project on tool consumption in hero cycles in rim plant

7/28/2019 Project on Tool Consumption in Hero cycles in rim plant

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4.5 PROCESS FLOW CHART OF RIM MANUFACTURING

Loading of coil on decoiler

Tig welding

Drain hole

Stamping

Knurling

Form rolling

Seam welding

Profile rolling

Auto cutting

Butt welding

Sizing machine

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Auto punching

Loading of coil on de-coiler:-

Hero cycle used coils for the manufacturing of the rims. It has own plant that made steel coils

named as CR Division

Size of the coil for standard cycle rim: 76.20*0.850 mm

Picture shows mounting of coil on de-coiler-:-

Tigwelding:-

In rim plant tig welding is used for making a joint of coils during one coil is finished.

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Accumulator:-

Fig. shows construction of accumulator. Accumulator is mainly a well. It is usage is that the

worker can made a joint in coils without stopping the mill machine.

Drain hole:-

These are the small hole made in inner side of the rim to remove the water and other type of

fluid during the different process.these holes are produced on strip in the zigzag way.

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Stamping:-

during this process stamp of hero cycle is made on rim. Manufacturing date, and size of therim is stamp on the rim

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Knurling:-

In ranger cycle the knurling is made at the outer sides of the rim for making braking system

more effective.

View on one side view on other side

Form rolling:-

In form rolling, rollers of different shapes are used for rolling of the coil at its outer edges.

Picture shows the process of form rolling.

Seam welding:-

Seam welding used for welding a coil after rolling of coil at the inner side of the rim.fig

shows process of seam welding.

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Profile rolling:-

During the profile rolling roller of different shapes are used for giving the shape to the rim at

the middle portion of the rim. Picture shows the process of profile rolling.

Auto cutting:-

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There are many other machines are used in rim plant. These machines play important role in

a rim plant. Following are the machines.

Re-seem welding

Manual punching machine

Cutting press

Re-rolling machine

Take knowledge under the maintance department.

Repairing of gear boxes used in form rolling and profile rolling.

Assembling and disassembling of gear boxes.

Electrode changing of seem welding in case of faulty electrode

Seeing all processes under supervisor that made for converting the steel coil into final rim

Rim plant also containing electroplating of rim and polishing of rim

Project on reduction of tool consumption in mill of manufacturing by-cycle rim:

In rim plant, there are seven mills for manufacturing of rim of different shapes and sizes.

During the manufacturing of rim, rim undergoes in seem welding operation as shown above

in manufacturing processes of a rim. Seem welding is used to weld the inner sides of the steel

coil after the form rolling processes. In seem welding the 350v of current is set for the

effective welding of the rim.

During the seem welding operation the electrode of the seem welding machine is sparked at

the contacting surface of electrode and rim coil due to high voltage and the electrode get

darked with black colour at its outer periphery due to this rim made defective. To remove this

defect electrode is mounted with electrode sharping tool.Fig shows the mounting of tool with

electrode

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This tool is made of high speed steel. The high speed steel containing many elements other

than iron.

The chemical composition of HSS is

Carbon0.65 to 0.80 percent

Chromium 3.75 to 4.00 percent

Tungsten 17.25 to 18.75 percent

Vanadium 0.90 to 1.30 percent

And in very small proportions cobalt, molybdenum and aluminium and other elements that

may be present in small quantities are manganese, silicon, nickel, copper, phosphorus and

sulphur.

I do our project with the guidance of Mr. Pardeep verma manager of rim production dept. On

mill no. 9 and mill no. 10 of rim plant.

The tool used in seem welding is shown in this fig.

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Tool

Electrode


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As shown in a fig. this single tool is used up to above lines after that there is no further usage

of this tool. After that new tool is used for sharpening the electrode

Collection of past data regarding the consumption of tool:

MONTH CONSUMPTION OF TOOL/MONTH

December 11

January 9

February 10

The average consumption of tool per month is 10

HSS tool comes in industry as rectangular piece as shown below. After that it is designed in

required shape as per the requirement.

Grinding operations is done on rectangular piece of HSS tool, for giving required shape.

Approximately one and half day of workers is consumed in giving the required shape to the

tool used in one month.

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So about this study, I talked with Mr. Pardeep Verma and get decision for doing changes in

design of the tool so that consumption of that tool is reduced.

Changes in design of Tool used in Seem welding operation:

There is a small change between the old design of the tool and the modified design of tool. Inold design as shown in below fig there is a cutting portion of tool shank. That is the week part

of that tool. The tool is used only above that portion. If that tool is again used it will break

because of low strength.

Cutting portion

Modified design of the tool:

Fig shows the modified design of the tool. There is no week section of tool,the cutting portionin the shank of tool is eliminated. In operation or in mounting of the tool, there is no usage of

that cutting portion.

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Result and Cost Benefit:

Tool consumption reduced from 10 tools/month to 5 tools/month.

Grinding operation eliminated which resulted into saving of 1.5 man days/month.

Cost saved : Cost of the one tool is = Rs.1891

Cost of the man power = Rs. 1000

Cost of the 5 tool is 1891*5 = 9455

Total cost saved: 9455+1000 = 10455 per month

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project on tool consumption in hero cycles in rim plant

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