PROCESS STRATEGY NG I. General The production line is WETLUX technology.

. The factory has prepared to build a new production line with NOF technology. Productivity: 5000-6000 ton/month (the ratio is 80% Zinc plated Steel plate, 50% Color plated steel plate. Recently, the ratio is changed to 50% plated Steel plate and 50% Color plated steel plate. And last month, the ratio of production is that the percentage of color plated steel plate is more that one of zinc plated steel plate. ) Effective output is 30% or 40% of design capacity. Instruction includes 4 independent production lines. Maybe the product of this production line becomes raw material for another one (internal traffic) II. Detail A. Galvanized Iron There are 8 sections in Zinc plated Steel plate production line Step 1: Checking input Materials: From production schedule, checking the specification of materials and define quantity. Weighing the Black Sheet bundle, writing and recording the data such as: standard weight, actual weight, suttle, specification and mode into the quality logbook of Black Sheet. Checking the quality: Round check: specification, place of origin Unpacking the bag, checking inside materials. To some bundles which are not enough equality such as : distorted, exothermic, iron-mould .they will be carried out without producing. In the production process, workers often monitor the quality of Black Sheet (level of fertile, exothermic, rupture) then record in the quality logbook of Black Sheet. Step 2: Direct feed material continuously: If the materials are enough quality to produce, they are inflow exhaust system and hood up with the first bundle to provide continuously for production line. Step 3: Deoiling and Pickling: Before Steel plates was entering to plate, they had had to through the deoling and pickling section, this section has 4 parts :

First, the Sheet band must go through the cistern concentration from 23 to 40, the temperature is 600C 800C here with steam, then next to two flushing chambers. Those flushing chambers is including : pump high pressure team system and small detergent from the cistern. It atomizes two faces of black sheet bundle; use the crane to cleanse deoiling parts. It continues going through the hot water flushing chamber (600C 800C) to reclean some dirty elements on Sheet. After that, sheets are gone into HCl bath with 10% - 20% strength. This is checked twice per turn ad record in the quality logbook. The last part is a water bath to make HCl out, and Sheets go through the hot water flushing chamber again. Then they are dried by a couple of rubber crane before come to next section. Step 4: Heating the sheet before coming Pan: This process makes the temperature of black sheet bundles go to 2000C. Step 5: The process of plating ZINC: With the temperature of 1800C 2000C, sheets is entered soldering flux chamber (Ammonium Chloride, antimony, aluminum) to flush, increase the brightness and mechanical behavior of materials Then, sheets are gone through zinc chamber, second to radiator grouping to finish this process. Step 6: The process of Cooling: The air duct system and booster perform this process. But after cooling sheets with air duct system, the temperature of sheets still are high. So they is bathed with a water chamber, here the temperature is slow down 600C-800C. And the water chamber makes sheets clear more. Step 7: Surface Passivation: Here, sheets are dipped in chromium chamber with the 3 7 strength and the temperature is 550C-600C. Sheets are overlapped by a protective coating chromium against to pickling. Then they are dried by a couple of rubber crane before come to next section. Step 8: Packaging and Inventory: Steel plates are categorized with the level of A, B, C of management department. After making steel plates become bundles, they are weighed, labeled and move to inventory. Some bundles which are not quality enough, are taken out and recorded in the document. B. Pre-painted Galvanized Iron Step 1: Input area Raw sheets feed consecutive into manufacturing process, choose good material to manufacture the best quality product

