COLLEGE OF ENGINEERING, PUNE

(An Autonomous
Institute of Govt.
of Maharashtra)
DEPARTMENT OF
PRODUCTION ENGINEERING

INPLANT TRAINING REPORT

SUBMITTED BY

YARGATTIKAR PRASAD BHALCHANDRA

B.TECH PRODUCTION (S/W)
ROLL NO : 709304
TICKET NO : 84454

2009 - 2010

DEPARTMENT OF PRODUCTION ENGINEERING

AND WORKSHOP

1
 COLLEGE OF ENGINEERING, PUNE
(An Autonomous Institute of Govt. of Maharashtra)

CERTIFICATE

This is to clarify that Mr. YARGATTIKAR PRASAD

BHALCHANDRA has carried out his Industrial In Plant Training during the
course of his Training at THERMAX LTD. In partial fulfillment of the
requirement of the VII – VIII Semester B.Tech. Course of Production
Engineering (Sandwich), at the Department of Production Engineering and
Workshop, College of Engineering, Pune 411005. During the Second
Academic term : 2009 – 2010.

(EXAMINER) Dr. B.B.AHUJA MR.S.ANASANE

(Prof & Head) (Guide)

DATE :
PLACE: PUNE.

2
 ACKNOWLEDGEMENT

I wish to express my sincere gratitude and regards to my report

Prof.S.Anasane. His guidance and support throughout the program has been
a major factor in the successful completion of the present work. This work
would not have culminated in to the present form without his invaluable
suggestions and generous help. I am thankful to the faculty of COEP for
providing me with an excellent education during my B.Tech Program.

Also I am thankful to Mr.Rahul Joshi my company guide for his

guidance and support for completion of my project and also I would thank
Mr. Uttam Gaikwad and Mr. Laxmikant Malage who helped me in giving their
valuable ideas for my project .

I am thankful to all my seniors and friends who provided

valuable suggestions and constant help during my report making.

3
 CONTENT

SR NO. TITLE PAGE NO.

1 COMPANY PROFILE.

2 ORGINISATION STRUCTURE FOR MFG.

10

COMPANY PROFILE

4
BIRTH OF THERMAX
In the beginning there was fire. Then there was steam. Steam heated
produced mechanical movement. It could be used to produce electricity too.
The use of steam rewrote the history of human civilization. It was the driving
force of industrial revolution, the precursor of modern age, as we understand
it. Even in this age of cybernetics, genetic engineering and information
superhighways, boilers that produce steam are critical on-line equipment,
across diverse industry segments – be it a small-scale unit, which needs a
600 kg/hr, or a fertilizer plant, which needs a 300-tones/hr high-pressure
steam generator.

Years ago there was a small company in Mumbai called National Steel
Equipment Company (Nat Steel), which made hospital sterilization equipment
and hospital beds. They soon started manufacturing heaters for the hospitals.
Its founder A.S.Bathena (1908-1991) and his son Jamshed decided to go in
for collaboration with a Brussels based company Wansons for manufacturing
of so-called “Baby Boilers”. Wansons was one of the largest manufacturers of
coil type boilers in Europe while Nat. Steel was 5000 Sq. Ft. asbestos go
down in a corner of Mumbai.

Nevertheless, the new venture took off meeting a market need that the
customers not even aware of: while Indian industry in the mid-sixties was
largely familiar with bulky hand fired boilers, the Wansons India “Vaporax”
boilers produced steam within two minutes of cold start.

In two years the new company sold over a hundred boilers, while a
market survey predicted a turnover of RS.3 million in the third year, the
company got in that year a single order for that figure. The order was from
L&T.

Mr. Rohinton D. Aga (1935-1996) soon joined Bathena, a Cambridge

educated economist by training and manager by profession. A visionary, Aga
laid down many of the fundamental principles and value systems that have

5
guided Thermax (as Wansons India was renamed in 1980). One of Aga’s
favorite words was “Synergy” and it was synergy that is at the core of
Thermax’s diversification and growth.

Thermax has been rolling out a company-wide initiative to transform

the way it does business; aimed at significant increase in customer
satisfaction and top line and bottom line growth. The company is investing
substantial resources in attaining operational excellence – focusing on
processes and systems that have a direct impact on cost, quality, and lead-
time and on-time performance at every point of customer engagement. The
following is the detailed description of the whole organization. It includes the
following divisions.

1) Boilers & Heaters.

2) Cooling & Heating.

3) Water & Waste Heat Recovery Solutions.

Thermax has been rolling out a company-wide initiative to transform

the way it does business; aimed at significant increase in customer
satisfaction and top line and bottom line growth. The company is investing
substantial resources in attaining operational excellence – focusing on
processes and systems that have a direct impact on cost, quality, and lead-
time and on-time performance at every point of customer engagement. The
following is the detailed description of the whole organization. It includes the
following divisions.

1) Boilers & Heaters. 3) Water & Waste Heat Recovery Solutions

2) Cooling & Heating.

.DEPARTMENTAL PROFILE

ENERGY SYSTEM DIVISION (ESD)

6
INTRODUCTION

Waste heat utilization has become a very important sector of the

industry, owing to which the above division came into being in THERMAX.
This division deals with the Heat Recovery Units (HRU) operating on waste
heat.

The products of this division include:

 Exhaust gas waste heat boilers for PG sets, gas turbines and other
industrial application.

 Economizers: plain tubes, cast iron, extended surfaces, cast iron

muffled.

 Process integrated waste heat boilers.

 Waste gas fired heaters & metal recuperates

 Special purpose pressure vessels, heat exchangers, towers, columns

radiation coils and reactors for critical applications.

PRODUCTS OF ENERGY SYSTEM DIVISION

7
 Basically there is no standard format to divide the product for this
division; this can be divided as per customer, capacity or functions.
Products are:-

1. EGB (exhaust gas boiler). This can also divided as

a. 1DRC (Single Drum Reverse Circulation)

b. 1DNC (Single Drum Natural Circulation)

c. 2DNC (Two Drum Natural Circulation)

2. Bi drum (steam or power generation).This can divided as

a. BD (Without Fluidized Bed)

b. BDF(With Fluidized Bed)

3. PIB (Process Integrated Boiler)

4. WHRB (Waste Heat Recovery Boiler)

Generally it deals with drum shop

DRUM SHOP

8
 Drum is part of boiler used for steam separation & is also used as
reservoir. Single or twin drums are required based on type of boiler. Drums for
ESD & TBW are manufactured in drum shop.
Types of design and construction codes for drums:

1. ASME

2. IBR 1950

3. BS

4. AS

Inspection agencies for drum manufacturing:

1. IBR

2. ASME

3. LRIS

4. EIL

5. Customer appointed third party inspection agency.

Types of materials used for drums:

