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ESSAR STEEL INDIA LIMITED
ACKNOWLEDGMENT
A summer training is a golden opportunity for learning and self-development. I co...
In 1956, Nand Kishore Ruia, founder of the South group moved to Chennai starting the activities
of Independent Business.
I...
diversity offers great operational flexibility and protects the company against the vagaries of the
commodities market.
Bl...
large thickness (1.6 mm - 20 mm) and the width of range (of 800 to 2000 mm).
PICKLING
Two pickling lines with a combined c...
COLD ROLLING
A 2 MTPA sophisticated cold rolling mill adds muscle for steel manufacturing
facilities. Equipped with a 0.2 ...
GALVANIZING
Essar Steel Hazira complex has two galvanizing lines with a total capacity of 1 MTPA. By
applying a molten zin...
IMAGE OF GALVANISED ROLLED COIL
INFRASTRUCTURE FACILITIES
The Essar Steel Hazira complex has a complete infrastructure in ...
conveyors for transport of raw materials to the house battery, a rail network, dredgers, tugs and
mooring boats.
POWER PLA...
IMAGE OF ESSAR STEEL POWER PLANT
INTRODUCTION TO CMD
What is 'Maintenance'?
Maintenance can be defined as a constant effor...
Medium to large installations predictive based on observation No loss of productivity cost is high
(but less than preventi...
-No Consequence and likelihood
-No people, property, environment, and reputation
-Converting business risk the priority
-D...
-Cost Estimate
-No risk assessment (PPA)
-Safety requirements (JSA / JHA)
PROGRAMMING
-When you do the job?
-Planning invo...
-Compliance PM Maintenance Technician
-Orders by End Date Maintenance Technician
CLOSE-OUT
-Often forgotten part of the pr...
MAINTENANCE EVENTS - GP
-If you do a job, then there is a 80% probability that you'll do it again in the next two years
-W...
-Four arrest management phases
Initiation
JUDGMENT OF MANAGEMENT GROUP
-Manage upwards or downwards management of a large ...
RISK ANALYSIS
-Use a risk management process
-Kepner Tregoe n PPA (Potential Problem Analysis) PPP Criteria
-No critical q...
-Meeting 3:00 p.m. managers
EARNED VALUE
-No tools for tracking progress report of schedule
-Put immediately if you fall b...
POST SHUTDOWN REVIEW
-Perform SWOT Analysis
-Consolidate issues
-Back in the future judgments Management Plan
-Some proble...
The planning department is CMS dept chief who is ordered other plants and fabrication,
machining and inspection are the de...
Welding
CMS uses mainly arc welding. Sometimes they can use the oxyacetylene welding fuel. In arc
welding, they have the m...
If there are cracks on the surface and then grinding is done until it disappears. In some critical
cases it may even requi...
Inspection dept. CMS is concerned by the inspection and detection of specific problems that
occur in any machine or its co...
This is the most common test for the detection of surface defects. It involves four steps:
Pre-cleaning: Clean the surface...
If the team gives a yellow sticker then it is supposed to give an inspection report for the tested
component to the planni...
Store:
CMS store is concerned about material planning, planning for manpower and infrastructure
planning and management.
-...
- Purchase PR: includes ordering products from the main store or external supplier.
PR is a kind of reserve that you do fo...
Reliability Centered Maintenance
Reliability centered maintenance (RCM) is a CMS department that is concerned with the
sup...
frequently and less critical jobs of the tests are conducted over a relatively longer period of time
or if the plant apply...
