPONGE IRON 16
iii. ALUMINIUM 17
iv. SILICO MANGENESE 17
v. CARBON COKE 17
b. OTHER REQUIREMENTS 18
i. COAL 18
ii. RAMMING MASS 18
c. MANUFACTURING UNIT FLOWs DIAGRAM 19
d. MORE DETAILS OF ASSAM TUBES LIMITED MANUFACTURING
UNIT 20
5. MANUFACTURING OF INGOTS 21
a. DEFINITION OF INGOTS 21
b. WHY INGOTS ARE MANUFACTURED? 21
c. COMPOSITION OF RAW MATERIALS 21
3

d. CONTRIBUTION OF RAW MATERIALS 22
i. SCRAP AND CAST IRON 22
ii. SPONGE IRON 22
iii. FERROMANGENESE 22
iv. SILLICA MANGENESE 22
v. ALUMINIUM WIRES 22
vi. COKE 22
e. OVERALL COST OF RAW MATERIAL 23
f. DESCRIPTION OF PROCESS 23
g. PICTURES OF MANUFACTURING UNIT REGARDING INGOTS
MANUFACTURING 25
h. INGOTS MOULDS 26
i. INGOT DEFECTS 26
i. PIPE FORMATION 26
ii. BLOW HOLES 27
iii. NON METALLIC INCLUSIONS 27
iv. INGOT CRACKS 28
6. MANUFACTURING OF PRODUCTS 29
a. REHEAT AND BULK DEFORMATION 29
b. PICTURES OF MANUFACTURING UNIT REGARDING REHEAT AND
BULK DEFORMATION 30
7. DETAILS OF FINAL PRODUCTS MANUFACTURED 32
8. OTHER COMPLIMENTARY DEPARTMENTS TO MANUFACTURING UNIT 34
a. LATHE MACHINING UNIT 34
b. POWDERED COAL STORAGE UNIT 35
c. INGOTS MOLD MANUFACTURING UNIT 35
9. TIME FACTOR ANALYSIS FOR PRODUCTION OF INGOTS 36
a. FOR EOT(ELECTROMAGNETIC) 36
b. FOR INDUCTION FURNACE 36
c. FOR CASTING 36
d. FOR EOT(MULTIPLE HOISTS) 36
e. IDEAL TIME CALCULATION FOR EOT(ELECTROMAGNETIC),
INDUCTION FURNACE, EOT (MULTIPLE HOISTS) 37
f. DAILY PRODUCTION OF INGOTS 37
4

g. INGOTS PRODUCTION ANALYSIS PER MOULD 37
h. FOR POLISHING OF INGOTS 38
i. NUMBER OF PERSONS AT DIFFERENT STATIONS 38
10. TIME FACTOR ANALYSIS FOR REHEAT AND BULK DEFORMATION 39
a. FOR REHEAT FURNACE 39
b. FOR 3 HIGH SIX STAND ROLLING MILL 39
c. FOR SHEARING UNIT 39
d. NUMBER OF PERSONS REQUIRED AT DIFFERENT STATIONS 40
11. CALCULATION REGARDING PRODUCTION OF STEEL 41
12. CHALLENGES FACED AND MEASURES TAKEN BY THE ORGANIZATION
IN MANUFACTURING DEPARTMENT 43
a. LABOURS 43
i. HIGH LABOUR DEPENDENCY 43
ii. LACK OF SKILLED LABOUR 44
b. POWER SUPPLY 44
c. RAW MATERIAL 45
d. WEAR AND TEAR OF ROLLERS 45
e. COAL FEEDING TO THE REHEAT FURNACE 45
f. SERVICE AND MAINTAINENCE COST 45
13. THREATS 46
a. MARKET FLUCTUATION 46
b. COMPETITORS 46
c. POLITICAL AND SOCIAL ISSUES 48
d. LOW INTEGRATED INDUSTRIES 48
14. OPPURTUNITIES 49
a. HUGE INFRASTRUCTURE DEMAND 49
b. AVAILABILITY 49
c. OUTSOURCING TO OTHER COUNTRIES 49
d. ONLINE BUSSINESS 49
15. FUTURE PLANS 50
16. BIBLIOGRAPHY 51

5

LIST OF FIGURES
FIG NO. DESCRIPTION PAGE
NO.
FIG1 ASSAM TUBES LIMITED 9
FIG2
DIFFRENT STEEL STRUCTURE PRODUCTS
MANUFACTURED BY THE COMPANY
10
FIG3 ROLLING MILL AT ASSAM TUBES LIMITED 14
FIG4 CAST IRON 16
FIG5 SPONGE IRON 16
FIG6
INDUCTION FURNACE AND RAW
MATERIALS
18
FIG7 INGOTS AT INGOT STORAGE UNIT AT
ASSAM TUBES LIMITED
21
FIG8 (A) SILLICA MANGENESE (B) FERRO
MANGENESE (C) ALUMINIUM WIRES
22
FIG9 EOT with electromagnet lifting scrap and cast iron. 25
FIG10 AT THE TOP TABLE OF INDUCTION
FURNACE
25
FIG11 CONTROL ROOM FOR THE INDUCTION
FURNACE
25
FIG12 MOULD FOR CASTING OF INGOTS 25
FIG13 COMBINED PICTURE OF MELTING AND
CASTING UNIT
25
FIG14 INGOTS STORED AT INGOTS STORAGE FOR
FURTHER PROCESSING
25
FIG15 FINAL POLISHING OF INGOTS WITH
GRAPHITE FOR BETTER FINISHING OF
FINISHED PRODUCTS
25
FIG16 NARROW END UP MOULD FOR INGOT
CASTING
26
FIG17.1 NARROW END UP MOULD SHOWING LONG
PIPE IN KILLED STEEL
27
FIG17.2 RIMMING AND SEMI-FINISHED STEEL SHOW 27
6

VERY LESS TENDENCY FOR PIPE
FORMATION
FIG18 PRIMARY ROLL FOR STRUCTURAL SHAPES.

29
FIG19 SIDE VIEW OF REHEAT FURNACE 30
FIG20 INGOTS FED INTO REHEAT FURNACE OF
TEMPERATURE TREATMENT
30
FIG21 PILED UP POWDERED COAL ACTING AS
FUEL FOR REHEAT FURNANCE
30
FIG22 BUCKET ELEVATOR, HOOPER AND FEEDER
ARRANGEMENT FOR TRANSPOTING COAL
TO REHEAT FURNACE
30
FIG23 SKILLED LABOURS TRANPORTING HEATED
INGOTS TO THE ROLLING MILL
31
FIG24 SKILLED LABOURS WORKING AT REHEAT
FURNACE UNIT
31
FIG25 SIX ATND STANDING ROLLERS 31
FIG26 DIFFERENT ROLLERS USED
MANUFACTURING DIFFERENT PRODUCTS
31
FIG27.(A) USED ROLLERS FROM ROLLING MILLS
WHICH WILL UNDERGO MACHINING
34
FIG27.(B) ROLLERS AFTER MACHININHG FOR REUSE 34
FIG27.(C) GROOVING IS PERFORMED ON A ROLLER
OVER LATHE MACHINE
34
FIG27.(D) PICTURE OF A ROLLER FITTED BETWEEN
LATHE CHUCK AND TAIL STOCK.
34


7

LIST OF TABLES
TABLE
NO.
DESCRIPTION PAGE
NO.
TABLE1 TABULATED FORM OF MANUFACTURING
FURNACE, MACHINERY AND MATERIAL
HANDLING SYSTEM DETAILS
15
TABLE2 SPONGE IRON COMPOSITION 16
TABLE3 TABULATED FORM OF RAW MATERIALS
PROCUREMENT, USAGE, COMPOSITION
AND COST
17
TABLE4 COMPOSITION OF RAW MATERIAL 21
TABLE5 TOATAL COST OF RAW MATERIAL 23
TABLE6 FURNACE DETAILS 24
TABLE7 DAILY PRODUCTION 28
TABLE8 PRODUCTS AVAILABLE STOCK DETAIL 32
TABLE9 PERSON REQUIREMENT AT INGOT
MANUFACTURING UNIT
38
TABLE10 PERSON REQUIREMENT AT REHEAT AND
BULK DEFORMATION UNIT
40
TABLE11 TABULATED FORM OF PRODUCED
LENGTH
41
TABLE12 RATE OF PRODUCTION 42
TABLE13 APPROXIMATE PEOPLE REQUIREMENT AT
DIFFERENT WORKSTATIONS
43
TABLE14 COMPANYS LONG AND SHORT TERM
PLANS
50

PREQUISITE KNOWLEDGE
1. DUCTILITY 5. MOULDS
2. BUCKLING 6.HOT ROLLING PROCESS
3. ROLLING MILLS 7. ROLLERS
4. LATHE MACHINES 8. WELDING MACHINES
8

ACKNOWLEDGEMENT
I am grateful to my college Lovely Professional University for giving me this opportunity
to work as a trainee in an organization which gave a profound practical experience of what
theoretical knowledge I have gained during my college period. I am immensely grateful to all
the concerned staff respective of their work area inside the organizations campus whose
guidance and co operations was beneficial and made the training worth learning. My sincere
thanks to:
Mr. Gowardhan Royal Human Resource Department
Mr. Ashok Kumar Manufacturing Department
Mr. Pritambar Kumar Sales and Marketing Department
Mr. Samir Paul Training Department
I would also like to thank Mr. Prashant Bagde as my training supervisor assigned by the
university, who was immensely helpful and supportive throughout my training period.