A) Shell plates, dished end, and manhole

Carbon steel - SA516 GR 70

Low alloy steel SA302 GR b

B) Nozzles, flanges, forgings, fittings

Carbon steel - SA106, SA105, SA234wpb

PARTS OF DRUM

9
 1. Shell: Plate - Rolling - Welding

2. Dished end: Plates – Pressing – Hot or Cold

3. Manhole: Plates – Press – Weld

4. Manhole cover: Plates – Cut – Machine

5. Nozzles: Pipes, Flanges, Forgings – Cut – Machine - Weld

6. Attachments: Plates, Flats, Angles, Channels

7. Saddles: Plates

8. Lifting hooks: Plates

9. Steam purifier assembly

MANUFACTURING PROCESSES FOR DRUM SHOP

10
Sr. No Processes Skill Required Machine used

1 Marking Fitting Hand Tools

Oxy-Acetylene
2 Gas cutting Welding torch pug cutting
machine

Electrical and
3 Grinding Fitting pneumatic
grinders

Machine Himalaya plate

3 Plate Bending
Operation bending machine

4 Fitting Fitting Hand tools

Welding Rectifier,
5 SMAW, SAW, Welding generators, saw
GTAW boom

6 Machining Machining Lathe

Kollmann and
7 Drilling Machining
radial drilling

8 Boring Machining Union drilling

9 Painting Painting

STEPS FOR DRUM MANUFACTURING

1. Plate Marking and Cutting

11
 2. Shell Rolling, Pre-Pinch Cutting, Closing

3. Shell L Seam Setup

4. Shell Welding - Inside SMAW + SAW, Back Grinding, Outside Saw

5. Shell Re-rolling & Radiography

6. Shell C Seam Setup

7. C Seam Weld & Radiography

8. Internal Attachments Set & Weld

9. D/E Setup

10. D/E to Shell Weld & Radiography

11. Nozzle Opening

12. Nozzle Setup & Weld

13. External Attachment Set & Weld

14. Full Welding Clearance

15. Stress Reliving

16. Hydraulic Blank Welding

17. Hydro Testing

18. Tube Hole Drilling Marking

19. Tube Hole Rough Drilling

20. Tube Hole Finish Drilling

21. Tube Hole De-burring

22. Hydro Blank Cut & Nozzle Trimming

23. Drum Internal Assembly

24. Drum Painting & Handing Over

D/E FABRICATION

1. D/E Marking

2. M/H Opening Cutting

12
 3. M/H to D/E Setup & Weld

4. Nozzle Opening Drilling

5. Nozzle Setup & Weld

NOZZLE FABRICATION

1. Pipe Cutting & Machining

2. Pipe to Flange Set, Weld, Radiography

SHOP LAYOUT:

13
14
15
Through Put Time reduction by
Visual management

16
Introduction:
The drum shop mainly was divided as Capsule Area, All Weld Area,
Machine Shop and Assembly. The Capsule Area is further divided into Shell
fabrication and Capsule Fabrication. Mainly the Shell Area was a mere point
of concern as it had a higher through put time which finally was leading to
higher through put time of the drum.
So, the data collection in shell area was to be made in order to find out
the causes of higher through put time. Hence as a project we decided to
monitor the shell area on daily basis in order to reduce the problems which led
to lower output.

Problems faced:
1) No streamlining of job.
2) Non Value adding activities.
3) Non traceability of shells.

Need of the project:

4) To reduce the Through Put Time (TPT).
5) To balance Work in Progress (WIP).
6) To increase safety.
7) To ease material handling.
8) To increase the visual management.

Actions taken:
1) Daily station wise data collection in Shell area.
2) Finding out routine problems leading to lower output.
3) Maintaining data of day to day job tracking.
4) Visual management through layout modification.
5) Implementation of KANBAN.

17
Steps taken to complete the project:
Shell area mainly comprised of the processes from Pate marking, Pate
cutting, Pate rolling, Pre-pinching cutting, Shell Closing, L Seam Setup, L
seam Inside SAW, L Seam Back Gauging, L Seam Outside SAW, L Seam
Flush, Shell Rerolling, Shell Radiography.
So, as shown above there were total 12 detailed stages in the Shell
area. So it was very important to study each and ever stage on daily basis as
it was not easy to find where exactly the problems are. The target WIP set by
shop was 2 jobs at each station. And total WIP in shell area was to be brought
below 20 so that automatically the TPT is controlled.
The problem found after 2 months of data collection was that the jobs
were not kept properly after each stage. Especially in L Seam Setup area, L
Seam flush area and Pre Pinching area the job searching time was more as
the jobs from previous station were not kept at right place resulting in loss of
time to take the job. So for that purpose we decided to modify the existing
layout so that there is a foolproof type arrangement which will avoid the
misplacing of jobs in wrong position.

18
OLD LAYOUT:

L SEAM I/S L SEAM BG

WELDING
PRIPINCHING
CUTTING

ROLLING D/E
L SEAM SETUP
MACHINE INSIDE
AREA
SAW

SHELL FOR FLUSH

GRIND, SHELL FOR NEW AND OLD L SEAM
CLOSING & READY OUTSIDE SAW
SHELL

NEW LAYOUT:

L SEAM I/S L SEAM BG

PRIPINCHING WELDING
CUTTING
SHELL SHELL
ROLLING L SEAM SHELL
FOR L FOR L
MACHINE SETUP FOR
SEAM SEAM
AREA IBR
SETUP O/S

SHELL FOR FLUSH

GRIND, SHELL FOR NEW AND OLD L SEAM
CLOSING & READY OUTSIDE SAW
SHELL

19
 Above figure shows the old and new layout for the shell area, In the old
layout first the job come to rolling then as shown in the arrow it goes for pre-
pinching cutting, then comes in flush area for pre closing flush and MPI then
goes on rolling machine for closing. Now in this whole process the flush area
consists of jobs for L seam flushing, Shell Closing and ready shell (i.e. for
radiography). So, according to the old layout these shells were placed in any
direction irrespective of the type. Also in pre-pinching area as soon as the
rolled shell was brought there was no such specific place for the shell to be
kept.
So, in order to create some streamlining we concentrated on these
areas. Primarily in pre-pinching area with the help of MED we made railings
so that as soon as the job comes from rolling machine it will be placed in
ahead of the area where actual pre-pinching operation is done. Due to this the
searching time or waiting time for handling the job reduced and also mainly
that area was visually managed.
Similarly in the flush area as there were different type of jobs. So,
previously there was a lot of ununiformity in the way the jobs were kept thus
resulting in stagnation. Thus, in the flush area we changed the position of the
rotators. And then separate area was allocated for shells for closing and
radiography. Due to this the space utilization in that area also increased and
the operator could easily lift the job because as compared to the previous
condition the working space had increased.

20
 Now considering the L Seam Setup area, the jobs were so variedly
distributed that there was no scope of any discipline in the movement pf job.
In L Seam Setup area the Shells for L Seam Setup, Shells for IBR offering,
Shells for L Seam BG and Shells for L Seam Outside SAW used to lie
anywhere in that area of 13.5 meter by 4 meter.
So, the main task here was how the WIP can be balanced and how can
the jobs be placed to avoid further non value added activities. So, detailed
analysis was made in this area. Firstly we calculated the area which was
utilized at present which came to be 13.5 meter * 4 meter. Then we found that
there was unutilization of space. So, we physically calculated the area which
could be utilized for modifying the L Seam area.
From this we came to know that the Dished End to barrel inside SAW
machine was much into L Seam Setup side and space in between Dished
End to barrel inside SAW machine and C Seam Inside SAW machine was
unutilized. So, we made decision to shift this machine about 1.5 meters from
current position. Thus now we had area of about 15 meter * 4.5 meters for our
use.
Then in order to modify the actual L Seam setup area we prepared a
CAD layout and we mathematically calculated the number of jobs that will be
accumulated in the area. We decided to segregate the L Seam area into three
sections according to the type of shells always occurring in that area. First we
left around 3 meters for L Seam Setup operation, then from that at 1.55
meters the first railing was there then successive railing was at 1.2 meter. And
gangway was at 650 mm. A gangway of 500 mm was left between each
section. Thus successive 2 more stations were there. Of the three sections
the first was of Shells for L Seam Setup, second was of Shells for IBR
offering and third was of Shells for L Seam BG. Thus we made the L Seam
Setup area totally visually managed. 2 gangways of 500mm each were kept in
between for easy access in the area for handling the job, for easy inspection
of the jobs offered for setup.
Now the overall layout was decided but there were 2 possibilities
1) Layout by keeping job with test plate facing rolling machine
side.
2) Layout by keeping job with test plate facing office side.

