Project Report Based on The Analysis of the Breakdown in Tube Mill

MANUFACTURER OF TUBES & TUBULAR COMPONENTS FOR AUTOMOTIVE APPLICATION

ANS Steel Tubes Limited, Plot No.268, Sector-24, Faridabad- 121005

SUBMITTED TOSUBMITTED BYMr. Satish Kapasia Pooja B.tech (SEM- IV)

(HR. Head)

CERTIFICATE BY THE GUIDE

This is to certify that the contents of this report entitled Analysis of the Breakdown in Tube Mill by Miss. Pooja submitted to U.I.E.T, Kurukshetra University, Kurukshetra for the Award of Bachelor of Technology (SEM-IV) is original research work carried out by her under my supervision. This report had not been submitted either partly or fully to any other university or institute for award of any degree or diploma.

Date: Place: Kurukshetra

Mr. Sanjay Kajal H.O.D Mechanical U.I.E.T, Kurukshetra University, Kurukshetra

CANDIDATE`S STATEMENT

I hereby declare that the work incorporated in this report entitled Analysis of the Breakdown in Tube Mill in partial fulfillment of the requirement for the award of Bachelor of Technology (Sem-IV) is the outcome of original study undertaken by me and it has not been submitted either to any other university or institution for the award of any Degree or Diploma.

Date: Place: Kurukshetra

Name: POOJA Roll No.2508521

AKNOWLEDGEMENT
It universally knows truth that there is some one behind the success of ones career. That`s the reason I am not giving the whole credit to some one for the successfully completion of this training. It is the guidance from auditic luminaries of the different field which prove to be rewarded. First of all I wish to express my sincere and heartful thanks to Mr. Sanjay Kajal (HOD-Mechanical), who provided me this anxiously awaited opportunity to undergo six week practical training at ANS Steel Tubes Limited, Faridabad a unit of Jai Bharat Maruti (JBM). I would like to thank all the family members of ANS Steel Tubes Limited, Faridabad for their support and guidance they have provided to me which has proved vital for my training. I would like to thank Mr. R. P. Singh ( General Manager- Production), Mr. Vinod Tolambia (HOD Finance),Mr. Dinesh Rana (HOD Quality), Mr. Anshu Khurana (HOD Materials), Mr. Ajay Kumar (PPC), Mr. Satish Kapasia (HR Head) and specially to Mr. C. Mishra (HOD Maintenance) for reading this report and providing vital suggestions based on his practical experience in the industry for the betterment of this report Last but not the least I would like to thank all the Staff members and workers for the support which they readily offered to me in-spite of their busy schedule. Without anyone of them, this training might not be so successful.

-- POOJA

COMPANY PROFILE
ANS STEEL TUBES- Established as a 3 way Joint venture among Neel Metal Products Ltd.(a JBM Group company), Nissin Steel and Sumitomo corporation of Japan,. The ANS Steel Tubes is a premier tube manufacturing company. ANS blends engineering capabilities of JBM, Cutting edge technology of Nisshin Steel (Japans no. 2 company in tubes) and trading expertise of Sumitomo Corporation. The company boasts of latest state of the art machinery together with world class testing facilities. The company has carved a niche for itself in providing high-end global tubular solutions to the OEMs. The company aims at effectively meeting the increasing market demands and specific customer requirements through its well established production system for electric resistance welded M.S. tubes, Medium carbon steels, Aluminum coated tubes and Ferritic stainless steel tubes. The companys strict quality standards, expert knowledge, state-of-the-art equipments and a group of dedicated and experienced employees helps it in maintaining market goodwill and confidence for reliability and advance technological capability and a trusted customer base. ANS manufacture the ERW Steel Tubes from 12 mm to 85 mm OD in 0.7 to 4.0 mm thickness in various shapes like Round, Rectangle, Square, Oval and Flat

oval for automobile parts applicable and also for furniture accessories. Plant Particulars Establish Year- 2005 Address- ANS Steel Tubes Ltd.

