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FOUR MONTHS INTERNSHIP REPORT TATA STEEL LTD GLOBAL WIRES- INDIA. Report Date: 24 TH MAY 2015 Title: “ To study handling time of wire drawing machine no 107& 108 and find a solution to reduce the same ” Submitted by: Mr. ABHISHEK DHIMAN B.TECH (OPERATIONS) CHANDIGARH GROUP OF COLLEGES(GHARUAN CAMPUS,MOHALI) Duration: 22 JAN 2015 TO 30 JUNE 2015 Project Guide: Mr. DAVID WILLIAMS {SENIOR MANAGER(Engineering & projects )TATA STEEL LTD.

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FOUR MONTHS INTERNSHIP REPORT

TATA STEEL LTDGLOBAL WIRES- INDIA.Report Date:24TH MAY 2015

Title: To study handling time of wire drawing machine no 107& 108 and find a solution to reduce the same

Submitted by:Mr. ABHISHEK DHIMANB.TECH (OPERATIONS)

CHANDIGARH GROUP OF COLLEGES(GHARUAN CAMPUS,MOHALI)

Duration: 22 JAN 2015 TO 30 JUNE 2015

Project Guide:Mr. DAVID WILLIAMS{SENIOR MANAGER(Engineering & projects )TATA STEEL LTD.

ACKNOWLEDGEMENT I take this opportunity to express my sense of thankfulness to all those who guided me and helped me whenever going the second difficulty and road ahead was not visible.I extend my special thanks to Mr. DAVID WILLIAMS (SENIOR MANAGER (Engineering & projects) for giving me this opportunity to enhance my knowledge. I am also thankful to Mr.Sagar Bhosekar (Operations manager) for assigning me to the project which was truly enriching in nature and scope.I would also like to thank Mr.SHAILAV PRAKASH (Sr. HR Manager) for providing me necessary support throughout the project.Last but not the least I would like to thank the staff and all other those who helped me in my project.

PROBLEM STATEMENT

PROBLEM DEFINITION: To study the handling time of wire drawing machine no 107 & 108 and to find a solution to reduce the same

OBJECTIVE : Minimize the time consumption of operational activities. Increase the productive time. Optimize the use of human resources. Find the problems related to wire drawing machine no 107& 108

EXECUTIVE SUMMARY

Project report on To study the handling time of wire drawing machine no 107 & 108 and to find a solution to reduce the same

TATA STEEL SS-Plant is located at tarapur MIDC at boisar. This plant is designed to manufacture steel spring wire rods. This plant comprises of many automatic and manual wire drawing machines.

This project is study of various operations of wire drawing machine which involves in manufacturing of wires. This operations requires certain time to complete and this is considered as handling time.

The project shows the impact of handling time on production, workers working efficiency and recommended process time for various operational activities. The operational activities which takes long setting time or operation time like Program Change, Killing Setting, Wire Break Issues, Operational Issues, etc, and their impact on productive time. As this operations take longer time, production decreases, so this time should be decreased if possible by finding other method.

Increasing the production with less cost and time and considering the essential factors is ultimate goal. To achieve this company implements various production tools like KAIZEN, JIT, SGA for continuous improvement and increasing productivity.

Safety is considered at all points in company to ensure prevention of accidents.

The objective considering improvement area are:

1) To increase green belt.2) To reduce use of water, energy.3) To ensure zero accidents in plant.4) To prevent injuries and ill health.

To conclude had a great learning experience at TATA STEEL SPRING STEEL-PLANT.

INDEXSR NO.CONTENTPAGE NO.

1INTRODUCTION TO TATA GROUP06

2INTRODUICTION TO TATA STEEL09

3INTRODUCTION TO WIRE DRAWING PROCESS15

4WIRE DRAWING PROCESS ACTIVITY SEQUENCE DIAGRAM17

5 METHODOLOGY USED FOR PROJECT18

6STUDY OF HANDLING TIME OF ACTIVITIES OF WORKERS19

7WIRE DRAWING MACHINE 107 IDLE TIME ISSUES26

8WIRE DRAWING MACHINE NO 107 PROBLEMS 3333

9WIRE DRAWING MACHINE 108 IDLE TIME ISSUES

10WIRE DRAWING MACHINE NO 108 PROBLEMS 33

11SUGGESSION

1. INTRODUCTION TO TATA GROUPTATA GROUPThe Tata Group of Companies, founded by Jamsetji Tata, has emerged as one of the most respected and successful business conglomerates in the world today. With an illustrious history of over a hundred and thirty years behind it, the Tata group has followed a route of growth. Tata group helped steer Indias ascent in the global map by focusing on sustainable development. Over 350,000 people worldwide are currently employed in the Tata Group. There are seven business sectors (114 companies and subsidiaries) in which the Tata Group Companies operate. It is the largest employer in India in the Private Sector and continues to lead with the same commitment towards social and community responsibilities as it had shown in the past. Tata group has its operations spread in over 80 countries, with products and services available in over 85 countries. The different sectors where Tata has spread its business are shown in this figure :