21
Layout by keeping job with test plate facing rolling machine
side:

Layout by keeping job with test plate facing office side:

22
Data collection
Date - 20/02/10
WIP OF SHELL AREA
TIME: 9.30 am
Plate Marking
WA 104100 WA 104100 LW 245/1
Plate Cutting
SD S1 SD S2 BWD S1
WA 104100 WAO99200
Plate Rolling
SD S3 SD S3
WAO99200
P/P Cutting
SD S2
WAO99200
Shell Closing
SD S1
WCO19100
L Seam Set up
SD S4
WCO19100 WCO19100 WCO19100 WCO19100
L Seam I/S
SD S1 SD S1 SD S3 SD S5
BDF 300/2
L Seam BG
SD S1
LW 242 SD LW 242 SD BDF 300/12
L Seam O/S
S1 S2 SD S2
BDF 350/4 WA101100 LW 242 SD
L Seam Flush
SD S1 SD S3 S3
Shell Re
Rolling
BDF 350/4
X Ray
SD S2

Date - 21/02/10
WIP OF SHELL AREA
TIME: 9.25 am
LW 245/1 LW 247 SD LW 247 SD
Plate Marking
BWD S2 S2 S1,S3
Plate Cutting
WA 104100 WA 104100 WA 104100 LW 245/1 BDF 300/12
Plate Rolling
SD S3 SD S1 SD S2 BWD S1 WD S1, S2
WAO99200
P/P Cutting
SD S2
Shell Closing NO LOAD
WAO99200
L Seam Set up
SD S1
WAO99100 WAO99100 WAO99100
L Seam I/S
SD S2 SD S3 SD S1
L Seam BG NO LOAD
L Seam O/S BDF 300/12 LW 242 SD
(NEW/OLD) SD S1 S2
WA101100 BDF 300/12 LW 242 SD BDF 350/4 WA101100
L Seam Flush
SD S2 SD S2 S1 SD S1 SD S3, S1
Shell Re LW 242 SD
Rolling S3
X Ray

23
ate - 22/02/10
WIP OF SHELL AREA
TIME: 9.45 am

Plate Marking

LW 247 SD LW 247 SD LW 247 SD LW 245/1

Plate Cutting
S1 S3 S2 BWD S2
WA 104100 LW 245/1 BDF 300/12
Plate Rolling
SD S2 BWD S1 WD S1, S2
WAO99200 WA 104100 WA 104100
P/P Cutting
SD S3 SD S1 SD S3
WAO99200
Shell Closing
SD S2
WAO99200
L Seam Set up
SD S1
WAO99100 WAO99100 WAO99100
L Seam I/S
SD S2 SD S3 SD S1
L Seam BG NO LOAD
L Seam O/S BDF 300/12
(NEW/OLD) SD S1
BDF 300/12 LW 242 SD WA101100
L Seam Flush
SD S2 S2 SD S1
Shell Re BDF 350/4 WA101100 LW 242 SD
Rolling SD S1 SD S3 S1
WA101100 LW 242 SD
X Ray
SD S2 S3

Date - 23/02/10
WIP OF SHELL AREA
TIME: 9.15 am
LW 245/2
Plate Marking
BWD S1 , S2
LW 247 SD LW 245/1 LW 245/1
Plate Cutting
S2 TWD S1,S2 BWD S2
LW 245/1 BDF 300/12 LW 247 SD
Plate Rolling
BWD S1 WD S1, S2 S3, S1
WA 104100 WA 104100
P/P Cutting
SD S2 SD S1
WA 104100
Shell Closing
SD S3
WAO99200 WAO99200
L Seam Set up
SD S3 , S1 SD S2
WAO99100
L Seam I/S
SD S3
WAO99100
L Seam BG
SD S2
L Seam O/S WAO99100
(NEW/OLD) SD S1
LW 242 SD BDF 300/12
L Seam Flush
S2 SD S1
Shell Re BDF 300/12 WA101100
Rolling SD S2 SD S1
WA101100 LW 242 SD BDF 350/4 LW 242 SD
X Ray
SD S2 S3 SD S1 S1

24
Date - 24/02/10
WIP OF SHELL AREA
TIME: 9.35 am
Plate Marking NO PLATE
LW 245/2 LW 245/1 LW 245/1
Plate Cutting
BWD S1 , S2 TWD S1,S2 BWD S2
LW 245/1 LW 247 SD
Plate Rolling
BWD S1 S3, S1 , S2
BDF 300/12 BDF 300/12 WA 104100
P/P Cutting
WD S1 WD S2 SD S1
WA 104100
Shell Closing
SD S3 , S2
WAO99200 WAO99200
L Seam Set up
SD S3 SD S2
WCO19100
WAO99200
L Seam I/S SD
SD S1
S2,S3,S4,S5
WCO19100
L Seam BG
SD S1
L Seam O/S WAO99100 WAO99100 WAO99100
(NEW/OLD) SD S2 SD S1 SD S3
LW 242 SD BDF 300/12
L Seam Flush
S2 SD S1
Shell Re BDF 300/12 WA101100
Rolling SD S2 SD S1
WA101100 BDF 350/4
X Ray
SD S2 , S3 SD S1

25
26
27
Date - 26/02/10
WIP OF SHELL AREA
TIME: 9.30 am
WF113100
Plate Marking WD
S1,S2,S3
LW 245/2 LW 245/1
Plate Cutting
BWD S1 , S2 TWD S1,S2
LW 245/1 LW 247 SD
Plate Rolling
BWD S1,S2 S3, S1 , S2
WA 104100
P/P Cutting
SD S1
WA 104100
Shell Closing
SD S3 , S2
BDF 300/12 BDF 300/12 WA 104100
L Seam Set up
WD S1 WD S2 SD S2
WCO19100 WCO19100
L Seam I/S
SD S2 SD S3,S4,S5
L Seam BG
L Seam O/S WAO99100 WAO99100 WCO19100
(NEW/OLD) SD S2 SD S3 SD S1
WAO99100 LW 242 SD
L Seam Flush
SD S1 S2
Shell Re BDF 300/12 WA101100
Rolling SD S1 SD S1
WA101100 BDF 350/4
X Ray
SD S2 , S3 SD S1
Date - 27/02/10
WIP OF SHELL AREA
TIME: 9.45 am
WF113100
Plate Marking
SD S1,S2,S3
WF113100
LW 245/1
Plate Cutting WD
TWD S1,S2
S1,S2,S3
LW 247 SD LW 245/1 LW 247 SD LW 245/2
Plate Rolling
S2 BWD S2 S3, S1 , S2 BWD S1 , S2
LW 245/1
P/P Cutting
BWD S1
Shell Closing
WA 104100
BDF 300/12 BDF 300/12 WAO99200
L Seam Set up SD S1,S3 ,
WD S1 WD S2 SD S3
S2
WCO19100 WCO19100 WAO99200
L Seam I/S
SD S4 SD S3,S5 SD S2
WCO19100
L Seam BG
SD S2
L Seam O/S WCO19100 WAO99100 WCO19100
(NEW/OLD) SD S1 SD S3 SD S1
WAO99100 WAO99100 LW 242 SD
L Seam Flush
SD S1 SD S2 S2
Shell Re BDF 300/12 WA101100
Rolling SD S1 SD S1,S3
BDF 350/4
X Ray
SD S2