9

5.

FIG1: ASSAM TUBES LIMITED
1. COMPANY PROFILE
1. a. OVERVIEW- Established in 1962, Assam tubes Ltd is among the top ten steel
companies in North East with an annual steel capacity of 72000 tons per annum (Mtpa). It is
now one of the most geographically-diversified steel producers, with operations in the seven
sister states of North Eastern Region along with Bhutan, Bangladesh and Myanmar.
Assam Tubes Ltd. with a turnover of Rs.115.70 Crs in Financial Year 2011-2012, has over
250 employees. The companys vision is to achieve maximum product mix in the steel
manufacturing industry through the excellence of its people, its innovative approach and
overall conduct. The structural steel products being manufactured are widely accepted in
highly discerning consumer sectors such as construction, automotive, infrastructure,
engineering, telecom, white goods etc.The Company enjoys a network of a large number of
reliable dealers since last 30 years.

1. b. COMAPNYS VISION- Assam Tubes Ltd. is dedicated to safely produce the best
quality structural steel products for the customers, delivering them on-time and providing
them with outstanding service. Assam Tubes Ltd. is committed to being a responsible
10

corporate citizen. It is our intention to operate ethically with all constituents, maintaining fair
and honest relationships and to operate within both the letter and the spirit of the law. From
the shop floors of all of our plants to the executive offices, Assam Tubes Ltd. is devoted to
achieving excellence in all we do on behalf of each stakeholder every day.

1. c. COMPANYS QUALITY- Assam Tubes team is dedicated to being the leader in safely
producing superior products with pride and integrity with management commitment to
continually improve the effectiveness of the quality management system. We are committed
to increasing profitability through mutually beneficial relationships with our employees,
customers and suppliers. Assam Tubes Ltd. shall seek to achieve excellence in safety, quality
and productivity through the selection and monitoring of key indicators.

1. d. PRODUCTS-

FIG 2: DIFFRENT STEEL STRUCTURE PRODUCTS MANUFACTURED BY THE
COMPANY
11

2. INTRODUCTION
2. a. STRUCTURE STEEL- Structural steel is steel construction material, a profile, formed
with a specific shape or section and certain standards of chemical composition and
mechanical properties. Structural steel shape, size, composition, strength, storage, etc., is
regulated in most industrialized countries.
2. b. ADVANTAGES OF STRUCTURE STEEL-
I. High strength/weight ratio. Steel has a high strength/weight ratio. Thus, the dead
weight of steel structures is relatively small. This property makes steel a very
attractive structural material for
a. High-rise buildings
b. Long-span bridges
c. Structures located on soft ground
d. Structures located in highly seismic areas where forces acting on the structure due
to an earthquake are in general proportional to the weight of the structure.
II. Ductility. As discussed in the previous section, steel can undergo large plastic
deformation before failure, thus providing a large reserve strength. This property is
referred to as ductility. Properly designed steel structures can have high ductility,
which is an important characteristic for resisting shock loading such as blasts or
earthquakes. A ductile structure has energy-absorbing capacity and will not incur
sudden failure. It usually shows large visible deflections before failure or collapse.
III. Predictable material properties. Properties of steel can be predicted with a high
degree of certainty. Steel in fact shows elastic behaviour up to a relatively high and
usually well-defined stress level. Also, in contrast to reinforced concrete, steel
properties do not change considerably with time.
IV. Speed of erection. Steel structures can be erected quite rapidly. This normally results
in quicker economic payoff.
V. Quality of construction. Steel structures can be built with high-quality workmanship
and narrow tolerances.
VI. Ease of repair. Steel structures in general can be repaired quickly and easily.
VII. Adaptation of prefabrication. Steel is highly suitable for prefabrication and mass
production.
VIII. Repetitive use. Steel can be reused after a structure is disassembled.
12

IX. Expanding existing structures. Steel buildings can be easily expanded by adding
new bays or wings. Steel bridges may be widened.
X. Fatigue strength. Steel structures have relatively good fatigue strength.
2. c. DISADVANTAGES OF STRUCTURE STEEL-
I. General cost. Steel structures may be more costly than other types of structures.
II. Fireproofing. The strength of steel is reduced substantially when heated at
temperatures commonly observed in building fires. Also, steel conducts and transmits
heat from a burning portion of the building quite fast. Consequently, steel frames in
buildings must have adequate fireproofing.
III. Maintenance. Steel structures exposed to air and water, such as bridges, are
susceptible to corrosion and should be painted regularly. Application of weathering
and corrosion-resistant steels may eliminate this problem.
IV. Susceptibility to buckling. Due to high strength/weight ratio, steel compression
members are in general more slender and consequently more susceptible to buckling
than, say, reinforced concrete compression members. As a result, considerable
materials may have to be used just to improve the buckling resistance of slender steel
compression members.


13

3. COMPANYS MANUFACTURING DEPARTMENT
3. a. INTRODUCTION- The Manufacturing Department is the heart of the industry
supervised by Mr. Ashok Kumar. The department controls the manufacturing processes from
the raw materials procurement to the finished product transportation to storage cell. More
than 85% of the human workforce is contributing to this department. The manufacturing
department is responsible for the functioning and periodic maintenance of the machineries.
The department is working on the principle of batch size production. The manufacturing unit
compromises of furnace, machineries, material handling system, electric motors etc.which
will be discussed in the following section.
3. b. FURNACE-
i. INDUCTION FURNACE- An induction furnace is an electrical furnace in which
the heat is applied by induction heating of metal. The advantage of the induction
furnace is a clean, energy-efficient and well-controllable melting process compared to
most other means of metal melting. The greatest advantage of the Induction Furnace
is its low capital cost compared with other types of Melting Units. Its installation is
relatively easier and its operation simpler. Among other advantages, there is very little
heat loss from the furnace as the bath is constantly covered and there is practically no
noise during its operation. The molten metal in an Induction Furnace is circulated
automatically by electromagnetic action so that when alloy additions are made, a
homogeneous product is ensured in minimum time. The time between tap and charge,
the charging time, power delays etc. are items of utmost importance are meeting the
objective of maximum output in tones/hour at a low operational cost. An induction
furnace is highly sophisticated equipment consisting of a crucible with a lid. Heat is
generated by the induction of medium frequency electricity. The furnace is equipped
with the necessary control panel, which receives electrical power at normal 50Hz
frequency and converts the same to DC power. The DC power generated is again
converted to AC power of medium frequency, which induces the heating effect to the
furnace. In addition to the control panel, the entire furnace system is thoroughly
cooled for protection. A separate water supply system along with cooling tower is
installed to feed the furnace continuously with demineralised cool water. The furnace
can also be titled to pour out the molten metal. The inside surface of the crucible is
normally coated with castable ceramics and fire clay in intervals of the crucible is
14

normally coated with castable ceramics and fire clay in intervals of 7 days. This
practice protects the crucible and gives a longer life to the furnace.
ii. REHEAT FURNANCE- Reheating Furnace is the heart of any hot rolling mill where
in the charge is heated to rolling temperature. The charge could be in the form of
billets, blooms, slabs or ingots. The type of furnace could be pusher, walking hearth
or walking beam either top fired or top and bottom fired. The fuel used could be
either oil or gas. The burners are located in a manner so as to achieve uniform heat
distribution. The radiation heat energy is efficiently transferred through the useful
heat transfer area created by the charge bed. The furnace is basically divided into
three zones namely preheating, heating and soaking zones. The actual heating takes
place in the heating zone. The temperature uniformity up to desired limits between the
core and the surface is achieved in the soaking zone. The flue gases move in a
direction opposite to that of the charge thereby ensuring considerable amount of waste
heat recovery by convection in the preheating zone, which is also termed as the
recuperative zone.
3. c. MACHINERY-
i. ROLLING MILLS- 3-HIGH SIX STAND ROLLING MILL, 5 STAND
TANDENEM ROLLING MILL
ii. LATHE MACHINES
iii. ARC WELDING MACHINES
iv. METAL SHEARING UNIT