Fig 1: TATA BusinessesTATA Group has seven sectors and each has its individual contribution to the business. The Engineering sector has the highest contribution to the overall business followed by Materials.

Fig 2: TATAs Business sectors

The Tata group has a robust presence in Engineering, with operations in automobiles and auto components and a variety of other engineering products and services. Engineering sectors is classified as two one being automotive and the other as engineering. Some companies that come under 1) Automotive Sector: Jaguar Land Rover, Tata Daewoo Commercial Vehicle Company, Tata Hitachi Construction Machinery, Tata Motors, Tata AutoComp Systems, Tata Cummins.2) Engineering : Tata consulting engineers, Tata manufacturing solutions, Tata precision industries, Tata Projects, TRF, VoltasThe Tata group is among the global leaders in Materials business sector, with operations in steel and composites. Some companies that come under 1) Metals: Tata Metaliks, Tata Sponge Iron, Tata Steel Europe, Tata Steel 2) Composites: Advanced materialsThe next major contributor is the IT & Communications. The Tata group has well-established enterprises in the fields of software and other information systems, telecommunications and industrial automation. Some companies that come under1) Information Technology : CMC, Computational research Laboratories, Nelito Systems, Tata Business support services, Tata Consulting Services, Tata Elxsi2) Communications: Tata Sky, Tata Teleservices, Tata Communications.Rest of the sectors contribution is relatively lesser and hence, not taken into consideration now. 2. INTRODUCTION TO TATA STEEL2.1. TATA STEEL Tata Steel was established in the year 1907. It is amongst the top ten global steel companies with an annual crude steel capacity of over 28 million tonnes per annum. It is now one of the world's most geographically-diversified steel producers, with operations in 26 countries and a commercial presence in over 50 countries.The Tata Steel Group, comes under the material sector of the Tatas business sectors. It had a turnover of US$ 24.82 billion in FY 2012- 2013 and is a Fortune 500 company.Tata Steels vision is to be the worlds steel industry benchmark through the excellence of its people, its innovative approach and overall conduct. Underpinning this vision is a performance culture committed to aspiration targets, safety and social responsibility, continuous improvement, openness and transparency.Tata Steel India is the first integrated steel company in the world, outside Japan, to be awarded the Deming Application Prize 2008 for excellence in Total Quality Management (TQM). Operating companies within the Group include Tata Steel Limited (India), Tata Steel Europe Limited (formerly Corus), NatSteel, and Tata Steel Thailand (formerly Millennium Steel).Tata Steel manufactures a wide range of products both branded and non-branded under different divisions which are as under1. Flat Products 2.Long Products 3. Agrico4. Bearings 5. Tata Tubes 6. Tata Wiron

2.2. TATA STEEL GLOBAL WIRESTata Steel has brought all its wire manufacturing under the scope of the Global Wires Business. Manufacturing facilities have spread across India, China, Thailand and Sri Lanka. The Company has fully integrated manufacturing cycles, from sourcing of raw materials to in-house steel making and wire rod rolling facilities. In India, the division is setting up a world class manufacturing facility at Tarapur and also modernising the existing facilities at The Indian Steel & Wire Products in Jamshedpur. The Wire Division has been the sole supplier of pre-stressed concrete strands used in the construction of precast segments for the 4.7 kms, 8-lane- cable-stayed Bandra-Worli Sea link at Mumbai, India.

Fig 3: Global Division

2.3. TATA STEEL WIRE DIVISION, INDIATata Steel Wire Division (TSWD) is the pioneer of steel wire industry in India and today is the largest manufacturer and leader in India. It was started as Special Steel LTD in 1958. And it was acquired by TATA Steel in 1984. It had started off as an umbrella ribs manufacturer and now it is serving four industries of Auto, Construction, Power and Retail. Tata Steel Wire Division was one of the founder members and has over the years managed to get many of the medium sized wire manufacturers under one trade association The Steel Wire Manufacturers Association of India (SWMAI) to ensure that there is a platform for sharing concerns and a single-body representative with regulatory authorities and customer/supplier. Wire Division has thus adopted the following benchmarking processes- Product& Services benchmarks are based on customer perception and satisfaction and by laboratory comparisons with competitor product samples. TWSD has been constantly striving to create customer value by offering these differentiated products.