28
29
30
 Date- -28/02/10
Date 01/03/10 WIP OF SHELL AREA
TIME: 9.15
TIME: 9.45 am am WIP OF SHELL AREA
PlateMarking
Marking LW 243/1 SD LW 245/2
Plate
S1,S2,S3 TWD S1,S2
WF113100
Plate Cutting WF113100
WF113100 SD
Plate Cutting WD
SDS1,S2,S3
S1,S2,S3
S1,S2,S3
Plate Rolling LW 245/1 LW 245/1 WF113100
LW 245/2 LW 245/1 LW 247 SD LW 245/2 LW 245/1
Plate Rolling BWD S2 TWD S1,S2 WD
BWD S2 BWD S2 S3, S1 , S2 BWD S1 , S2 TWD S1,S2
S1,S2,S3
P/P Cutting LW
LW 245/1SD LW 247 SD
247
P/P Cutting
BWD
S3 S1 S1 , S2
Shell Closing
Shell Closing LW 245/2
WA 104100
BDF 300/12 BDF 300/12S2
BWD S1 , WAO99200
LLSeam
SeamSet Setupup WD
WAS1104100 SDWDWA SD LW
104100 S1,S3 245/1
, WAO99200
S2 SD S3
S2 SD S1,S3 S2 BWD S1 SD S3
L Seam I/S WCO19100
WAO99200 SDWCO19100
WAO99200 WAO99200
L Seam I/S
SD
S1S4 SDSD
S3,S5
S2,S3 SD S2
L Seam BG WCO19100 SDWCO19100
WCO19100
L Seam BG
S4 SDSD
S4 S3
LL Seam
Seam O/S O/S WAO99100
WCO19100 SDWCO19100
WCO19100
(NEW/OLD)
(NEW/OLD) S5S5
SD SDSD
S2 S2
L Seam Flush WAO99100
WAO99100 SDWAO99100
WAO99100 WCO19100WCO19100
L Seam Flush S3 SD S2 SD S1
SD S1 SD S2,S3 SD S1
Shell Re WAO99100
Shell Re BDF 300/12
Rolling
Rolling SDSD
S1 S1
X Ray WA101100 SD LW 242 SD S2 BDF 300/12
WA101100
S1,S2 SD S1
X Ray
SD S1,S3

31
32
 Date- -02/03/10
Date 03/03/10 WIP OF SHELL AREA
TIME: 9.20
TIME: 9.10 am am WIP OF SHELL AREA
Plate Marking LW LW 243/1
243/1 SD
SD
Plate Marking S2
S2
Plate Cutting WF113100 SD
WF113100 SD WF113100
WF113100SD
SD LW243/1
LW 243/1SD
SD LW 245/2
LW 245/2
Plate Cutting S2
S3 S2S2 S1,S3
S1,S3 TWDS1,S2
TWD S1,S2
Plate Rolling WF113100 SD WF113100 SD LW 245/1 WF113100
WF113100
S1 LWS3 245/1 LW
BWD S2245/1 WD WF113100 SD
Plate Rolling WD
BWD S2 TWD S2 S1,S2,S3 S1
S1,S2,S3
P/P Cutting LW 247 SD LWLW 247 245/1
SD LW 245/1
P/P Cutting
S1 S2TWD S1 TWD S1
Shell Closing LWLW 247
247 SDSD
Shell Closing S2,S1
S3
L Seam Set up WA 104100 SD LW LW 245/1
245/1 LW 245/2
LW 245/2 LW 247 SD
L Seam Set up BWDS1S1 BWDS1,S2
S1,S2 S3
S3 BWD BWD
L Seam I/S WA
WAO99200 104100 BDF 300/12
WA 104100 BDF 300/12
L Seam I/S SD S2,S3 WD S1
SD S2,S3 SD S1,S2 WD S1,S2
L Seam BG BDF
WAO99200 300/12
SD WAO99200
L Seam BG WD S2
S3 SD S2
LL Seam
Seam O/S
O/S WAO99200 SD WAO99200
WCO19100 SD WCO19100 WAO99200
(NEW/OLD)
(NEW/OLD) S1
S4 SDSDS3S3 SD S1
L Seam Flush WCO19100
WCO19100 SD SD
L Seam Flush S1,S2,S3,S4,S5
S1,S2,S5
Shell
Shell Re
Re WAO99100
WAO99100 SD WAO99100
Rolling
Rolling S3 SDSDS1,S2
S1,S2
X Ray WAO99100SD
WA101100 SD
X Ray S3
S3
Date - 05/03/10 WIP OF SHELL AREA
TIME: 6.15 pm
Plate Marking
LW 245/2 TWD LW 243/1 SD LW 243/1 SD WCO19200
Plate Cutting
S1,S2 S1,S3 S2 SD S1,S2
WF113100
LW 245/1
Plate Rolling WD
BWD S2
S1,S2,S3
WF113100 SD WF113100 SD
P/P Cutting
S2 S1
WF113100 SD
Shell Closing
S3
LW 247 SD LW 247 SD LW 245/1 LW 245/2 LW 245/1
L Seam Set up
S3 S2 BWD S1 BWD S2 TWD S1
WA 104100 SD WA 104100 LW 245/2 LW 247 SD
L Seam I/S
S2 SD S3 BWD S1 S1
WA 104100
L Seam BG
SD S1
L Seam O/S WAO99200 SD WAO99200 BDF 300/12
(NEW/OLD) S2 SD S3 WD S1,S2
WAO99100 WAO99200
L Seam Flush
SD S2 SD S1
Shell Re
Rolling
WAO99100 SD
X Ray
S1
Date - 06/03/10
WIP OF SHELL AREA
TIME: pm

33
Plate Marking new plate
LW 245/2 TWD LW 243/1 SD LW 243/1 SD WCO19200
Plate Cutting
S1,S2 S1,S3 S2 SD S1,S2
WF113100
Plate Rolling
WD S1,S2,S3
LW 245/1 BWD WF113100 SD
P/P Cutting
S2 S1
WF113100 SD
Shell Closing
S2,S3
LW 247 SD LW 245/1 LW 245/1
L Seam Set up
S2 BWD S1 TWD S1
LW 245/2 BWD LW 245/2 LW 247 SD
L Seam I/S
S1 BWD S2 S1,S2,S3
WA 104100 SD WA 104100
L Seam BG
S2 SD S3
L Seam O/S BDF 300/12 BDF 300/12 WA 104100
(NEW/OLD) WD S1 WD S2 SD S1
WAO99100 WAO99200
L Seam Flush
SD S2 SD S3
Shell Re WAO99200 SD
Rolling S1
WAO99100 SD
X Ray
S1
Date - 07/03/10
WIP OF SHELL AREA
TIME: 11.15am
Plate Marking
WCO19200
LW 243/1 SD
Plate Cutting SD
S2
S1,S2,S4,S5
WF113100
LW 245/2 TWD LW 243/1 SD LW 245/2
Plate Rolling WD
S1 S1,S3 TWD S2
S1,S2,S3
WF113100 SD LW 245/2
P/P Cutting
S1 TWD S1,S2
LW 245/1
Shell Closing
BWD S2
LW 245/1 WF113100 LW 245/1
L Seam Set up
BWD S1 SD S2,S3 TWD S1,S2
LW 247 SD
L Seam I/S
S1,S2,S3
LW 245/2 BWD LW 245/2
L Seam BG
S1 BWD S2
L Seam O/S WA 104100 SD WA 104100 WA 104100
(NEW/OLD) S2 SD S1 SD S3
WAO99100 WAO99200 BDF 300/12
L Seam Flush
SD S2 SD S3 WD S1,S2
Shell Re
Rolling
WAO99100 SD WAO99100
X Ray
S1 SD S3