Plot No. 268, Sector- 24, Faridabad-121005 (Haryana) India

Firm Type Public limited Nature Of Business - Manufacturing Partners- Nisshin Steel, Japan

Sumitomo Corporation, Japan

Total Area- 35000 m2 Manpower- 200 Level Of Expand- International

Operation & Facilities Welding, Forming, Cutting, Profiling

Tube Mill Mas Seuth Multicutter Mair Hydraulic Tube cutting Chamfering- Soco Major Product Coated (SA1D- Aluminized coated, Ni Coated) & Stainless Steel (SS409L,

SS436L).
Hot & Cold Rolled Tubes(Carbon Steel)

Cold drawn Tubes Application Frame for Motorcycle Handle Bar for Motorcycle

Bus Body Building Dead Axle Tubes Door Impact Beam Seat Frame Tubes Fuel Neck Tubes Drive Shaft Applications Steering System Gear Shifting System Railway Coaches Furniture Applications

Certification ISO 9001: 2008 Customers Honda Seil Yamaha Bestex Escorts and JBM sister concerned.

Our Vision:

EXPANDING LEADERSHIP IN OUR BUSINESS THROUGH PEOPLE KEEPING PACE WITH MARKET TRENDS AND TECHNOLOGY

ANS Values:
We believe in
.simplicity by focusing a low profile externally and having clear frame and effective communication in the organization.

.... teamwork and well defined responsibility and accountability. .... relationship of trust amongst people through well defined responsibility and authority. . according top priority to customer focus through prompt and appropriate response. .respect and care for all those associated with us by meeting commitment.

Process Flow Chart

Identify rejec ted material through rejec tion Tag& Paint and return bac k to Raw

Id e ntific a tio n thro ug h c o lo ur c o d e & Ta g s se g re g a tio n & a lte rna te d isp o s

SLITTING LINE

SLITTING LINE: COIL SLITTING LINE: As the name indicates this machine is used to make coils of required size and shape. The power of the motor used in coil slitting line is 55 kw. for Cutter DC motor & 77 kw. for Recoiler. This machine is based on hydraulic circuit. The devices used in coil slitting lines are:
Radiator: This device is used to cool the hydraulic coil used in slitting line.

Radiator creates air by which hydraulic coil gets cool.

Valves: Valves in the coil slitting line are used to operate different cylinders

fitted on the slitting line.

Pressure Gauge: Pressure gauge is a device which is used to vary the pressure

inside the operating machine. It increases or decreases the pressure according to the requirement.
Roller: As a roller, hydraulic press is used. It is used to make sheet flat.

 Cutting: The cutters which are used to cut the coil are made of HSS i.e. high

carbon stainless steel. Operation: There are different operations in a coil slitting line which are as follows:
Decoiler: In a Decoiler a sheet of higher width is loaded, with the help of crane,

And the Decoiler starts decoiling the coil which is loaded on it.
Pinch Roller: Pinch roller guide is used to push the coil towards the slitting.

There are different rollers over which sheet is passed towards the slitting.
Slitting Cutter Shaft:

It is used to cut the sheet into different slits of required width. To get the required dimensions one have to set the cutters according to required dimension.

Looper: Looper is used to roll different slits of different widths. Leveller: It is used to push the slits towards the pressure pads. Pressure Pads: It is used to flat the slits by applying pressure. The pressure

used in coil slitting line is hydraulic pressure.

Recoiler: It is used to recoil the slits or to make roll of different slits.

TUBE MILL-1(R-1)

TUBE MILL-1 ( R-1)

The function of this machine is to make tubes or pipes of given slits. It can make pipes of radius from 12.00mm to 28.60mm. It is a completely automatic machine. The slits of width according to required diameter are entered and form the pipes by the tube mill The different operations in the various parts of tube mill are given as fallows:
Decoiler/ Uncoiler: Firstly coil is loaded over the spindle with the help of crane

in decoiler. It is the initiating part of the tube mill.

Leveller: Leveller is used to flat the slits and remove roughness of the slits. A

number of different rollers are fixed in a leveller by which slits are made flat.

Shear Cutter: It is used to cut that part of the slit which is not of required size

or which is not straight.

TU D BE IAM E

Butt Welder: It is used to weld those parts of the slit which being cut in the

shear cutter. Hydraulic Pressure is used to press both parts of slits to do butt welding. (Butt welding is a type of pressure welding in which pressure is applied on both pieces to held together and then butt joint comes into picture)

 Floop/ Accumulator: In this portion: 1.

Sheet is inserted between pitch roll rollers.

2. Form free loop in `A` position. 3. Drive the sheets around the deviation roll on the exit rolls system above &

around the central shaft and then drive it to the exit.

Forming Mill: Forming mill is used to give rough dimension to the slit so that

we can get an idea about the pipes to be make and pipes are made in this portion with the help of Rolls. We can increase or decrease the radius of pipes by using different size of Rolls.

