REDUCTION OF PLATE SCRAP OF A BATTERY BY

USING MECHANICAL METHODS

By
P.Satyanarayana 06191A0310
D.Sudhakar Reddy 06191A0325
D.Dinesh Kumar 06191A0314
P.Sravani 06191A0304
P.Anusha 06191A0321
Company Introduction
ARBL is one of the biggest plant in Asia (area of 165 acres), most
advanced microprocessor controlled and fully integrated state of the art
manufacturing facility located at Tirupati, Andhra Pradesh with capital outlay of
Rs.180 crores.
Amara Raja is a public limited company whose scip is a joint venture between
Amara Raja group and Johnson Control Inc., USA. As of now 26% equity is with
JCI & Amara Raja group each and the rest 48% is with the public.
Amara Raja is the tenth largest MF-VRLA battery manufacturer in the world.
Amara Raja is also the largest supplier of VRLA batteries for various applications to
Indian Railways such as Train Lighting, Air Conditioning, Signal and Telecom
Batteries & AC Loco Batteries

Oxide Plant
Grid
Casting
Paste
Mixing &
Pasting
Plate
Curing
Plate
Cleaning
Stacking
Group
Burning
Insertion
Heat sealing
Post
Burning
Leak
Testing
Cell
Packing
Acid Filling
Cell
Forming
Cell Cleaning
& Insertion
Finishing
Packing &
Dispatch
Process flow for LVRLA
Process flow for MVRLA
Heat sealing
Post
Burning
Leak
Testing
Cell
Packing
Acid Filling
Cell
Forming
Cell Cleaning
& Insertion
Finishing
Packing &
Dispatch
Oxide Plant
Grid
Casting
Paste
Mixing &
Pasting
Plate
Curing
Plate
Cleaning
Envolop
Stackin
g
Cast on
Strap
Insertion
Inter cell
welding
Manufacturing
Section
Plate
Preparation
Assembly
Formation
Finishing
Industrial Battery
Industrial Battery Division (IBD) - LVRLA
Oxide Plant
Grid Casting
Pasting
Manufacturing Sections of IBD - LVRLA
Sub-Section
Busbar Casting
Plate curing
Plate cleaning
Dispatch
Plate Preparation
Oxide Plant
Grid casting
Pasting
Oxide Plant
Grid Casting
Pasting
Oxide Powder
Pbo2+H2So4 + Dm Water+
Chemicals = Paste
Grid + Paste=Plate

+
Pure Lead (99.97 %)
MFX & LCA
Lead Alloys
Paste
Section/Process
Input
Output
Oxide Plant
Pasting
Grid Casting
POS & NEG Plate
POS & NEG Grid
Grid
Lead Oxide Manufacturing
Process Flow Diagram
Lead Ingot
Lead Ingot Melting
Reaction
Oxide Powder Filtering
Quality Check Points:
1. % Free Lead
2. Apparent Density
3. Acid Absorption
Transfer to Silos
Oxide Storage in Silos
1. Molten Lead
2. Water
3. Air
Balox & Eagle
Oxide plants
Silos
Hammer Milling
Additional activity
For MVRLA
Lead Oxide Plant
Input & Out put Diagram
Oxide Preparation
Exothermic
reaction
Pure Lead(Pb)
Ingots 99.97 %
Lead
Oxide(PbO)
Pb + O2
Pbo
H2O
Pasting
Process Flow Diagram
Plate cleaning
Quality Check Points:
1. Free Lead %
2. Dry plate Moisture
3. Vibration loss%
Curing & Drying
Dry Plates Storage
1. Wet plates
2. Boiler
Cleaned Plates
Curing Ovens

Lead oxide powder stored in silo for min of 18hr. Then it is used to produce paste mix.


Composition used:

For Positive Paste:

Lead oxide 1000kg
Binder 0.5Kg
SPTH 2Kg
DM water 126lt
Sulfuric acid 110kg(Sp. gravity 1.4)

For Negative Paste:

Lead oxide 1000kg
Binder 0.5Kg
Barium Sulphate 20Kg
Vanisperse 2Kg
Carbon Black 2Kg
DM water 116lt
Sulfuric acid 110kg(Sp. gravity 1.4)

PASTE PREPARATION:
Plate Curing
Input & Out put Diagram LVRLA & MVRLA
Curing
Wet pasted
plates
Dry
plates
PROBLEM:

Plate scrap in pasting

OBJECTIVE:

To reduce the plate scrap in pasting.