Date - 08/03/10
WIP OF SHELL AREA
TIME: 11.15am

34
 LW 245/1 SD
Plate Marking
S1,S3
WCO19200 SD LW 243/1 SD WCO19200
Plate Cutting
S2 S2 SD S1,S4,S5
WF113100
LW 243/1 SD LW 245/2
Plate Rolling WD
S1 TWD S2
S1,S2,S3
LW 243/1 SD
P/P Cutting
S3
WF113100 SD LW 245/2
Shell Closing
S1 TWD S1
LW 245/1 BWD LW 245/1 WF113100 LW 245/1
L Seam Set up
S2 BWD S1 SD S2,S3 TWD S1,S2
LW 247 SD
L Seam I/S
S2
LW 245/2 BWD LW 245/2 LW 247 SD
L Seam BG
S1 BWD S2 S3
L Seam O/S WA 104100 SD WA 104100
(NEW/OLD) S3 SD S1
WAO99200 BDF 300/12 WA 104100
L Seam Flush
SD S3 WD S1,S2 SD S2
Shell Re
Rolling
X Ray
Date - 09/03/10
WIP OF SHELL AREA
TIME: 11.15am
Plate Marking
WCO19200 SD WCO19200 LW 245/1 SD
Plate Cutting
S4 SD S1,S4,S5 S1,S3
WF113100
LW 243/1 SD WCO19200 LW 243/1 SD
Plate Rolling WD
S1 SD S2 S2
S1,S2,S3
LW 245/2 TWD
P/P Cutting
S2
LW 243/1 SD
Shell Closing
S3
WF113100 LW 245/1 LW 245/2
L Seam Set up
SD S1,S2,S3 TWD S1,S2 TWD S1
LW 245/1
L Seam I/S
BWD S1,S2
L Seam BG
L Seam O/S LW 247 SD LW 245/2 LW 247 SD LW 245/2
(NEW/OLD) S1 BWD S1 S2,S3 BWD S2
WAO99200 BDF 300/12 WA 104100
L Seam Flush
SD S2,S3 WD S1,S2 SD S2,S3
Shell Re WA 104100
Rolling SD S1
X Ray

Date - 10/03/10
WIP OF SHELL AREA
TIME: 11.15am
Plate Marking

35
 WCO19200 SD WCO19200 LW 245/1 SD
Plate Cutting
S1 SD S4,S3 S1,S3
WF113100
LW 243/1 SD WCO19200
Plate Rolling WD
S2 SD S2
S1,S2,S3
LW 243/1 SD
P/P Cutting
S1
Shell Closing
WF113100 SD LW 245/2 LW 243/1 SD
L Seam Set up
S1,S2,S3 TWD S1,S2 S3
LW 245/1 TWD LW 245/1
L Seam I/S
S2 BWD S1,S2
L Seam BG
L Seam O/S LW 247 SD LW 245/2 LW 247 SD LW 245/1
(NEW/OLD) S3 BWD S2 S2 TWD S1
WAO99200 BDF 300/12 WA 104100 LW 247 SD
L Seam Flush
SD S2,S3 WD S1,S2 SD S1,S2,S3 S1
Shell Re
Rolling
X Ray
Date - 12/03/10
WIP OF SHELL AREA
TIME: 9.40am
LW 240/1 BWD LW 240/1
Plate Marking
S1,S2 TWD S1,S2
WCO19200 SD LW 245/1 SD
Plate Cutting
S3,S5 S1,S3
WF113100 WD WCO19200
Plate Rolling
S2 SD S1,S2,S4
WF113100 WD WF113100
P/P Cutting
S1 WD S3
LW 243/1
Shell Closing
TWD S1,S2
LW 245/2 TWD WF113100 SD LW 243/1 SD
L Seam Set up
S2 S1,S2,S3 S3
LW 245/1 LW 245/2
L Seam I/S
BWD S1,S2 TWD S1
LW 245/1 TWD
L Seam BG
S2
L Seam O/S LW 247 SD LW 245/2 LW 245/1
(NEW/OLD) S3 BWD S2 TWD S1
WA 104100 SD WAO99200 BDF 300/12 LW 247 SD
L Seam Flush
S1 SD S2,S3 WD S1,S2 S1
Shell Re WA 104100
Rolling SD S2,S3
BDF 300/12
X Ray
WD S1,S2

Date -
13/03/10 TIME: WIP OF SHELL AREA
9.15am

36
 LW 240 TWD
Plate Marking
S1,S2
LW 245/1 SD LW 240 BWD
Plate Cutting
S1,S3 S1,S2
WCO19200 SD
Plate Rolling
S1,S2,S3,S4,S5
WF113100
P/P Cutting
WD S2
LW 243/1 TWD WF113100
Shell Closing
S1,S2 WD S1,S3
WF113100 SD WF113100 SD
L Seam Set up
S1 S2
WF113100
L Seam I/S LW 243/1 SD S3
SD S3
LW 245/1
L Seam BG
BWD S2
L Seam O/S LW 245/1 LW 245/1 TWD
(NEW/OLD) TWD S2 S1
LW 245/2 LW 245/2 BWD LW 247 SD
L Seam Flush
BWD S2 S1 S1,S2,S3
Shell Re WA 104100 SD
Rolling S1S2,S3
X Ray
Date - 14/03/10
WIP OF SHELL AREA
TIME: 9.40am
LW 245/1 SD
Plate Marking
S2
LW 240 TWD LW 240 BWD
Plate Cutting
S1,S2 S1,S2
WCO19200 SD LW 245/1 SD
Plate Rolling
S1,S2,S3,S4,S5 S1,S3
P/P Cutting
LW 243/1 TWD
Shell Closing
S1,S2
WF113100 WD WF113100 WD
L Seam Set up
S3 S1,S2
LW 245/2 TWD LW 243/1 SD WF113100 LW 245/2
L Seam I/S
S2 S3 SD S1,S2,S3 TWD S1
L Seam BG
L Seam O/S LW 245/1 LW 245/1 BWD
(NEW/OLD) BWD S1 S2
LW 247 SD LW 247 SD LW 245/1
L Seam Flush
S2 S1,S3 TWD S1,S2
Shell Re WA 104100 SD LW 245/2
Rolling S1S2,S3 BWD S1,S2
X Ray

Date - 15/03/10
WIP OF SHELL AREA
TIME: 9.20am
LW 245/1 SD LW 245/2 SD
Plate Marking
S2 S2

37
 LW 240 BWD
Plate Cutting
S1,S2
WCO19200
WCO19200 SD LW 245/1 SD LW 240 TWD
Plate Rolling SD
S2 S1,S3 S1,S2
S1,S3,S4,S5
P/P Cutting
Shell Closing
LW 243/1 SD WF113100
L Seam Set up
S2 WD S1,S2,S3
LW 245/2 TWD LW 243/1 SD WF113100 LW 245/2
L Seam I/S
S2 S3 SD S1,S2,S3 TWD S1
L Seam BG
L Seam O/S LW 245/1
NO LOAD
(NEW/OLD) BWD S2
LW 247 SD LW 245/1
L Seam Flush
S1,S3 TWD S1,S2
Shell Re
Rolling
LW 247 SD WA 104100 LW 245/2
X Ray
S2 SD S1S2,S3 BWD S1,S2
Date - 17/03/10
WIP OF SHELL AREA
TIME: 9.30am
LW 245/1 SD
Plate Marking
S1,S3
LW 245/1 SD LW 245/2 SD
Plate Cutting
S2 S2
WCO19200 SD WCO19200 LW 245/1 SD LW 240 TWD LW 240 BWD
Plate Rolling
S1 SD S3,S4,S5 S1,S3 S1,S2 S1,S2
WCO19200 SD
P/P Cutting
S2
Shell Closing
WF113100 WD WF113100
L Seam Set up
S1 WD S2,S3
LW 245/2 TWD LW 243/1 SD WF113100
L Seam I/S
S1 S1,S2,S3 SD S1,S2,S3
LW 245/2 TWD
L Seam BG
S2
L Seam O/S
NO LOAD NO LOAD
(NEW/OLD)
LW 245/1 BWD LW 247 SD LW 245/1 LW 245/1
L Seam Flush
S1 S2 TWD S2 BWD S2
Shell Re LW 247 SD LW 245/1
Rolling S1 TWD S1
LW 247 SD LW 245/2
X Ray
S3 BWD S1,S2