Black sheet bundle or zinc plated sheet plate which was be warm up and checked carefully, will be choose to be material for Color plated steel plate product. Material feed into input area by a couple of rubber crane and carry on carriage To prepare for feeding raw sheets tin into manufacturing , material bring in drum to decompress raw sheets by carriage After bringing in drum to decompress raw sheets, hydraulic system decompress tang , brace the core of raw sheets and move them into the center of route. Some devices is such as junctors, sheets reserves place by Korea technology to ensure route will be consecutive from input to output Step 2: Cleanse area Cleaning oil, dust on sheets to make higher adhesive strength of coat on tin interface. Cleanse area includes one clear oil bath with an injection blow molding system; inject hot Alkali solution into both 2 surface of tin. Then sheets were reamed by crane system ( imported from Korea) to clean oil and dust which adhere on tin interface ( Notes: if tin material still have oil or dust on its surface, so coat will be appear easy.) oil in the clear oil bath will be recycle and check carefully before exhaust outside. After clear oil bath are 2 hot and cold flushing water bath, injection system, squeeze crane. To clear chemical drains from clear oil bath and squeeze tin conveyor careful when it exit from clear baths. Step 3: Coating ,baking, cooling Coating, baking and cooling area or center area are some main parts of tin plate route in order to output products Center area include 3 lacquering machine (imported from Korea) after lacquering machines are drying ovens which laboratory heat could be more than 600oC a. Lacquering machine: 2 coat axis technology, coating 2 surfaces in parallel. The axes are driven by AC vector motor which purpose is to cover coat interface by a chromate solution cover. This solution is a good protection from corrosion and it is also play a role like a bonding layer to adhesive other coats b. After lacquering machines are baking ovens; baking oven with the firing system import from German, using LGP to bake the chemical surface and help it adhere on base metal c. After baking oven is air-blast system with high capacity to cool tin surface before feed into other lacquering machines d. Rough lacquering machine: 2 coat axis technology, coating 2 surfaces in parallel. The axes are driven by AC vector to adjust the thickness of lacquer film by driving engine, infinitely variable control and modern load cell system. Lacquer using here is lacquer base chromate, import from well know trade mark like Becker, KCC, Duracoat - help to

protect from corrosion it is also play a role like a bonding layer to adhere between tin surface and lacquer coat e. After coating a rough lacquer, tin bring in baking process by using baking ovens in order to the lacquer cell stick together and produce a strong adhesive lacquer. High temperature baking oven system use LPG fuel with the burner from German , Italia, help to avoid produce carbon black which will affect the quality of product. f. After baking, sheets will be cooled by high capacity air-blast system and water spray system. g. Fine lacquering machine: lacquer used here is lacquer base Polyester - import from well know trade mart like Becker, KCC, and Duracoat. Using three - axial lacquering in order to produce a glossy surface, uniformity on whole surface (using to high quality domestic product such as washing machine' shell, refrigerators shell.), coat 2 surface in parallel which The axis are driven by AC vector motor which purpose to adjust lacquer film density until 25mm easily by driving engine, infinitely variable control and modern load cell system. Lacquer film cover uniformly on whole surface, help tin increase color fastness from severe weather condition in our country and protect from Corrosion, commit to coastal area and industry zone

h. After coating the last lacquer film, sheets will bring in the baking process by using baking ovens in order to the lacquer cell stick together and produce a strong adhesive lacquer. High temperature baking oven system use LPG fuel with the burner from German, Italia, help to avoid produce exhaust fume into natural. Heating system from German, Italia burned almost fuel in order to avoid produce carbon black. i. j. After baking, sheets will be cooled by high capacity air-blast system and water spray system. After exit from the last water spray system, sheets cooled by high-pressure fan system and became final product.

Step 4: Output area a. Main function test product quality, divide raw sheets into parts like customer's order form. b. After sheets type exit from center area, it is driven by AC vector motor into looper in order to the central part run stably and consecutively in scroll product process. c. After testing by eye on both 2 surface, sheets is printed meter number and logo like customer requirement and scroll by ripe.

d. After testing enough meter quantity sheets is cut, carry on carriage, packaged and moved to finished products store. TATA STEEL INDIA Automation

Aimed at achieving a virtually seamless integration of automation solutions, the Automation Division of Tata Steel offers facilities for design, development, integration and implementation of process automation for the steel industry at home and abroad. The Automation Division of Tata Steel was created in 1990 in order to bring a structured approach to the on-going process. In an age of strictly knowledge-based economy, automation was realised as a strategic choice in gearing for the future in the fastest possible way, to counter the inertia of size and diversity that is intrinsic to a large steel plant. Though Information Technology and Automation were integrated in the initial stages, a bifurcation subsequently happened in January 1992. This enabled the Automation Division with its competencies to devote itself solely to the solution of real plant problems in real time. Automation Division of Tata Steel is the central agency for design, development, integration and implementation of Process Automation for the Steel Company and is also an international supplier of high level automation for the metal industry. It is situated in the premises of the steel plant at Jamshedpur in its highly advanced Automation Development Center and also in various plant sites developing and implementing process automation systems. The Automation Division has a dedicated team of professionals and experts in various disciplines from laser, robotics and instrumentation to mathematical modelling and simulation. The division works in close association with premier Research and Academic Institutions like the IITs, ERDC, MIT USA etc. for knowledge sharing in various fields.