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INTRODUCTION TO COMPANY
In the year 1997, Godrej & Boyce celebrated their centenary year. This dynamic organization has progressed tremendously since its inception and has been gaining strength consistently. Quality is the hallmark of all the Godrej products and any product with the 'Godrej' mark represent quality, dependability & satisfaction to its customers. What now is a gainful industrial organization was a brainchild of Mr. Ardeshir GODREJ, which through the help dedicated men with tremendous foresight and finely honed engineering and marketing skills, has become one of the biggest houses in India. Godrej also made a significant contribution to self-reliance of the century by building the engine for the PSLRU locker launched by India. In the year 1978 Godrej diversified in to the field of chemicals by starting the manufacturing of soaps and further diversified into production of chemicals for various industries like textile mills, pharmacies, confectioneries, etc. The most recent achievement by Godrej was made when it acquired the ISO 9000, ISO 9001 and ISO 14000 certificate, which former reinforced the rest of not only the Indian market but also the global market in the product of Godrej Today Godrej employee over 15,000 people and has grown in to a multi-core professionally managed group with far reaching service and distribution network. "Economy and Services” are being the main motto of Godrej they have already diversified in to field of Indian industry thus helping in the economic growth of the country.
Century old brand name, 'Godrej', it now also provides electronic security systems products and is angered with the supply and installation of the electronics safes, electronics security alarm systems, access control systems, closed circuit television systems and very highly sophisticated advanced electronic surveillance systems.
1.1 VAROUS PLANTS IN GODREJ
GODREJ & BOYCE MFG. CO LTD.:-
It is truly a mullet-faceted company. This is the major collaboration of Godrej with Boyce Company. The maximum of the business of Godrej is known by this name. At present all the divisions mentioned below come under this company. OFFICE EQUIPMENT (O.E.) DIVISION: The manufacturing activities in this division are distributed in the following plants:
➢ ➢ ➢ ➢ ➢
Plant 1: Steel processing plant Plant 4 & 14: Furniture systems plant Plant 13: Industrial storage system Plant 17: Security equipment LOCKS DIVISION: -Plant 18 A
TYPEWRITER DIVISION: – Plant 18 B
➢ ➢ ➢ ➢
MATERIAL HANDLING DIVISION: -Plant 16 MACHINE TOOL DIVISION: -Plant 9 & 19 TOOL ROOM DIVISION: -Plant 7 OFFICE AUTOMATION DIVISION: -Plant 19 A
PROCESS EQUIPMENT DIVISION: -Plant 15
This division is located in Plant 15 and it designs and fabricates a large range of custom-made sophisticated equipment for chemicals, petrochemicals and fertiliser industries such as heat exchangers, boiler shells, tower internals, etc., as well as equipment for nuclear and aerospace applications such as parts of atomic reactor, cryogenic engines and projects of ISRO (Indian Space Research Organisation).
The process equipment division consists of five main production departments as follows: ♦ Columns.
♦ ♦ ♦ ♦
Heat exchanger. Reactors & Vessels. Aerospace Division. Trays & tower internals.
Product range – • Heavy Walled Reactors
• • •
Equipment Internals Fractionating / Distillation Columns High Pressure Shell & Tube Heat Exchangers Custom built Equipment
Fig.no-4:-High Pressure Vessels Fig.no-3:-Heavy Walled Reactor
1.2 INTRODUCTION TO MACHINE SHOP DEPARTMENT
Machine shop department is one of the vital departments in the ‘Process Equipment Division’. It possesses machines that are required for machining the various components of the pressure vessel assembly. The department produces components that are related to the heat exchanger of the pressure vessel assembly. The machine shop department is a service department and works in tandem with other departments of the plant.The components produced in machine shop department can be given as follows: ♦ ♦ ♦ ♦ ♦ Tube sheets Baffles Tie rods Spacers Flanges
The various machines used in the machine shop department can be given as follows: ➢ CNC DRILLING MACHINES: ♦ ♦ ARBOGA 1 ARBOGA 2
♦ ♦ ♦ ♦
HARTFORD 1 HARTFORD 2 BATLIBOI KOLB DRILLING MACHINES:- The Drilling machine is in tends fro
drilling medium to large and heavy work pieces. The machine consists of a heavy round, vertical column mounted on a large base. The column supports a radial arm which can be raised and lowered to accommodate work pieces to different heights.
