FOUR MONTHS INTERNSHIP

REPORT
TATA STEEL LTD

Report

GLOBAL WIRES- INDIA.

Date:

24TH MAY 2015

To study handling time of wire drawing

Title:

machine no 107& 108 and find a solution to

reduce the same

Submitted
by:

Mr. ABHISHEK

B.TECH

DHIMAN

(OPERATIONS)

CHANDIGARH GROUP OF
COLLEGES(GHARUAN CAMPUS,MOHALI)

Duration:

22 JAN 2015 TO 30 JUNE

2015

Project

Mr. DAVID WILLIAMS

Guide:

{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 staf
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
2) To
3) To
4) To

increase green belt.

reduce use of water, energy.
ensure zero accidents in plant.
prevent injuries and ill health.

To conclude had a great learning experience at TATA STEEL

SPRING STEEL-PLANT.

INDEX
SR
NO.

CONTENT

PAGE
NO.

INTRODUCTION TO TATA GROUP

06

INTRODUICTION TO TATA STEEL

09

INTRODUCTION TO WIRE DRAWING PROCESS

15

4
5
6
7
8
9
10
11

WIRE DRAWING PROCESS ACTIVITY SEQUENCE

DIAGRAM
METHODOLOGY USED FOR PROJECT
STUDY OF HANDLING TIME OF ACTIVITIES OF
WORKERS
WIRE DRAWING MACHINE 107 IDLE TIME
ISSUES
WIRE DRAWING MACHINE NO 107 PROBLEMS
33
WIRE DRAWING MACHINE 108 IDLE TIME
ISSUES
WIRE DRAWING MACHINE NO 108 PROBLEMS
33
SUGGESSION

17
18
19
26
33

1.INTRODUCTION TO TATA GROUP

TATA GROUP
The 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 diferent sectors where Tata
has spread its business are shown in this figure :

Engineering

Materials

Services
Information
technology
and
communicatio
n

TATA Business

Energy

Consumer
Products
Chemicals

Fig 1: TATA Businesses

TATA 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.

M
I
S
E
C
T
h
n
o
e
a
g
e
&
r
n
t
v
e
m
r
n
i
su
g
ic
r
e
ia
y
ic
m
e
e
s
ls
a
r
e
in
ls
r g

C
P
r
o
o
m
d
u
m
cu
t
sn
ica
Pe
r ce nta g
e
o n
s

t
i

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, Voltas

The 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 materials
The 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 under
1) Information

Technology

CMC,

Computational

research

Laboratories, Nelito Systems, Tata Business support services, Tata

Consulting Services, Tata Elxsi
2) 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 STEEL

2.1. 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

countries and a commercial presence in over 50 countries.

in

26

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 nonbranded under diferent divisions which are as under
1. Flat Products

2.Long Products

4. Bearings

3. Agrico

5. Tata Tubes

6. Tata Wiron
2.2. TATA STEEL GLOBAL WIRES
Tata 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-lanecable-stayed Bandra-Worli Sea link at Mumbai, India.
Fig 3: Global Division
2.3. TATA STEEL WIRE DIVISION, INDIA
Tata 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 of as an umbrella ribs manufacturer and now it is

GLOBAL
WIRES

LANKA
SPECIAL
STEELS
LTD., SRI
LANKA

TATA
STEEL
WIRE
DIVISION

WUXI
JINYANG
METAL
PRODUCTS
, CHINA

SIAM
INDUSTRIA
L WIRE CO.
LTD.,
THAILAND

INDIAN
STEEL &
WIRE
PRODUCTS
LTD.

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

customer/supplier.

Wire

with

Division

has

regulatory
thus

authorities

adopted

the

and

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 ofering these diferentiated products.

Product
s

Institutio
nal

Automot
ive
-Tyre
bead
wire
-Spoke
wire
-Spring
wire

Retail

Infrastruc
ture

Power

Anneale
d

-LRPC
-PC

-Cable
Armour
-ACSR

Card
Clothin
g Wire

Galvani
sed

Welding

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

TATA
STEEL
WIRE
DIVISION
1. WIRE
ROD MILL
(WRM) AT
TARAPUR.