--Forming Gear-Box: It`s function is same as the sizing gear box. It is used to vary RPM in the forming section.
HF Welder: HF welder means high frequency welder. It is used to weld the joint

of pipes without using any filler material. It is a type of ERW (Electric Resistance Welding). The Pressure of 2.5 bar is used. ---Heat Exchanger: Heat exchanger is used to convert heat to the cooling system. Its main function is to change the heat to other form.
Cooling station: The purpose of coolant are:

1. To cool pipes.
2. To prevent pipes from rust. 3. To get clean, dustless and scrap less (Cutting Burada) pipes.

When machining of pipes get finished then these are hot due to machining so cooling of them is needed. Coolants are also used to prevent pipes from rust and to get dustless & clean pipes. These are the major purposes of using coolant.
Sizing Mill: Sizing mill is used to give accurate size to the pipes.

--Sizing Gear-Box: It is used to vary RPM (revolution per minute) of wheels. We can increase or decrease the RPM of wheels by using sizing gear box.

Metal Spray: The spray of zinc or aluminium is done over the slits so that is

can be prevented from rust. So zinc or aluminium spray is done to prevent rusting of metal.

COC (Cut off Carriage): In this, pipes or tubes are cut in required length.

ROC (Run Out Conveyer): After cutting pipes are run on the conveyer to the

another machine.

TUBE Mill- 2 (R-4)

Tube Mill-2(R-4):

The function of this machine is to make tubes or pipes of given slits. It can make pipes of diameter from 29.50mm to 85.00mm. It is a completely automatic machine. In this, slits of width according to required diameter are entered and form the tubes by the tube mill. The different operations in the various parts of tube mill-2 are given as follows:
Decoiler/ Uncoiler: Coil is loaded over the spindle with the help of crane in

decoiler. It is the initiating part of the tube mill.

Leveller: Leveller is used to flat the slits and remove roughness of the slits. A

number of different rollers are fixed in a leveller by which slits are made flat.

 Shear Cutter: It is used to cut that part of the slit which is not of required size

or which is not straight.

Butt Welder: It is used to weld those parts of the slit which being cut in the

shear cutter. Hydraulic Pressure is used to press both parts of slits to do butt welding. (Butt welding is a type of pressure welding in which pressure is applied on both pieces to held together and then butt joint is formed.)
Floop/ Accumulator: It stores the extra material for efficient running of mill. It

helps to make the process of mill continuous. It has two brackets. One is outer bracket and other is inner bracket. The extra coil is stored on outer bracket firstly and then from inner bracket, coil strip is taken out to mill for making tubes.

Forming Section: In the forming section the required shape and size of the

pipes are given with the help of roll stand. The diameter to be given to the pipes can be get by using required size of rolls.

HF Welder: HF welder means high frequency welder. It is used to weld the joint

of pipes without using any filler material. It is a type of ERW (Electric Resistance Welding). The Pressure of 2.5 bars is used. ---Heat Exchanger: Heat exchanger is used to convert heat to the cooling system. Its main function is to change the heat to other form.

 Cooling station: The purpose of coolant are:

4. To cool pipes.
5. To prevent pipes from rust.

6. To get clean, dustless and scrap less (Cutting Burada) pipes. . When machining of pipes get finished then these are hot due to machining so cooling of them is needed. Coolants are also used to prevent pipes from rust and to get dustless & clean pipes. These are the major purposes of using coolant
Sizing Mill: Sizing mill is used to give accurate size to the pipes.

--Sizing Gear-Box: It is used to vary RPM (Revolution per Minute) of wheels. We can increase or decrease the RPM of wheels by using sizing gear box.

Turk Head Section: It contains sizing mill. The final size to the pipes is given

by using rolls and in this portion diameter of pipe is measured.

Metal Spray: The spray of zinc or aluminium is done over the slits so that is

can be prevented from rust. So zinc or aluminium spray is done to prevent rusting of metal.

Flying Saw: It is used to cut the pipes of required length. A saw is fixed in this

section. This is used to cut the pipes.

 Run out table: Through run out table, pipes move towards the tube check

section with the help of a conveyer.

Tube Check Section: O.D, length, Surface, Thickness, Flaring test at 0 degree

and 90 degree, flattening test, Drifting test, Hubbing Test and Corner Radius For Section Tubes and Oval tubes are checked on tube check section.