Date - 20/03/10 WIP OF SHELL AREA

Plate Marking
LW 245/2 SD LW 240 BWD LW 240 TWD
Plate Cutting
S1,S3 EV- II S1,S2 EV- II S1,S2

38
 LW 240 TWD LW 240 BWD
Plate Rolling
EV- I S1,S2 EV- I S1,S2
LW 245/1 SD LW 245/2 SD LW 245/1 SD
P/P Cutting
S1 S2 S3
WCO19200
Shell Closing
SD S4,S5
WCO19200
L Seam Set up
SD S3
WF113100
WF113100 SD WCO19200 WF113100
L Seam I/S WD
S1 SD S1,S2 SD S1,S2
S1,S2,S3
WF113100 SD
L Seam BG
S3
L Seam O/S LW 243/1 SD LW 243/1 SD
(NEW/OLD) S1 S3
LW 245/2 TWD LW 247 SD LW 245/1
L Seam Flush
S2 S2 TWD S2
Shell Re LW 245/1 BWD LW 245/2 LW 245/1
Rolling S1 TWD S1 BWD S2

Date - 21/03/10 WIP OF SHELL AREA

LW 240 BWD LW 240 TWD
Plate Marking
EV- III S1,S2 EV- III S1,S2
LW 245/2 SD LW 240 BWD LW 240 TWD
Plate Cutting
S3 EV- II S1,S2 EV- II S1,S2
LW 240
LW 245/2 SD LW 240 TWD
Plate Rolling BWD EV- I
S1 EV- I S1,S2
S1,S2
LW 245/1 SD LW 245/2 SD LW 245/1 SD
P/P Cutting
S3 S2 S2
LW 245/1 SD WCO19200
Shell Closing
S1 SD S4,S5
WCO19200 SD WCO19200
L Seam Set up
S1 SD S3
WF113100
WCO19200
L Seam I/S WD
SD S2
S1,S2,S3
WF113100 SD
L Seam BG
S1
L Seam O/S LW 243/1 SD WF113100 SD WF113100
(NEW/OLD) S1 S2 SD S3
LW 243/1 SD
L Seam Flush
S2,S3
Shell Re
Rolling
X Ray
Date - 22/03/10 WIP OF SHELL AREA
Plate Marking
LW 240
LW 240 TWD LW 240 BWD LW 240 TWD
Plate Cutting BWD EV- III
EV- II S1,S2 EV- II S1,S2 EV- III S1,S2
S1,S2
Plate Rolling NO LOAD

39
 LW 245/2 SD LW 240 BWD LW 240 TWD
P/P Cutting
S2 EV- I S1,S2 EV- I S1,S2
WCO19200
Shell Closing
SD S4,S5
LW 245/1 SD LW 245/1 SD WCO19200
L Seam Set up
S3 S1 SD S3
WCO19200
L Seam I/S
SD S2,S1
WF113100 WD WF113100
L Seam BG
S2 WD S3
L Seam O/S WF113100 SD WF113100 SD WF113100 WF113100
(NEW/OLD) S3 S2 SD S1 WD S1
LW 243/1 SD
L Seam Flush
S1,S3
Shell Re
Rolling
LW 243/1 SD
X Ray
S2

Date - 23/03/10 WIP OF SHELL AREA

LW 240 BWD LW 240 TWD
Plate Marking
EV- IV S1,S2 EV- IV S1,S2
LW 240 BWD LW 240 BWD LW 240 TWD
Plate Cutting
EV- II S1,S2 EV- III S1,S2 EV- III S1,S2
LW 240 TWD
Plate Rolling
EV- II S1,S2
LW 245/2 SD LW 240 BWD LW 240 TWD
P/P Cutting
S3 EV- I S1,S2 EV- I S1,S2
LW 245/2 SD WCO19200
Shell Closing
S1 SD S5
LW 245/1 SD LW 245/2 SD WCO19200
L Seam Set up
S2 S2 SD S3,S4
WCO19200
L Seam I/S
SD S2,S1
LW 245/1 SD LW 245/1 SD
L Seam BG
S1 S3
WF113100
L Seam O/S WF113100 SD WF113100 SD
WD
(NEW/OLD) S3 S1
S1,S2,S3
WF113100 SD LW 243/1 SD
L Seam Flush
S2 S1
Shell Re LW 243/1 SD
Rolling S3
X Ray

Date - 24/03/10 WIP OF SHELL AREA

Plate Marking
LW 240 BWD LW 240 BWD LW 240 TWD LW 240 TWD
Plate Cutting
EV- IV S1,S2 EV- III S1,S2 EV- III S1,S2 EV- IV S1,S2

40
 LW 240
LW 240 TWD
Plate Rolling BWD EV- II
EV- II S1,S2
S1,S2
LW 240
LW 240 TWD LW 240 TWD
P/P Cutting BWD EV- I
EV- I S1 EV- I S2
S2
LW 240 BWD
Shell Closing
EV- I S1
LW 245/2 SD LW 245/2 SD WCO19200
L Seam Set up
S1 S2,S3 SD S3,S4,S5
LW 245/1 SD WCO19200
L Seam I/S
S2 SD S2,S1
LW 245/1 SD
L Seam BG
S1
L Seam O/S WF113100 WD WF113100 SD WF113100 LW 245/1 SD
(NEW/OLD) S3 S1 WD S1,S2 S3
WF113100 SD WF113100 SD
L Seam Flush
S2 S3
Shell Re LW 243/1 SD
Rolling S1
X Ray

Date - 26/03/10 WIP OF SHELL AREA

LW 240 BWD LW 240 TWD
Plate Marking
EV- V S1,S2 EV- V S1,S2
LW 240 TWD LW 240 BWD LW 240 TWD
Plate Cutting
EV- IV S2 EV- III S1,S2 EV- III S1,S2
LW 240 TWD LW 240 TWD LW 240 BWD
Plate Rolling
EV- II S1,S2 EV- IV S1 EV- IV S1,S2
LW 240 BWD LW 240 BWD LW 240 TWD
P/P Cutting
EV- II S1 EV- II S2 EV- I S2
LW 240 BWD
Shell Closing
EV- I S2
LW 240 BWD LW 245/2 SD WCO19200
L Seam Set up
EV- I S1 S3 SD S4
LW 245/2 SD WCO19200
L Seam I/S
S1 SD S2
LW 245/1 SD LW 245/2 SD
L Seam BG
S2 S2
L Seam O/S WF113100 WD WF113100 LW 245/1 SD
(NEW/OLD) S1 WD S2 S1,S3
WF113100 SD WF113100
L Seam Flush
S1,S2 WD S3
Shell Re
Rolling
LW 243/1 SD
X Ray
S1,S3