TARAPUR
WIRE
PLANT
(TWP) 1

TARAPUR
WIRE
PLANT
(TWP) 2

SPRING
STEEL
(SS)
PLANT

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

2.7.

ARCELORMITTAL.
ESSAR STEEL.
JSW STEEL.
SAIL.
VISA STEEL.

ORGANIZATIONAL STRUCTURE OF TATA

DIVISION.

STEEL WIRE

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 division

Organizational 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 diferential value to our customers through innovative

oferings.

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

PROCESS
In 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

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

STEP 1
RM LOADDING

STEP 6
CONTINUE STEP 4 &
5
(AS PER PROGRAM
HOW MANY DIES TO
PASS)

STEP 7
PASSING WIRE
THROUGH FINAL
PASS

STEP 2
RM WELDING

STEP 3
POINTING WIRE

STEP 5
LOADING WIRE
TO DRUM

STEP 4
PASSING WIRE
THROUGH DIE
BOX

STEP 8
KILLING
SETTING

STEP 9
TIE WIRE TO
COIL CATCHER

STEP 11
DISPACTH

STEP 10
MOVING COIL
CATCHER TO
DIVIDE COIL.

5. METHODOLOGY USED FOR PROJECT

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

Study variours handling processes of wire drawing

machine (machine no 107 & 108).

Study past data collected by operators regarding

handling time

Take the actual readings of handling time of all

activities of operators on machine 107 & 108

Find the processes or activities which are more

time consuming on basis of past and present data.

Find the solution or method to reduce the

handling time of such activities

Suggest action plan or suggestion if any.

6.STUDY OF HANDLING TIME OF ACTIVITIES

OF WORKERS

1) RM LOADING :
LOAD COIL
TO
PAYOFF

LIFT COIL
BY CRANE

PROCESS DISCRIPTION:

This is the process where operators lift the coils or the RM by the
crane from storage area and load to the Payof 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:

Operator handling time

25

24

23
Time in min.

22

21

20

19
K.B.H

V.S.G

S.Y

S.B.D

P.B.S

V.G.B

DISCRIPTION:

The above graph shows the diferent time taken by diferent

operators for same process of RM loading.

The graph is based on actual observation during internship.

2) WELDING WIRES

CUTTING WIRE

POINTING

WELDING

FINISHING

GRAPHITE PASTING

PROCESS DISCRIPTION:

This is the process where operators join the wires at payof 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 diferent 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:
8

cutting

pointing

weilding

finishing

0
V.G.B

Y.A.M S.B.D

S.Y

K.KG

V.S.G K.B.S

P.B.S

graphite pasting

DISCRIPTION:

The above graph shows the diferent time taken by diferent

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 :

WIRE UNLOAD
FROM DRUM

JOIN WIRE
BREAK

PROCESS DISCRIPTION:

LOAD WIRE TO
DRUM

This is the process where operators join the wire which breaks
anywhere in the wire drawing machine while in process. The
operators carry out diferent 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:

OPERATOR WIREBREAK HANDLING TIME GRAPH

48
46
44
TOTAL

Time in Minutes 42
40
38
36

V.G.B Y.A.M S.B.D S.Y K.K.G V.S.G K.B.H P.B.S

Name of Operators

DISCRIPTION:

The above graph shows the diferent time taken by diferent

operators for same process of Wire Break Handling..

The graph is based on actual observation during internship.

3) PROGRAM CHANGE :

UNLOAD
MACHINE

RM
LOADDING

RM WELDING

DIE CHANGE

POWDER
CHANGE

POINTING
WIRE

LOADING
WIRE TO
DRUM

PASSING
WIRE
THROUGH
ALL DIE BOX

KILLING
SETTING

DISPACTH

MOVING
COIL
CATCHER TO
DIVIDE COIL.

TIE WIRE TO
COIL
CATCHER

PROCESS DISCRIPTION:

This is the process where operators new program of wire drawing

.The operators carry out diferent 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 payof 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 diferent time taken by diferent

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 diferent 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 diferent

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 :

IDLE TIME
30
25
20
15
10
5
0

IDLE TIME

DISCRIPTION:

The above graph shows the wire break reasons of machine no 107.
The blue bar in graph shows the time taken by diferent 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 diferent activities under

operational issue during last six months.