Fig 4: Classification of TATA Steel wires products

Typical of Steel industry, and more so in wires, a key point is to be noted is thatproduct changes are few and far in between. Tata wires are intermediate products which are converted or assembled into products which in turn touch the end consumers. TWSD customers in the institutional business are OEMs such as tire manufacturers like MRF, JK Tyres, APOLLO Tyres, etc. with clearly defined technical specifications.

2.4. WIRE DIVISON COMPRISE OF THE FOLLOWING PLANTS

Fig 5: TATA Steel wires division plants.

2.5. TATA STEEL MAJOR CUSTOMER TATA STEEL-WIRE DIVISION manufactures a variety of single and stranded, coated and uncoated steel wires catering to various industrious like construction, cable and conductor manufacturing infrastructure, automation, tyres industry, bearing and fastener industry, textile industry. Tata steel WD sells about 81% of its production in the domestic market and the rest is exported to USA, Australia, New Zealand, Middle East and south Asian countries. In the domestic market 40% of the sales are in the Western region, 35% in the southern region and 25 % in the Northern region and the rest in the eastern region.

2.6. TATA STEEL MAJOR COMPETITORS ARCELORMITTAL. ESSAR STEEL. JSW STEEL. SAIL. VISA STEEL.

2.7. ORGANIZATIONAL STRUCTURE OF TATA STEEL WIRE DIVISION.

MANAGING DIRECTOR

DEPUTY MANGING DIRECTOR

VICE PRESIDENT LONG PRODUCTS

EXECUTIVE IN CHARGE

CHIEF HEAD SR.MANAGER MANAGER ASSOCIATE

STAFF GROUP LEADER WORKERS

Fig 6. TATA STEEL wire divisionOrganizational position structure

2.8. ORGANIZATIONAL CULTURE

1)VALUES :

INTEGRITY UNDERSTANDING UNITY RESPONSIBALITY

2) VISION STATEMENT :

To seize the opportunities of tomorrow and create a future that will make us an EVA positive company. To continue to improve the quality of life of our employees and the communities we serve.

3) MISSION STATEMENT :

Achieve sustainable, profitable growth in steel wire and related businesses. Create differential value to our customers through innovative offerings. Continuous improvement of business processes and technologies. Foster partnership with key stake holders. Enhance employees competencies to create a high performing and innovative organization. Be a responsible corporate citizen and enhance the quality of life of employees and key community.

3. INTRODUCTION TO WIRE DRAWING PROCESSIn the drawing process, the cross-sectional area and/or the shape of a rod, bar, tube, or wire is reduced by pulling through a die. One of the oldest metal-forming operations, drawing allows excellent surface finishes and closely controlled dimensions to be obtained in long products that have constant cross sections. In drawing, a previously rolled, extruded, or fabricated product with a solid or hollow cross section is pulled through a die at exit speeds. The die geometry determines the final dimensions, the cross-sectional area of the drawn product, and the reduction in area. Drawing is usually conducted at room temperature using a number of passes or reductions through consecutively located dies. An important exception is the warm drawing of tungsten to make incandescent lamp filaments. Annealing may occasionally be necessary after a number of drawing passes before the drawing operation is continued. The deformation is accomplished by a combination of tensile and compressive stresses that are created by the pulling force at the exit from the die and by the die configuration.

Fig1.Wire Drawing Process

1) A TYPICAL MULTI-PASS WIRE DRAWING MACHINE.

2) DIE THROUGH WICH WIRE PASSES.

3) DIES OF DIFFERENT SIZES TO GET DESIRED DIAMETER OF WIRE.

4.WIRE DRAWING PROCESS ACTIVITY SEQUENCE DIAGRAM

5. METHODOLOGY USED FOR PROJECT

The methodology followed during the course of the project is shown below:

6.STUDY OF HANDLING TIME OF ACTIVITIES OF WORKERS

1) RM LOADING :

PROCESS DISCRIPTION: This is the process where operators lift the coils or the RM by the crane from storage area and load to the Payoff for further processing. This handling process usually takes time of 8-10 minutes depends on operators efficiency. The recommended time for handling this activity is 10 minute.