FIG3:5 STAND TANDENEM ROLLING MILL AT ASSAM TUBES LIMITED
3. d. MATERIAL HANDLING SYSTEM
i. ROLLERS
ii. EOT CRANES (ELECTRONIC OVERHEAD CRANE) - An overhead crane,
commonly called a bridge crane, is a type of crane found in industrial environments.
15

An overhead crane consists of parallel runways with a travelling bridge spanning the
gap. A hoist, the lifting component of a crane, travels along the bridge. This is most
common type of overhead crane, found in most factories. As obvious from name,
these cranes are electrically operated by a control pendant, radio/IR remote pendant or
from an operator cabin attached with the crane itself.
iii. INGOTS MOULDS
TABLE1: TABULATED FORM OF MANUFACTURING FURNACE, MACHINERY
AND MATERIAL HANDLING SYSTEM DETAILS
FURNACE MACHINERY MATERIAL HANDLING SYSTEM

INDUCT
ION
FURNAC
E
REHEA
T
FURNA
CE
SIX
STAND
S
ROLLIN
G
MILLS
LATH
E
MAC
HINE
TANDE
NEM
FIVE
SERIES
ROLLE
RS
WELD
ING
MACH
INE
ROLLERS
BED
EOT
CRANES
INGO
TS
MOU
LDS
SHEARI
NG
UNIT
TYPE
COPPER
COILED,
HYDRA
ULIC
BASED
COAL
FIRED
SECTIO
N MILL
(SIMP
LE) V
BELT

ELEC
TRIC
ARC
WELD
ING

WITH
HOIST AND
ELECTROM
MAGNET
UNIF
ORM
VARI
NG
CROS
S
SECTI
ON
AREA
HYDRA
ULIC
FLEXIB
LE
SHEARI
NG
TOOL
QUANTIT
Y
TWO ONE
ONE
UNIT
WITH
FLEXIB
LE
ROLLE
RS
FIVE TWO FOUR THREE TWO
CAPACIT
Y
70
TONNES
/ DAY

10 TONNES
WEIGHT

POWER
CONSUM
PTION
800KW
DEPN
DENT
ON
COAL
SUPPL
Y
33KW
200 HP
ELEC.
MOTOR
500 HP
ELEC.
MOTOR
EACH

USES
MELTIN
G OF
SCRAPS,
CAST
IRON
FOR
PRODUC
TION OF
INGOTS
TO
SOFTE
N THE
INGOT
S FOR
ROLLI
NG
PROCE
SS
FINAL
PRODU
CTS
SHAPE
AND
SIZE
ARE
PERFOR
MED
HERE
TO
REMO
VE
BUE
FROM
THE
ROLL
ERS
AT
THE
ROLLI
NG
MILL
S
TO
FLATE
N
ANGLE
FOR
MAKIN
G
STEEL
STRIPS
GENE
RAL
WELD
ING
PURP
OSE
TRANSER
MATERIA
L FROM
ROLLING
UNIT TO
SHEARING
UNIT,
ALSO
TRANSFER
INGOTS
TO
REHEATF
URNA
HADLING
OF SCRAPS,
INGOTS
AND
INGOTS
MOULDS
USE
FOR
CASTI
NG
INGO
TS
FOR
MAKIN
G
STAND
ARD 12'
FINISH
ED
PRODU
CT


16

4. MANUFACTURING PROCESSES
4. a. RAW MATERIALS REQUIRED-
i. SCRAPS- It forms the major constituents for the production of ingots. The recyclable
material is easily available in north eastern region of India and the company purchase
from local dealers. Due to no iron ore resources near Assam and high transportation
cost, production of ingots (semi finished product) is viable and economical from scrap
iron. 80% of constituent poured in the arc furnace consist of scrap iron. Scrap
generally comes in two main grades: shred (whitegoods, cars and other objects made
of similar light-gauge steel) and heavy melt (large slabs and beams).

FIG4: CAST IRON FIG5: SPONGE IRON
ii. SPONGE IRON- Direct-reduced iron (DRI), also called sponge iron, is produced
from direct reduction of iron ore (in the form of lumps, pellets or fines) by a reducing
gas produced from natural gas or coal. The reducing gas is a mixture, the majority of
which is hydrogen (H
2
) and carbon monoxide (CO) which act as reducing agents. This
process of reducing the iron ore in solid form by reducing gases is called direct
reduction. Sponge iron contributes 10% of the constituent for the production of
ingots. Metals that have a poorer affinity for oxygen than iron, such
as nickel and copper, cannot be removed through oxidation and must be controlled
through scrap chemistry alone, such as introducing the direct reduced iron. Assam
Tubes limited procure sponge iron from TATA Sponge Iron Limited. Orissa.
TABLE2: SPONGE IRON COMPOSITION
Product Name Specifications
Sponge Iron - Fe (M) - 80 % Min
- Fe (T) - 90-92 % Min
- C - 0.09 % Min
- S - 0.045 % Max

17

iii. ALUMINIUM- It is used for improving the physical quality of the ingots such as
strength, ductility etc. A very small amount is used as a constituent.
iv. SILICO MANGENESE-Silicomanganese (SiMn), a ferroalloy with high contents
of manganese and silicon, is made by heating a mixture of the oxides manganese
oxide (MnO
2
), silicon dioxide (SiO
2
), and iron oxide(Fe
2
O
3
), with carbon in a furnace.
They undergo a thermal decomposition reaction. It is used as a deoxidizer and an
alloying element in steel.
v. CARBON COKE- It acts as a reducing agent and mainly reduces the impurities
oxides and releasing as CO
2
gas.
TABLE3: TABULATED FORM OF RAW MATERIALS PROCUREMENT, USAGE
COMPOSITION AND COST
SR.
NO.
NAME OF RAW
MATERIAL
AREA OF
PROCUREMENT
USE AS RAW
MATERIAL
COMPOSITION

COST
(INCLUDING
RAW
MATERIAL
AND
TRANSPORT)
1 SCRAP IRON LOCAL AREAS
MAJOR
CONSTITUENT
85%
RS. 26500/KG
TONNES
2 SPONGE IRON
TATA SPONGE IRON
LTD., ORISSA
REMOVAL OF
COPPER AND
NICKEL, MAINTAIN
PROPORTIONATE
IRON CONTETNT
10%
RS.20000/ KG
TONNES
3 ALUMINIUM
LOCAL
DISTRIBUTORS
QUALITY
IMPROVEMENT
<0.4% APPROX. RS. 100/KG
4
SILICO
MANGENESE
SHIVAM GROUP,
KOLKATTA
DE-OXIDIZER <2% APPROX. RS.65/KG
5 CARBON COKE
APCL & ICL,
NOONMATI,
GUWAHATI ASSAM
REDUCING AGENT,
CARBON CONTENT
IN STEEL
2.5%-3% RS.14/KG


18

4. b. OTHER MATERIAL REQUIREMENTS- Apart from the raw materials required for
production the manufacturing department also some other materials during the process such
as ramming mass and coal.
i. RAMMING MASS- It is used as refractory material in the induction furnace. It
prevents the copper coil wounded around the furnace to get melt. It also neutralizes
the magnetizing effect produced by the current through copper coil. Mainly silica
powder is used as ramming material.
ii. COAL- It is used as fuel in the furnace for temperature gain. It is mainly procured
from Meghalaya through local distributors. Coal powder is fed into the reheat furnace
by proper installation of bucket elevator, hooper and feeder.
Carbon Coke Sponge Iron Scrap & Cast iron Silico- manganese Aluminium & Ramming mass





