A REPORT ONINDUSTRIAL INPLANT TRAINING AT THERMAX LIMITED, CHINCHWAD, PUNE-411 019 FROM 1ST JANUARY 2006 TO 30TH JUNE 2006 SUBMITTED BY ANAND DHARIYA B.E. MECHANICAL (SANDWICH) ROLL NO. 4212 EXAM SEAT NO. B2211212 UNDER THE GUIDANCE OF PROF. P.V. DESHMUKH DEPARTMENT OF MECHANICAL ENGINEERING, ALL INDIA SHRI SHIVAJI MEMORIAL SOCIETY’S, COLLEGE OF ENGINEERING, PUNE-411 001 2005-2006 ABSTRACT The following report gives a detailed and comprehensive insight into the work done i.e. the various projects and assignments completed during the course of 6 months ‘Industrial Inplant Training’ while working in the Manufacturing Department, Machine shop at Plant 11 of the Cooling & Heating Division of Thermax Ltd. Chinchwad, Pune from 1st January to 30th June 2006. TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. ACKNOWLEDGEMENT 1 INTRODUCTION TO ‘THERMAX LIMITED’ 1. History of Thermax ltd. 2. Divisional Profile 3. Group Companies 4. Plant profile 01 – 21 01 05 15 16 2 TUBE-PLATE STAND 1. Objective and Need 2. Chiller tube plates 3. Design of Stand 4. Salient features 5. Benefits 6. Savings 7. Future Prospects 8. Conclusion 22 – 29 22 24 26 27 28 28 28 29 3 TPM STEP 3 OF CNC ARBOGA-3 CO-ORDINATE DRILLING MACHINE 1. Introduction to TPM 2. AM Step 1 3. AM Step 2 4. AM Step 3 5. Savings 6. List of other TPM undertaken 30 – 68 30 37 50 59 66 68 Preparation of Drawings of templates 3. Design of Shadow Board 4. Cost saving 6.4 DESIGN OF TEMPLATE BOARD FOR ROUNDO ROLLING MACHINE 1. Benefits of Shadow Board 5. Conclusion CONCLUSION REFERENCES 69 – 74 69 70 72 73 74 74 75 76 . Objective & Need 2. and allowing me to pursue and complete my second phase of Industrial in-plant training of Mechanical Engineering (sandwich) course at their Chinchwad plant. P. Lastly. I consider myself privileged in doing so. but a big ‘THANK YOU’ to THERMAX LTD. Head of Mechanical Engineering Department. thanks to the employees of ACD who always extended a helping hand. . for his keen observation on my progress. 28th June 2006. guided me throughout the course of my training with great affection and patiently answered all my questions. All my efforts reached fruition. and for developing a strong friendship. Ashok Sakpal for keeping trust in me and granting me the opportunity to work in this great organization. Sachin Bhakade from Plant 11 Machine shop who also doubled up as friends. Yet.. Ravi Inamdar and his colleagues Mr. My sincere thanks to Prof. it was a great pleasure to undergo my second phase of training with the company. Mahendra Kadam deserves special thanks for making the drawings on Auto CAD and helping in other drafting work due to which all our designs could be materialized. Chaitanya.ACKNOWLEDGEMENT Even after completing the first phase of sandwich training at Thermax. I would also like to thank all my trainee colleagues who always stood by me as brothers. I would also like to thank Mr. Anand Dhariya.V. college guide. for making it possible for me to undergo training and Prof. Vinod Patil and Mr. What can I say. to which I shall always remain indebted for the faith it has placed in me by letting me once again be a member of this great family. Thanks are also due to my company guide Mr. Deshmukh. Mr. It is very difficult to express in a few words the gratitude towards people so near to the heart. . across diverse industry segments – be it a small scale unit which needs a 600 kg/hr. name itself specifies the accuracy and efficiency of this fast growing organization. as a small boiler-manufacturing unit in Dadar (Mumbai). chemicals. industrial & domestic water treatment.I.Pune-1 1 . had occupied an area of 5000 square feet. Even in this age of cybernetics. & grain storage system A. THERMAX means maximum utility of thermal energy. boilers that produce steam are critical on-line equipment. It began manufacturing coil type packaged boilers unit called ‘Vaporax’ and then thermic fluid heater (Thermopac).S.INTRODUCTION TO THERMAX INTRODUCTION TO THERMAX: 1. History of Thermax: In the beginning there was fire. The use of steam rewrote the history of human civilization. but are extended to the growing line of businesses like pollution control. It was named initially as WANSON (INDIA) PVT. the precursor of modern age.S. surface coating heat recovery unit.M. or a fertilizer plant. From then till now. Steam produced mechanical movement. It could be used to produce electricity too. In 1980. Today activities of Thermax are no longer confined to boiler making. as we understand it. Pune. It was the driving force of industrial revolution. which needs a 300 tones/hr high pressure steam generator. the company decided to go ahead individually and was named as ‘THERMAX’. ‘Thermax’ has grown by leaps and bounds.S. a Pune based engineering company ‘Thermax’ LTD was started in the year 1966. LTD as had technical collaboration with Belgian Company called WANSON’. absorption cooling. Then there was steam. but with increase in production and development of new techniques and wide varieties of boilers it faced the need for more space and hence was shifted to Chinchwad. The then factory. genetic engineering and information superhighways.’s CoE. At present. The following is the detailed description of the whole organisation.I. UAE.000 square meters. quality.M. It’s management system conforms to ISO 9002 (1994) and follows national and international standards such as ASME Standards (USA).Pune-1 2 . It includes the following divisions.’s CoE. Boilers & Heaters. 3. 2. lead-time and on-time performance at every point of customer engagement. Nepal etc and territorial representative in many other countries. Current manufacturing facility of ‘Thermax’ in Chinchwad includes 14 plants & production utilities measuring 66. BS (UK). Kazakhstan. It also obeys IBR (INDIA) standards & DIN (GERMANY) standards for boilers manufacturing. The company is investing substantial resources in attaining operational excellence – focusing on processes and systems that have a direct impact on cost.S. In international market ‘Thermax’ holds office in Russia. aimed at significant increase in customer satisfaction and top line and bottom line growth. USA.INTRODUCTION TO THERMAX Thermax has been rolling out a company-wide initiative to transform the way it does business. Involvement of ‘Thermax’ in multi-products makes it necessary to collaborate with other companies and thus it entered into following ventures- A. Cooling & Heating.S. Kenya. Malaysia. Water & Waste Solutions.S. Indonesia. Thailand. UK. Sri Lanka. 1. I.S. Divisional Profile: (I) Boilers and Heaters projects: a. Gas / Oil fired Shell Type steam boilers in capacities upto 30 tons per hour.Pune-1 3 .1 Organisational structure of B&H Products: Hot Water Generators Hot water boilers in capacities upto 20 million kcal/hour.5 million kcal per hour. 1.S.INTRODUCTION TO THERMAX 2. Thermal Oil / Thermic Fluid heaters in capacities upto 3. (Coil) Steam Boilers (Shell Type) Thermal Oil / Thermic Fluid Solid boilers Process Boilers Exhaust Gas Boilers Fired Heaters Fuel Gas / Oil fired Coil Fired Steam Boilers in capacities upto 850 kg/hr. Boilers & Heaters: Fig.M. fired Boilers firing fossil fuel and agro-wastes in capacities upto 30 tons/hr Integrated Process Integrated boilers for recovering useful heat from process gases Waste heat recovery boilers on DG system exhausts Fired Heaters for critical process A. Steam Boilers.’s CoE.S. husk and even agricultural waste (like Bagasse in sugar Cogen plants) to generate inexpensive energy. Cogen Division has the EPC expertise to design. The Cogen plants from Thermax can utilize fuels like coal. erect and commission: Captive Power Plants Cogeneration Systems Sugar Cogen Plants Cogen Division works in synergy with the other divisions to offer 30 .S. where power is increasingly becoming scarce and expensive.Pune-1 4 .S. This Division caters to industry requirements of inexpensive and high quality power.INTRODUCTION TO THERMAX b. Cogen Division: Backed by its strong competencies in thermal engineering and energy management and its close familiarity with a wide range of fuels. lignite.’s CoE. Thermax offers 'freedom from large power stations' through decentralized power. thus reducing overall energy costs upto 50%.50 % of the systems and equipment of a power plant: Steam Generation Equipment Water Management Products and Systems Inlet Air Cooling for turbines & Control room air-conditioning Cooling Water Chemicals Air pollution Control Systems Construction Backup A.I.S. The power business of Thermax is conducted through Cogeneration Division.M. In the current scenario. Thermax provides competitive power solutions. Cogen Division offers captive power systems including Cogeneration. Catering to a wide range of industries. environment protection systems are no longer end-of-the-pipeline fixtures.I. Enviro Division has the expertise to design and execute pollution control systems for varying industry requirements. Some of the ducts handled by the Division are: Aluminum Dust Bentonite clay Clinker Gypsum Coal Ammonium Sulphate Carbon black Coffee Latrite Fly ash Asphalt Cement Detergent Limestone Dead burnt magnesite Projects Gas cleaning plants Gaseous scrubbing (including wet ESP) Coal preparation plants A. Thermax has kept pace with international technologies to offer turnkey projects as well as air pollution control products. from concept to commissioning.S.S. 50 ESPs and 55 Scrubbers and 20 pneumatic conveying systems.INTRODUCTION TO THERMAX c. the Division has installed 3000 cyclones. Designing for Different Dusts Depending on the differing properties of various kinds of dust such as dust chemistry and flue gas composition. 