To reduce the plates scrap from 2.4% to 1.35% per month
12-STEPS FOR PROBLEM SOLVING
STEP-1 IDENTIFICATION OF PROBLEMS
STEP-2 SELECTION OF THE PROBLEM
STEP-3 DEFINITION OF THE PROBLEM
STEP-4 ANALYSIS OF THE PROBLEM
STEP-5 IDENTIFICATION OF CAUSES
STEP-6 FINDING OUT THE ROOT CAUSE
STEP-7 DATA ANALYSIS
STEP-8 DEVELOPING SOLUTION
STEP-9 FORESEEING PROBABLE RESISTANCE
STEP-10 TRIAL IMPLEMENTATION & CHECK PERFORMANCE
STEP-11 REGULAR IMPLEMENTATION
STEP-12 FOLLOW UP/REVIEW
Step-1 Identification of Problems
Using Brainstorming
S.NO IDENTIFICATION OF PROBLEMS CAT:A\B\C
1 Plate Weight variation. A
2 Improper Filling of paste on grids A
3 Lug side over paste A
4 Filling problem of paste on grids A
5 Tool setting problem A
6 Flash Drier chain Vibration A
7 Parter timing problem A
8 Temp problem in Flash Drier B
9 Grid cutting problem A
10 Parter center chain sprocket problem B
11 Belt Nylon bed problem B
12 Heaters set fixing problem C
13 Feeder chain timing problem A
14 Grid feeding Rubber roller problem A
15 Knurling roller Bush problem B
16 Knurling roller Shaft problem B
17 Drive roller problem A
18 Drive roller Pins problem A
19 Drive roller Black bush problem B
20 Hopper Shaft bush problem B
Step-1 Identification of Problems
Using Brainstorming
21 Hopper Guard bush problem B
22 Hopper Bottom shoe guard problem B
23 Transfer roller bush problem B
24 Lug cleaning brush problem A
25 Parter Speed control Sensor problem B
26 Oxide leakage (Near Oxmaster lids ) B
27 Mixer Scrapers worn-out A
28 Slide gate Sensor problem B
29 Thermo couple problem in mixer B
30 Thermo couple Sensor problem in mixer B
31 Thermo couple cylinder problem B
32 Mixer Dumping Door Sensor problem B
33 Slide gate Water leakage problem B
34 Air leakage in mixer B
35 Acid leakage in mixer B
36 Acid Valve (Filling and Dumping) problem B
37 Mixer motor guard problem B
38 Oxmaster cone gear box problem B
39 Oxmaster cone Cylinder problem B
40 Oil leakage in mixer B
41 Plates scrap in pasting A
42 Hydraulic oil leakage in Hydraulic unit B
43 Hydraulic pressure problem B
44 Plates pallet Down in Assembly A
45 Plate Sagging problem A
Using Brainstorming
Step-1 Identification of Problems
46 Scissor lift problem at plate collecting area B
47 Bottom paste Tray problem B
48 Parter width Adjustment problem B
49 Fresh Air not working properly (Pressure low ) B
50 Pallet truck problem in pasting B
51 Plate Cross cutting problem in parter A
52 Heaters Failure in Flash drier B
53 Hydraulic pressure gauge Oil leakage B
54 Feeder center guide not working properly A
55 Lifting plates problem B
56 "D" Type Ovens Plates Moisture problem B
57 Transfer roller Speed problem B
58 Parter chain Bearing problem B
59 Forklift problem B
60 Oxide transfer problem to Day tank B
61 Day tank bin vent problem B
62 Day tank load cells problem B
63 Silos load cells problem B
64 Lighting problem in Grid feeder B
65 Weighing scale problem B
66 Plate storage Stands problem A
67 PP sheets problem A
68 High pressure pump problem B
PROBLEM CLASSIFICATION
ABC-ANALYSIS
CATEGERORY
N
O
.
O
F