FIG6: INDUCTION FURNACE AND RAW MATERIALS


19

4. c. MANUFACTURING UNIT FLOW DIAGRAM-

















SCRA
INGOTS
COOLING AND
STORAGE
R
O
L
L
E
R
SHEARING UNIT
S
C
R
A
P
A
N
D

C
A
S
T

I
R
O
N

S
T
O
R
A
G
E

I
N
D
U
C
T
I
O
N

F
U
R
N
A
C
E

R
O
L
L
E
R
S
L
A
T
H
E

M
A
C
H
I
N
E

U
N
I
T

POWDERED
COAL
STORAGE
REHEAT
FURNACE
3 HIGH SIX
STAND ROLLING
MILLS
I
N
G
O
T
S

C
A
S
T
I
N
G


S
T
O
R
A
G
E

O
F

F
I
N
I
S
H
E
D

P
R
O
D
U
C
T
S

TANDENEM
ROLLERS FOR
ANGLE FLATENING
R
O
L
L
E
INGOT
SHEARI
NG
UNIT
INGOT
POLISHI
NG UNIT
20

4. d. MORE DETAILS OF ASSAM TUBES LIMITED MANUFACTURING UNIT-
Material transportation from scrap and cast iron storage to induction furnace is
through electromagnetic EOT.
There is a domestic transformer installed at the Induction Furnace station for higher
power supply.
Molten metal from the induction furnace is poured to the ingots moulds by tilting
through hydraulic force.
The ingots are transported to the ingots storage unit with the help of EOT having
multiple hoists.
Before supplying ingots to the reheat furnace the ingots are first sheared into two
halves and stacked together aside for better heat distribution.
Powdered coal storage unit is fitted with bucket elevator, hooper, feeder and conveyor
for feeding coal into reheat furnace from bottom.
Lathe machine unit is installed for removing BUE from the rollers surface and make it
available for reuse.
The rollers as well as the ingots cooling unit are fitted with motor driven fans of 10hp
for convection cooling.
The temperature of the induction furnace is higher than the melting point of steel and
the temperature of the reheat furnace is lower than the melting point of steel.

21

5. MANUFACTURING OF INGOTS -
a. DEFINITION OF INGOTS- An ingot is a material, usually metal, that
is cast into a shape suitable for further processing. Non-metallic and
semiconductor materials prepared in bulk form may also be referred to as ingots,
particularly when cast by mould based methods.

FIG7: INGOTS AT INGOT STORAGE UNIT AT ASSAM TUBES LIMITED
b. WHY INGOTS ARE MANUFACTURED- The ingots are temperature treated
in a reheat furnace below its melting point to soften and by bulk deformation
rolling process the required finished product is achieved.
c. COMPOSITION OF RAW MATERIALS-
TABLE4: COMPOSITION OF RAW MATERIAL
Sr.
No.
Raw Material %Composition
1 Scrap or cast iron 85%
2 Sponge iron 10%
3 Ferro manganese <.8%
4 Silica manganese <.8%
5 Aluminium wires <.4%
6 Coke 4-5% approx.


22

d. CONTRIBUTION OF RAW MATERIALS
i. SCRAP OR CAST IRON- Apart being the major constituent of the
ingots, its one of the cheapest of the raw materials available for steel
structure production in North Eastern States of India. Scraps can be easily
procured from local dealer. Current market price is about Rs. 26 per kg.
Though it contains impurities such as metal oxides, dust etc, due to its
surplus availability and cost effectiveness, scraps are still preferred over
iron ore in the organization.
ii. SPONGE IRON- Metals that have a poorer affinity for oxygen than iron,
such as nickel and copper, cannot be removed through oxidation and must
be controlled through scrap chemistry alone, such as introducing the direct
reduced iron. Assam Tubes limited procure sponge iron from TATA
Sponge Iron Limited. Orissa. It is available at market price of Rs. 20 per
kg.
iii. FERRO MANGENESE- It is added for better strength to the ingots.
iv. SILICA MANGENESE- It is used as a deoxidizer and alloying element
to steel. Its market price is around Rs. 65 per kg.

(A) (B) (C)
FIG8: (A) SILLICA MANGENESE (B) FERRO MANGENESE
(C) ALUMINIUM WIRES
v. ALUMINIUM WIRES- Aluminium wires serves as a source of
aluminium which provides good surface finish and addition of quality
improvement. Very little amount of aluminium wires are mixed with other
raw materials. It is available at a market price of about Rs.100-Rs. 110 per
kg.
vi. COKE- It serves as reducing agent to remove metal oxides and releases in
the form of CO
2
gas and addition of carbon contents for the formation of
steel. These are coal cokes procured directly from coking unit such as
23

APCL (Assam Petro-Chemical Limited) or ICL (India Coal Limited) at
market price of about Rs.14 per kg.
e. OVERALL COST OF RAW MATERIAL-
TABLE5: TOATAL COST OF RAW MATERIAL
For 100 kgs of ingot:
Raw material Required per 100
kgs
Amount per kg Total amount
Scraps 85 kgs Rs. 26 Rs. 2210
Sponge iron 10 kgs Rs. 20 Rs. 200
Aluminium 0.4 kgs Rs. 100 Rs. 40
Ferromanganese 0.8 kgs Rs. 80 Rs. 64
Silica manganese 0.8 kgs Rs. 65 Rs.52
Carbon coke 3 kgs Rs. 14 Rs. 42
TOTAL 100 Rs. 2608

f. DESCRIPTION OF PROCESS-For design of structures, the structural engineer
uses long and flat products. The long products include: angles; channels;
joists/beams; bars and rods; while the flat products comprise: plates; hot rolled
coils (HRC) or cold rolled coils (CRC)/sheets in as annealed or galvanised
condition. The starting material for the finished products is as given below:
i. Blooms in case of larger diameter/cross-section long products
ii. Billets in case of smaller diameter/cross-section long products
iii. Slabs for hot rolled coils/sheets
iv. Hot rolled coils in case of cold rolled coils/sheets
v. Hot/Cold rolled coils/sheets for cold formed sections.
The production process depends upon whether the input material to the steel
plant is steel scrap or the basic raw materials i.e. iron ore. In case of former,
the liquid steel is produced in Electric Arc Furnace (EAF) or Induction
Furnace (IF) and cast into ingots or continuously cast into blooms/billets/slabs
for further rolling into desired product. The steel mills employing this process
route are generally called as mini or midi steel plants. Since liquid steel after
melting contains impurities like sulphur and phosphorus beyond desirable
24

limits and no refining is generally possible in induction furnace. The structural
steel produced through this process is inferior in quality.
The organization ASSAM TUBES LIMITED uses the technology of
induction furnace to melt down the scraps and waste cast iron procured from
the local dealers. Following are the steps involved in the manufacturing unit of
the organization to make ingots:
Scraps and waste caste iron are transferred to the induction furnace
unit from the scrap unit with the help of EOT (electrical overhead
travelling) having electromagnet.
Max. Load carrying capacity of EOT is 10 tonnes kg/ per lift.
At the melting unit, the scraps and other raw materials are mixed in
definite composition for more than 60 minutes. This melted steel in
then poured into the ingots moulds.
The ingot moulds are the kept for 30-45 minutes for melted steel to be
casted.
After casting, the moulds are carried away by the EOT cranes fitted
with hoist to the ingots storage section. Moulds are again replaced back
to the casting unit.
TABLE6: FURNACE DETAILS











FURNACE DETAILS
1 RATED CAPACITY(KG)
5
TONNES
2 RATED POWER (KW) 2500
3 INPUT VOLTAGE (V) 660-662
4
TRANSFORMER
CAPACITY (KVA) 3500
5 OUTPUT VOLTAGE (V) 3500
6 MELTING TIME (MINS) 60-70
7 NO. OF FURNACE 2
25

g. PICTURES OF MANUFACTURING UNIT REGARDING INGOTS
MANUFACTURING-
FIG9: EOT with electromagnet lifting scrap and cast iron.
FIG10: At the top table of induction furnace.
FIG11: Control room for the induction furnace.
FIG12: Moulds for the casting of ingots.
FIG13: Combined picture of melting and casting unit
FIG14: Ingots stored at the ingots storage unit for further
processing.
FIG15: Final polished ingots with graphite for better
finishing of finished structure.
26

h. INGOTS MOULDS- Cast iron is used to fabricate the mould. Thermal
coefficient of cast iron is lower than steel as a result, steel on solidification
contracts more than cast iron which makes detachment of ingot easier from the
mould. Inner walls of the mould are coated by tar or fine carbon. The coated
material decomposes during solidification which prevents sticking of solidified
ingots with the inner walls of the mould.
The company uses narrow end up or big end down types of mould as shown in
fig16. But they have partition in between to produce two ingots in single
mold.
FIG16: NARROW END UP MOULD FOR INGOTS CASTING

Narrow end up moulds are commonly used to produce rimming and semi-killed
steel ingots. Narrow-end-up molds facilitate easy escape of rimming reaction
product, CO. Insulating and exothermic materials are put on the top ingot which
ensures availability of hot metal towards the end of solidification. Both bottom
pouring and top pouring of steel are used in ingot casting.

i. INGOTS DEFECTS- CAUSES AND REMEDIES
i. PIPE FORMATION:
Cause: Steel contracts on solidification. The volumetric shrinkage leads to
formation of pipe. In killed steels pipe formation occurs toward the end of
solidification. Fig11.1 shows primary and secondary pipe in narrow end up
mould while casting killed steel. Only primary pipe can be seen in wide
end up mould. The rimming and semi-finished steel show very less
tendency for pipe formation as shown in fig11.2.

