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“Achieving excellence through IT and Automation a Bharat Forge Experience”

Ninth ARC India Forum, Pune August, 2011Achieving Operational Excellence Through IT and Automation

SolutionsMukund V Mavalankar

Director Technical

Bharat Forge Limited

mukund@bharatforge.com

Photograph of Speaker

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CHINA USAINDIAKey Companies in the Group

EUROPE

• Marsing, Denmark• Hikal Chemicals LtdSpecialty Chemicals

• Kalyani Steels Ltd

• Kalyani Carpenter Special Steels

• Kalyani Gerdau

Engineering Steel

• FAW Bharat Forge

• BF America• CDP Bharat Forge GmbH, Germany

• Bharat Forge Daun GmbH, Germany

• Bharat Forge Aluminiumtechnik GmbH, Germany

• Bharat Forge Kilsta AB, Sweden

• Bharat Forge Ltd

• Kalyani Thermal

Forgings

Auto Components • Automotive Axles Ltd

• Kalyani Lemmerz

• BF Utilities

• Kenersys India

• BF Alstom

• Khed Earth – The City

Energy & Infrastructure

Global Profile of Kalyani Group

• Kenersys GmbH, Germany

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5

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BFL

Bharat Forge – Global Profile

•Capacity over 750,000 Tons per annum •Crankshaft machining capacity of over 1 ,200,000 nos.

•Capacity to machine 500,000 FAB & 750,000 steering knuckles

CAPACITY

60,000 tons

• Strong Foray in the largest auto market USA

• Strong customer relationship

• Dual Shore manufacturing

• Manpower: 83 People

CAPACITY

200,000 tons

• Production base close to the customer

• Proximity to large marquee Customers

• Dual Shore manufacturing

• Manpower: 1060 People

CAPACITY

365,000 tons

• Worlds largest single location forging facility

• Technologically advanced, flexible forging & machining facility

• Proximity to fast growing Auto markets of China & india

• Dual Shore manufacturing

• Manpower: 4700 People

BF AMERICA Lansing4

6

BHARAT FORGE KILSTA,Sweden5

CDP BHARAT FORGE Ennepetal, Germany1

BF ALUMINIUMTECHNIK Dresden, Germany

3

CDP FORGEDaun, Germany2

FAW BF (Changchun) Co. Ltd. Changchun, China

CAPACITY

135,000 tons

• JV with FAW in China with 52% stake

• Foothold into fastest growing market

• Dual Shore Manufacturing

• Manpower: 1500 People

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ObjectivesObjectives

■ Till 1989 BFL was using manually operated pneumatic hammers for making forged parts.

■ Under the technology up-gradation initiative investment in two large completely Automatic forging lines.

■ The benefits envisaged

Improvement in Quality Improvement in Productivity Reduction in costs Saving in Energy Saving in Raw material

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Layout of First Fully Automatic forging lineLayout of First Fully Automatic forging line

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Scheme Sequential control for forging lineScheme Sequential control for forging line

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• Integration of diverse programmable controllers.

• Ease of sequential control and programming multiple part

types .

• Ease of diagnostics.

• Ease of monitoring complete line.

• Consistent process parameters leading to consistent quality

and higher OEE.

Advantages of hierarchical control

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Second wave of automation 1997Second wave of automation 1997

Automatic, programmable screw press with controlled energy for every blow and regenerative braking.

Judicious use of combination of • Fully programmable Hydraulic Robots

• First use of Electric robots,

• Dedicated manipulators

• Power and conveyors and walking beams.

Complete line integration with • Animated displays

• Single Console Operation

• First Use of Profibus

• Hierarchical PLC controls

Use of Automatic application of Die lubricant

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Up-gradation of Central Control 2011

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Third wave of automationThird wave of automation

The Kurimoto line was set up in 2006. This has taken BFL to next level of Automation. The salient features are

First Use of High speed Carbide sawsFirst Use of Transfer PressesFirst fully integrated single flow line in BFLPower and free cooling conveyor and over head gantries.Robots 6 Axis all ElectricReduced cycle time 8 sec untwisted/ 12 sec twisted cranksIncreased productivity Mass production of passenger car cranks.

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Next level of automation with remote I/Os

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Case Studies in machined components divisionCase Studies in machined components division

Cooling tower Flow control through automation to achieve Energy Conservation.

Automatic Monitoring of machine Parameters & pop up error messages on machine screen.

Two case studies

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Flow Control in Cooling tower Flow Control in Cooling tower

Per Day Energy Consumption @ 3000 Units

Sudden Starting tend to reduce Switch-gear life. Also Flow control adjustment required.

No Control on Real Time Basis

Before Implementation

Before3000

Cooling Tower is used for Cooling the Electrical switch-gear as well as quenching media.

In MCD1 we have used single cooling tower for more than 15 machines.

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DRIVE PANELMOTOR

CONTROL

DrivePLC

Interface

M/C M/C M/C M/C M/C

M/C M/C M/C M/C M/C

M/C M/C M/C M/C M/C

Temperature Sensor

Temperature Sensor

WATER IN

WATER OUT

COOLING TOWER

Sense the number of machine running & decide the flow

requirement

Sense the Difference in

Temperature of Incoming &

outgoing lines & Decide the Flow &

Exhaust Fan requirement

On Real Time basis switch On & off the

Cooling tower in Lunch / Dinner time

Flow Control in Cooling tower

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Sr No

Parameter Before After*

1 Power by the Cooling tower 120 KW 72 KW2 Power Factor 0.8784 >0.943 Unit Consumption per month 65000 Units 35000 Units4 Energy Cost (per Month) ` 325,000/- ` 175,000/-5 Savings in Energy cost 46%Per Million Contribution reduced by `1000 for MCD1

Flow Control in Cooling tower

After1750

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Manual monitoring of Machine Parameters

Machine Parameters are monitored for Predictive / Preventive Maintenance Plan.

This was done manually by the operator and relevant data was entered in the logbook.

Action Plan is communicated manually by each operator.

No interlock with machine Logic if any parameter is out of range.

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Machine

Pressure

Temperature

Oil Level

Programmable Controller Machine CNC System

Preventive Maintenance

Machine Parameter Monitoring

Machine CNC System (To generate Fault on

machine screen)

Machine CNC System (To generate Fault on

machine screen)

Separate Control System Designed & programmed for automatic monitoring of Machine Parameters

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Summing upSumming up

However we have challenges to overcome• Challenging Environment for Automation products

• High Temperatures• High level of Dust, Scale, Graphite and water• High impacts and rough use

We have huge scope to automate our forging lines by• Automatic application of Die Lubricant• Automatic control of Die Temperature• Automatic monitoring of presses and motors• Automatic inspection of Forged parts with Vision systems• Automation of Post Forging operations

► We have consistently used Robots and automation effectively to be

• More Productive

• More cost Effective

• More Energy efficient

• More Environmental Friendly