1400 bag filters. The Enviro Division has the necessary infrastructure to undertake any small to large pollution control projects on a turnkey basis. With the growing realization that pollution abatement pays. It can handle more than 100 types of dusts.’s CoE.M.S. Enviro Division: Clear the air for better returns… Thermax's Enviro Division was set up with the belief that pollutants are inevitable but pollution is not. as it means better use of resources and improved competitiveness.Pune-1 5 . Small capacity steam boiler (Baby boiler) was much in demand. which were out side the purview of the Indian Boiler Regulation Act. A. Thermax has begun its business way back in 1966 by manufacturing baby boiler. Process Heat Division: Process Heat Division (PHD) is the flagship Product Business Division of Thermax Ltd. In order provide the customer complete solution PHD began its voyage into the Core sector of Energy by collaborating with Wanson of Belgium. The division then made a modest beginning with a turnover of USD 0.I. PHD is the seed for business growth for the company. Today every industry looks to thermal oil heating as a most potential energy saving solution.M. Today its high quality products are demand in India and in International markets. The baby boilers. were the most demanded product.05 million in 1968. all under one roof with a singular Mission. The collaboration introduced baby boilers in India. and now has grown to a USD 140 million group which offers a wide range of solutions to its customers in the areas of energy generation and conservation and environment Protection. steam-cum-electrical.Pune-1 6 . Its products and expertise find applications in every conceivable heating application in the world. Thermal Oil heating took the Indian industry by storm and today in India its brand Thermopac has become a generic name.S.S. the company made a modest beginning to manufacture sterilizers for Hospitals way back in 1966.’s CoE. The main reason is its highest energy saving capability due to high system efficiency. Thermal oil heating replaced several other heating methods such Electrical. steam.INTRODUCTION TO THERMAX (II) Cooling and Heating (C&H) a.S. History To share the fond memories of Thermax and PHD. which has its core business in the area of providing cost-effective process heating solutions for both energy generation and energy conservation. ’s CoE.… Light & Heavy oil Natural gas LPG Bio-gas Coal – Low and high Calorific values Lignites Non conventional / agro-based fuels… Rice Husk Bagasse Groundnut shell Mustard stalk De-oiled bran De-oiled cake A. Energy & Environment.INTRODUCTION TO THERMAX To pursue this mission Process heat division has been continuously designing and upgrading its products and services that results in energy efficient heating solutions to the customer making optimum use available energy resources .S.M.S.conventional.I. non conventional and the renewable energy sources.S. Process Heat Division over the last 30 years has evolved into an Engineering major well known for it’s core competencies in the field of Process Heating. Products and Services Our product portfolio encompasses providing process heating through different mediums such as… Steam Hot Oil Hot Water Hot Air The product technology facilitates use of wide range of fuels viz.Pune-1 7 . M. who are fully trained and have the right competence to service all the varied needs of customers in India & Overseas. Service at your doorstep: Our aim is to provide prompt and efficient service to customers. tools & techniques of Total Quality Management. Support With an engineering base of over 50 Design engineers of Process Heat Division can provide solutions to all your.INTRODUCTION TO THERMAX All these innovations of providing energy efficient solutions have been evolved through a close association of our R & D along with engineering to be abreast in the market with the changing needs of the customer across the world. R & D Facility Research and Development is continuously striving to upgrade the existing technologies to provide a product leadership edge and thus ensure the customer benefits through energy efficient solutions. Process Heat Division with it’s strength of over 150 qualified sales and service engineers are present where the customer needs them most.Pune-1 8 . develop. From the R & D the core technology is drawn by the business division and which are taken for commercialisation through the well-established Product Development Process (PDP). manufacture and carry out proto-type tests on newer technologies. 11 regional offices in India & 10 Overseas offices. R & D has the entire necessary infrastructure to design.I. To meet the growing demand of customer the division strives on it’s strength of… Market Reach Through a network of 100 sales representatives & Service Franchises and Spares parts stockists.S.’s CoE. A. using the principles. R & D primarily focuses on new technology development in the chosen core areas.S.S. To issue out this aim into action we have created a wide network of Service Franchises and our own Service engineers based in the local office. India.I.’s CoE. GOST. from the American Society Of Mechanical Engineers (ASME) and also accredited by the ISO 9002 certification by LRQA. Reputed agencies like SGS. and package boilers. un – fired vessels. BS. Meters and open area of 14. The plants are equipped with specialised machinery for light. medium & heavy fabrication. ASME. reaction vessels.S.S.345 sq. With the strengths Process heat division caters to the need of variety of applications in process industries like… Agro products Bottling & beverages Breweries & distilleries Chemical & petrochemicals Engineering Food & dairy Hotels Packaging Drugs & pharmaceuticals Plywood Rubber Edible oil / solvent extraction Textile / synthetic fibres Hospitals A. heat exchangers. The main manufacturing complex consists of 14 plants with total built up area of 51.M.INTRODUCTION TO THERMAX State of the art manufacturing set up State of the art manufacturing facilities are located in Pimpri Chichwad Industrial Zone of Pune in Maharashtra. The manufacturing facilities have been accredited by the SUHR and PP stamp of quality. With commitments to quality manufactures to national & international standards and codes like IBR. (Switzerland). LIOYEDS (UK). TUV (Germany) and BUREAU VERITAS (France) are involved in customer inspection. assembly. testing in “ferrous & non ferrous metals” in the area of fired. DIN.600 square meters.Pune-1 9 . ISO.S. pressure vessels. S.’s CoE. hospitals. Offers 93% efficiency Specialized containerized hot water systems for ambient temperatures down to –40°C are exported A.M. Thermopac (exported to overseas markets as 'Deltatherm'). smoke tube. corrugated paper. Pressurized and non pressurized 6000 installations world over Pioneered the use of thermic fluid heaters in India Known in India under the brandname. the prime mover of Thermax business continues to maintain its leadership in the Indian market for packaged boilers and heating systems.S. The wide ranges of customers further reinforce the dominance of the division in the market.Pune-1 10 . The Division exports to several countries around the world. For indirect heating Heaters confirm to DIN 4754 specifications Thermic Fluid Heater upto 380°C. Heating: Heating.S.INTRODUCTION TO THERMAX b.000 kcal/hour to 15 million kcal/hour. rubber. range offered is 70. hotels. leather. water tube and combinations of these. packaging. The customer portfolio includes industries such as… Textiles Farm Beverages Paper Distilleries Chemical And many small and medium industrial units .I.garments. Products and Systems Products Range Features Meet the stipulations of the Indian Boiler Regulations Small packaged Act Offer 88% efficiency to larger ones of Steam Boilers boilers from 100 to 25 tons/hour capacity 850 Kg/ hour Boiler design-coil type. ’s CoE. Gas (natural gas. Chemicals (boiler and water chemicals).100 to 1.Pune-1 11 . wood. LSHS).S. and de-oiled spent earth with as little calorific value as 1. A. liquid and gaseous fuels-Light and heavy oil (FO.S. Propane. HSD.S.INTRODUCTION TO THERMAX Hot Water Generators widely Non pressurized hot water generators are suitable for hotels. The Heating works in synergy with the other Thermax Divisions like Water Treatment (Boiler feed water treatment). Other products Hot air generators Closed loop Thermosyphon for indirect heating Ideal for the drying applications of the agricultural sector in Indiafor cashew nuts. Bagasse. chilies and various types of grains. Service & Spares The systems and products are backed by after sales service for both standard and customized products. biogas). and solid fuel (coal. hospitals. The Division has the combustion expertise to