Date - 27/03/10 WIP OF SHELL AREA

LW 240 TWD
Plate Marking
EV- V S1,S2
LW 240 BWD
Plate Cutting
EV- V S1,S2

41
 LW 240 LW 240
LW 240 TWD LW 240 TWD
Plate Rolling BWD EV- IV BWD EV- III
EV- IV S1,S2 EV- III S1,S2
S1,S2 S1,S2
LW 240 BWD LW 240 TWD
P/P Cutting
EV- II S2 EV- II S2
LW 240 BWD LW 240 TWD LW 240 TWD
Shell Closing
EV- II S1 EV- II S1 EV- I S1
LW 240 BWD LW 240 BWD LW 240 TWD
L Seam Set up
EV- I S1 EV- I S2 EV- I S2
LW 245/2 SD
L Seam I/S
S3
LW 245/2 SD
L Seam BG
S1
L Seam O/S LW 245/1 SD LW 245/1 SD LW 245/2 SD
(NEW/OLD) S2 S3 S2
WF113100
WF113100 SD LW 245/1 SD
L Seam Flush WD
S2 S1
S1,S2,S3
Shell Re WF113100 SD
Rolling S3
WF113100 SD
X Ray
S1

Date - 28/03/10 WIP OF SHELL AREA

Plate Marking
LW 240
LW 240 TWD LW 240 TWD
Plate Cutting BWD EV- V
EV- III S1,S2 EV- V S1,S2
S1,S2
LW 240 LW 240
LW 240 TWD
Plate Rolling BWD EV- IV BWD EV- III
EV- IV S1,S2
S1 S1,S2
LW 240
LW 240 BWD LW 240 TWD
P/P Cutting BWD EV- IV
EV- II S2 EV- II S2
S2
Shell Closing
LW 240
LW 240 TWD LW 240 TWD LW 240 TWD
L Seam Set up BWD EV- II
EV- I S2 EV- I S1 EV- II S1
S1
L Seam I/S NO LOAD
L Seam BG NO LOAD
L Seam O/S LW 245/2 SD LW 245/2 SD LW 245/2 SD
(NEW/OLD) S1 S2 S3
WF113100 WD LW 245/1 SD WF113100
L Seam Flush
S1 S1,S2,S3 WD S2,S3
Shell Re WF113100 SD
Rolling S1
WF113100 SD
X Ray
S2,S3

Date - 29/03/10 WIP OF SHELL AREA

Plate Marking
LW 240
LW 240 TWD LW 240 TWD
Plate Cutting BWD EV- V
EV- III S2 EV- V S1,S2
S1,S2

42
 LW 240
LW 240 TWD
Plate Rolling BWD EV- III
EV- III S1
S1,S2
LW 240 BWD LW 240 BWD LW 240 TWD
P/P Cutting
EV- IV S2 EV- IV S1 EV- IV S1,S2
LW 240 BWD
Shell Closing
EV- II S2
LW 240
LW 240 TWD LW 240 TWD LW 240 TWD
L Seam Set up BWD EV- II
EV- I S2 EV- I S1 EV- II S1,S2
S1
L Seam I/S NO LOAD
L Seam BG NO LOAD
L Seam O/S LW 245/2 SD LW 245/2 SD
(NEW/OLD) S3 S2
WF113100 WD LW 245/1 SD LW 245/2 SD
L Seam Flush
S3 S1,S2,S3 S1
Shell Re
Rolling
WF113100 WD
X Ray
S1,S2

Date - 30/03/10 WIP OF SHELL AREA

Plate Marking
LW 240
LW 240 TWD
Plate Cutting BWD EV- V
EV- V S1,S2
S1,S2
LW 240
LW 240 BWD LW 240 TWD
Plate Rolling BWD EV- III
EV- III S1 EV- III S1,S2
S2
LW 240 TWD LW 240 TWD
P/P Cutting
EV- IV S1 EV- IV S2
LW 240 BWD
Shell Closing
EV- IV S1,S2
LW 240 BWD LW 240 BWD LW 240 TWD
L Seam Set up
EV- II S2 EV- II S1 EV- II S1,S2
LW 240 BWD
L Seam I/S
EV- I S2
LW 240 BWD
L Seam BG
EV- I S1
L Seam O/S
NO LOAD NO LOAD
(NEW/OLD)
LW 245/1 SD LW 245/2 SD
L Seam Flush
S1,S2,S3 S1,S2,S3
Shell Re
Rolling
WF113100 WD
X Ray
S1,S2,S3

Date - 31/03/10 WIP OF SHELL AREA

Plate Marking
LW 240 TWD LW 240 BWD
Plate Cutting
EV- V S1,S2 EV- V S1,S2

43
 LW 240 TWD LW 240 BWD
Plate Rolling
EV- III S2 EV- III S2
LW 240 TWD LW 240 BWD
P/P Cutting
EV- III S1 EV- III S1
LW 240 BWD
Shell Closing
EV- III S2
WCO19200 SD LW 240 BWD LW 240 TWD WCO19200 LW 240 BWD
L Seam Set up
S3 EV- II S1,S2 EV- II S1,S2 SD S5 EV- IV S1,S2
WCO19200
L Seam I/S
SD S4
WCO19200
L Seam BG
SD S1
L Seam O/S LW 240 BWD LW 240 BWD WCO19200
(NEW/OLD) EV- I S2 EV- I S1 SD S2
LW 245/1 SD LW 245/2 SD
L Seam Flush
S1,S2,S3 S2,S3
Shell Re
Rolling
LW 245/2 SD
X Ray
S1

Date - 02/04/10 WIP OF SHELL AREA

Plate Marking
LW 240 TWD LW 240 BWD
Plate Cutting
EV- V S1,S2 EV- V S1,S2

44
 LW 240 TWD
Plate Rolling
EV- III S2
LW 240 BWD LW 240 BWD
P/P Cutting
EV- III S2 EV- III S1
LW 240 TWD
Shell Closing
EV- III S1
LW 240
LW 240 TWD LW 240 TWD WCO19200 LW 240 TWD
L Seam Set up BWD EV- IV
EV- I S1,S2 EV- II S1,S2 SD S5 EV- IV S1,S2
S1,S2
L Seam I/S
WCO19200 SD
L Seam BG
S3
L Seam O/S WCO19200 SD WCO19200 WCO19200
(NEW/OLD) S1 SD S2 SD S4
LW 240
LW 245/1 SD LW 245/2 SD
L Seam Flush BWD EV- I
S1,S3 S2,S3
S1,S2
Shell Re LW 245/1 SD
Rolling S2
LW 245/2 SD
X Ray
S1

Date - 03/04/10 WIP OF SHELL AREA

BDF 450/6 WD
Plate Marking
S1,S2
LW 240 TWD LW 240 BWD
Plate Cutting
EV- V S1,S2 EV- V S1,S2
Plate Rolling
P/P Cutting
LW 240 TWD
Shell Closing
EV- III S2
LW 240
LW 240 BWD LW 240 TWD LW 240 TWD LW 240 TWD
L Seam Set up BWD EV- IV
EV- II S1 EV- II S1,S2 EV- III S1 EV- IV S1,S2
S1,S2
LW 240 TWD
L Seam I/S
EV- I S1
LW 240 TWD
L Seam BG
EV- I S2
L Seam O/S WCO19200 SD WCO19200 WCO19200
(NEW/OLD) S5 SD S4 SD S3
LW 240
LW 245/1 SD LW 245/2 SD WCO19200
L Seam Flush BWD EV- I
S1,S3 S2,S3 SD S1,S2
S1,S2
Shell Re
Rolling
LW 245/1 SD
X Ray
S2

Date - 04/04/10 WIP OF SHELL AREA

Plate Marking
BDF 450/6 WD LW 240 TWD LW 240 BWD
Plate Cutting
S1,S2 EV- V S1,S2 EV- V S1,S2