The blue bar in graph shows the time taken by diferent 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 diferent 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 diferent activities under
the Program Change.

DISCRIPTION:

The above graph shows the time taken by diferent 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) Payof 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) Payof 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 efective 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 diferent 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 :

W/B AT 108
70
70
69
68
67
66
65
64
63
62
61

67
64
IDLE TIME

DISCRIPTION:

The above graph shows the wire break held at which block of
machine. The blue bar in graph shows the time taken by diferent

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 :

80
80
78
76
74
72
70
68
66
64

72
70
IDLE TIME

DISCRIPTION:

The above graph shows the time taken by diferent 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 Blocks-

12+1 Skin Pass.

1st
(OTO) type.

Block 650mm dia. Vertical overhead take of

2nd to 9th Pass 650mm dia inclinded tuner roller

blocks.

10 th to 11th pass 650mm dia vertical full dancer

blocks.

12 th pass 650/650mm dia vertical double desk block

with str
-aightners and non riding stripper.

Die BoxAll 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 7 th 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 Size53die30 mm is standard size.

Cooling Of Blocks And DiesA complete piping system for water cooling of the
blocks and
0

to 32 c
Additionally

Die stands are provided. A max. water temp. of 25 0c

And a pressure of 2.8 Kg/cm 2 is to be ensured

The block surface is cooled by air blower.70to75 lts

per min.
Per block water is required. Also, dry compressed air
with
Kg/cm2is

FRL unit with capacity of 15 CFM at a pressure of 6

Required for surface cooling of blocks.

Power TransmissionDrive to the blocks are provided through motors,vpulley 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 ASSEMBLY
sr.
no.

Types Of
Bearings

Taper Roller
Brg.
Taper Roller
Brg.
Deep Groove
Ball Br

1
2
3

Bearing No.
33024
30209 j2/Q
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

Spherical Roller Brg.

23122CC/W33

Final Block Assembly

1

Taper Roller Brg

33024

Spherical Roller Brg.

23122CC/W33

Stripper Assembly
1

Thrust Ball Brg.

51104

S.T. Assembly
1

Double Row Ang. Ball Brg.

3303A-2Z

Deep Groove Ball Brg.

6305-2Z

Upper Guide Shave Assembly

1

Spherical Roller Brg.

22207-CC

Full Dancer Assembly

1
2

Deep Groove Ball Brg.

Deep Groove Ball Brg.

6213-2Z
6213-2Z

Sensor Arm Assembly

1
2

Deep Groove Ball Brg

Deep Groove Ball Brg

6208-2Z
6005-2Z

Die Holder Assembly

1

Deep Groove Ball Brg.

61907-2Z

Drive Assembly
1
2

Taper Roller Brg.

30316J2

Taper Roller Brg.

30314J2/Q

Roller Assembly
1
2

Deep Groove Ball Brg.

6004-2Z

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

TION
FOR

Sr.
NO.

Types
of
Lubrica
nt

Grade

Applicat
i-on

Grease
oil
change
Interval
s

Grease

Servog
en 2 or
3

Bearings,
slides
chain
and
guides

Every
200
operatin
g hours

ISO VG
220

Gear
Box,Pivchain
Type

Change
every
10000
operatin
g hours
Change
every
20000
operatin
g hours
Fill Every
15 Days
Once

Gear
Box Oil

Hydrauli
c
POWRE
Pack oil

ISO VG
68

Hydrauli
c
Cylinders

Pneuma
tic
Lubricat
or Oil

ISO VG
10

Lubricati
on of
Pneumat
ics

DRAWINGS MACHINE

LUBRICA
CHART
WIRE

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 change
3) 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) Payof 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 nonscientific.

BIBLIOGRAPHY

1)
2)
3)
4)
5)

www.Wikipedia.com
www.TataSteel.com
www.
Companys reports
Daily CommunicationBook
6) Machine Record Book.