burn coffee grounds with as high a moisture content as 80%. LPG. High pressure steam and hot water for temperature requirements upto 260°C and operating pressures of 70 bar Table 1.500 kcal/kg.I. lignite. and stock points at strategic locations to ensure timely availability of spares. Thermax has established an extensive network of franchisees and dealers for after sales service. husk.M. dairies and similar industries.1 Product details of Heating division Expertise on Fuels The Heating has extensive experience of burning the widest possible range of solid. ground nut shells and many other types of agro waste). environment concerns of CFCs and HCFCs and CO2 emissions.2 Comparison between Vapour compression m/c & VAM A. Cooling has a technical collaboration with Kawasaki. Today the division offers the largest product range in the world to suit every cooling requirement. Absorption Cooling has re .emerged as a viable alternative to the conventional electrical machines.INTRODUCTION TO THERMAX Enviro (for checking boiler emissions) and Waste Management (effluent treatment) to give customers integrated expertise.S. Cooling: The Cooling that pioneered Vapor Absorption Technology in India offers global solutions for industrial cooling and air conditioning.I.S. Japan.’s CoE.S. Some of the other advantages of these machines are: Conventional Electric Machines Operates on electricity Higher operating costs High maintenance Noisy operation Higher life cycle costs Uses CFCs/ HCFs leading to ozone depletion More moving parts Absorption Machines Uses Heat energy Lower operating costs Negligible maintenance Noiseless Lower life cycle costs Uses water which is Nature's gift No moving parts Table 1. move towards distributed power. world leaders in Absorption Cooling technology and offers cost-effective and "best in class" eco-friendly Vapor Absorption Machines (VAMs). Why Absorption Technology? In the changing energy and environment scenario the world over: power crisis.Pune-1 12 . c.M. heating and cooling. Customised solutions for specific requirements.5 ºC.S. Value Added Cooling Solutions With its vast experience in the field of power.I.2 Working of chiller (VAM) These low-grade energy resources substantially reduce cost of operation. These machines are eco-friendly as they do not use synthetic refrigerants like CFCs/HCFCs. heating and cooling needs. they use water as the refrigerant. Thermax can offer: Integrated total solutions for power.S. the absorption machines produce chilled water upto 4. In addition to this.Pune-1 13 . Network Thermax has an extensive network of domestic and overseas offices. 1. instead. an extensive decentralized franchisee network ensures prompt service within India and across the globe.M.INTRODUCTION TO THERMAX The Concept of Absorption As illustrated below. using various forms of low-grade heat energy sources such as: Steam Oil/gas Hot water Waste heat source Fig. thereby making the absorption machines the most viable option for cooling.S.’s CoE. A. dissolved minerals and metals.S.I. Germany. (IV) Waste Management Division The activities of this division covers. Hungary. Disposal of toxic and non-toxic effluents in liquids. Fabric filters: pulse jet. Portugal.INTRODUCTION TO THERMAX Global Presence Cooling exports to more than 25 countries including America's. Condense polishing and waste water treatment plants using ion exchange theory. Spain. Fluidized Bed dryers for cement and other industries. UK. Indonesia. solids and sludge form.’s CoE. Thailand. Denmark. Vacuum and forced deaerators. Malaysia. Iran. Saudi Arabia.S. A. and dealkalisers Water treatment plants for ultra pure water. Filters for the removal of suspended solids.S.Pune-1 14 . Philippines. (III) Water Treatment Division This division is bit new and products of this division are Water softener and demineralization Unit -standard and custom make. Multiclone and large diameter cyclones. Refinery wastewater treatment plants. (V) Air Pollution Control Division This division has the following range of products.M. degassers. Australia. UAE. Evaporation plants for distilleries and paper mills. using chemicals incineration. electrolysis and effluents technologies. Bangladesh. reverse air and insertable type. INTRODUCTION TO THERMAX Rigid frame electrostatic precipitators for utility /industrial boilers. M. steel and nonferrous. High and low energy wet scrubbers for gas and particulate cleaning application. Thermax Hong Kong ltd. Thermax INC. Industrial fans and blowers: standard and custom built. Thermax Europe Limited.UK 5. 6. Engineering ltd. Thermax Engineering Construction Company Limited 4. U.S.’s CoE. Thermax Do BRASIL A.Pune-1 15 . expansion joints.S. Group companies: 1.A. Chemical Division This division is involved in processing of following products: Water treatment and softener chemicals Thermic fluid processing..S. 8.I. Anti scaling and rusting chemicals 3.E.S. Thermax Babcock & Wilcox Limited 2. UK 7. Air washer units and ventilation systems Pneumatic conveyors & Zero leak dampers of various designs.M. cement. Thermax Energy Performance Services Limited 3. Since it’s just an assembly area. Multitherm Combipac Woodpac Multipac Huskpac Integral furnace boiler.S. as per the engineering division. PLANT 2/2A PLANT 2:.Pune-1 16 .S. After that.S. the box so formed is used for welding tube plates.’s CoE.INTRODUCTION TO THERMAX 4. PLANT 3 This plant is used as a support system for plant no 12 and hence all the operation of pl 12 and pl 3 are similar.M.This plant is used for storage and dispatch of all solid fuel boilers. Here the plates are bended in bending machine. A.I. high efficiency radial drilling machine and shapers are highlights of this plant The main type of boilers dealt with in this plant. PLANT 2/2A:-Responding to the oil crises world wide THERMAX introduced fluidized bed concept to the boiler business. A high capacity 350 tones press. extensive drilling is carried out on these plates for insertion of tubes and whole IBH & MBH ASSEMBLY is fabricated and thus header section for fluidized bed is prepared. there are no special purpose machines in this section. In this plant fluidized bed combustion system for MULTITHERM boilers is manufactured. Plant profile: PLANT 1 Burner and oil pre-heater assembly section: This section is used for assembly of burner & OPH with boilers like REVOTHERM. headerdrilling m/c. coiling. Aquatherm & Revomax.I. Coil assembly & hydraulic aseembly. This plant also has radiographic enclosures for components produced.INTRODUCTION TO THERMAX PLANT 4: Newer to the academic concern coil type boilers such as RX. for main HRU are manufactured this plant follows activity of plate rolling. rotators & SAW units are used in this plant. PLANT 5: This shop is well known as drum shop and mainly undertakes project for ESD (Energy System Division) Here ESD products such as drum.M. ‘L’ seam & ‘C’ seam setup –weld & back-gauging. This shop concerns with complete production of the boiler right from tube to tube welding. AMW.S. Electrical control panel & assembly. Himalaya rolling m/c. headers etc. coils calibration. Coil winding & seal winding. giant horizontal and vertical coiling machine. back-gauging rail.’s CoE. The main products of this plant are Thermopac. TP. which is very popular unit. DELTATHERM are manufactured in this plant. coil calibration m/c and above all a paint shop for final dispatch of these boilers. Huge radial drilling m/c. Vertical Thermopac.Pune-1 17 . Long tube to tube welding.S. coil and shell setup and final assembly with all accessories. Shell & burner assembly. The main operations of this plant are as follows Tube penetration. Machine in this shop includes automated TIG & MIG units.S. Radiography test is also carried out. A. 3 pass.S. SAW units and many other type of welding machines for MMAW. This plant is yet to develop .S. oil or gas fired type boilers is manufactured. Special thermic fluid heaters are also produced in this plant. Machine such as rotators. shell type.M. TIG.P.’s CoE. This shop mainly undertakes the projects of “ESD”. MAG. There are three Radial drilling machines.S.but some operations are done here as nozzle opening & drilling on drums. all the process upto painting & handing over is done. Capacity of 20 T.H. Due to impact of the shots.M shop because here SHELLMAX i. This plant also has a hydro-testing bay for coil type boilers PLANT (15) 7: This is newly developed shop in year 2005 and well known as ‘Drum shop’. In This plant after ‘L’ seam welding. are manufactured here .I. A stress-reliving furnace to remove all concentrated stress that is produced during welding is also located in this plant. In this plant shot blasting of shell type boilers is done. The plant has two tilting fixtures for full welding of boilers. Small capacity boilers upto max. FCAW are used in this shop. PLANT 9: This plant is involved in following activities 1) Shot blasting 2) Painting of completed assembly with spray gun & anti –rusting coating.INTRODUCTION TO THERMAX PLANT 6: Same as like plant 4 here also coil type boiler’s components are manufactured & assembled. Separate rail lining are provided for loading A. This plant consist of Spain made Juaristi m/c(cnc) for horizontal boring & drilling of holes. the corroded layer is removed.Pune-1 18 . PLANT 8: This plant is also called as S.e. ’s CoE. This plant is also having an advanced chiller testing bay.S. chilled water so formed is send through tubes to ducts with fans to provide room cooling. The plant is mainly involved in process of plate cutting (Note – these plates are special BQP inspected by IBR officials). to name a few are Versagraph & Flotech CNC plate cutting m/c. PLANT 11: This is an ACD shop and is involved in manufacturing of chillers. the plant is having highly modernized welding equipment & highly skilled workers. also.circulation system.I. PLANT 10: This plant may be called as heart of shell type boiler production.e. water to be chilled is passed through no. A.Pune-1 19 . Pacific high tonnage press and SAW units. used to test newly made chillers.M. rolling these plates on rolling m/c then welding these rolled shells (‘L’ seam & ‘C’ seam welding) and dispatching these shells as req.INTRODUCTION TO THERMAX & unloading jobs & process is carried out in enclosed shed with dust collection unit & re. the reason being manufacturing of shells & tube plate for boilers and cover plates for heat exchanger.A chemical named Li Br is used for this purpose.S.A chiller is an air conditioning device that works on vapour absorption cycle rather than vapour compression cycle for cooling . Himalaya rolling m/c. This plant is equipped with modern m/c such as ‘Arboga’ CNC drilling m/c. The chiller mainly consist of evaporator & absorber. This plant owns highly advanced machines. by other plants for further processing. heat pump. the whole chiller assembly is carried out in single production line . This is the only plant that is own by ACD and works on the principle of assembly line i.S. which can drill numerous holes with high accuracy &tolerances. and industrial cooling eqpt. of tubes placed in vacuum in chiller body. the hydro testing of complete boiler for pressure is done in this plant.S. This plant also has stationery as well as mobile radiographic enclosures. superheaters. welding machine. CX. PLANT 13: The main products of this plant are all solid fuel boilers (CP. CPF. After completing the fabrication of boiler . WP. waste heat boilers and many other kinds of HRU. Other special thing about this plant is its CORRUGATION MACHINE’.INTRODUCTION TO THERMAX These days’ chillers are gaining more markets than conventional air conditioning. They also find their application in western countries as process cooling units. HP. PLANT 14: This shop is known as TD (Twin Drum Boilers) shop. named commercially as COMBIMAX. superheaters. Apart from this. this boiler is modification of SHELLMAX in the region of capacity & efficiency.I. This plant has got two tilting fixture. MXP & MTFH) . PLANT 12: This shop is mainly dealing with ESD projects and manufactures economizers. This plant is also involved in manufacturing of high capacity SHELLMAX & Solid Fuel Boilers. Projection welding m/c is used for the fabrication of fin tubes used in economizer.All these boilers are manufactured in this plant.S. CM. This plant is equipped with biggest overhead Crane of THERMAX (120 TONNAGE).S. and lathe for flange machining & hacksaw for pipe cutting. Highly precise pipe bending m/c. rotators.Pune-1 20 . which is used.M. which is used for strip welding to produce coiled finned tubes. for corrugation of large furnace shell to provide it strength & high heat A. it also consists of major machine projection welding machine’.’s CoE. ’s CoE. A. PLANT 15: This shop is newly constructed and is mainly a drilling shop.I. Also there are 3 heavy duty China radial drilling machines. This plant is also having a stress relieving furnace named ‘Modular Furnace’ used for relieving stress formed during welding.S. Other operations include nozzle welding. The shop houses the newly procured ‘Juaristi’ horizontal boring machine imported from Spain.Pune-1 21 . The main operation of this shop is nozzle opening in mainly capsule type boiler shells.INTRODUCTION TO THERMAX transfer.S.M.S. . 1 Earlier layout A. The tube-plate stand is a small but significant step towards realisation of this goal. To implement this method of plate movement in the shop and for shot blasting and thereby reduce material handling. To construct a stand able to carry all tube-plates and baffles belonging to a single unit up to model SD-50. Objective: i. These shells and tube-plates are then handed over to fabrication department for subsequent working.2. Need: The ACD Manufacturing machine shop of Plant 11 is involved in the following main activities: 1. Shell and tube-plate cutting on CNC ‘Flotech’ gas/plasma plate cutting machine. The target laid down is of 1 chiller per day.’s CoE.S.S.I. It was observed that lot of time and efforts are wasted in tracing the tube-plate as well as determining which particular operation is being carried out on it. Pune-1 22 . Rolling of shells. ii. Earlier method: ` PLATE CUTTING GRINDING STACKING OF TUBEPLATES MATERIAL HANDLING HAND-OVER TO ASSEMBLY DRILLING SHOTBLASING Fig.S. Also to reduce material handling time and time required for shot-blasting is possible with this stand.8 chillers per day. 2.M. Drilling of tube-plates. 3. Present plant production rate is of 0.TUBE-PLATE STAND DESIGN OF UNIT-WISE TUBE-PLATE STAND:1. A. The same stand can be used for material handling to shot-blasting yard and plate grinding can be done with the tube-plates mounted in the stand.M. each plate after drilling was handed over to the fabrication.S. the tube-plates get mixed with other models and lot of time is consumed in locating them. To counter all these problems it was decided to construct a tube-plate stand such that: 1.’s CoE. This method was unsafe since loading of tube plates on fork-lift was hazardous.2.2 Present layout Previously.I. Moreover the tube-plates could not be handled using yard crane and hence lot of time gets wasted in material handling to and from the shot-blasting yard.S. 2.TUBE-PLATE STAND Present Method:MATERIAL HANDLING PLATE CUTTING GRINDING LOADING IN STANDS HAND-OVER TO ASSEMBLY DRILLING SHOTBLASTING Fig.S. All tube-plates belonging to the same job are mounted on the stand and this stand is moved as a single unit through the shop floor. Due to this it gets difficult to trace the location and condition of individual tube-plates. the tube-plates after grinding were stacked together and then moved to the shot-blasting yard using fork-lift. Also. Since these are not treated as a lot depending on the chiller model. Pune-1 23 . At a given time work is carried on various chiller models. 16 GROSS WT. Pune-1 24 .06 4423.22 1618.14 90. The largest possible sizes of respective tube plates are considered: WEIGHT AND DIMENSION ANALYSIS MODEL WEIGHT SD-20 SD-30 SD-40 SD-50 SD-60 SD-70 SD-80 315 389.M. The following is a brief description of chiller tubeplates.74 1788. Chiller tube plates: It is desired to construct the stand only to accommodate tube-plates belonging to the chiller models GD-20 to GD-50 (80% of units covered). Each chiller job is allocated a stand.28 208.24 2073. Tube-plates of higher models are very large to be housed into a stand and demand for bigger models is not as frequent. 4.S.1 A.’s CoE. and yard crane. Table 2.62 333 450 USTP DIMENSION 25 X 645 X 665 25 X 745 X 732 25 X 864 X 813 25 X 932 X 951 36 X 1246 X 912 36 X 1350 X 1074 36 X 1634 X 1184 WEIGHT 50.58 LSTP DIMENSION 25 X 1264 X 1274 25 X 1315 X 1509 25 X 1497 X 1762 25 X 1939 X 1618 36 X 1735 X 2149 45 X 1995 X 2296 45 X 2730 X 2150 WEIGHT 84.TUBE-PLATE STAND 3.19 107 135.63 62.S.14 1116.I. The stand should be such that it can be easily handled by EOT.71 630 1050.69 260.02 74.36 517.S.02 173.32 3157.6 5627.8 290 HTGTP DIMENSION 25 X 487 X 531 25 X 589 X 538 25 X 630 X 590 25 X 640 X 720 45 X 745 X 793 45 X 908 X 813 45 X 973 X 845 1000. forklifts. 2. and just by looking at the stand one can find out the whereabouts of the tube-plates as well as the work required to be done on them.76 1453.88 319. required. LSBF: Lower shell baffles are required as intermediate tube support plates in case of bigger models to prevent sagging of tubes.’s CoE. USTP: Upper Shell tube-plates are used to support the tubes at its end and they are mounted on the extremities of upper shell. 2. A.S.S. 3. Normally 2nos.3 Tube-plates of model SD-50 1.TUBE-PLATE STAND Fig. These plates are smaller in size and required only in lower shell.M. 4.S. These tube-plates are for low temperature generator section. Normally 2nos. These are tube-plates for the absorber/evaporator section. LSTP: Lower Shell tube-plates are used to support the tubes at its end and they are mounted on the extremities of lower shell. 5.2. Pune-1 25 .I. USBF: Upper shell baffles are used as intermediate tube supports in upper shell. HWGTP: Hot water generator tube-plates are required in HTG section of chillers. required. S. Once the trials were taken on pilot stand. Salient features: 1.S. Fig2. Pune-1 26 .I. orders were made for 2 more stands. The stand is a skeletal structure made only by welding box-channels and supporting rods and hence there is sufficient open space to enable the shots/grinding burr to fall freely out of it. The cost of fabrication of one stand is Rs.TUBE-PLATE STAND 3. and it was found satisfactory.S. workers and material handling persons the shot blasting stand was designed.M. 23.4 Workers loading tube-plates in stand A.000 /-. After designing.’s CoE. 4. Design of stand: With all these considerations and constraints in mind and after extensive brain-storming and exhaustive discussions with all concerned persons such as supervisors. quotations for stand were taken from vendors and the design was given to vendor for fabrication. 