COMPARATIVE STUDY:

DISCRIPTION: The above graph shows the different time taken by different operators for same process of RM loading. The graph is based on actual observation during internship.2) WELDING WIRES

PROCESS DISCRIPTION: This is the process where operators join the wires at payoff for the continuation of wire drawing process so that workers need not repeat the whole process of passing wires through each die block. The operators carry out different activities in wire joining like pointing, welding, finishing and graphite pasting. The operators ensure the welding is proper and will not break. Handling this process usually takes time of 20-30 minutes depends on workers efficiency and skills. The recommended time for handling this activity is 21 minute.

COMPARATIVE STUDY:

DISCRIPTION: The above graph shows the different time taken by different operators for the same process. The graph compares the operators on basis of individual activity as well as overall activity. The graph is based on actual observation during internship.

3) WIRE BREAK HANDLING :

PROCESS DISCRIPTION: This is the process where operators join the wire which breaks anywhere in the wire drawing machine while in process. The operators carry out different activities in wire break like wire unloading from machine, wire joining pointing, loading wire again to drum. The operators ensure the welding is proper and will not break. Handling this process usually takes time of 40-45 minutes depends on workers efficiency and skills. The recommended time for handling this activity is 40 minute.

COMPARATIVE STUDY:

DISCRIPTION:

The above graph shows the different time taken by different operators for same process of Wire Break Handling.. The graph is based on actual observation during internship.

3) PROGRAM CHANGE :

PROCESS DISCRIPTION: This is the process where operators new program of wire drawing .The operators carry out different activities for program change in sequence. First the operator removes the powder and the old wire from the machine. Then he loads the RM to the payoff and welds the two RM start and end point. The operator then removes the dies and installs the number of dies of various sizes as per program and required diameter of wire. This process takes more time than all other processes. Then the operator points the wire by pointing machine so that the diameter of wire is reduced to pass form all dies .the wires is then passed from first die block and load to roller drum using dog chain. Same way it is passed through the die blocks as per program to get required diameter of wire. Then the important step is killing setting. in this the operator sets the finish pass block in such a way that the whenever the wire is cut the end of wire is in perfect shape. Samples are checked to get proper killing setting. After killing setting wire is attached to coil catcher and wire drawing process starts. Handling this process usually takes time of 20-30 minutes depends on workers efficiency and skills and recommended time for handling this activity is 199 minutes.

COMPARATIVE STUDY:

DISCRIPTION: The above graph shows the different time taken by different operators for the same process. The graph compares the operators on basis of individual activity as well as overall activity. The graph is based on actual observation during internship.

7.WIRE DRAWING MACHINE 107 IDLE TIME ISSUES

7.1DISCRIPTION: The above graph shows the time taken by the activities during last six months. The blue bar in graph shows the time taken by different activities and red line shows the action to be taken on activities which cuts at 80. To reduce the handling time and increase the productive time the activities to which red line cuts at 80 should be focused first as this has major impact and then rest of activities. Here researcher found that Program change, Wire break, Operational issue are the major impactors of handling time so they must be further studied and try to reduce the handling time of this activities.

7.2 WIRE BREAK ISSUE :

DISCRIPTION: The above graph shows the wire break held at which block of machine. The blue bar in graph shows the time taken by different wire break during last six months. This graph shows us which block of machine have more wire breaks so that we can take action on it or try to find the problem in particular block for wire break. To reduce the handling time and increase the productive time the blocks with major time consuming should be focused for taking action. Here researcher found that Block no 1, Block no 2, Block no 3, and Payoff Entanglement are major problems of wire break in machine no 107.

7.3 WIRE BREAK REASONS :

DISCRIPTION: The above graph shows the wire break reasons of machine no 107. The blue bar in graph shows the time taken by different reasons of wire break during last six months. This graph shows us reasons of wire break in machine so that we can take action on it or try to find the solution problem. To reduce the handling time and increase the productive time this problems must be solved.

7.4 DISCRIPTION: The above graph shows the time taken by different activities under operational issue during last six months. The blue bar in graph shows the time taken by different activities and red line shows the action to be taken on activities which cuts at 80. To reduce the handling time and increase the productive time the activities to which red line cuts at 80 should be focused first as this has major impact and then rest of activities. Here researcher found that Killing Setting, Powder Change, Wire Overlapping are the major impactors of handling time, so they must be focused and try to reduce the handling time of this activities.