P
R
O
B
L
E
M
S

A-21
B-46
C-01
Problems solved
by qc members
Where help is required
from other departments
Where management
help is required
Using Brainstorming
VICTORY
Step-2 Selection of the Problem
Ranking method
Ranking 01 - Low 05 - Moderate 10 - High
Sl No Problems V.R.R K.V D.S G.G Y.M Total
1 Plate Weight variation. 6 7 5 8 6 32
2 Improper Filling of paste on grids 5 6 4 5 4 24
3 Lug side over paste 9 9 10 9 10 47
4 Filling problem of paste on grids 5 6 2 4 5 22
5 Tool setting problem 5 6 4 3 6 24
6 Flash Drier chain Vibration 5 5 5 5 5 25
7 Parter timing problem 6 6 6 6 6 30
8 Temp problem in Flash Drier 6 4 4 4 4 22
9 Grid cutting problem 5 6 6 6 7 30
10 Parter center chain sprocket problem 4 5 5 5 5 24
11 Belt Nylon bed problem 5 7 5 4 5 26
12 Heaters set fixing problem 6 5 6 5 4 26
13 Feeder chain timing problem 5 5 7 7 6 30
14 Grid feeding Rubber roller problem 6 8 6 7 3 30
15 Knurling roller Bush problem 5 4 7 2 5 23
16 Knurling roller Shaft problem 6 6 4 5 4 25
17 Drive roller problem 5 5 5 4 5 24
18 Drive roller Pins problem 7 4 5 6 3 25
19 Drive roller Black bush problem 5 6 6 4 6 27
20 Hopper Shaft bush problem 6 7 7 3 8 31
21 Hopper Guard bush problem 8 4 6 4 4 26
22 Hopper Bottom shoe guard problem 5 6 7 5 6 29
23 Transfer roller bush problem 8 5 4 6 5 28
24 Lug cleaning brush problem 6 7 6 4 7 30
25 Parter Speed control Sensor problem 7 6 5 5 2 25
26 Oxide leakage (Near Oxmaster lids ) 6 8 4 7 4 29
27 Mixer Scrapers worn-out 6 5 8 8 6 33
28 Slide gate Sensor problem 6 6 6 4 5 27
29 Thermo couple problem in mixer 5 8 7 5 4 29
30 Thermo couple Sensor problem in mixer 4 7 6 4 7 28
31 Thermo couple cylinder problem 5 6 8 5 5 29
32 Mixer Dumping Door Sensor problem 6 5 2 6 6 25
33 Slide gate Water leakage problem 5 8 4 5 4 26
34 Air leakage in mixer 4 6 6 6 3 25
35 Acid leakage in mixer 5 5 4 7 4 25
36 Acid Valve (Filling and Dumping) problem 6 7 6 6 4 29
37 Mixer motor guard problem 5 4 5 5 5 24
38 Oxmaster cone gear box problem 4 5 5 4 5 23
39 Oxmaster cone Cylinder problem 6 4 7 6 6 29
40 Oil leakage in mixer 7 5 6 5 4 27
Ranking method
Step-2 Selection of the Problem
Ranking 01 - Low 05 - Moderate 10 - High
41 Plates scrap in pasting 10 9 9 10 9 47
42 Hydraulic oil leakage in Hydraulic unit 5 5 6 6 4 26
43 Hydraulic pressure problem 5 7 5 5 7 29
44 Plates pallet Down in Assembly 10 9 9 10 9 47
45 Plate Sagging problem 5 6 4 6 4 25
46 Scissor lift problem at plate collecting area 2 6 6 8 6 28
47 Bottom paste Tray problem 5 5 5 5 5 25
48 Parter width Adjustment problem 4 4 4 6 4 22
49 Fresh Air not working properly (Pressure low ) 6 4 5 5 5 25
50 Pallet truck problem in pasting 3 5 7 6 4 25
51 Plate Cross cutting problem in parter 5 5 6 7 6 29
52 Heaters Failure in Flash drier 4 5 4 5 4 22
53 Hydraulic pressure gauge Oil leakage 3 5 6 6 7 27
54 Feeder center guide not working properly 4 7 5 5 5 26
55 Lifting plates problem 6 6 4 6 8 30
56 "D" Type Ovens Plates Moisture problem 2 4 6 7 4 23
57 Transfer roller Speed problem 6 5 5 4 5 25
58 Parter chain Bearing problem 5 4 5 6 6 26
59 Forklift problem 5 3 4 5 4 21
60 Oxide transfer problem to Day tank 4 5 3 4 4 20
61 Day tank bin vent problem 5 4 4 2 2 17
62 Day tank load cells problem 4 5 4 4 3 20
63 Silos load cells problem 5 4 2 3 4 18
64 Lighting problem in Grid feeder 4 3 3 5 2 17
65 Weighing scale problem 4 4 2 2 5 17
66 Plate storage Stands problem 5 5 4 4 2 20
67 PP sheets problem 4 3 5 3 4 19
68 High pressure pump problem 5 2 2 2 5 16
Step-2 Selection of the Problem
Ranking method
Ranking 01 - Low 05 - Moderate 10 - High
Step-2 Selection of the Problem
PRIORITY METHOD
S.NO Problem NOT URGENT(0) URGENT(2) VERY URGENT(5) TOTAL
1 Lug side over paste 1 2 2 14
2 Plates scrap in pasting . 2 3 19
3 Plates pallet Down in Assembly 2 2 1 9
PLATES SCRAP IN PASTING HAS SCORED MAXIMUM MARKS
AND IS SELECED FOR OUR PROJECT
Step-3 Definition of the Problem
Pasting Process Flow Chart
PASTING
GRID FEEDER
HOPPER PASTE MIXER
FLASH DRIER
PARTER
PASTE
STACKING
Step-4 Analysis of the Problem
Problem analysis was carried out through
4W 1H Technique