7 Tube-plate status monitoring board A.S. 2. tube-plate status monitoring boards are also prepared.S. It can carry upto 3ton load.6 Lifting the stand with EOT 3. The stand has required capacity to bear the load of tube-plates.2. Using these any tube-plates can be easily found out. Pune-1 27 . Along with the stand. Fig. The safety officer has certified the stand and it has been put into use.M. Fig.TUBE-PLATE STAND 2.I.S.’s CoE. M. Gross saving = 280 x 375 = Rs. Future prospects: Implementation of unit-wise system throughout plant 11.000 = Rs. Plant layout modification and streamlining. A. Elimination of shot-blasting. Benefits: TPT reduced by one day. 1.S.’s CoE. 69.S.000 x 3 = Rs. Time saved per day = 25 x 3 = 75 min.05.I. 7.000 – 69. Time saved annually = 75 x 300 = 22500min = 375 hrs.280/per hr. Reduction in material handling time. Pune-1 28 . Time required for material handling & shot blasting reduced from 3hrs to 45min.S.000 /Cost of stand fabrication = Rs. 36.05. 23. Savings: The following is finance approved saving: Time saved in material handling per shift = 25 min. Man hour rate = Rs. Safer material handling. Trolley of shot blasting plant is not required 6. Reduction in tube plate searching time.TUBE-PLATE STAND 5.000 /- This signifies that the cost of fabrication of stand will be paid up within one year of implementing this system.000 /Net saving per year= 1. S. 2.S. Pune-1 29 . A.I.’s CoE.S.TUBE-PLATE STAND 8. Check kept ensuring that workers get accustomed and do not revert to earlier method. 3.M. Workers educated and coaxed into using the stand in safe and correct way. Conclusion: 1. Shot blasting stand designed and fabricated. . The important ones are listed below.S. TPM brings maintenance into focus as a necessary and vitally important part of the business. A.’s CoE.I.S. Producing goods without reducing product quality. Goods sent to the customers must be non defective. Produce a low batch quantity at the earliest possible time. It is no longer regarded as a non-profit activity. in some cases. Introduction to TPM: Total Productive Maintenance (TPM) can be considered as the medical science of machines. Why TPM? TPM was introduced to achieve the following objectives. The goal of the TPM program is to markedly increase production while. at the same time. Reduce cost. It is a maintenance program which involves a newly defined concept for maintaining plants and equipment. as an integral part of the manufacturing process. The goal is to hold emergency and unscheduled maintenance to a minimum.S. Down time for maintenance is scheduled as a part of the manufacturing day and. increasing employee morale and job satisfaction. Avoid wastage in a quickly changing economic environment. Pune-1 30 .TPM of ARBOGA-3 m/c TOTAL PRODUCTIVE MAINTENANCE 1.M. Pune-1 31 .S.1: Pillars of TPM A.I.S. Education training 5. Early management 6.’s CoE. Planned maintenance 4.TPM of ARBOGA-3 m/c Implementation of TPM has to be done in steps. Quality management 7.1 shows the eight pillars of TPM. Focused Improvement 2. Office Efficiency 8.M.S. Figure 2. Autonomous maintenance 3. Safety and Environment Fig 3. 1. Ability to determine and judge if operating conditions becomes abnormal 2.I.S. Respond quickly to abnormalities by repairing the machine or having some technician take care of it when he (she) does not have enough knowledge.TPM of ARBOGA-3 m/c A very important aspect of TPM is the establishment of autonomous maintenance.’s CoE. Ability to preserve normal conditions 3. According to Kunio Shirose: The purpose of autonomous maintenance is to teach operators how to maintain their equipment by performing: • • • • • • Daily checks Lubrication Replacement of parts Repairs Precision checks Early detection of abnormal conditions As most of the Lean Manufacturing techniques and tools.S.M. autonomous maintenance is based on education and training. Autonomous maintenance is done in seven steps. Pune-1 32 .S. To that purpose we will help them develop three skills: 1. It is about raising awareness of the operators on the knowledge and understanding the operation principles of their machines. A. skill or resources. Initial cleaning Ability to determine machine abnormalities Ability to design and make 2.1: Seven steps of AM opportunities and to make the improvements and solve the abnormalities improvements Understanding of the relationship between equipment conditions and product quality Data organization to describe optimal conditions and how to maintain them A. Organization and housekeeping 7.TPM of ARBOGA-3 m/c Development of the skill to spot abnormalities and 1. Autonomous Inspection 6. Pune-1 33 . teach the least experienced 5.’s CoE. Eliminate sources of contamination and inaccessible areas 3.M. Creation of a checklist for cleaning and lubrication standards Operators determine by themselves what they have to do More skilled Understanding operation 4.S. General inspection principles of machine and its systems operators and maintenance techniques.S. Full Implementation Continuity Table 3.I.S. Develop specific tools for cleaning difficult to access areas. Identify areas which are difficult to clean lubricate inspect & take appropriate counter measures.’s CoE. Innovative Kaizens by workmen & supervisor. Ranking the priority places for daily cleaning. Make approach easy for CLRI. e. Put tags on abnormalities. Adopt concepts of localized guards. Make easy to do CLRI.H. coolant splashing.I.g. flying chips oil leakage’s. Find out seven types of abnormalities. Use five senses for cleaning. Counter measures for major problems for making machine dirty.S. Shorten cleaning lubrication time. Step 3: Formulation of clean up and lubrication standards/ preparation of tentative J. A. Step 2: Counter measures against sources of contamination and hard to clean areas Counter measures against sources of contamination. Pune-1 34 . Prepare list of unfulfilled basic condition Changing look of machine.TPM of ARBOGA-3 m/c Steps of Autonomous maintenance: Step 1: Initial Cleaning Cleaning is inspection.S.M.S. standards Standards for cleaning and lubricating and tightening. Everyone should easily understand standards. pneumatics. drives.’s CoE. Generally Subjects Covered Are Hydraulics.S. lubrication.I. Step 4: Conduct general inspection training and develop inspection procedures: (i) General Inspection: The Operator Acquires Equipment Related Technical Knowledge and trouble Shooting Skills.M. This Stage Activities are: Review the Item.S. Step 5: Conduct General Inspection Autonomously In This Step an Overall Inspection Processes is formalized by combining Tentative standard created in Step 3 with additional check items for routine inspection. Introduce extensive visual control. Produce Excellent Results. Consult With Maintenance About Inspection Points and Make Specific and Clear Assignments Between Two. bolts and Nuts Etc. (ii) The Key Activities in Step 4 are: Learning the Structure.M. method and Time Standards for Cleaning Inspection and Lubrication. functions and Mechanism of Equipment. Pune-1 35 . Check Whether or Not Inspection Tasks Can Be Done Within Time & Make Time Saving Improvements A. Correct New Problems Found. coolant. Test the Understanding and then actually inspect the Equipment.TPM of ARBOGA-3 m/c Operators make standards themselves with guidance by P. electrical. To Impart Technical Knowledge to Operators Team Should Decide. Standards are made by using 5Why analysis.S. Revise tentative inspection standards. and workplace change. Step 7: Ongoing Autonomous maintenance and advanced improvement activities.after Review of Standard and firming up.S.S. Pune-1 36 . In respect of operators following skills have been acquired. 1. Muri (Strain) . The ability to detect. 