MULTICUTTER- 1

Multicutter-01:

This machine is used for cutting and finishing of the pipes. It is a semi- automatic machine. There are 8 motor cutters in this machine which are used to cut the pipes and there are 8 flow regulator lubricant units. Through air liner, air mix with oil in lubricant unit and it acts as a lubricant when cutting of pipes is performed in cutting tube when it fall over the pipes. The different operations are performed in tube multi cutting machine, which are as follows:
De-burring machine: It is used to carry the long pipes which are to be cut. A

no. of chain are fixed in de-burring machine and pipes to be cut are fixed in teeths attached with chain. When chain rotates, pipes come in cutting arm.
Cutting Arm: Cutting arm contain motors and flow regulator lubricant unit. The

long pipe from de-burring machine comes under cutting motors and coolant is fall over them when they are cut by cutter in different parts. They may be of same length or different length as we require.
Conveyer: After cutting, pipe falls over a conveyer and move towards the

Champhering machine where champhering of pipes is done.

Champhering Machine: Like de-burring machine, moving chains are fixed in

Champhering machine over which teeth are attached and cut pipe goes to the tube stacker.
Tube stacker: Tube stacker is used for finishing of the pipes internally as well

as externally.

After finishing, pipes are kept in a trolley and either they are stored or supplied to another company.
Cutting Control Panel: This panel has whole control over the tube multi

cutting machine. The tube multi head cutting machine is operated by cutting control panel.

MULTICUTTER- 2

Multicutter-02:

The basic difference between the multi head cutting machine (M-1) and multi head cutting machine(M-2) is that the M-1 is PLC i.e. programming logic control operated but on the other hand M-2 is electrically operated and contractor are fixed. This machine is used for cutting and finishing of the pipes. It is an automatic machine. There are 12 motor cutters in this machine which are used to cut the pipes and there are 12 flow regulator lubricant unit. This machine is used for cutting and finishing of the pipes. It is a semi- automatic machine. There are 12 motor cutters in this machine which are used to cut the pipes and there are 12 flow regulator lubricant units. Through air liner, air mix with oil in lubricant unit and it acts as a lubricant when cutting of pipes is perform in cutting tube when it falls over the pipes.The different operations performed in different parts of tube multi cutting machine are following:

De-burring machine: It is used to carry the long pipes which are to be

cut. A no. of chains are fixed in de-burring machine and pipes to be cut are fixed in teeth attached with chain. When chain rotates pipe comes in cutting arm.

Cutting Arm: Cutting arm contain motors and flow regulator lubricant
unit. The long pipe from de-burring machine comes under cutting motors and coolant is fall over them when they are cut by cutter in different parts. They may be of same length or different length as we required.

Conveyer: After cutting, pipe falls over a conveyer and move towards
the Champhering machine where Champhering of pipes is done.

Champhering Machine: Like de-burring machine moving chains are

fixed in Champhering machine over which teeth are attached and cut pipes goes to the tube stacker.

Tube stacker: Tube stacker is used for finishing of the pipes internally
as well as externally. After finishing, pipes are putted in a trolley and either they are stored or supplied to another company.

Cutting Control Panel: This panel has whole control over the tube multi
cutting machine. The tube multi head cutting machine is operated by cutting control panel.

Project Report Based Analysis of Breakdown in the Month of Aug,2010 & 5 S +Safety+ Kaizen

MAINTENANCE OBJECTIVES

o Improve productivity
o

Reduction in Downtime frequency & increase the Availability of Machine.

o Establish system for energy audit and energy saving projects.

o

Satisfying the needs of customers by minimizing the variation Diminish the risk of personnel injury resulting from maintenance tasks and by the use of organizations equipment.

STRENGTH AND WEAKNESSES

Strength: Situational Leadership
Effective Technical Base Group for Problem Solving.

Set accurate standards of performance which accurately reflect the ANS objectives by scientific method.

 Check operations against the standards. Set indicated corrective measure in motion. Scheduled preventive maintenance. Always look for new improvement areas (Kaizen purpose).

Weaknesses: Inadequate Manpower in Maintenance Deptt. Insufficient/ improper information flow.

Old fashioned machinery. No on time availability of spares and parts.

Limited fund sources.