RADIAL 1,2,3,4,5,6,7 CNC LATHE MACHINE:HMT LATHE HORIZONTAL LATHE MACHINES:- The Lathe has got all the
basic parts e.g. Bed, Headstock and Tailstock. The Headstock contains mechanisms for driving a spindle at multiple speeds. Lathe can feed the tool both in cross and longitudinal direction with reference to lathe axis. A lathe receives its power from an individual motor known as motor driven lathe. ♦ BOMBAY LATHE ♦ THREE JAW LATHE ♦ MODULAR LATHE ♦ BECO LATHE
♦ NEW LATHE
VERTICAL LATHE MACHINES:- This type of boring
machine combines the advantages of vertical boring machine and turret lathe. It has an indexable turret lathe mounted the cross rail above the table for multiple tooling. A four station square turret side head which enables facing, turning under cutting and many other operations. ♦ VTL1 SINGLE ARM (CNC) ♦ VTL5 DOUBLE ARM (CNC) ♦ VTL6 (FARREL)
HORIZONTAL BORING MACHINE:- In a Horizontal Boring machine, the work is supported on a table which is stationary and the tool revolves in a horizontal axis. A Horizontal machine can perform boring, reaming, turning, threading, facing, milling, milling, grooving, recessing and any other operation with suitable tools.
VERTICAL MILLING MACHINES:-
A Milling machine is a
machine tool that removes metal as the work is fed against a rotating multipoint cutter. In a vertical milling machine position of the spindle is vertical or perpendicular to the work table. The spindle head can be swivelled at an angle. This machine is adapted for machining grooves, slots and flat surfaces.
INTRODUCTION TO PROJECT
“IMPROVING OVERALL EFFICIENCY OF THE CUTTING MACHINES”
MACHINE 1: BEHRINGER BANDSAW
MACHINE 2: CNC GAS CUTTING MACHINE – SUAG
MACHINE DETAILS: (BEHRINGER BANDSAW)
Morgantown, PA (April 7, 2010) – A new line of bandsaws engineered to accommodate and cut large diameter tubing quickly and efficiently is available from Behringer Saws, Inc. HBP-800AXL Automatic and HBP-800XL Semi-Automatic Series Bandsaws allow companies to save on upfront capital expenditures and avoid buying more expensive bandsaws for everyday cutting while expanding their capability to specifically cut large tubes when needed. The HBP-800AXL Automatic and HBP-800XL Semi-Automatic Bandsaws deliver all the performance and capabilities of “standard” HBP-800 Series Bandsaws cutting solid bars and structurals up to 31.5”. In addition, these new bandsaws allow for
the cutting of tubes up to 39" in diameter. Companies can now purchase a lower cost bandsaw to handle day-to-day production cutting needs at the standard size range while utilizing this additional feature to accept new projects requiring the cutting of large diameter tubing.All HBP-800 Bandsaws are built with strong cast iron frame construction and a twin column parallel down feed design for proper saw blade tensioning to deliver quick, efficient and forceful low vibration cutting for smooth cuts. These bandsaws also come with a heavy-duty roller conveyor for quick and efficient handling of heavy materials pre- and post-cut. HBP-800 Bandsaws feature a frequency controlled 14.7 horsepower main drive motor with a variable speed range of between 55-393 Surface Feet Per Minute (SFM) which is easily selected at the operator’s control panel. Hydraulic and hardened clamping jaws on the bandsaw ensures steady and precise cuts at all speeds. This bandsaw is available in both automatic and semi-automatic versions and requires minimal operator intervention as it is controlled by a programmable logic controller (PLC). It features an easy-to-use operator’s terminal with diagnostic display, data entry and program storage. The speed is easily set, controlled and monitored before and during the cutting process. Behringer Saws, Inc. provides a full range of sawing and turnkey pre- and post-cut material handling productivity-enhancing products. Behringer supplies world-class quality automatic bandsaws to corporations, service centers, job shops and manufacturers throughout the world. The company also offers the Behringer Eisele brand of manual, semi-automatic and automatic miter circular cold saws, high performance circular cold saws utilizing bi-metal or carbide saw blades and CNC miter circular sawing systems. Also, the Vernet Behringer line of structural fabricating equipment includes high performance drilling, punching, shearing, notching and marking machines along with beam coping and drilling and sawing lines.
For more information on the HBP-800AXL and HBP-800XL Bandsaws, contact Behringer Saws, Inc., 721 Hemlock Road, Morgantown, PA 19543. Call toll-free at 888234-7464.