2.’s CoE.M.Operator Should Be in Position to carry Out the Standards Easily without Much Strain. A. each step emphasized different developmental activities and goals.Make standards for cleaning inspection and lubrication. muda of Cleaning.S. & lubrication and Muda of Unnecessary CLRI Points Are to Be Revived and Finalized.TPM of ARBOGA-3 m/c Activities related to step 5. In the implementation of jishu hozen steps 1 to 6. inspection. operators change. Mura (Inconsistency) . The ability to understand equipment. and prevent equipment abnormalities and make improvements. functions and mechanism upgrading capability of operator in production activities to challenge any problem that may occur in his equipment. Step 6: Set standards and manage the workplace This stage is called as “Maintenance Management “ Importance of 3 mu’s Muda (Waste) . Each stage develops through understanding and brings results such as equipment change.I. correct.Muda of Operator Movement. Consistently Follow the Standard and Time. but when you touch it. Hard to adjust parts. Hard to tighten parts. Hard to inspect areas. When you clean.TPM of ARBOGA-3 m/c 2. Putting Tags & making Tag matrix and Generating One point lessons. Autonomous Maintenance: Step-1 Introduction: Step 1 is initial cleaning. While cleaning the operator has to follow the given list- List for Initial cleaning: Cleaning areas are classified as followsHard to clean areas. which prevents it from becoming a big fault. of seeing what is invisible. Refer to the old history records.g.S. preparation of schedule.M. Initial CleaningInitial Cleaning needs to be done because: Cleaning is Inspection. For e. you realize it is loose. Early detection allows early correction. the nut-bolt appears ok. Let’s look into initial cleaning first. you develop new eyesight. Meeting after the daily activities.I.’s CoE. For initial cleaning the machine needs to be observed under stopped and running conditions. Carry out audit on first step.S.S. It is further divided into 4 events that include initial cleaning. Abnormalities can be of different types A.: While looking. Hard to lubricate areas. Pune-1 37 . Record cleaning time. 1. ) Adhesion. Gases.S. Contamination Sources. Checking. Lubricating. Oil level gauges. Lubrication supplies. Scrap. Liquids. incorrect pressure or current. Lubrication.’s CoE.TPM of ARBOGA-3 m/c Seven types of Abnormalities: Minor Flaws: Contamination. Operation. A. Product.S. Damage.I. Abnormal phenomenon. Adjustment. Unfulfilled Basic Conditions. Raw material.S. Play (eccentricity wear distortion corrosion) Slackness.M. Tightening. Lubricants. Tightening. Others.(unusual noise strange smells. Inaccessible Places. Pune-1 38 . Pune-1 39 .M.S. Jigs & fixture. Rotating machinery. Concentration. Lubrication check points. Spare parts. Floors.S. Electrical Equipment’s. Hydraulic check points. Lifting devices.TPM of ARBOGA-3 m/c Quality Defect Sources. Pneumatic check points. Points to be checked during Initial Cleaning.’s CoE. Machinery. Foreign matter. Check points for nuts and bolts. Moisture. Transmission system check points. A. Lights. Viscosity. Shock. Unnecessary and Non Urgent Items. Electrical check point. Piping Equipment. Make shift repairs.(Checkered plates) Steps. Grain size. Unsafe Places.S. Measuring Instruments. Others.I. keep 2 to 3 hours a week. White tag has to be removed by the operator. Ideally.this can be pending.S. weekly and monthly checkpoints. 3. White tag means that the operator himself can cure the abnormality.S. Tag RemovalAfter putting tags and making tag list.M.do it in three days -Low priority & easy to do . rather than waiting for the perfection. Tagging and preparation of Tag matrixEvery time an abnormality is found. white and red.do it within a week -Low priority and & to do . according to a schedule. Red tag means the abnormality cannot be removed by the operator alone and will need a maintenance person’s help. Tags are attacked according to priority set. it has to be tagged. At least temporary countermeasure is taken on the spot. by which operator and when. A tag is a small paper. a schedule is prepared which tells which machine part is to be cleaned. It also includes daily. Members are A. The tags are written on the TAG LIST and then white tag original copy is given to Shift Manager. and Red Tag original to Maintenance. Simplest classification is: -High Priority . (You are welcome to do it during free time ALSO).’s CoE. Production Planning must keep time aside for Initial Cleaning. Pune-1 40 .S. The tags are then classified. tags are removed by correcting the abnormality. It should never be done ONLY when there is free time.I. Preparation of ScheduleInitial cleaning is NOT one-time cleaning. which bears the information about the machine and its abnormality. Tags are of two types. It has to be done by the team repeatedly.TPM of ARBOGA-3 m/c 2. To ensure that cleaning is done regularly. I. The one point lesson has to be certified before it is put up to ensure that a wrong lesson is not taught. it is realized that if the pump that sucks out the water is switched off.M. 4. An OPL is generated in a specific format and put up on the AM board so that the other operators learn it too. Pune-1 41 .S.’s CoE. And so it is necessary to lift the pump and let air enter before switching off.S. Operators are encouraged to remove more white tags – it enhances his skills and capabilities by providing more opportunities to remove tags by him. A tag matrix is a graph drawn that gives a comparative status of number of tags put and tags removed. so that siphon effect does not occur.S. the water comes back by siphon effect from the tank. while cleaning the wash basin in the washing room. For example.TPM of ARBOGA-3 m/c assigned responsibility for tag removal. One Point LessonsA one-point lesson is a learning Point that the operator may have realized while doing the cleaning. A. S.I.M.TPM of ARBOGA-3 m/c AM STEP 1 IMPLEMENTATION ON ARBOGA 3 M/C 1. lubricants Missing or choked filters Corrosion Deformation Dents on machined surfaces Imperfections b) When machine is in running conditionVibrations Leakage of oils.S. The things to look for while inspection on ARBOGA machinea) When machine is in stopped and electrically isolated conditionVery Dirty AreasUn-lubricated AreasLoose fasteners/ belts/ electrical connectionsPlayOut of alignmentOut of straightnessSigns of wear and tearInaccessible or difficult to clean areasDifficult to inspect areasCan cause frequent breakdownsCan cause unsafe conditions Can cause quality problems Parts and accessories not in use but still attached to machine Gauges and instruments which are non-functional/ not calibrated Contaminated fluids. steam. lubricants. water Unusual noise Working of cooling fans A. air.’s CoE. Pune-1 42 .S. pressure and other process parameters against standards A. Pune-1 43 .I.’s CoE.S.M.TPM of ARBOGA-3 m/c Unusual smells Wobbly movements Eccentricity Malfunctioning gauges Function of safety devices Function of error proofing devices Function of proximity and limit switches Function of sensors Measure things like current drawn by motor.S. it’s insulation resistance Speeds and feeds Temperature.S. S.S.’s CoE. The cleaning schedule for ARBOGA 3 m/c- A. Pune-1 44 Table 3.S.TPM of ARBOGA-3 m/c 2.I.M.2 AM Cleaning Schedule . GAS SPRING NA. FOR GEAR BOX SEATING. OILY CABLES.TPM of ARBOGA-3 m/c 3. OIL LEAKAGE FROM SPINDLE. OILY FLOOR AREA LUBRICATOR OUTLET RUBBER PIPE LEAK. SPINDLE HEAD MOTOR COVER BOLT MISSING. Y-AXIS BALL SCREW BOLTS ARE LOOSE. RESTRICTION OF BURR FLOWING ON CP. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 OBSERVATION TAG DETAILS RED WHITE RED WHITE WHITE WHITE RED RED WHITE RED RED RED RED RED RED RED RED RED WHITE RED WHITE WHITE RED WHITE WHITE WHITE RED WHITE WHITE WHITE WHITE WHITE WHITE RED IDENTIFI ED ON 8/11/2005 COMP DATE CONTROL PANEL BUTTON LED NOT WORKING CONTROL PANEL RUSTY M/C LAMP BRACKET LOOSE. AXIS MOTOR FITTING WITHOUT WASHER. BURR ON CONTROL PANEL DUST ON CP. DRAG CHAIN LOOSE. Pune-1 45 . M/C PAINTING.C CABINET DOOR RUBBER LINING NOT AVAIL. COMPRESSOR COVER NOT AVAIL.M.S. M/C LAMP GLASS NOT CLEAR. Tag list for ARBOGA 3- TAG NO. PAINTING OF CONTROL PANEL.S. DRILL SPINDLE BOX BOLTS LOOSE.3 Tag list 8-Aug 8-Aug 8-Aug 8-Aug 8/12/2005 8/12/2005 8-Aug 8/12/2005 8/12/2005 8/12/2005 8-Aug 8-Aug 8/12/2005 10-Aug 8/1/2005 10-Aug 10-Aug 10-Aug 10-Aug 10-Aug 10-Aug 10-Aug 10-Aug 8-Aug A. GLAND LEAKAGE FOR COOLENT PUMP. MOTOR SUPPORTING NUTS ARE LOOSE. SPINDLE COVER RUSTY GEAR BOX WIRE CLAMP NA. SPINDLE MOTOR TERMINAL BOX GLAND NOT AVAIL. COOLENT PUMP FOUNDATION LOOSE. TELESCOPIC GUARD RUBBER LINING NA. SPINDLE MOTOR WIRING CONNECTION. GASKET NOT AVAIL. Table 3. BROKEN PLASTIC ADAPTOR COVER OBSERVED ON TROLLEY.I. M/C LAMP WIRING CUT . NO GUARD FOR COOLENT PUMP MOTOR.S.’s CoE.. COOLANT PRESSURE SWITCH NOT WORKING. A . SEALING FOR GEAR BOX NA.C. Z-AXIS JERKY MOVEMENT. OIL LEAKAGES. SIDE GUARD COVERS DIRTY& RQD. CLAMPING STUDS ARE DIRTY. D C VOLTAGE MISSING.S. UNWANTD MATERIAL REMOVED.I. POWER SOURCE NOT WORKING. Z-AXIS SHOCK ABSORBER NA. Pune-1 46 .CABINET EXCESS CHILLED Table 3.: tag list WHITE WHITE WHITE WHITE WHITE WHITE RED RED WHITE RED RED WHITE RED RED RED RED RED RED RED RED RED RED WHITE WHITE WHITE WHITE WHITE RED RED RED WHITE WHITE RED WHITE RED WHITE WHITE WHITE WHITE WHITE RED WHITE RED RED WHITE WHITE WHITE RED 10-Aug 8-Aug 10-Aug 10-Aug 8-Aug 8-Aug 10-Aug 8/12/2005 10-Aug 8/12/2005 8/13/2005 5-Sep 9-Aug 9-Aug 9-Aug 9-Aug 9-Aug 9-Aug 9-Aug 28-Aug 8/18/2005 8/18/2005 28-Aug 28-Aug 24-Aug 8/24/2005 8/24/2005 29-Aug 30-Aug 8/24/2005 9/3/2005 9/5/2005 9/6/2005 A. FLOORING PATCH WORK PENDING. FLASH GUARD FLAP CUT.CABINET WATER LEAKAGE ARRENGAMENT FOR FLASHING GUARD LUBRICATION POINT MARKING COOLENTPUMP AREA CLEANING PAINT FOUND ON FOUNDATION BOLT STAND FOR FLASHING GUARD MACHINE CLAMP GLASS NOT AVAILABLE CONTROL PANEL BUTTON CLEANING OIL LEVEL NOT VISIBLE LOOSE WIRES PEEP MARKING OIL COLLECTION TRAMP NOT AVAILABLE COLUMN PAINTING READ A.3 contd. OIL INDICATOR NOT WORKING . JOB SUPPORT BLOCK DIRTY. HYDRAULLIC OIL TANK DIRTY. LUBRICATION PIPE GUARD COVER DIRTY. SHIFTING FOUNDATION SPACER ALIGNMENT PAINT REMOVEL ON FOUNDATION BLOTS AC. SPINDLE