OBJECTIVES

OBJECTIVES:
The basic objective of this report is to find out the root cause of frequent machine breakdowns & give specific solution to resolve the problem permanently. The main objective of the project was to study the frequent breakdowns of machine in the month of Aug,2010. The study is based on the Monthly Stoppage Report and Maintenance Log Book which is the starting point of the analysis of Machine Breakdown. Stoppage report & Maintenance Log book: During the analysis of stoppage report & Maintenance log book, the main problematic area which came into the month of Aug,2010 is the Tripping/ Failure of HF Welder frequently. On studying the stoppage report, the highest frequency and the highest downtime noticed in Tube Mill-01 is because of failure of High frequency welder. The study has been divided into two category :

 Facts or Data collected :

During the study of the stoppage report the amazing result came into existence was that the maintenance department was suffering form this problem for a long time but have not found any permanent measures even not in present condition. Because of this failure, company has to face the productivity loss and at the same time, if any abnormalities appear in HF Welder, can create defect in the Tubes Or Pipes like: Pin Holes, lack of fusion, white penetration(Pre Arcs),cold weld etc. (For more details refers to AnnexureI).
TOTAL TIME (IN MIN.) 270 265 235 120 110 75 60 10 1145

REASON FOR STOPPAGEMECHANICAL MAINT.

HF TRIPPED Mill Drive Jerking COC Tripped Crane B/d - Coil Loading Mill Ready Power Change Over Bundling / ROT Tripped Length Variation
TOTAL TIME

Cumula tive % 24% 47% 67% 78% 87% 94% 99% 100%

Data: stoppage report of the month of Aug,10

Decision/ Action taken to solve the problem:

The last records showed that no permanent measure has been taken yet, because the same problem reoccur every month. Maintenance team every time suffer form this problem.

RESEARCH METHODOLOGY

RESEARCH METHODOLOGY
Research is an important pre requisite for a dynamic organization to be precise research is a more systematic activity directed towards the discovery and development of organized body of knowledge. Some of the characteristics of the research methodology are follows. Research is directed towards a solution of problem. It may attempts to answer a question or to determine the relation between two or more variables. Researches involve gathering new data from primary of first hand source or using existing data for new purpose. Research is based on observable experience or empirical evidence. Nature of data:-

A characteristic of research studies in business management is their reliance on secondary data source in particular and primary source in general. Primary data:The primary data, which is Monthly stoppage report, was collected by help of Production & Maintenance department at gamba (Gamba Japanese word which means to visit on problem site). Secondary data:The secondary data and facts were taken from Maintenance log book in which action taken in past and how many times the problem reoccur also mentioned. Research instruments:Mainly the data was collected from past and present records and to visit at gamba. .

Data Analysis & Interpretation

The data collected from Monthly stoppage report shows that the highest number of breakdown occurred in HF Welder which is nearly 20 times while the breakdown/ stoppage time is 500 min in a month of Aug,10. As the pareto analysis shows, HF welder has highest stoppage frequency and stoppage time rather than others, so it is the main area of concern & improvement for maintenance.

REASON FOR STOPPAGEMECHANICAL MAINT. HF TRIPPED COC Tripped Mill Drive Jerking Mill Ready Bundling / ROT Tripped Power Change Over Crane B/d - Coil Loading Length Variation TOTAL TIME

TOTAL FREQUENC Y 35 11 8 7 5 4 2 1 73

Cumulati ve % 48% 63% 74% 84% 90% 96% 99% 100%

REASON FOR STOPPAGEMECHANICAL MAINT.

HF Tripped Mill Drive Jerking COC Tripped Crane B/d - Coil Loading Mill Ready Power Change Over Bundling / ROT Tripped Length Variation TOTAL TIME

TOTAL TIME (IN MIN.)

500 265 235 120 110 75 60 10 1375

Cumula tive %
36% 56% 73% 81% 89% 95% 99% 100%

High Frequency Welding :

In the high frequency welding process, the preformed tube is passed through an induction coil excited by a high frequency (generally between 100 kHz and 800 kHz) electrical current. The high frequency current in the induction coil creates a magnetic field that induces a current on the surface of the tube wall directly under it and flowing in the opposite direction of the current in the coil. This is illustrated in the picture.