Description of machine: Stainless steel and tool steel. Tempered steel, special alloys and aluminum. In different thicknesses, shapes and diameters. Singly, in bundles of fixed lengths. Whatever you aim to saw, our HBP, HBV and HBM high-performance and automatic bandsaw series offer the solution you are looking for. In every cutting range. Despite their outstanding performance, our machines are all designed to offer maximum operating simplicity and space savings. And like everything from BEHRINGER, they are unbeatable in terms of speed, precision and quality.
SPECIFICATION OF BEHRINGER BANDSAW:-
Model Cutting range 90° round (inch) 90° flat (W x H) (inch) 90° square (W x H) (inch) 75° meter left dia. / flat (W x H) (inch) 60° meter left dia. / flat (W x H) (inch) 45° meter left dia. / flat (W x H) (inch) Working height (inch) Single stroke of the feeding gripper (inch) Drive motor (H.P.) – frequency controlled Cutting speed (FPM) Cutting capacities Saw blade dimensions Weight (lbs) Space requirement (inch) Large dual column - parallel down-feed design Solid cast bow frame Cast Meehanite band wheels
HBP 413A 16.1 19.7x15.7 15.7x15.7 31.5 15.7 5.4 65-459 47.2" x 31.5" 19’0”x1-1/2”x .050” 5,170 116x77
Fully automatic hydraulic blade tensioning & carbide blade guides
MACHINE DETAILS: (CNC GAS CUTTING MACHINE - SUAG)
The RUM is the latest generation of CNC profile cutting machine that combines the quality of construction of the MAXI machine with the advantages of the price/output ratio of RUR machine. Standard equipment of the RUM includes all available automation facilities. Basic equipment
fully welded beam without bolted joints linear bearing in cross axis AC servomotors digital synchronization in longitudinal axis BURNY 10 LCD Plus control system with touch screen membrane keyboard floating cutting heads electric ignition capacitive height control of oxy-fuel torch automatic gas console torch selection from control panel automatic initial height sensing of plasma torch arc voltage height sensing of plasma torch parking facility for heads out of cutting area limit switch in each axis Optional equipment plasma system by customer request pneumatic anti-collision system pneumatic, plasma or inkjet marker air cooling of portal frame control system heating (for winter operation)
SPECIFICATION OF CNC GAS CUTTING MACHINE - SUAG:RUM max. number of torches rail span cutting width * - 1 torch 3500 6 3500 mm 3100 mm 4000 mm 3600 mm 4500 mm 4100 mm 4000 4500
cutting width * - 2 torches cutting width * - 3 torches cutting width * - 4 torches cutting width * - 5 torches cutting width * - 6 torches cutting length min. parallel cut cutting speed standard cutting thickness machine width machine length machine height incl. rails cutting table height plasma system supply voltage
3100 mm 3100 mm 3080 mm 2945 mm 2810 mm by customer request 90 mm 0 - 20000 mm/min. 200 mm 4100 mm 1200 mm 1700 mm 700 mm by customer request 230V/50Hz
3600 mm 3600 mm 3580 mm 3445 mm 3310 mm
4100 mm 4100 mm 4080 mm 3945 mm 3810 mm
Plate widths 1,000 to 2,000mm Speed 0 to 8,000mm/min Track 2,000mm (standard) 1,000mm (optional) Drives: Longitudinal Rack and pinion Transverse Rack and pinion Plasma: Upto 200amp plasma system. Full height sense and heavy duty head Gas and heads: Hi Lo preheat (standard) 2 stage pierce (optional) Cutters: 2 Maximum Controller: C.N.C. controller mounted on a pedestal
Burny 1250 control system includes a fully-integrated Burny 2.5 CNC Shape Cutting Control, Plasma process controls and a servopak 120 watt pulse with modulated drive CNC Width 2000mm Track length to be advised Maximum Cutting Speed 6000mm/min Maximum Cutting Thickness with gas 300mm Single sided drive Combined gas and plasma post with ESAB Cool jet Cutting Post Operational Manuals Mains input would require 240 volts single phase Photographs taken on site PRIOR to any work commencing.
1. METHODS: Time to process Raw-material. Lack of proper understanding. 1. PEOPLE: Lack of availability of designers. Conflicting mindsets of designers. Inadequate skill-mapping. Lack of motivation & understanding. 1. MANPOWER: Dedicated personnel for planning. Lesser no. of designers involved. Dynamics of self-help groups.
Government oriented(Time-consuming) paper work. Lack of finance to create larger SHG’s. Investment. 1. PLACE: Time & cost incurred. Proximity to large markets slightly less. 1. SURROUNDING: Traditional barriers & mind-sets. Linguistic barriers(biggest issues). 1. PROCEDURES: Material constraints. Requires fine tuning of mind towards market. Requires deeper market understandings by designers.