27


FIG17.1: NARROW END UP MOULD SHOWING LONG PIPE IN
KILLED STEEL
FIG17.2: RIMMING AND SEMI-FINISHED STEEL SHOW VERY
LESS TENDENCY FOR PIPE FORMATION

Remedy: use of hot top on the mold. The volume of the hot top is 10-15%
higher than ingot volume. Pipe formation is restricted in the hot top which can
be discarded. Use of exothermic materials in the hot top keeps the metal hot in
the top portion and pipe formation can be avoided. Another method is to pour
extra mass of metal.
ii. BLOW HOLES:
Cause: Evolution of gas during solidification of steel. Entrapment of gas
produces blow holes in the ingot. Blow holes located inside the ingot can
be welded during rolling. Rimming steels show blow holes due to rimming
reaction between carbon and oxygen. The rimming reaction produces CO,
which when is unable to escape during solidification, produces blow holes.
Semi-killed steels also show tendency to blow hole formation.
Remedy: Control of gas evolution during solidification so that blow hole
forms only within the ingot skin of adequate thickness.
iii. NON METALLIC INCLUSIONS:
Non metallic inclusions are inorganic oxides, sulphides and nitrides
formed by reaction between metal like Fe, Ti, Zn, Mn, Si, Al with non
metallic elements like oxygen, nitrogen, sulphur etc.. An inclusion is a
mismatch with the steel matrix. Fine size inclusions when distributed
uniformly are not harmful. Non deformable inclusions like Al
2
O
3
are
undesirable. Inclusion modification is the remedy to alleviate the harmful
effect of inclusions on properties of steel.
28

iv. INGOT CRACKS:
Surface cracks are formed due to friction between mold and ingot
surface. The improper design of mold taper and corner radius cause
surface cracks. Different types of cracks are:
Transverse cracks: They are parallel to the base of ingot and are
formed due to longitudinal tension in the ingot skin. As the aspect
ratio of the ingot increases, tendency to transverse crack formation
increases.
Longitudinal cracks are formed due to lateral tension in the skin.
They are parallel to vertical axis of ingot. Alloy steels are more
prone to longitudinal cracks than mild steels.
Sub- cutaneous cracks are internal fissures close to the surface. The
cracks are formed due to thermal shocks.
Restriction cracks can be near the corner radius of the ingot.
Smooth corners of the mould and gradual curvature minimize
restriction cracks.
TABLE7: DAILY PRODUCTION
INDUCTION FURNACES (INGOTS) 130-140 TONNES
ROLLING MILL 11 50-55 TONNES
ROLLING MILL 9 30-35 TONNES
ROLLING MILL 7 15-20 TONNES
ROLLING MILL 6 4-6 TONNES
TOTAL PRODUCTION 240- 250 TONNES










29

6. MANUFACTURING OF PRODUCTS
a. REHEAT AND BULK DEFORMATION- Liquid steel is cast into ingots, which
after soaking at 1280-1300
0
C in the soaking pits are rolled in the blooming and billet
mill into blooms/billets or in slabbing mill into slabs. But the organization doesnt
require forming billets or blooms. They directly use the ingots in process
manufacturing once cooled and stored in ingot storage unit. Firstly the ingots are
divided into equal halves by shearing action and then are fed into reheat furnace. The
ingots are further heated in the reheating furnaces at 1250- 1280
o
C . The ingots after
heating to similar temperature are rolled into angles, plain rods, channels etc. Even
though the chemical composition of steel dictates the mechanical properties, its final
mechanical properties are strongly influenced by rolling practice, finishing
temperature, and cooling rate and subsequent heat treatment.
In the hot rolling operation the material passes through two rolls where the gap
between rolls is lower than the thickness of the input material. The material would be
repeatedly passed back and forth through the same rolls several times by reducing the
gap between them during each pass. Plain rolls are used for flat products such as
plate, strip and sheet, while grooved rolls are used in the production of structural
sections, rails, rounded and special shapes. The rolling process, in addition to shaping
the steel into the required size, improves the mechanical properties by refining the
grain size of the material.
Final rolling of structural and bars/rods is done in respective rolling mills.

FIG18: PRIMARY ROLL FOR STRUCTURAL SHAPES.



30

b. PICTURES OF MANUFACTURING UNIT REGARDING REHEAT AND
BULK DEFORMATION-
FIG19: SIDE VIEW OF REHEAT FURNACE

FIG20: INGOTS FED INTO REHEAT FURNACE OF TEMPERATURE
TREATMENT

FIG21: PILED UP POWDERED COAL ACTING AS FUEL FOR REHEAT
FURNANCE


FIG22: BUCKET ELEVATOR, HOOPER AND FEEDER ARRANGEMENT FOR
TRANSPOTING COAL TO REHEAT FURNACE


31

FIG23: SKILLED LABOURS WORKING AT REHEAT FURNACE UNIT

FIG24: SKILLED LABOURS TRANPORTING HEATED INGOTS TO THE
ROLLING MILL

FIG25: SIX STAND ROLLING MILL

FIG26: DIFFERENT ROLLERS USED MANUFACTURING DIFFERENT
PRODUCTS


Rollers for manufacturing angles Rollers for channel manufacturing Rollers for manufacturing thin rods
32

7. DETAILS OF FINAL PRODUCTS MANUFACTURED
All the products are formed by hot roll process. This indicates the following:
These are low carbon steel.
The surface on the steel will be somewhat rough.
Yield strength will be significantly low.
Machinability of this grade material is poor.
These steel materials have excellent heat treatability, cold forming, weldability, cost
efficiency.
They are good for general purpose uses where high strength is not required.
They doesnt possess the closer size tolerances that cold rolled does.
TABLE8: PRODUCTS AVAILABLE STOCK DETAIL
Sr.
No.
Name of the
product
Available stock size
Standard
length
(feet)

1 Equal leg angles
1" x 1" x 1/4", 2" x 2" x
1/4", 3" x 3" x 1/4"
12'


2 Unequal leg angles
1" x 2" x 1/4", 1-1/4" x
2" x 1/4", 2" x 3" x 1/4"
12'


3 Steel tees
2" x 1-1/4" x 1/4", 3" x
2" x 1/4"
12'


4 Steel Bar Channels
1" x 1/2" x 1/8", 1-1/2"
x 1/2" x 1/8", 2" x 1/2"
x 1/8"
12'

5 Steel Hot Rolled Flats
1/4" x 2", 1/2" x 1-1/2",
1/2" x 2"
12'


6 Steel Hot Rolled Rods 1",1-1/4" 12'




33

Angles are L-shaped structural steel represented by dimension of sides & thickness.
For e.g. 1x1x1/4 means, both the sides of angles are 1 inch & thickness is of
inch.
Channel is represented by its Web height, Flange width and Thickness of the channel.
For e.g. 1x1/2x1/8 channel means, the Web height = 1 inch, Flange width = inch
and Width = 1/8 inch.
Representation of Steel hot rolled Flats is done by the Width (W) & the Thickness (T)
of the Flat. For example: When we say 1/4 X 2 FLAT, it means Width = &
Thickness = 2.
Representation of steel hot rolled Rods is done by Diameter (D). For example, 1 D
represents diameter = 1.