Introduction:

Figure - The High Frequency Welding Process

In Figure, the black lines represent the magnetic field and the current is illustrated in green. The current induced on the tubes surface must follow a closed path. When it reaches the tubes open edges, a high frequency principle called the Proximity Effect causes it to close almost totally following the edges of the weld vee. The current concentration on the weld vee edges is much higher than on the tube surface under the induction coil because the current path is much narrower. In fact the current concentration is high enough to heat the vee edges to the tube materials forging temperature. The tube is then squeezed together at the vee apex by the tube mills forge pressure rolls and a forge type weld is formed. A forge weld is much like that produced by a Blacksmith and has the advantage of having no cast structure as occurs with any of the melt weld processes such as laser welding. In fact the material properties of the forge weld zone can be controlled through proper choice of welding frequency and vee length! Finally, the other major advantage of the high frequency welding process is that it is very productive. Mill speeds between 50 meters per minute and 150 meters per minute are readily achieved for most tubes produced for hydro forming parts. WHAT IS HF? High Frequency, in these applications, is AC current alternating at between 100 and 800 Kilohertz (kHz), that is,100,000 and 800,000 cycles per second. Until relatively recently, to boost the frequency of 60 cycle line current to HF, the AC current was converted to DC current, fed into a vacuum tube oscillator (triode) used in conjunction with a resonant tank circuit to maintain the output of high frequency power. Today, this is accomplished in a similar fashion using MOSFETs (Metal Oxide Silicon, Field Effect Transistors) in place of the triode. THE NATURE OF HF CURRENT: HF current has two very unusual features that distinguish it from 60 Hz line current. First, line frequency current flows through the entire conductor where HF current flows only on the surface of the conductor. This is called the skin effect. Second, when two conductors carrying HF current are placed close to one another, the current concentrates on the two adjacent surfaces of the conductors. This is called the proximity effect.

SPEED AND POWER: HF welders have been produced with power ratings from 60 kilowatts to over 1 megawatt. The tank circuits can be tuned for frequencies of 100 kilohertz to 1 megahertz. This broad range of frequency and power can be applied to pipe as large as 24 (610mm) diameter by .900 (22.9mm) wall running at 30 feet per minute (9.1 meters per minute) to 1 (25.4mm) diameter x .090 (2.3mm) wall running at 1000 fpm (304 mpm).The HF process has been successfully applied to steel, copper, brass, aluminum, stainless steel, titanium, and gold. It can be applied to any electrically conducting material and in shapes other than tubular. For instance it has continuously welded structural I-beams from 3 separate coils of strip steel at 70 fpm (21 mpm). It can be used to weld a spiral fin onto a tube to make boiler tubes at 450 rpm. Many other examples are presented at the end of this paper. METHODOLOGY Although the application varies, the basic principle of HF welding involves creating a vee where the two surfaces to be welded are brought together. The example below illustrates this in a tube welding application showing both the contact and induction method.

As the previous two illustrations show, forming the flat strip into a cylinder creates the HF vee. The edges are heated by the resistance of the HF current

flowing in the edges of the vee. As they get closer, the contribution of the Proximity Effect concentrates the current and more heat is created until at the apex of the vee, the metal on the edge surface is molten. As the edges pass through the weld rolls, the molten metal is ejected and the forge weld is formed.

THE HF VEE
To successfully utilize the HF process, the apex of the vee should be as near the weld point as possible. The degree of opening is influenced by the material being welded but is generally kept between 3 and 7 degrees. The edges should be kept parallel and flat as they approach one another. Any variation in vee length during the process will result in variations in heat and thus, weld quality.

THE HF WELDER
Shown below is a state-of-the-art Solid State HF welder. This system will supply up to 600 kW of power at a frequency of 100 kHz to 1MHz. Larger and smaller units are available from several manufacturers. In the pages following, you will find numerous examples from actual HF welding applications.

HYDROFORMING APPLICATIONS

The renewed interest in tube hydro forming has prompted many people to supply tube to this market. Many have succeeded and a few have failed and those who fail usually cite bad welds as the problem. This is usually due to faulty set-up and execution of the HF weld. Done properly, with the care and attention demanded by any critical application, HF welded tube can be readily hydro formed. Low carbon contents seem to perform better although HSLA and stainless steels have been successfully hydro formed. Nonferrous HF welded tubes are also easily processed. Seam annealing of the weld is not usually necessary but may improve the ductility in the Heat Affected Zone of higher alloy materials.

Problem No 01: Frequent Tripping of High Frequency Welder due to

impeder leakage.