WHAT - Plates scrap in pasting

WHEN - During pasting
WHERE - In pasting section

WHO - Pasting operators

HOW - By analysing the causes and developing solution
Step-4 Analysis of the Problem
Manufacturing cost
Productivity
Operator stress
WEEKS PRODUCED SCRAP
PLATE REJECTION
COST(Rs)
WEEK1 287130 1747 37300
WEEK2 357637 14363 30665
WEEK3 467330 8375 17881
WEEK4 406708 12813 27355
AVERAGE: 9324 No 28308 RS
Step-5 Identification of Causes
Men Machine
Method
Material
Lack of awareness
Lifting problem feeder
Feeder chain timing change
Driver roller bush
and block worn out
Driver roller worn out
Oxide usage with out aging
Grids usage with out aging
Paste problem

Improper tool setting
Cause and effect diagram
Plates
scrap
Conveyor chain vibration
Porter dog chain
timing change

V belt worn out
Brush worn out
Pressure plate improper setting
First sample checking
Cross cutting

Improper pate filling
198400
55007
41956
30958
20832
18024
15496
10109
7221 6376
5081
4116 3483 3445
2372 1384
672 600 500 118 28
46.6%
59.5%
69.3%
76.6%
81.5%
85.7%
89.3%
91.7%
93.4%
94.9%
96.1%
97.0%
97.9%
98.7%
99.2% 99.5% 99.7% 99.8% 100.0%100.0%100.0%
0
50000
100000
150000
200000
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0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
90.0%
100.0%
Pareto analysis
N
o

o
f


p
l
a
t
e
s

76% OF REJECTIONS OCCURING DUE TO VIBRATION LOSS,CROSS CUTTING
PARTER JAMMING,IMPROPER PASTE FILLING
Causes
Step-4 Analysis of the Problem
Step-6 Root Cause Analysis
Data collection
FROM DATA COLLECTION 76% OF REJECTIONS OCCRING DUE TO