34

8. OTHER COMPLIMENTARY DEPARTMENTS TO
MANUFACTURING UNIT
a. LATHE MACHINING UNIT:
This unit is not directly involved in the production of steel structures. However, this
unit is installed for the maintenance purpose.
In single point cutting of metals, a built up edge (BUE) is an accumulation of
material against the rake face that seizes to the tool tip, separating it from the chip.

The built up edge effectively changes tool geometry and rake steepness. It also
reduces the contact area between the chip and the cutting tool, leading to:
A reduction in the power demand of the cutting operation.
Slight increase in tool life, since the cutting is partly being done by the built up
edge rather than the tool itself.
However, the formations of BUEs have negative effects on the quality of the
workpiece, specifically:
Excessive work hardening at the surface of the workpiece.
Poor surface finish, since bits of the BUE eventually break off and stick to the
workpiece. These bits tend to be problematic since, due to the work-hardening
they underwent, they are very hardened so become abrasive.
A reduction in the dimensional control of the process, due to the dynamically
changing geometry of the cutting tool.
Therefore, in the organization they set up this complimentary lathe machining unit
to remove BUE from the rollers and reuse them which will be cost effective.
There are five 12 feet simple V-belt lathe machines. Most general purpose
performed is step turning, grooving, tapper turning and chamfering.
There are two shop cranes available for material handling.
FIG27: (A) USED ROLLERS FROM ROLLING MILLS WHICH WILL
UNDERGO MACHINING (B) ROLLERS AFTER MACHININHG FOR
REUSE (C) GROOVING IS PERFORMED ON A ROLLER OVER LATHE
MACHINE (D) PICTURE OF A ROLLER FITTED BETWEEN LATHE
CHUCK AND TAIL STOCK.
35


(A) (B)

(C) (D)
b. POWDERED COAL STORAGE UNIT
As the name suggest, this unit is basically a storage unit for coal which is the required
fuel for gaining temperature level in reheat furnace. Coal is mainly procured from
local dealers of Meghalaya at Rs.6 per kg.
A bucket elevator is fitted which lift the coal powder to the hopper. The hopper is for
temporary storage for the powdered designed to dump the material into the feeder
from its bottom end by the gravity action. From the feeder as per requirement the coal
is fed into the reheat furnace.
c. INGOT MOLD MANUFACTURING UNIT
The company has setup a ingot mould manufacturing and repairing unit to save time,
dependency on other firm, and making the process more cost effective. This unit
works as per requirement of the molds in the casting unit. Raw materials used for
manufacturing are green sand, refractory inbuilt gating bricks, and bentonite as a
binder. The mould has a single runner at the middle, multiple cavity and two risers on
either side of the mould.



36

9. TIME FACTOR ANALYSIS FOR PRODUCTION OF
INGOTS
a. FOR EOT (ELECTROMAGNETIC):
AVERAGE LOADING CAPACITY- 10 TONNES KG
LOADING TIME (t
1l
) - 3 MINS
UNLOADING TIME (t
1u
) - 3 MINS
TRAVELLING TIME BETWEEN WORK STATIONS (t
1s
) - 6 MINS
RETRACING TIME (t
1r
) - 3 MINS
NOTICE: since while retracing the path the EOT is free of extra load. Hence it requires less
time for retracing.
b. FOR INDUCTION FURNACE:
MELTING CAPACITY (t
fm)
- 5 TONNES KG/ 60 MINS
INPUTING TIME (MECHANIZED WORK) (t
fi
) - 10 MINS
POURING LIQUID METAL RATE (t
fp
) - 10 MINS
c. FOR CASTING:
CASTING TIME (t
cc
) - 30 MINS
MOULDS REARRANGEMENTS (BEFORE CASTING) (t
cr
) - 30 MINS
REMOVAL OF COPE AND DRAG (AFTER CASTING) (t
cd
) - 10 MINS
d. FOR EOT (MULTIPLE HOISTS):
AVERAGE LOADING CAPACITY- 10 TONNES KG
LOADING TIME (t
2l
) - 10 MINS
UNLOADING TIME (t
2u
) - 3 MINS
TRAVELLING TIME BETWEEN WORK STATIONS (t
2s
) - 6 MINS
RETRACING TIME (t
2r
) - 3 MINS
NOTICE: since while retracing the path the EOT is free of extra load. Hence it requires less
time for retracing. Here the loading time is greater than the loading time of EOT
(ELECTROMAGNET) because of manual loading.
The process of casting is the highest time consuming process. Therefore, it decides the
rate of production of ingots.

37

e. IDEAL TIME CALCULATION FOR EOT (ELECTROMAGNET),
INDUCTION FURNACE, EOT (MULTIPLE HOISTS)
i. IDEAL TIME FOR INDUCTION FURNACE
The time the furnace has to remain still with no heating process going on to pour the
liquid metal into the mould is the ideal time for induction furnace in one periodic
cycle of manufacturing.
IDEAL TIME (I
F
) = (t
cc
+t
cd
+t
cr
+t
21
) -

(t
fm
+t
fi
)
= (30+10+30+10) (60+10) = 10 MINS
ii. IDEAL TIME FOR EOT (ELECTROMAGNET)
The time for which the EOT is unused for one periodic cycle of ingot manufacturing
is the ideal time for EOT. Here, the ideal time will be time at rest after retraced from
induction furnace unit till the time to load again from the scrap storage unit in the
consecutive cycle.
IDEAL TIME (I
EE
) = (t
fm
+t
fi
+I
F
+t
fp
) (t
1l
+t
1t
+t
1u
+t
1r
)


= (60+10+10+20) (3+6+3+3) = 85 MINS
iii. IDEAL TIME FOR EOT (MULTIPLE HOISTS)
Here the ideal time will be the time period for which the EOT is at rest after
unloading the moulds from casting unit till the loading of moulds for the transporting
to ingots storage unit.
IDEAL TIME (I
EH
) = (t
cc
+t
cr
+t
cd
+t
fp
) (t
2l
+t
2t
+t
2u
+t
2r
)
= (30+30+10+20) (10+3+6+3) = 68 MINS
f. DAILY PRODUCTION OF INGOTS
CAPACITY OF ONE INDUCTION FURNACE- 5 TONNES KG
NUMBER OF INDUCTION FURNACE- 2
TOTAL TIME TAKEN BY EACH IDUCTION FURNACE- TOTAL TIME +
IDEAL TIME = 90 MINS
TOTAL WORKING HOURS- 20 HOURS OR 1200 MINS
THEREFORE DAILY INGOTS PRODUCTION IS= (2*5)*1200/90
= 133 TONNES KG APPROX.
g. INGOTS PRODUCTION ANALYSIS PER MOULD
NUMBER OF DOUBLE INGOT MOLDS FITTED WITH COPE AND DRAG- 32
TOTAL KGS OF MOLTEN METAL POURED FROM FURNACE- 5 TONNES KG
HENCE WEIGHT OF ONE INGOT CASTED IS = 5000/(32*2) = 78.125 KGS
38

FOR CONVINIENCE WE ASSUME 75KGS APPROX SINCE METALS WILL BE
LEFT IN THE GATING AND THE RISERS AS WELL.
THEREFORE WEGHT OF ONE INGOT CASTED = 75 KGS
h. FOR POLISHING OF INGOTS
Ingots are polished with graphite so that after bulk deformation the finished product
has better surface finish.
TIME TAKEN TO POLISH ONE INGOT AT A TIME = 3 MINS
i. NUMBER OF PERSONS REQUIRED AT DIFFERENT STATIONS
TABLE9: PERSON REQUIREMENT AT INGOT MANUFACTURING
Unit
Number of
persons required
Task to perform
EOT CONTROLLER
UNIT
2 persons
Control the timing and
movement of the EOT
INDUCTION FURNACE
UNIT
3 at each furnace
and 1 supervisor
for guidance
To constantly remove impurities
from the furnace and keeping the
nearby surface clean.
INGOT CASTING UNIT At least 5
To hook up moulds, for
arrangements of cope and drag,
INGOT POLISHING
UNIT
2 persons
To coat a layer of graphite over
the casted ingot
INGOT COOLING AND
STORAGE UNIT
3 persons For proper storage management