.
After getting the information of the HF Welder tripping( Mill stoppage due to tripping), Maintenance head went at gamba and conduct the Brainstorming session with worker and maintenance team. In the brainstorming session the maintenance leader explained the problem in front of all worker and team member and analyze the responses to find out the most potential reason (which showed the strong relationship) by using relationship matrix and then to reach the root cause of the problem conduct the whywhy analysis. The details are given below:

Why-Why Analysis:
WHY WHY WHY
It was Made as per old EPOXY tube thickness.

WHY
Lack of material Equipment & knowledge

WHY
Support from manageme nt (since we does not get the same size of EPOXY tube)

TM-01 Impeder Leakage

Due to Low thickness Wall

Corrective Countermeasure :
As the why-why analysis shows that the wall thickness of the impeder was low and the impeder wall was made up of old Epoxy tube, so that HF welder frequently tripped. After getting the root cause of the problem maintenance team decide to placed newly manufactured impeder from TEFLON ROD with increased wall thickness from inside portion, but its life can`t be compare with the impeder that was installed by THERMATOOL ( Previous one- Epoxy tube).

Horizontal Deployment: So we installed the same pattern impeder from

THERMATOOL (Impeder, with Increased wall thickness & made up of Epoxy Tube) since it has a good life and this can also maintain the good frequency for HF welder that can timely increased the efficiency of HF welder.

Result: After installing the Newly pattern based impeder (Epoxy Tube with
increased thickness) the frequency of the breakdown has been decreased and machine availability has been improved. The final result is no re-occurrence of the same problem has been noticed.

Problem No.02:

HF welder tripping due to presence of carbon particle.

Why-Why Analysis:

Problem
HF Welder Tripping

WHY
Current flow variation

WHY
Sparking near by the work coil

WHY
Soots formation at the Vee angle

WHY
Presence of carbon particle on the surface of the tube

Corrective Countermeasure :
Due to sparking near the work coil the HF welder tripped. After why-why analysis we came to the final conclusion that due to foreign carbon particle on the surface of the tube, soot`s are formed and these soot`s create sparking near the work coil. Maintenance team decided to install the inert gas mechanism. This inert gas helps in removal of carbon particle and cleaning of the surface. At the same time it also help in creating the inert environment near the welder because presence of oxygen and foreign particle can create sparking in vee angle, result fluctuation in current create and welder tripped.
B EF O RE K A IZ EN S K ETC H AF TER K AIZE N S K E TC H

Result: No repetition of this problem noticed. And the life of induction coil has
improved. This mechanism also helpful in defects reduction because, due to the presence of the foreign particle production and quality department were facing the weak weld problem.

Problem No.03:

HF welder tripping due to Oscillator Tube.

WHY

WHY

WHY

WHY
Every Oscillator tube are design to work for 10000 Hrs which was completed month earlier.

WHY

TM-01 HF welder not Working

Due to Oscillator tube

Due to expiry of the Oscillator tube`s life

----

Corrective Countermeasure :
New Oscillator tube has been placed and remove the older one. Since only timely replacement is necessary so maintenance has added this point in Monthly check sheet as a preventive maintenance.

Horizontal Deployment:
We have maintained the working Hours of Oscillator tube and will be informing approx. 100000 Hrs. before, So to make available one spare tube to get rid of critical breakdown.

Result: No same problem has been found again.

Other Improvement Project:

In ANS Steel Tubes Limited, Maintenance department is fully involve in Kaizen & safety activities. So time to time they perform some improvement projects.

the betterment.

Kaizen is a Japanese word which mean- Continual improvement for

KAI Change ZEN For the Betterment.

some Kaizen in the month of Aug,2010. is given below: Kaizen No. 01 Problem
Stucking of the Hydraulic Piston in the top most position.

Kaizen Action Taken

Limit Switch Provided to prevent extra travel of the Hydraulic piston in the top position.

Result
Prevented frequent stucking of the Hydraulic piston enabling quick on line sampling and frequent opening of the Hydraulic Cylinder.