BOLT COVER DIRTY FLOORING PAINTING. SPINDLE LUBRICATION LEAKING.S. GEAR BOX LUBRICATION LEVEL INDICATOR NW.’s CoE. SCREW JACK DIRTY. SIDE GUARD BEND.TPM of ARBOGA-3 m/c 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 INTERNAL COOLENT VALVELOOSE EXTERNAL COOLENT VALVE LOOSE. GROSS POSITIONING ERROR. DUST ON SPINDLE MOTOR FAN GUARD RUSTY & OILY DRILL TOOL TROLLEY. TRAMPPED OIL SHIFTING . ACRYLIC SHEET ON CONTROLL PANEL TOOL TROLLEY MODIFICATION COOLENT PUMP DIRTY AREA UNWANTED MATL . PAINTING.M.S. PECK DRILLING CYCLE NOTWORKING. Oct.S.Apr. The updated tag matrix is put up on the AM board at the end of each month.M.Nov. OF TAGS 200 150 100 50 0 Aug.Dec. Pune-1 47 .Jan.2: Tag matrix Putting and removal of tags is a never-ending process.Feb. A straight graph indicates cleaning is not done regularly.S. An increasing graph shows that the exercise is followed seriously.S. A. 3.I.M 05 05 05 05 05 06 06 06 06 ay06 MONTH Fig.TPM of ARBOGA-3 m/c Tag Matrix for the past 10 months- TAG STATUS TAG DETECT TAG CORRECTED 250 NO.Mar. The tag list is to be updated at the end of every week.’s CoE.Sep. M.S.I.3: OPL 1 . Pune-1 48 Fig 3.’s CoE.TPM of ARBOGA-3 m/c 4.S.S. One Point Lessons on ARBOGA 3 m/c- A. S. 3.’s CoE. A. All have not been included due to space limitations.4: OPL 2 .M.S.S. Pune-1 49 Fig.TPM of ARBOGA-3 m/c There are in all 19 One-point lessons on the ARBOGA 3 machine.I. S. Autonomous Maintenance: Step-2 Step 2 is about taking Corrective Action to permanently eliminate the abnormalities that are encountered during step 1. In step2 the source of dirt is attacked so that the origin of dirt and cleanliness is eliminated thus resulting in cleaning-time reduction.I.S. step 2 is done.’s CoE. Pune-1 50 .S. 3.TPM of ARBOGA-3 m/c 3. Since cleaning is a never-ending activity.5 Steps in AM 2 A. To reduce operator’s monotony and facilitate cleaning-time reduction.M. it is likely that the operators get fed up and became careless about it. Considering the aim of step 2 following three things can be doneMake Visual Prevent Dirt/Dust Outbreaks Eliminate Hard to Access Areas Workplace How? Identify Sources Of dirt/ dust/ leaks/ spills How? Open the areas Cannot Enclose the areas Plug the sources •Sign boarding •Outlining •Color coding •Direction/Levels •Grease/Oil Points •Footprints •Transparent guards Cannot / Too Difficult / Costly Localize Dirt/ dust/ leak/ spill Make Special cleaning tools Make it easy to monitor: basic conditions usage conditions Reduces Cleaning Time Fig. I.why analysis is done to find out the root cause of the repeated tags. Mapping is locating the areas the identified areas on the machine. Pune-1 51 . Spillage points v.M. The next step is to eliminate those areas or make an arrangement such that they can be easily monitored.’s CoE. For this purpose a why. Leakage areas Once the areas are identified the machine should be mapped accordingly.S.TPM of ARBOGA-3 m/c To take the above given actions we’ll have to follow certain procedure. Difficult to check areas ii.6 Procedure of AM 2 Identifying areas for working in step 21.S. This procedure can be explained as followsIdentify Tags that repeat Visual Workplace contributes to easy detection Corrective action: Eliminate Root cause Find Root Cause .Perform 5-Why Analysis Take Countermeasure against root cause Cannot Cannot Adaptive Action: Prevent ill effects from Spreading Make Detection easy. Easy to find at start Fig. If outbreak begins. 3. Difficult to access areas iv. Difficult to clean areas iii.S. these locations can be classified asi. showing: Locations where repeat tags occur . Initially make a map of machine or workplace. A. One of the examples is given as follows. make hard to access areas easy to accessa. i.M.S.no time for training Table 3. Asking a why Question every time till we get the root cause of the problem.m-60 sm-17783 category4109 re-10295 re category. Following are some of the countermeasures.TPM of ARBOGA-3 m/c 2. Countermeasures The actions taken on the root causes detected by why-why analysis are termed as counter measures.S.engg.26640 phb. Pune-1 52 . Enclose machines if there is no way to prevent dirt/dust/spills coming out A. Make transparent guards & covers c. Why-Why Analysis: It involvesi.4: WHY-WHY Analysis 3. Put cables together 121 114 p-26 c-28 –b-67. Identifying of problem ii. Observation Why Oil spills on floor Valve drips on closing Why Spout too long Why Why Why Countermeasure Make platform to keep bucket No action To reach Bucket bucket too low Oil viscous Oil specs Bucket Last drop drips after not wiped pouring from it Operator Not does not trained know to put cloth at end of pouring Production Plan production to pressure kep time for training . It deals with the oil spillage problem.’s CoE.I.S. A. Use color codes e.S. Results of countermeasures The results of countermeasures are displayed as before and after chars.TPM of ARBOGA-3 m/c ii. Also countermeasures should be taken to the extent where it takes not more than 10 minutes for machine cleaning. Show max and min levels Write any specific data on the equipment itself 4. Following things are to be done while making m/c visual a.S. Show eye marks or footprints to indicate where and what manager should see d.S. It is for the manager to control without losing time.’s CoE. Make machines VisualVisual management is not for the operator. Pune-1 53 . Show arrows on pipeline directions of rotation b. Mark dials in red/green c.M. Name each piece of equipment f. The difference should be clearly visible to all.I. S.TPM of ARBOGA-3 m/c AM STEP 2 IMPLEMENTATION ON ARBOGA 3 M/C: 1. Pune-1 54 .Difficult to clean DA – Difficult to access DCH – Difficult to check CODE PARTICULARS DC1 DC2 DC3 DC4 DC5 DC6 DC7 DC8 DC9 DC10 DC11 DA1 DA2 DA3 DA4 DA5 COOLANT SPILAGE ON FLOOR BURR SPILAGE ON FLOOR Z-AXIS MOTOR FAN CABLE ON TOP TABLE SLOT BOTTOM SIDE OF M/C TABLE TRENCH LUBRICATION TANK BACKSIDE A/C CABINET CABLE TRAY COOLANT OUTLET Z-AXIS SCALE CABLE ON TOP Z-AXIS SCALE Z-AXIS MOTOR CABLE TRAY BOTTOM SIDE OF M/C COUNTERMEASURE FLASH GAURD MODIFIED FLASH GAURD MODIFIED YET TO BE DECIDED TO BE WRAPPED IN PLASTIC YET TO BE DECIDED YET TO BE DECIDED TABLE TRECH FILTRATION SYSTEM FIXTURE PLATE FOR CLEANING TO BE CLOSED FROM TOP YET TO BE DECIDED YET TO BE DECIDED TO BE WRAPPED IN PLASTIC YET TO BE DECIDED YET TO BE DECIDED TO BE CLOSED FROM TOP YET TO BE DECIDED LUBRICATION SYSTEM REPAIRED ADDED IN P.I. all the major areas are classified as: DC .e.’s CoE.M CHECK LIST VISUAL INDICATOR YET TO BE DECIDED YET TO BE DECIDED YET TO BE DECIDED ALARM LIST TO BE DISPLAYED Table: 3.5: Machine mapping STATUS COMPLETE COMPLETE COMPLETE COMPLETE COMPLETE PENDING COMPLETE COMPLETE COMPLETE COMPLETE COMPLETE COMPLETE COMPLETE COMPLETE COMPLETE PENDING DCH1 DCH2 DCH3 DCH4 DCH5 DCH6 DCH7 X-AXIS BALL SCREW X-AXIS SLIDE A/C CABINET FAN Z-AXIS MOTOR Y-AXIS BACKLASH Z-AXIS BACKLASH M/C ALARM COMPLETE COMPLETE INPROCESS COMPLETE COMPLETE COMPLETE COMPLETE A.S.S. Machine mapping of ARBOGA 3The complete machine is mapped i.M. ’s CoE.7: Machine mapping A.S.M.TPM of ARBOGA-3 m/c MACHINE MAPPING DC 1 DC 2 DC 3 DC 4 DC 5 DC 6 DC 7 DC 8 DC 9 DC 10 DC 11 DA 1 DA 2 DA 3 DA 4 DA 5 DCH 1 DCH 2 DCH 3 DCH 4 DCH 5 DCH 6 DCH 7 Fig.S. Pune-1 55 .S. 3.I. 6: WHY-WHY Analysis .S.S.TPM of ARBOGA-3 m/c 2. Pune-1 56 Table 3.’s CoE.I.M.S. WHY-WHY Analysis: A. Pune-1 57 .5 3 2.5 0 13/11/05 14/11/05 15/11/05 16/11/05 17/11/05 DATE HR. Fig.9: Effect of countermeasures A. HRS. Countermeasures: Before Fig. 3.8: Countermeasures After 4. to 0.’s CoE.5 1 0. 3.TPM of ARBOGA-3 m/c 3.S. CLEANING TIME 3.5 hrs.S.S.I.5 2 1. Effect of countermeasures: (i) Reduction in cleaning time from 3 hrs.M. ’s CoE.Dec.TPM of ARBOGA-3 m/c (ii) Reduction in MTTR (Mean time to repair): MTTR 300 250 HS R 200 150 100 50 0 MTTR Aug.Jan.10: Effect of countermeasures (iii) Increase in MTBF (Mean time between failure): MTBF 1000 900 800 700 600 500 400 300 200 100 0 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05 Jan-06 Feb-06 Mar-06 HRS MONTH Fig.11 Effect of countermeasures A.S. Pune-1 58 . 3.Feb.Mar05 05 05 06 06 06 191 191 130 110 91 87 MONTH Fig.I.S.Sep05 05 248 248 Oct.M. 3.Nov.S. Pune-1 59 . One can inspect several parts of the machine just by standing at these particular points. The action being performed is described by pointing at the appropriate area and explaining what actually is being done.I. Help of maintenance personnel is taken in preparation of these checklists. The checklist is prepared for individual part of machine and areas requiring lubrication. Thus the speak and point technique gives the technically correct and suitable way of performing a particular action. touch etc.M. These checklists are similar to cleaning schedules.’s CoE. A. Autonomous Maintenance: Step-3 1.S. 3. They give a picture in totality of the condition of machine and we also can conclude about the corrective actions to be taken if any.TPM of ARBOGA-3 m/c 4. Kiken Yochi Technique (KYT – Speak and point technique): A particular activity in the checklist such as cleaning of oil filter is broken up into individual actions and these are represented in chronological order.S. frequency of checking as well as tool/sense organ (like eye. Visuals on machine: The various areas of machine which can be inspected from a particular point on the Gemba are marked on the shop floor as foot-prints. Tentative checklists: In AM Step 3 we are involved in making tentative checklists for lubrication as well as maintenance. in that the time to be given for the particular activity. 