39

10. TIME FACTOR ANALYSIS FOR REHEAT AND BULK
DEFORMATION
Firstly the ingots are sheared into two equal halves so that temperature distribution is even.
Therefore, weight of each part = 75/2 kgs = 37.5 kgs.
a. FOR REHEAT FURNACE
TEMPERATURE RANGE- 1280 TO 1300
O
C
TIME TAKEN FOR HEAT TREATMENT (t
rfh
) - 10 MINS
TRANSPORTING TO ROLLING MILLS (t
rft
) - 3MINS
b. FOR 3 HIGH SIX STAND ROLLING MILL
NO. OF TIMES INGOTS PASSING THROUGH ROLLER IN ONE CYCLE- 12
TIME TAKEN FOR BULK DERFORMATION ON EACH ROLLING MILL (t
rd
) -
0.25 MINS (AVERAGED).
ANNEALING TIME (t
a
) - 2 MINS
TIME TAKEN FOR TRANSPROTATION TO SHEARING UNIT (t
t
) - 0.5 MINS
c. FOR SHEARING UNIT
TIME TAKEN FOR SHEARING (t
S
) - 0.083 MINS (AVERAGED)
TIME TAKEN FOR PASSING THE UNIT (t
P
) - 0.25 MINS (AVERAGED)
TIME TAKEN TO TRANSFER TO STORAGE UNIT- 1MIN/LOT
QUATITY IN ONE LOT OF FINSHED PRODUCT- 10
Since the first step, which is temperature treatment in reheating furnace, is most time
consuming, therefore, rate of production depends upon this.
NOTE: Rate of production for different products differs but up to shearing unit the time
taken is same for production. This is due to the fact that volume remains constant for all the
products but cross sectional areas and length varies. This will learnt in next section.
Hence time taken by the product before reaching shearing unit is = (t
rfh
) + (t
rft
) +
(12*trd) + (t
a
) + (t
t
) = 10+3+3+2+0.5 = 18.5 MINS






40

d. NUMBER OF PERSONS REQUIRED AT DIFFERENT STATIONS
TABLE10: NUMBER OF PERSONS REQUIREMENT AT REHEAT AND
BULK DEFORMATION UNIT
Unit
Number of persons required
at each unit

INGOT SHEARING
UNIT
3 persons
To load. shear down the ingots
into two equal halves and transfer
to reheat furnace
REHEAT FURNACE
(FEEDER SIDE)
2 persons
To control the federate and stack
the ingots at the back end of the
reheat furnace.
REHEAT FURNACE
(END SIDE)
3 persons
For pushing and pulling out the
halved heat treated ingots and
load to shop cranes for
transportation to rolling mills.
3- HIGH SIX STAND
ROLLING MILL
15 persons
1 personas a supervisor, 12
persons on either side of the
rolling mill, 2 persons for
transferring to rollers with the
help of tongs
ROLLERS No person requirement
SHEARING UNIT 4 persons
1 at the control unit of shearing
machine which is hydraulically
driven, 2 for pile up aside for
storage unit, 1 for proper loading
for tooling.
41

11. CALCULATIONS REGARDING PRODUCTION OF
STEEL PRODUCTS
Taking density (D) of the material of structural steel after bulk deformation be =
0.109kg/cubic inches. Mass (M) of the part of ingot = 37.5 kgs
Therefore, volume produced after rolling for any product is fixed = M/D = 37.5/0.109 cubic
inches = 344 cubic inches approx. Hence [cross-sectional area (A)* length (L)] = 344 cubic
inches.
By the given dimensions we can know the cross sectional area of the product. Therefore,
L=344/(12*A) feet and N=L/2.
TABLE11: TABULATED FORM OF PRODUCED LENGTH
SR.
NO.
PRODUCT
NAME
DIMENSIONS
CROSS
SECTI
ONAL
AREA
(SQ.
INCHE
S)
PRODUCED
LENGTH
(FEET)
NO. OF
PIECES ON
STANDARD
SIZE (12)
(N)
1
EQUAL
ANGLES
1" X 1" X 1/4" 0.5 57 4
2" X 2" X 1/4" 1 28 2
3" X 3" X 1/4" 2.25 13 1
2
UNEQUAL
ANGLES
1" X 2" X 1/4" 0.75 38 3

1-1/4" X 2" X
1/4"
0.8125 36 3
2" X 3" X 1/4" 1.25 24 2
3
STEEL HOT
ROLLED
FLATS
1/4" X 2" 0.5 57
1/2" X 1-1/2" 0.75 38 4
1/2" X 2" 1 28 2
4
STEEL HOT
ROLLED
RODS
1" 0.785 36 3
1-1/4" 1.22 24 2


42

RATES OF PRODUCTION
Up to shearing unit the time taken by every product undergoing bulk deformation is same
which IS 18.5 mins as discussed in previous section. Now number of times required for
shearing will decide the rate of production of products.
Shearing time taken = N*t
s,
total time taken = 18.5+ (N*t
s
)

MINS
Rate of production = N/ [18.5+ (N*t
s
)]
Hence a tabulated form has been given:
TABLE12: RATE OF PRODUCTION
SR.
NO.
PRODUCT
NAME
DIMENSIONS
PRODUCED
LENGTH
(FEET)
NO. OF
PIECES ON
STANDARD
SIZE
(12)(N)
SHEARING
TIME
TAKEN
(MINS)
TOTAL
TIME
TAKEN
(MINS)
RATE OF
PRODUCTION
(PIECES/MIN)
1
EQUAL
ANGLES
1" X 1" X 1/4" 57 4
0.332 18.832 4.7
2" X 2" X 1/4" 28 2
0.166 18.666 9.3
3" X 3" X 1/4" 13 1
0.083 18.583 18.3
2
UNEQUAL
ANGLES
1" X 2" X 1/4" 38 3
0.249 18.749 6.25
1-1/4" X 2" X
1/4"
36 3
0.249 18.749 6.25
2" X 3" X 1/4" 24 2
0.166 18.666 9.3
3
STEEL
HOT
ROLLED
FLATS
1/4" X 2" 57 4
0.332 18.832 4.7
1/2" X 1-1/2" 38 4
0.332 18.832 4.7
1/2" X 2" 28 2
0.166 18.666 9.3
4
STEEL
HOT
ROLLED
RODS
1" 36 3
0.249 18.749 6.25
1-1/4" 24 2
0.166 18.666 9.3


43

12. CHALLENGES FACED AND MEASURES TAKEN BY
ORGANIZATION IN MANUFACTURING DEPARTMENT
a. LABOURS
i. High labour dependency-
The different work stations of the department are highly labour dependent. As in India
the labour cost are cheap and the production department of Assam Tubes Limited
follows batch size production hence automation will not be economical. Even for
automation, a constant and dependable power supply is required and the state lack in
this sector. There is shortage and extremely fluctuating power supply due to poor
infrastructure of ASSAM STATE ELECTRICAL DEPARTMENT. But being
dependent on man power workforce, the department has setup a training department
to train new workers and even work on field in the absence of labours due to any
uncertainties.

TABLE13: APPROXIMATE PEOPLE REQUIREMENT IN DIFFERENT
WORK STATIONS
Unit Number of persons required
EOT CONTROLLER UNIT 2 persons
INDUCTION FURNACE UNIT
3 at each furnace and 1 supervisor for
guidance
INGOT CASTING UNIT At least 5
INGOT POLISHING UNIT 2 persons
INGOT COOLING AND STORAGE
UNIT
3 persons
INGOT SHEARING UNIT 3 persons
REHEAT FURNACE (FEEDER SIDE) 2 persons
REHEAT FURNACE (END SIDE) 3 persons
3- HIGH SIX STAND ROLLING MILL 15 persons
SHEARING UNIT 4 persons
TOTAL 43 persons