7.5 PROGRAM CHANGE TIME :

DISCRIPTION: The above graph shows the time taken by different programs of machine 107. These programs are set according to the diameter of wire to be input and diameter of wire to be obtained. The above graph is prepared by calculating the recommended times of all the processes to be carried out during the program change and overall time required for the particular program can be determined approximately. The program change time can vary from operator to operator, depending on his efficiency, skill and experience.

7.6 PROGRAM CHANGE PROCESS :

DISCRIPTION: The above graph shows the time taken by different activities under the Program Change.

DISCRIPTION: The above graph shows the time taken by different activities under the Program Change. The graph is based on observation during internship . In the above graph there is comparison of actual time taken for program change by operators and recommended time to be taken by operators. Here the researcher found that actual time taken by the operators is more than the recommended this leads to increase in idle time. To get the maximum productive time this time must be reduced, so the operators need to work efficiently.

8) WIRE DRAWING MACHINE NO 107 PROBLEMS

1) MAIN ISSUES:1) Crane availability is issue, which causes delay or leads to increase in idle time. 2) Machine no 107 is has less automatic control like auto machine stop on wire break. 3) Payoff entanglement is problem for machine 107.4) Block no 2 in wire drawing machine gives problem of wire break.

2) POSSIBLE CAUSES FOR THE LONG SETTING TIME :1) Payoff arms work manually, so operators needs to lift them manually which is heavy task. 2) System not synchronous i.e. wire feeding and extraction time delay.3) Long distance to be covered for the operator in case of any problem (like when wire snaps).4) Requirement of more efficient personnel.5) Requirement of effective cooling arrangement due to high temperatures causing wire to expand while passing through the dies.6) Die not rotating properly.

3) POSSIBLE CAUSES FOR DEFECTS OCCURRING DURING WIRE EXTRACTION :1) Threading not done properly.2) Die oversize.3) Wire not rounded properly.

4) PROBABLE CAUSES FOR WIRE SNAPPING :1) Defects in the original wire.2) Butt-welding not strong enough. 3) Wire gets entangled.4) Inappropriate die used (when die too small for wire diameter).

9.WIRE DRAWING MACHINE 108 IDLE TIME ISSUES

9.1DISCRIPTION: The above graph shows the time taken by the activities during last six months. The blue bar in graph shows the time taken by different activities and red line shows the action to be taken on activities which cuts at 80. To reduce the handling time and increase the productive time the activities to which red line cuts at 80 should be focused first as this has major impact and then rest of activities. Here researcher found that Program change, Wire break, Operational issue are the major impactors of handling time so they must be further studied and try to reduce

9.2 WIRE BREAK ISSUE :

DISCRIPTION: The above graph shows the wire break held at which block of machine. The blue bar in graph shows the time taken by different wire break during last six months. This graph shows us which block of machine have more wire breaks so that we can take action on it or try to find the problem in particular block for wire break. To reduce the handling time and increase the productive time the blocks with major time consuming should be focused for taking action. Here researcher found that Block no 1, Block no 2, Block no 3, and Payoff Entanglement are major problems of wire break in machine no 107.

PROGRAM CHANGE PROCESS :

DISCRIPTION: The above graph shows the time taken by different activities under the Program Change.

STUDY ON WIRE DRAWING MACHINE

DUTTY DESIGNED :-Wire Drawing Machine No.109 Is Designed For Following Dutty;

8mm(inlet tensile110-125 Kg/mm2) to 3.2mm at speed of 8m/sec. 7mm(inlet tensile110-135 Kg/mm2)to 2.77mm at speed of 9m/sec. 5.5mm(inlet tensile90-135Kg/mm2)to 2.47mm at speed of 9m/sec. 5.5mm(inlet tensile90-135Kg/mm2)to 1.4mm at speed of 12m/sec. 5.5mm(inlet tensile90-135Kg/mm2)to 1.2mm at speed of 12m/sec.

TECHNICAL SPECIFICATION OF WIRE DRAWING MACHINE

Following Specification For m/c No. 109

No. of dies- 12+1 Skin Pass. Blocks- 1st Block 650mm dia. Vertical overhead take off (OTO) type. 2nd to 9th Pass 650mm dia inclinded tuner roller blocks. 10th to 11th pass 650mm dia vertical full dancer blocks. 12th pass 650/650mm dia vertical double desk block with str -aightners and non riding stripper.