1. SKILLS: Newer skills not impaired.
Imbalance in skills.
A cutting torch head is used to cut metal. It is similar to a welding torch, but can be identified by having three pipes that go to a 90 degree nozzle and by the oxygen-blast trigger.
Only iron and steel can be cut using this method. The metal is first heated by the flame until it is cherry red. Once this temperature is attained, oxygen is supplied to the heated parts by pressing the "oxygen-blast trigger". This oxygen reacts with the metal, forming iron oxide and producing heat. It is this heat which continues the cutting process. The cutting torch only heats the metal to start the process; further heat is provided by the burning metal.
Cutting Torch for CNC Gas Cutting Machine Acetylene is the primary fuel for oxy-fuel welding and is the fuel of choice for repair work and general cutting and welding. Acetylene gas is shipped in special cylinders designed to keep the gas dissolved. Oxygen is not the fuel: It is what chemically combines with the fuel to produce the heat for welding. This is called 'oxidation', but the more general and more commonly used term is 'combustion'.
BAND-SAW CUTTING BLADE:
Band-saw Cutting Blade The typical metal cutting bandsaw machine is used for simple cutting of solid steel, tubing, and odd shaped material. The material to be cut is mounted in a vise attached to the bed of the machine. An electric motor drives the bandsaw blade through a belt and pulley arrangement from which three speeds may be obtained. The sawing machine frame, upon which the drive wheel, idler wheel, bandsaw blade, and motor are mounted, pivots from one corner of the sawing machine bed. The frame is counterbalanced by a tension spring between the frame and the bed. Feed is controlled by positioning a sliding weight along a bar fixed to the top side of the sawing machine frame. A dashpot is positioned between the frame and bed to stabilize the feed movement and prevent any quick movement of the frame that could cause damage to the bandsaw blade.
The vise used to hold the material being cut is a quick-positioning type and can be adjusted easily to any angle. An adjustable work piece stop is provided for rapid positioning of production work pieces.
Time study on Behringer Band Saw Cutting M/C
TIME STUDY ON BEHRINGER BAND SAW CUTTING M/C LOSSES
SR.NO. 1. 2. 3. 4. 5. 6. TOTAL ACTIVITY Setting if JOB Measurement Operator non availability Crane waiting time M/C down time Tool changing time TIME in min 115 83 35 15 313 30 581 % 19.79 14.28 4.30 2.58 53.87 5.16 100
TIME STUDY ON CNC GAS CUTTING M/C - SUAG
CNC SUAG CUTTING M/C LOSSES
SR.NO. 1. 2. 3. ACTIVITY Scheduled/Planned Stoppages Setting Time Start-up Losses[mock-up] TIME in min 698 17 288 % 49.75 1.22 20.52
4. 5. 6. TOTAL
Minor Stoppage[Time Loss] Non Availability of Material Non Availability of Operator
20 340 40 1403
1.42 24.24 2.85 100
SUGGESTIONS BEHRINGER BAND SAW CUTTING M/C:Three Major Losses in Behringer:1. 2. 3. M/C Down Time. Setting Time. Measurement.
1. M/C Down Time REASON
Preventive Maintenance of M/C to be done on time to avoid maintenance while M/C is in production.
2. Setting time REASON
Fatigue to Operator in Setting the Job.
Sensors are to be employ on machine.
3. Measurement REASON
1. Presently measurement is done manually by operator. 2. New measurement type equipment must be procured to minimize measurement time.
Sensors assembly has to be done near to the machine blade so measurement time will be minimum.
SUGGESTIONS CNC SUAG CUTTING M/C:Three Major Losses in CNC Suag:1. 2. 3. Scheduled/Planned Stoppages. Non Availability of Material. Start up Loss[mock-up].
1. Scheduled/Planned Stoppages REASON
1. Loading Time Of Plate Is Too High. 2. Time consumed for Setting the Job Plate.
1. Loading Time Should Be Minimized By Offline Setting Of Plate.
2. Special fixture to be Designed for Quick Setting of Job Plate.
2. Non Availability of Material REASON
Improper & Unplanned Stacking of Plates.
1. Proper stacking of plates as per priority. 2. Proper proactive planning to feed the m/c as per plan.
2. Start up Loss[mock-up] REASON
1. No cleaning before Operator reports the machine. 2. Major time consumed in Test Run.
1. Special Cleaning staff to be provided for cleaning of the m/c before operator reports on the m/c during each shift. 2. Special Fixture to be made to avoid Test Run.
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