44

NOTE: The above doesnt include the workers in the storage unit, lathe machine unit,
and coal storage unit. The above data is an estimated value.
ii. Lack of skilled labour
Even though the labours are easily available at a much viable salary but the working
capacity are quite inefficient. This directly affects the rate and quality of the products
being produced. The training department has been set up for the labours to get trained.
Every workstation has a supervisor for any assistance and guidance to the labours.
Advantages of skilled labours-
i. The rate of production and quality of the products depend on the quality of the
labours and machines used in the various steps. Hence more efficient work
will be achieved by trained labours.
ii. No training department will be required. Hence less effort by the organization
and more fruitful work.
But training the labours has some disadvantages-
i. Cost of extra department (the training department) and extra time have to be
incurred by the company.
ii. If the labours discontinues to work after the training period, the effort made by
the company doesnt gets paid off. Therefore, the company laid a strategy
stating that very small amount of salary will be paid during the period and the
remaining will be paid after they complete the training and start working in the
field.
b. POWER SUPPLY
List of machineries which requires low or heavy power loads-
i. EOT cranes
ii. Induction furnace
iii. Reheat furnace
iv. Standing and Tandem Rolling mills
v. Coal supply unit
vi. Rollers for material transportation
vii. Lathe machining unit
viii. Shearing unit
From the above list it is seen that almost every unit is dependent on heavy electric
power supply except the casting unit and the storage unit. But due to the inefficient
way of power supply causes a lot of hindrance to the production department.
45

c. RAW MATERIAL
Since the raw material used for manufacturing steel ingots is scrap and cast iron, the
exact composition and evenness cannot be achieved. Scrapes includes old corrugated
sheets, leftovers at construction sites such as TMT rods, rods used for trusses, steel
tubes etc. But despite of unevenness, the easiness and abundance in availability makes
it an upper hand for the organisation. Bringing the same amount of iron ore from
nearby state will cost much higher including the transportation cost.
There are many local distributors who deal with ferrous scraps and the organization
has a great link with them as they are their oldest customers.
d. WEAR AND TEAR OF ROLLERS
Since the process of rolling in the six stands hot rolling machine is a hot process, and
due to bulk deformation process under high pressure there are formation of built up
edges on the surface of the rollers. Hence the rollers of each stand goes under weekly
maintenance in the lathe machining department. The company has setup this extra
unit in order to save time and cost otherwise which would have been benefitted by the
third party.
e. COAL FEEDING TO THE REHEAT FURNACE
The bucket elevator, hooper and feeder have been arranged in the coal storage unit to
feed coal to the reheat furnace as a fuel source. The organisation have installed this to
reduce its human dependency work load. Though the machine doesnt have to run
continuously along with the reheat furnace but when power is supplied its very much
efficient and only the required amount coal is poured into the furnace to attain a
certain temperature. Hence less temperature variance occurs.
f. SERVICE AND MAINTAINACE COST-
This is a major problem to the company. Any damage to the machinery while working
takes a long time to get repaired as there is no local service centre of the company
from which the machineries are bought. The technicians available locally are not
enough skilled and the organisation doesnt take risk for better future.
The cost for calling a companys technician including the loss of time has to be
suffered.


46

13. THREATS
a. MARKET FLUCTUATIONS
Annual production of the varied products solely depends on the demand of the
product in the market. The company has seen very fluctuating demand in the market
during the past few years due to the following:
i. Rapid growth in industrial belts in the North Eastern State from the year 2003-
2007. Hence there was large demand of warehouses, industrial shades, and
civil structures. The pressure to meet market demand was directly on the
production department.
ii. Many other small and medium enterprises of structural steel manufacturing
came into play at the end of the booming period. Hence in order to pursue
their product in the market, costs of the products were reduced. Thus, the
company faced a highly challenged market. The new entrants were
Megashakti and Biscon. Again, the company has to sell their products at a
much competitive prices.
iii. Presently, a dull period is faced by the company due to central elections taking
place in the country. Hence a low market demand is seen.
iv. Graph of annual sale(Rs. crore) vs. year of production

b. COMPETITORS:
Large scale industries like Tata steel, SAIL JSW steel have also a great market setup
through various distributors in the retailing sector. The quality of these large scale
companies is better than SME Company like Assam Tubes Limited. But the price
factor dominates the quality factor at commercial level and the organization has a
upper hand in the its limited accessible market. The company has to face completion
125
115
110 110
100
115
110
0
20
40
60
80
100
120
140
2007 2008 2009 2010 2011 2012 2013
SALE
SALE

from various others small scale industries
Greyshakti, Nezone,Jaiswal Rolling.
Price comparison of Tata
Competitive Strength Grid
FACTORS
ATL
TUBES LTD.)
Product Quality
Market share
Service Quality
Production capacity
Brand name
recognition
Advertising
Management Skills
Variety of Products
Financial Capability

Less than average
Average
More than average


42
44
46
48
44.5
48
P
R
I
C
E


I
N

R
S
.
/
K
G
ASSAM TUBES LIMITED
TATA STEEL
from various others small scale industries BISCON, Megashakti, Virdi Iron,
Greyshakti, Nezone,Jaiswal Rolling.
Price comparison of Tata steel and Assam tubes limited.


ATL (ASSAM
TUBES LTD.)
BISCON










ASSAM TUBES LIMITED
TATA STEEL
47
BISCON, Megashakti, Virdi Iron,
MEGHASHAKT
I










48

Positive aspects
i. Since Guwahati is the major city in the North Eastern states of the India and
has a better connectivity to the entire seven sister states, hence being located in
the industrial sector of the city, the organization has a well setup market.
ii. Another advantage is that which is also a measure taken is that the company
has its own retailing shop in the Guwahati city. This gives the organization a
direct link to the customers.
c. POLITICAL AND SOCIAL ISSUES-
Due to infiltration of people from nearby countries like Bangladesh, there are
formations of many small organizations like KMSS, AASU etc. who in favour of
local people organises various campaigns and demands rights from the Assam
government to stop migration and promote employment to their fellow people. This
issue has disrupted the socio economical structure of the state. Thus various uncertain
holidays like Assam bandhs, Transport strike etc. hamper the business.
People working in the organization are from varied cultures and religions. And in
Assam, compared to the North Western States of the country, the local people follow
various rituals and have religious beliefs and hence many holidays for celebrating
their festivals and performing their customs has to be given.
d. LOW INTEGRATED INDUSTRIES-
North Eastern States have basically SME business structure. The economy of the state
is mainly on the outsourcing business, agricultural supply like tea, fruits etc., Crude
oil supply and refining at Digboi, Guwahati and Numaligarh and coal supply from
Meghalaya. There are very less or say no such industries where the company can
supply its products other than construction sector. Even the company has therefor
limited its products variety and producing all the products for a standard 12 feet
length.




49

14. OPPURTUNITIES
a. HUGE INFRASTRUCTURE DEMAND
i. The North Eastern States are developing at a faster rate. There is huge demand
for new infrastructures like highways, bridges etc.
ii. Various telecom services are getting into the market for this region of the
country, hence more requirement of telecom tower. For example, Reliance Jio,
a company to be launched by the end of this year by Reliance group.
iii. Since outsourcing business have a very good opportunity and consumers are
increasing day by day, requirements of new and bigger storage houses is at the
peak.
iv. Shopping malls, office buildings which have to be constructed at a faster pace
will require structural steel for constructing replacing the reinforced structure
which takes much longer time.
b. AVAILABILITY
i. Scraps and cast iron are easily available here for the fulfilment of raw
materials.
ii. The company has also a great advantage of obtaining coal as Meghalaya is a
good supplier of coal which is used as fuel in reheat furnace.
iii. Labours are easily available at an economical rate starting from about
Rs.3500/per month for permanent work. And daily wages persons charge from
about Rs. 200 to Rs.350 per day depending upon the type of work.
c. OUTSOURCING TO OTHER COUNTRIES
The company even has market in Myanmar, Bhutan and Bangladesh. These nations
are under developing stage and there is also a huge demand for infrastructural reform.
d. ONLINE BUSSINESS GROWTH
Now, customers can easily access our company website and check for product
features, size and specifications and even send us their enquiries. This will help us in
increase in sales.



50

15. FUTURE PALNS
i. Setting up a Re-rolling mill (11 inches) which will increase its production by 50 tons
per day.
ii. They are also planning to produce products like joists and heavy channel which are
rarely produced in North-eastern Region and market ingot moulds in the future. These
products will double our production and increase sales to a great extent.
iii. Also, the company has started procuring our raw material especially sponge iron in
bulk which will help in reducing costs.
iv. UNIQUE SELLING PREPOSITION: Variety of quality products and timely delivery
is our USP. As in North-East , steel manufacturers do not provide a variety of steel
products to their customers
v. TABLE14:COMPANYS SHORT TERM AND LONG TERM PLAN:
Sl. No. DETAILS PROPOSED
CAPACITY
PROJECT
COST
1. Sponge Iron 2x100 (TDP) 35.00 Cr.
2. Power Generation
(WHRB)
8 MW 40.00 Cr.
3. Induction Furnace 3x10 Ton
(TDP)
25.00 Cr.
4. Rolling Mills TMT 300 TDP 20.00 Cr.
TOTAL 120.00 Cr.
NOTE: TDP-total daily production