45
Plate Rolling
P/P Cutting
Shell Closing
LW 240 BWD LW 240 TWD LW 240 TWD LW 240 BWD LW 240 TWD
L Seam Set up
EV- III S2 EV- II S1,S2 EV- III S1,S2 EV- IV S1,S2 EV- IV S1,S2
LW 240 TWD
L Seam I/S
EV- I S1
LW 240 BWD LW 240 TWD
L Seam BG
EV- II S2 EV- I S2
L Seam O/S WCO19200 SD WCO19200 LW 240 BWD
(NEW/OLD) S3 SD S4 EV- II S1
LW 240 BWD WCO19200
L Seam Flush
EV- I S1,S2 SD S1,S2,S5
Shell Re Rolling
LW 245/2 SD
X Ray
S2,S3

Date - 05/04/10 WIP OF SHELL AREA

Plate Marking
LW 240
BDF 450/6 WD BDF 450/6 LW 240 TWD
Plate Cutting BWD EV- V
S1,S2 WD S3 EV- V S1,S2
S1,S2
Plate Rolling
P/P Cutting
Shell Closing

LW 240 BWD
L Seam Set up
EV- IV S1,S2

LW 240 TWD
L Seam I/S
EV- I S2

LW 240 TWD
L Seam BG
EV- I S1

L Seam O/S LW 240 BWD

(NEW/OLD) EV- II S1
LW 240
LW 240 BWD WCO19200 SD
L Seam Flush BWD EV- II
EV- I S2 S1,S2,S3,S4,S5
S2
Shell Re
Rolling
LW 240 BWD
X Ray
EV- I S1

Date - 06/04/10 WIP OF SHELL AREA

Plate Marking
Plate Cutting BDF 450/6 WD BDF 450/6 LW 240 TWD LW 240
S1,S2 WD S3 EV- V S1,S2 BWD EV- V

46
 S1,S2

Plate Rolling
P/P Cutting
Shell Closing
LW 240 BWD LW 240 BWD LW 240 TWD LW 240 TWD LW 240 BWD
L Seam Set up
EV- III S2 EV- IV S1,S2 EV- III S1,S2 EV- IV S1,S2 EV- III S1
LW 240 TWD LW 240 TWD
L Seam I/S
EV- I S2 EV- II S1,S2
LW 240 TWD
L Seam BG
EV- I S1
L Seam O/S LW 240 BWD
(NEW/OLD) EV- II S1
LW 240
LW 240 BWD WCO19200
L Seam Flush BWD EV- II
EV- I S2 SD S3
S2
Shell Re WCO19200 SD WCO19200 WCO19200
Rolling S2 SD S4 SD S5
WCO19200 SD
X Ray
S1

Date - 07/04/10 WIP OF SHELL AREA

Plate Marking
LW 240
BDF 450/6 LW 240 TWD
Plate Cutting BWD EV- V
WD S3 EV- V S1,S2
S1,S2
BDF 450/6 WD
Plate Rolling
S2
BDF 450/6 WD
P/P Cutting
S1
Shell Closing
LW 240 TWD LW 240 BWD LW 240 TWD
L Seam Set up
EV- IV S1 EV- IV S1,S2 EV- IV S2
LW 240
LW 240 BWD LW 240 TWD LW 240 TWD
L Seam I/S BWD EV- III
EV- III S1 EV- I S2 EV- III S1,S2
S2
LW 240 TWD LW 240 TWD
L Seam BG
EV- II S1 EV- I S1
L Seam O/S LW 240 TWD
(NEW/OLD) EV- II S2
LW 240
LW 240 BWD WCO19200 LW 240 BWD
L Seam Flush BWD EV- II
EV- I S2 SD S3 EV- II S2
S1
Shell Re
Rolling
WCO19200 SD
X Ray
S1,S2,S4,S5

47
 Above table shows all station wise day to day data. This data helped to
track the daily position of he job, it helped to calculate the Work in Progress,
and due to this we were also able to calculate the TPT for shells according to
day to day productions of shells.
Following are actual changes in Shell area

L Seam Setup area before

48
49
L Seam Setup area after modification

50
L SEAM FLUSH AREA MODIFICATION

PRE-PINCHING AREA AFTER MODIFICATION

51
CONCLUSION:

52
 1) Shell area is visually managed.
2) TPT of shell reduced from 40 up to below 25.
3) Shell WIP maintained due to the separate allocation of areas.
4) Job searching time reduced.
5) Space utilization increased

ASSIGNMENTS:

53
 1) Center marking on dished end using template.
2) Cover plate on manhole rim to avoid spatters while edge
cutting.
3) Fixture for supporting test plate during L Seam BG.
4) Work station visual in dished end area

Center marking on dished end using template:

54
Introduction:
Dished End is the part of a drum which is welded on both sides of a
barrel to form it into a capsule. Dished End’s are of 3 different type of shapes
i.e. hemispherical, torrispherical and ellipsoidal. Usually dished end are hot or
cold pressed. The dished end blanks are cut in the shop and then sent for
pressing of forging.

Conventional process:
In conventional process the pressed dished are initially brought from
stores. Then, initially hook is welded to the dished end. After that the four
quadrants are been marked manually. Also 100 mm is taken on the either
sides of the point. Then the dished end is tilted up side down. Then again both
points taken are used to bisect the quadrant point. Then we get another point
similar on all four sides. Then again curve is drawn from these four points.
Finally the diagonals of this curved rectangle is joined to get center.

Raw Dished End:

55
Dished End with hook welded:

Dished End tilted with quadrants marked:

56
Dished End with center marked

Problems of conventional process:

57
 1) Marking time was more
2) More skill was required.
3) The process was lengthy.

Conclusion:
1) Setup time reduced.
2) Less skill required for marking.
3) Time required for center marking is much less compared to
conventional process.

58
Cover plate on manhole to avoid spatters:

Introduction:
After Dished end to manhole inside submerged arc welding the edge
cutting operation is performed on the dished end. During this the spatters are
fallen onto the machined face of the manhole.
So, after edge cutting again to remove the spatters the manhole rim
face had to be ground again. Thus, there was a type of rework which had to
be made on the manhole rim.

Actions taken:
So, To avoid the spatters on the machined face we had to prepare a
cover plate which would help to avoid the spatters to fall on machined surface
of the manhole

59
Conclusion;
Thus due to the lid of manhole type we were able to avoid the spatters
from damaging the surface of machined manhole and thus rework was
eliminated.

60
Fixture for supporting the test plate while L Seam BG:
While doing L Seam back gouging the gouging wheel remains totally
in contact with the job and is the depth is given more force is applied on the
job.
When the wheel reaches near the test plate portion of the shell then
as the test plate of the shell is of cantilever type the back gouging wheel
exerts force on the test plate part. So in order to eliminate the vibration at this
section of the job it was very necessary to prepare a fixture which would
support the test plate portion. Hence we designed the fixture of such type.

61
 As shown in the above figure there are two bars which are telescopic
type. The two pipes are simultaneously drilled on the drilling machine. The
inner pipe with smaller diameter fits into the outer pipe. The outer pipe and
inner pipe both are welded with 20 mm thick plate. As the inner pipe fits in
outer pipe then 16mm bolt is used to adjust the height of the fixture. Thus this
fixture can be varied from job of 750 mm to 2000 mm.
Thus due to this there was much rigidity obtained on the job and more
stiffness is at the test plate section. Also we can see that there is a jack on the

62
Work station visual in Dished end area:
The Dished end area is that area which is from raw pressed dished
end from the stores to the dished end to man hole completely welded. So it
was necessary to separately visualize these areas in order to easily identify
the areas. So, we decided to create visual display of section with photographs
showing the existing station operation, post operation and pre operation.
So the main stages of dished end area were as follows
1) Raw dished end.
2) Dished end to manhole marking and opening cutting.
3) Dished end to manhole setup.
4) Dished end to manhole inside submerged arc welding and edge
cutting.
5) Dished end to manhole back gouging.
6) Dished end to manhole outside submerged arc welding

63
64