2.) to be used for checking are given.S. 3)Check&clean cartridge 1 min Sr. Tentative lubrication checklist for ARBOGA 3 m/c: AM STEP 3 IMPLEMENTATION ON ARBOGA 3 M/C: Z-axis slide 60 Table 3.S. (220no oil =0.S.I. 2)Check pressure Of lube tank.M.S.2cc) Look& feel 1)Check oil level of lube tank.2cc) Look &feel 13min 3min 1)Check oil level of lube tank.7: Lubrication checklist .Eqpt Part L1L6 2 min 50 min. 2)Check pressure Of lube tank.’s CoE. Pune-1 L7L18 Properly lubricated. Properly lubricated (220no oil =0.) When Daily Weekly Monthly TPM of ARBOGA-3 m/c A. No Standard Method Tool Action if not ok Time ( Min. 2)Check pressure Of lube tank. 3)Check&clean cartridge 15min L19 to L24 Properly lubricated (220no oil =0.2cc) Look &feel 1)Check oil level of lube tank. 3)Check&clean cartridge X-axis slide Y-axis slide 1. Check graphics as per drawing 5min Sr. No Standard Method Tool Action if not ok Time ( Min.Eqpt Part 4 10min Programme available on control panel Look And Feel Transferring of the programme .) When Daily Weekly Monthly TPM of ARBOGA-3 m/c A.S.’s CoE.8: Maintenance checklist . Pune-1 5 Check size of tool Availability of tools on tool trolley Look and feel Bring tools 2min 1min 6 Coolant level and concentration to bemaintained.S. Look and feel 15min 2min Add water and cutting oil Check coolant concentration Control panel Tentative maintenance checklist: Tool setting Coolant tank 61 Table 3.I.S.M. S. Speak and Point technique: STEP1: SWITCH OFF THE MACHINE.M. (STAR SCREW DRIVER TO BE USED) STEP 3: REMOVE LUBE TANK 4 SCREWS A.I. STEP 2: REMOVE TERMINAL BOX SCREWS 4NOS.S.S. Pune-1 62 .’s CoE.TPM of ARBOGA-3 m/c 2. S.’s CoE.S.S. Pune-1 63 . AVOID FOULING WITH PUMP&FILTER ASSEMBLY.I. STEP 5:REMOVE FILTER STEP 6: CLEAN FILTER BY USING AIR GUN ( OUTSIDE TO INSIDE) A.M.TPM of ARBOGA-3 m/c STEP 4: REMOVING OIL TANK. S.S. Pune-1 64 .S.TPM of ARBOGA-3 m/c STEP 7: REMOVING OIL FROM TANK STEP 8: CLEAN THE TANK WITH BRUSH AND CLOTH STEP 9: STRAINER CLEANING USING BRUSH AND CLOTH A.’s CoE.M.I. TPM of ARBOGA-3 m/c STEP 10: FITTING TERMINAL BOX OF TANK STEP 11: FITTING OF FILTER STEP 12: REFILLING OF OIL AND FIT THE LUBE TANK CAP.S.S.12 Speak and Point technique A.M. Pune-1 65 . Fig.S. 3.’s CoE.I. I.TPM of ARBOGA-3 m/c OEE Graph: CNC Arboga 3 100 90 80 70 60 VALUE 50 40 30 20 10 0 r eb ar 3A Fe Fe Ap Fe Ja ar ar M Ap 17 6F 6M M M 29 27 27 13 20 13 20 WEEK Fig.S.13 Overall Equipment Efficiency curve The overall equipment efficiency has increased from 70 % to 90 %.S.M. Pune-1 10 24 Ap A p r -2 9A pr eb eb ar b b Ap Ap -8 a Fe Fe 4M 1M 8M 5M 4F 1F -1 15 r- Ap r- a a 18 25 -1 -1 -1 n- b- -2 b- b- ar pr 22 r 66 . 3.S.’s CoE. Cost Saving: In 10 months since TPM of ARBOGA-3 was undertaken. A. the total cost saving due to reduction in breakdown hours has been Rs.700 / -. 12. This is the finance approved savings. 5. S.S.’s CoE.M.S.I.TPM of ARBOGA-3 m/c A. Pune-1 67 . 6.TPM of ARBOGA-3 m/c Conclusion: The TPM step-3 of ARBOGA-3 machine is completed.S.M.S. Pune-1 68 .I. STEP 1 of ROUNDO ROLLING m/c 4. STEP 1 of CNC FLOTECH plate cutting m/c 3. STEP 1 of CNC JAMESON (CONUCO) m/c A. Other TPM undertaken: 1. STEP 1 of CNC ARBOGA-2 co-ordinate drilling m/c 2.’s CoE.S. . The shadow of each template must be painted on the board. iii. the no. plate rolling machine used to roll the shells required in fabrication of Upper shell (housing of LTG/HTG) and lower shell (housing for evaporator/absorber section) of Vapour Absorption Machines. Since several curvatures are required for a given model of VAM and due to a large range of models manufactured. The storage of so A. The main objective of this assignment is to provide a suitable stand/board for keeping the templates (41 nos. The location of each template should be fixed on the board and must be labelled properly so that it can be easily visualised which template is removed from the board.e. Need: The ROUNDO machine is a 4-roller. The rolled plate is not achieved in a single step.S.) of ROUNDO rolling machine which are presently dispersed on the shop floor.DESIGN OF TEMPLATE BOARD DESIGN OF TEMPLATE BOARD FOR ROUNDO ROLLING MACHINE: 1.S. These templates are nothing but small plates which can be manually handled. of templates is very large. Pune-1 69 . This curvature is checked by the operator using rolling templates. ii. 41. that is it must be easy to remove the templates as well as place them again on the board.M. Objective: i. i. but the plate needs to be gradually rolled until the required curvature is achieved. No time must be wasted in finding the right template as per need. and confirm with the ideal design curvature required for the particular shell.S.’s CoE.I. The board should be easy to use. much time will be wasted in retrieving the appropriate template. We had to undertake the Herculean task of making the drawings of all the 41 templates on AutoCAD.’s CoE.S. Moreover. the shadow board is indispensable. Preparation of drawings of templates: The templates were in use since quite long time and hence their drawings could not be found out.S. A. earlier.I. the said rack would suffer from following drawbacks: 1. there was not much focus on improvement of plant aesthetics.S. 2. 2. However. In view of the Kaizen activities being undertaken.DESIGN OF TEMPLATE BOARD many templates is crucial. throughout plant 11. 3. The rack occupies much more space than a sleek board. Hence. since they should not be deformed/bent for giving reliable rolling of shells. it was decided to design and fabricate a template/shadow board based on the above requirements and constraints. Pune-1 70 .M. a bulky rack will be redundant. It will be difficult to find out which template is missing. 4. Another alternative to abovementioned problems is preparation of racks for storage of templates. It would be difficult to remove the template lying on the bottom of rack on which other templates are placed. Hence. Since the total weight of all templates combined is less than 30 kg. 1 Template drawings .I.’s CoE. Pune-1 71 Fig.S.S.M.DESIGN OF TEMPLATE BOARD A.S. 4. DESIGN OF TEMPLATE BOARD Fig. 4.2 Present condition of templates 3. Design of shadow board: Once the drawing of all templates was made, the particular templates were arranged so that they would cover the least area. The drawing of the shadow board was finalised and order given to vendor viz. Mr. Kiran Pankar. The shadow board is to be made from 3mm thick perforated sheet and is provided with stand for placing on shop floor and lifting hooks for moving using EOT crane. A.I.S.S.M.S.’s CoE, Pune-1 72 DESIGN OF TEMPLATE BOARD Fig. 4.3 Design of shadow board 4. Benefits of shadow board: 1. No time wasted in searching the templates while rolling of shells. 2. Easy to use. 3. Every template has a fixed location on board and hence template missing from board can be identified quickly. 4. Shop floor area remains uncluttered and plant looks neat and tidy. A.I.S.S.M.S.’s CoE, Pune-1 73 DESIGN OF TEMPLATE BOARD 5. Cost savings: • • • • • • • On an average 5 minutes saved per shift in finding the right template from the lot. 15 minutes saved per day Time saved per year = 15 x 300 = 4500 = 75 hours. Plant rate is more, but taking Rs. 100 per hour, we get gross Cost saving = Rs. 7,500 The cost of fabrication of shadow board is Rs. 3700 /Net cost saving = 7500 – 3700 = Rs. 3800 /This cost saving is for first year. The saving for next year will be greater. 6. Conclusion: The template shadow board is designed and given for fabrication to vendor. It is to be received from the vendor and implemented in the shop floor, hence the savings shown are projected ones and not finance approved. A.I.S.S.M.S.’s CoE, Pune-1 74 CONCLUSION CONCLUSION The 6 months of training at Thermax has greatly benefited me in several ways. I have witnessed the immense power of technology and how it can be put to productive purposes for the benefit of mankind. I also became aware of my role as a Mechanical Engineer in making this possible. During my stint at Thermax, I have learnt several things besides engineering which include, but are not limited to the working of a giant organization, interaction and communication skills, analytical skills, importance of safety in industry, time management and the most important fact that no work is small. The training has also inculcated in me professionalism and dedication to work. No textbook would have been able to do all this just within a span of 6 months. It has proved to be an important milestone in my academic life. A.I.S.S.M.S.’s CoE, Pune-1 75 6.I. 7. Operation & Maintenance manual – Vapour Absorption Machine.REFERENCES REFERENCES 1. Jain. 3.S. Production Technology… By R.M. Comprehensive approach to Zero breakdown – Planned Maintenance – Keikaku Hozen…By Kinjiro Nakano. A.S. 2. Pune-1 76 . TPM and Autonomous Maintenance manuals…THERMAX.K. ‘FLOTECH’ machine manual. ‘ARBOGA’ 5008 machine manual. Jhamb. 4. 5.S.C. Industrial Management I & II…By L.’s CoE. .