Die Box- All dies are made up of TUNGSTEN CARBIDE Fixed die boxes are adjustable in two planes and suitable for Accepting dry soap lubricant. There are provided two rotating Die boxes 7th Block and 12th Block. Blocks are made up of spec -Ial alloy forged steel and the drawing portion induction harde -ned. To 55-58 HRC For high wear resistance and are fastened To cast iron hub.

Die Case Size- 53die30 mm is standard size.

Cooling Of Blocks And Dies- A complete piping system for water cooling of the blocks and Die stands are provided. A max. water temp. of 250c to 320c And a pressure of 2.8 Kg/cm2 is to be ensured Additionally The block surface is cooled by air blower.70to75 lts per min. Per block water is required. Also, dry compressed air with FRL unit with capacity of 15 CFM at a pressure of 6 Kg/cm2is Required for surface cooling of blocks.

Power Transmission- Drive to the blocks are provided through motors,v-pulley and Cogged raw edge belts/gear reducers. Power should be 58Kw AC Motor with invertor drive at speed Of 1150 RPM. Same power required for RDH.

5. SPARE PARTS OF WIRE DRAWING MACHINE

LIST OF BEARINGS :

OTO BLOCK ASSEMBLYsr. no.Types Of Bearings Bearing No.

1Taper Roller Brg.33024

2Taper Roller Brg. 30209 j2/Q

3Deep Groove Ball Br 6005-2Z

2nd Intermediate block assembly 1 Tapper Roller Brg. 3302 3rd,4th,5th&6th Intermediate Block Assembly 1 Taper Roller Brg. 33024

7th,8th,9th,10th,11th Intermediate Block Assembly 1 Taper Roller Brg 33024 2 Spherical Roller Brg. 23122CC/W33 Final Block Assembly

1 Taper Roller Brg 33024 2 Spherical Roller Brg. 23122CC/W33

Stripper Assembly

1 Thrust Ball Brg. 51104

S.T. Assembly

1 Double Row Ang. Ball Brg. 3303A-2Z 2 Deep Groove Ball Brg. 6305-2Z

Upper Guide Shave Assembly

1 Spherical Roller Brg. 22207-CC

Full Dancer Assembly 1 Deep Groove Ball Brg. 6213-2Z

2 Deep Groove Ball Brg. 6213-2Z

Sensor Arm Assembly

1 Deep Groove Ball Brg 6208-2Z

2 Deep Groove Ball Brg 6005-2Z

Die Holder Assembly

1 Deep Groove Ball Brg. 61907-2Z

Drive Assembly

1 Taper Roller Brg. 30316J2 2 Taper Roller Brg. 30314J2/Q

Roller Assembly 1 Deep Groove Ball Brg. 6004-2Z

2 Deep Groove Ball Brg. 6305-2Z

Anti Chattering Assembly

1 Deep Groove Ball Brg. 6001-2Z

Transfer Pulley Assembly

1 Deep Groove Ball Brg 6305-2Z

LUBRICATION CHART FOR WIRE DRAWINGS MACHINE Sr. NO.Types of LubricantGradeApplicati-onGrease oil change Intervals

1GreaseServogen 2 or 3Bearings, slides chain and guidesEvery 200 operating hours

2Gear Box OilISO VG 220Gear Box,Piv-chain TypeChange every 10000 operating hours

3Hydraulic POWRE Pack oilISO VG 68Hydraulic CylindersChange every 20000 operating hours

4Pneumatic Lubricator OilISO VG 10Lubrication of PneumaticsFill Every 15 Days Once

SUGGESSIONS

1) Lunchtime could be utilized for cleaning and lubricating machine and machine parts to ensure longetivity.2) M.M.D and E.M.D work of regular maintenance should be performed during long operations like program change3) SMED if implemented can reduce the handling time and can lead to increase in productive time.4) DIE SET should be directly changed instead of removing it and changing die in it, this will result in saving the time of handling and result in increase of productive time .5) Payoff should be installed with hydraulic jacks as the arms are heavy and need to lift them manually to load coils.6) Crane should be utilized alternatively for coil loading, coil catcher unloading as it is used for both the 107 and 108 machine.7) A wire straightness apparatus (like the one having bubble using the centre of gravity principle) could be used to give the straightness. The existing method used is very crude and non-scientific.

BIBLIOGRAPHY

1) www.Wikipedia.com2) www.TataSteel.com3) www.4) Companys reports5) Daily CommunicationBook6) Machine Record Book.