presentation - production management
TRANSCRIPT
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MMM
Sr. No. Names Roll No.
1 AJANI KAJAL P. MM-10-01
2 SWAMIKUTTY ANISH RAJ MM-10-02
3 DHAS AMIT J. MM-10-08
4 JADHAV SAMIR S. MM-10-14
5 KAMATH VINAYAK R. MM-10-15
6 RAI ANIKET B. MM-10-23
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Overview of Hindalco
Capacity - Aluminium:
Hindalco : 531 kt
Novelis : 2,943 kt
Capacity Copper : 500 kt
Turnover FY10:
Hindalco- Novelis
$ 13.7 bn.
Employees: 36,000
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Renukoot
Taloja
Hirakud
Alupuram
MoudaSilvassa Belur
Hindalco :
Footprint inIndia
Muri
Belgaum
Kalwa
Kollur
Integrated Plant
Foil
FRP
Alumina
Extrusions
Sales offices:Mumbai, Delhi, Bangalore, Kolkata
DAHEJ
Copper Smelter
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CMO
SBU HeadPrimary
SBU HeadExtrusions
SBU HeadRolled - Domestic
SBU HeadRolled - Exports
Central Market
Development
IT
Training &
Development
MarketingServices
MHO (Primary Metal, Rolled & Extrusions)
FRP & Extrusions has Independent Market Development Cell
Hindalco - Marketing Structure
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A typical Product Structure
Hindalco - Marketing Structure
SBU Head- Flat RolledProducts
RMNorth RMEast R M - West R M South
Market
Development Cell
Business
Finance
ProductExecutive
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Primary Aluminium
Ingots Wire Rods Billets
Major Usage : Auto Industry / Construction/ Electrical Industry
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Primary Metal -Castings
STEERING KNUCKLE WHEEL SUSPENSION ARM
SPACE FRAME NODE GS BRACKET
High purity aluminium required to ensure grain structure
Control Arm
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Extrusions
Major Usage : Building Industry, Industrial Machinery, Defence
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Flat Rolled Products
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COOK WARE
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FAN BLADE & VENETIAN BLINDS
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Semi rigid containers
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Al - Containers
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Pharma Foils- Printed
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PP Cap & Vial seals
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Vial seals
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H V A C
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H V A C
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Flooring Sheets
http://images.google.com/imgres?imgurl=http://www.artistic-license-inc.com/b2b/pics/Aluminium_Alloy_Panel.jpg&imgrefurl=http://www.artistic-license-inc.com/b2b/furniture_stocks/1/&h=334&w=359&sz=36&hl=en&start=15&tbnid=8qQUjbtgj1DTGM:&tbnh=113&tbnw=121&prev=/images?q=aluminium+panneling&gbv=2&hl=en&sa=G -
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ALUMINIUM COMPOSITE PANELS
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Building Sheets
http://images.google.com/imgres?imgurl=http://www.liangiap.com.my/wp-content/uploads/2007/10/pic81.gif&imgrefurl=http://www.liangiap.com.my/building-sheets&h=170&w=272&sz=49&hl=en&start=14&tbnid=JNvMGKLWqSHiNM:&tbnh=71&tbnw=113&prev=/images?q=aluminium+building+sheets&gbv=2&hl=en&sa=G -
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Curvomatic Roofings
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Cabinets
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Reflectors & diffusers
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Lamp caps
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Metal Bridges
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Electrical bus bars
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Lithographic sheets
Process Flow
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Process Flow
Al. Ingot
Rolling Ingot Continuous Cast Coil
Scalping
Soaking/Pre-Heating
Hot Rolling
Annealing
Cold Rolling
Finishing
Melting andCasting
(Direct ChillMethod)
Melting andContinuous
Casting
Profiling Roll Forming Circle Blanking SheetingShearing Coiling
Packing
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Aluminium Ingots
C i C i P
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Continuous Casting Process
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A process/facility of production ofslabs of various desired dimensionsfrom molten metal by extracting
heat through direct cooling by water,keeping both metal flow &thermodynamics in equilibrium.
Direct Clill Slab Casting
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Why Scalping ?
1. The outer surfaces of the ingots (both the flat surface and theedges) contain more of impurities, oxides and have greateralloy segregation.
2. For any critical application like those requiring for subsequent
rolling to thin or ultra thin gauges it is necessary to get rid ofthese surface impurities and segregation.
3. The depth of the unsound casting zone could be anything fromabout less than a millimeter to as high as 10 12 mm
depending on the casting technology, process controls and alloyof the cast.
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Preheating, Homogenizing and
soaking:
1. Casting leads to some extent of alloy heterogeneity in theentire mass of the ingots.
2. This heterogeneity needs to be taken care so that the finalproduct shows uniform physical and chemical propertiesmuch needed for uniform and smooth behaviors in furtherprocessing.
3. In order this to happen, the ingots are heated as close to the
solidifying temperature as possible. This process is calledHOMOGENIZATION. It is best carried out at temperatureas close to the solidifying (solidus) temperature as possible.
Soaking Pit
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Soaking Pit
Soaking Pit
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INGOT
HEATER FAN
INGOT
TOP VIEW
COVER
HEATER
FRONT VIEW
Soaking Pit
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1.Rolling is defined as the reduction of the cross-sectional area ofthe metal stock, or the general shaping of the metal products,through the use of the rotating rolls .
2.It allows a high degree of closed-loop automation and very
high speeds, and is thus capable of providing high-quality, closetolerance starting material for various secondary sheet metalworking processes at a low cost .
What do u mean by Rolling??
S h i D i f R lli P
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Schematic Drawing of Rolling Process
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Hot Rolling Mill converts preheated cast Aluminium slabs of thickness
approx. 305 /330 mm into a sheet/coil of thickness 6 to 9 mm bypassing the slab between work rolls for an integral number of times
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Annealing:
is a particular process of Heat treatment used torelieve the metal from internal stresses by loosingstored energy.
Metal losses its stored energy in the following threestages:
Recovery
Recrystallisation
Grain growth
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Remove internal stresses by heating to arelatively low temperature.
Dislocations start reducing and rearrangethemselves.
It does not affect grain structure.
It does not affect hardness & strength
Recovery:
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Recrystallisation:
Strain free new grains are formed.Hardness and Strength decreasessharply.
Grain growth:
Grains grow in size due to combination ofindividual grains.Boundary area reduces, so total energydecreases and grains become stable.
Annealing Furnace
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Annealing Furnace
GECA Annealing Furnace
Annealing Furnace
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Annealing Furnace
Sunbeam Otto Junker
What is Cold Rolling ?
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What is Cold Rolling ?Cold rolling is the process of getting desired
thickness of material by passing it through workrolls at normal temperature (Below Re-crystallization
temperature)
Angle of Bite
Cold Mill
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4.00 MM
6.50 MM
Uncoiler Coiler
4 Hi Mill
Bridle
Pass LineRoll
Pinch Roll
Deflector
X-RayGauge control
VidimonShape control
Cold Mill
Bliss Cold Mill
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Bliss Cold Mill
Davy Cold Mill
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Davy Cold Mill
S i i & Fl i
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Spinning & Flanging
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Stretching
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Bending & embossing
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Blanking & shearing
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Sheet Forming: a combination of Processes
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Equipment - Roll Former
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Equipment Roll Former
Gauge : 0.28-1.63 mm
Width : 800/950 for CR
795/920 for ICR
Length: 545 - 10000 mm (1875-7000 preferred range)
Consists of 2 rafts (for CR & ICR); 4 sub-rafts; 5 forming
rolls in each raft
Forming - from centre to side; last 3 rolls for widthadjustment
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