MODIFICATION AND OPTIMIZATION OF INVERT VERTICAL DRAWING MACHINE

IVD 800

PROJECT REVIEW

DATE: 16-04-2012

GUIDED BY MEMBERSMR. S. BOOPATHI KARTHICK S -98608114017

M.E, (PH.D) GOWTHAM A B -98608114011

ASST PROFESSOR VIMAL RAJ K -98608114059

ABOUT THE INDUSTRY

Project done at TVS Sundram Fasteners Ltd, Krishnapuram, Madurai

Company specializes in manufacturing Fasteners using Cold Forging and also manufacture some powder metallurgy parts.

Gives lot of importance for quality and has implemented lot of quality tools like TPM, Kaizen, etc.

Has consistently got awards for quality like Deming Award, TPM award, etc

ABOUT THE PROCESS

Raw material coming to the plant is checked for quality and then it is treated by means of annealing, phosphating, acid bath to remove rust and soften the metal for Cold Forging.

Then the Raw Material is wire drawn using wire drawing machines including IVD 800.

The drawn wires are taken to the Bolt Modules where bolts are manufactured using automated machines.

The bolts are hardened, tempered and then packed for delivery.

ABOUT IVD 800

Invert Vertical Drawing Machine IVD 800 has been imported from Chengi Machine Co. Ltd, Taiwan.

The main purpose of the machine is to draw the raw material to the standard dimensions using roller dyes.

The wires are sent through rollers which reduce the dimension and after that they are pressed against cylinder by means of rollers.

MODEL OF IVD 800

PROBLEM FACED

The machine is not able to support wires of larger diameter.

The actual speed of the motor is 110 m/min. But it is currently run at 60-70 m/min due to the danger of wire getting out of the machine.

The rollers are not able to support wires of diameter greater than 14.6 mm, though the machine is actually capable of supporting wires up to 18 mm diameter.

PROBLEM SOLVING METHODOLOGY

In order to solve the problem, two management tools were considered.

They are Fishbone diagram (Cause and Effect Analysis) and Forced Field Diagram.

Fishbone diagram is done in order to find out the major cause of the problem.

Forced Field Analysis is done after deciding a solution. It is done in order to find out whether the solution is suitable or not.

FISHBONE DIAGRAM

Fishbone diagram also called as Cause and Effect diagram is a management tool invented by Prof. Kauro Ishikawa.

In the diagram the causes for the problem and the sub causes are described like the bones of a fish.

In IVD 800, the major causes found are workers, rollers, process, prior processing and motor.

FISHBONE DIAGRAM FOR IVD 800

FORCED FIELD ANALYSIS

After discussing the solutions, we decided to do a Forced Field Analysis to find out the optimum solution.

Forced Field Analysis is a new Management Technique in which we assign a score or mark to each parameter that supports the change and oppose the change.

The score is assigned after consultation with experienced staffs and labors.

If the supporting change has higher value then we can decide that the solution will be effective.

FORCED FIELD ANALYSIS FOR INTRODUCING THIRD ROLLER

SOLUTION

Based on the management tools, it is decided to introduce a new roller.

The first roller is kept undisturbed. The second roller is turned anticlockwise and

the length of the horizontal support is decreased in order to make the angle 120º

The third roller is introduced by drawing a circle with 45.5 cm radius, which is the length of second roller support that is going to be used for the third roller.

At a suitable point we fix the support.

GENERATION OF THE GEOMETRY

VIEWS BEFORE AND AFTER

MODIFICATION

BOTTOM VIEW BEFORE MODIFICATION

BOTTOM VIEW AFTER MODIFICATION

ISOMETRIC VIEW BEFORE MODIFICATION

ISOMETRIC VIEW AFTER MODIFICATION

PROPOSED MODEL

AMOUNT OF WIRE PROCESSED – BEFORE AND AFTER

If the machine is run at 65 m/min, then the amount of wire processed per hour is approximately 3900 m.

By introducing the third roller, we can run the machine at 110 m/min and let us consider that the machine is run at 90 m/min. The amount of wire processed in an hour will be

60 min *90 m/min = 5400m We will be able to process an additional 1500

m of raw material per hour.

GRAPH – FEED RATE OF WIRE PER HOUR

IMPROVEMENT IN THE MACHINE

Expected Improvement in Efficiency =(New Length – Old Length)/ Old

Length= (5400-3900)/ 3900= 38.46%

Be introducing the third roller, we would be able to process wires nearly 1.38 times the wires that are currently processed.

IMPROVEMENT IN EFFICIENCY

CONCLUSION

Thus the model generated will used to introduce a third roller in the existing machine.

The third roller will enhance safety for the workers, improve the speed of the machine and will ensure wires of higher diameter are run.

It will increase the amount of Raw Material supplied to the Bolt manufacturing Modules in the industry.

REFERENCES

Operating Manual of Invert Vertical Type Drawing Machine – Chi Ning Company Ltd.

http://www.mindtools.com/pages/article/newTED_06.htm

http://www.mindtools.com/pages/article/newTMC_03.htm

http://en.wikipedia.org/wiki/Ishikawa_diagram http://www.accel-team.com/techniques/force_

field_analysis.html https://forum.solidworks.com/thread/51997

THANK YOU!!!