1. VIBRATION LOSS
2. CROSS CUTTING
3. PARTER JAMMING,
4. IMPROPER PASTE FILLING
Vibration losses Cross cutting Parter jamming Improper paste filling
Action (3W 1H)
Step-8 Development of Solutions
WHAT WHO WHEN HOW
P.Satyanarayana 24feb-20marFlash drier chain modification
do Increasing quantity of binder addition
D.Dinesh Kumar do Sprocket modification
do Giving awareness to the operator
do Changing freuency of cutter fixing
D.Sudhakar Reddy do Brush level modification
p.Anusha do Prater on/off switch near to operator
do Pressure plate adjustment
IMPROPER FILLING
p.sravani do cone switch near to operator
VIBRATION LOSSES
CROSS CUTTING PLATES
PORTER JAMMMING
Step-8 Development of Solutions
Using Brainstorming
Vibration looses
Flash drier chain modification

Increasing quantity of binder addition


Cross cutting
Sprocket modification

Giving awareness to the operator

Fixing the changing frequency of cutter

Step-8 Development of Solutions
Using Brainstorming
Parter jamming
Brush level modification

Parter on/off switch near to operator
Improper paste filling
Pressure plate adjustment

Cone switch near to operator


BEFORE
Problem Improvement
Due to more length of chain, plates are
getting vibrated
The length of the chain has decreased
by removing six links
AFTER
Flash drier chain modification
Step-10 Trail Implementation & Check Performance
BEFORE
Problem Improvement
Due to frequent loosing of sprocket causing
Dog chains unlevel leading to cross cutting
Sprocket was fixed with supporting rod
provide to prevent frequent loosing
AFTER
Sprocket Modification
Step-10 Trail Implementation & Check Performance
Step-10 Trail Implementation & Check Performance
BEFORE
Problem Improvement
Due to brush unlevel causing plates
disturbance leading to cross cutting of
plates
Brush level is fixed with supporting rod
to avoid cross cutting
AFTER
Brush level modification
Step-10 Trail Implementation & Check Performance
BEFORE
Problem Improvement
Due to unlevel of pressure plate causing
over paste on lugs leading to disturbance at
the brushes
The springs in the pressure plate has
modified.
AFTER
Pressure plate modification
Step-10 Trail Implementation & Check Performance
BEFORE
Problem Improvement
switch is near to cone due to this operator
feeling difficult for frequent access
Cone switch provided near to operator
so that he can frequently fill the paste
in hopper
AFTER
Cone switch
Step-10 Trail Implementation & Check Performance
BEFORE
Problem Improvement
Cross cutting occurring due to Parter on/off
switch far from operator
Parter on/off switch provided near to
operator
AFTER
Parter switch


STANDARDISATION
Step-11 Regular Implementation





To avoid vibration losses binder addition increased from 1kg to 1.25kgs
for positive and 1kg to 2.5kg for negative.
Check list for Parter cutter changing for every 800000 plates
STANDARDISATION
Step-11 Regular Implementation
Step-12 Follow Up & Review
12813
5342
1137
1297
0
20000
40000
60000
80000
100000
120000
140000
PLATE REJECTIONS
N
O
.
O
F

P
L
A
T
E
S

R
E
J
E
C
T
E
D

GOAL: To reduce the plates scrap from 2.4% to 1.35%

TANGIBLE BENIFITS
INTANGIBLE BENIFITS
1. Developed leader ship Qualities
2. Pride in achievement
3. Opportunity of learning
4. Self motivation
Plates saved per week =4177 No
Cost saved per week =89178 Rs/-

Before modify scrap%=(avg.scrap/produced plates)
(9324/379701)=2.4%
After modify scrap%=5147/379701=1.35
1. Brain Storming
2. Bar Graphs
3. Ranking Technique
4. Flow Diagrams
5. 4W&1H Method
6. Ishikawa Diagram

Application Segments / Costumers
Industrial Batteries
Railways
Power Generation
Oil & Gas
Process Industry
Defence
Motive Power
DG Set- Auxiliary power
Telecommunications


Plates scrap in pasting has played prominent role in reduction and
wastage of huge amount , large amount of workers working hours so we
have reduced by implementing some of the mechanical techniques.

As we had the goal to reduce the plates scrap from 2.4% to 1.35%,
But we achieved 1% by implementing the all techniques and tools used.