Type of Waste
Over Production Transportation Motion

Cost saving

Result & Benefits

P- Productivity Q-Quality C-Cost Saving

Waiting Over processing Inventory Defects Under utilization of resources

D- Delivery S-Safety M-Morale

Kaizen No. 02 Problem

Not capable of producing diameters from 76.20 to 85.00 mm

Kaizen Action Taken

Increase the distance between the forming stands as well as the effective length of the shafts.
AFTER KAIZEN SKETCH

Result
Capable to produce dia. from 76.20 mm to 85.00 mm

Shaft

Forming Stand

Type of Waste
Over Production Transportation Motion Waiting Over processing Inventory Defects Under utilization of resources

Cost saving
A) Could develop import substitute size of 85.00x1.20 (SA1D) B) Could develop sizes for TELCO. C) Could undertake an additional business of Rs. 2.12 crores on account 'of A) & B)

Result & Benefits

P- Productivity Q-Quality C-Cost Saving D- Delivery S-Safety M-Morale

Kaizen No. 03

Problem
Stoppage of Tube mill after Rolling 1.5 MT of material resulting in Yield loss

Kaizen Action Taken

Increased the depth and angle of the Cutter's tooth.

Result
Cutter's life enhanced and a change is required now after 5.0 MT of Tube Rolling.

Type of Waste
Over Production Transportation Motion Waiting Over processing Inventory Defects Under utilization of resources

Cost saving
Cost saving per shift = Rs. 25,000

Result & Benefits

P- Productivity Q-Quality C-Cost Saving D- Delivery S-Safety M-Morale

Kaizen No. 04 Problem

Tube of Dia. 85.00 mm could not be accommodated in the accumulator.

Kaizen Action Taken

Modification undertaken in the floop, i.e. increase the length of support rollers and slight modification in the outer carriage ring.

Result
Continuous rolling of 85.00 dia. made feasible through accumulator thus avoiding stoppage after every coil and improving the yield.

Type of Waste
Over Production Transportation Motion Waiting Over processing Inventory Defects Under utilization of resources

Cost saving
A) On account of waiting, additional production gained is 3 MT per shift. B) Cost benefit obtained on account of added volume per shift is Rs. 39,000. C) Cost benefit on account of yield gain per shift = Rs. 17,388. D) Net Cost Saving per shift = Rs. 56,388 lacs. E) Net Cost Saving per month = Rs. 1,12,776 F) Cost saving for the year = Rs. 13,53,000 lacs.

Result & Benefits

P- Productivity Q-Quality C-Cost Saving D- Delivery S-Safety M-Morale

Kaizen No. 05 Problem

Metallic particles generated from Fin - Pass rolls causes fine surface defects

Kaizen Action Taken

Roll Cleansing brush provided

Result
Improvement in surface quality and strip edge condition.

Type of Waste
Over Production Transportation Motion Waiting Over processing Inventory Defects Under utilization of resources

Cost saving

Result & Benefits

P- Productivity Q-Quality C-Cost Saving D- Delivery S-Safety M-Morale

Kaizen No. 06

Fa reof Bra in Sy e ilu k g st m

Action taken:
Mechanical Disc braking system provided which operates brake during Non-availability of power.

When the failure of power occurs instant braking form elector pneumatic comes into action along with mechanical braking system.

When long time power not being available the braking system force from electro pneumatic system diminishing while the mechanical braking system remain activated.

Electro-pneumatic Braking System

Mechanical Disc Braking System

Electro- pneumatic with Mechanical Disc Braking System

Check:

Electro-pneumatic Disc Braking

Loosening of Coil Wraps

Mechanical Disc Braking System

Tighten of Coil Wraps

LIMITATION
While doing any job, any research, some obstacles always erect before our way. I also had some objectless and limitations during the research work. Some of them are:-

While

doing Brainstorming and why-why analysis, worker suggestions or ideas were not very appropriate/ good quality because of lack of proper exposure and knowledge. collected for the analysis was not very appropriate because the Operator/ Engineers note the stoppage time on the basis of their assumption. So there may be a chance of variation in stoppage-time. of the time was also a big barrier in the research. Maintenance department has to solve the problem as early as possible.(M/c remain stop during analysis.)

Data

Shortage

Secondary data was not so effective because whatever action has been taken in
past to solve the problem was ineffective and repetition of problem has been noticed.

FINDINGS OF STUDY OR RESEARCH

With the help of my study, I find the strengths and Weakness of study: Strengthen of the company:-

Quick Response time to solve the problem. Handle the problematic cases in very organized form.

Good information channel inside as well as outside the company

Adaptation of new technology for the betterment purpose.

Effective as well as knowledge sharing team.

Weaknesses:-

 Delay in the arrangement of consumable or other parts. No separate store for maintenance department. No time schedule is fix for maintenance staff. Some time they have to perform their duty more than 18 hours. It create fatigueness among the staff.

Limited skilled Manpower.