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INTERNSHIP REPORT

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INTERNSHIP REPORT

  1. 1. ESSAR STEEL INDIA LIMITED ACKNOWLEDGMENT A summer training is a golden opportunity for learning and self-development. I consider myself very lucky and honored to have so many wonderful people drive me through in the completion of this training. I wish to express my gratitude and special thanks to Mr. Gopalji Sinha (Head, ELC and ESSAR Academy) which, despite being very busy with his duties, took the time to listen, guide and me keep on track and allowing me to realize my work industrial project to their esteemed organization. I want to express my sincere thanks to my guide Mr. Manish Khanna (Executive Director, CMD) and Mr. Naveen Kumar(Assistant professor, AUUP) , for participating in the decision and give helpful tips and advice needed. I choose this moment to recognize his contribution with gratitude. It is my feeling brilliant record best regards, the deepest sense of gratitude to Mr. Arvind Verma (Head - Mechanical Department) for his wise and valuable tips that were invaluable to my study in both theoretical and practical. Finally, I would like to thank all the engineers and technicians who helped me throughout training help me learn every possible way. DHRUV DUA OVERVIEW OF ESSAR STEEL Essar Steel Hazira, Gujarat, fully integrated steel plant houses world class and is one of the complex, in the most sophisticated and well planned steel environmentally friendly. Essar Steel Hazira complex is the largest single flat steel plant site in India. Built with a total investment of over Rs. 300 billion, it has a steelmaking capacity of 10 MTPA. This highly integrated and modern complex with complete infrastructure in place is home to some of the most sophisticated manufacturing facilities and the steel manufacturing process. The Hazira complex is certified to ISO: 9001: 2000, 9002 and compliance certifications TUV, ISO 140001 and India Chiller Energy Efficiency Project (ICEEP Protocol). INTRODUCTION TO ESSAR STEEL
  2. 2. In 1956, Nand Kishore Ruia, founder of the South group moved to Chennai starting the activities of Independent Business. In 1969, following the death of Nand Kishore Ruia Shashi Ruia finally his son and Ravi Ruia look like today; Essar Group. The name of the company ESSAR receives the first letter of the two brothers; "Shashi" and "Ravi", "S" as "ESS" and "R" as "AR"; Thus the combination to "ESSAR". Growth "ESSAR" has already begun with contracts to contracts for port and Bertha jetties construction. In everything "ESSAR" make is that they measure performance through the highest international standards; security and absorb the best technologies and train the best people at all levels of their operations. From the beginning, the group was built on the company at the heart of the Indian economy, often replacing foreign companies in India; as in the oil and gas services; construction or shipping. ESSAR threw the longest underwater pipeline in India. The ESSAR Group which created a basic Rs.17000 active. has a significant presence in the core sector industries Telecom steel, shipping, power and Constructer especially in Gujarat. VISION ESSAR The five E may define the vision of Essar Group. Ø Efficiency Ø Efficiency Ø Entrepreneurship Ø Empowerment Ø Education IRON MAKING PROCESS The Hazira plant is the only plant in the world to have three iron making technologies to one place - blast furnace, Midrex (DRI) and Corex. It houses the largest factory direct reduction iron (DRI) in the world with six modules and a capacity of 6.8 MTPA. 2 Corex modules and a blast furnace iron making to add capacity and bring diversity in technology. This technological
  3. 3. diversity offers great operational flexibility and protects the company against the vagaries of the commodities market. Blast furnace Corex Iron Making Process is the new and ecofriendly technology Hot briquette iron Hot Rolled Coil The AEP CONARC facilities and provide liquid steel for the plant of 8.6 MTPA hot rolled coil (HRC), the first and biggest of new generation steel mills in India, and 3.5 MTPA Mill more Compact modern band. Essar Steel is the only Indian steelmaker with a 1.2 MTPA hot skin pass mill which improves the quality of the steel surface to correspond to international standards such as API X-80. It has a
  4. 4. large thickness (1.6 mm - 20 mm) and the width of range (of 800 to 2000 mm). PICKLING Two pickling lines with a combined capacity of 1.4 MTPA and turbulence technology ensure the production of a perfect steel strip with clean surfaces without scale-without stripping the steel strip. Process image of pickling plant model
  5. 5. COLD ROLLING A 2 MTPA sophisticated cold rolling mill adds muscle for steel manufacturing facilities. Equipped with a 0.2 MTPA mill back, a 1.2 MTPA tandem mill, a batch annealing furnace of 0.8 MTPA and a pass mill skin of 1.0 MTPA, the plant manufactures Best cold-rolled products.
  6. 6. GALVANIZING Essar Steel Hazira complex has two galvanizing lines with a total capacity of 1 MTPA. By applying a molten zinc coating on the surface of a cold rolled product, the lines produce galvanized coils which have excellent corrosion resistance and are widely used in various industries. Process of galvanizing plant (image)
  7. 7. IMAGE OF GALVANISED ROLLED COIL INFRASTRUCTURE FACILITIES The Essar Steel Hazira complex has a complete infrastructure in place, including power plants, lime and plants oxygen, township and captive port can receive ships capsize, and is equipped with hardware Modern handling. This inclusion makes the entirely self-sufficient complex by eliminating dependence on external inputs and forms the core of integrated Essar Steel process. This ensures that Essar Steel is still able to maintain a strategic and competitive advantage in a constantly changing market and growing. ESSAR PORT Essar Steel has a set-up of 30 MTPA, for all time, the proposed deep dry bulk port to Hazira in Gujarat. Located on the west coast of India, the port is used to import iron ore, pellets, limestone, other dry bulk cargoes and the export of finished steel. Existing facilities include a dedicated channel at any time, 550m long pier, unloading ships and storage facilities for finished products,
  8. 8. conveyors for transport of raw materials to the house battery, a rail network, dredgers, tugs and mooring boats. POWER PLANT The first plant came to Essar Steel Hazira, Gujarat, in 1997. The plant operated at 515 MW natural gas combined cycle and has consistently set new standards of excellence in the electricity sector in India since its inception Service. This environmentally friendly, ISO 14001 and OHSAS 18001 certified plant operates with an availability factor of the installation of over 94%. Be the first multi-fuel plant in India, it can run simultaneously on naphtha and gas. Essar Steel is one of the few companies to receive a security clearance by the International Safety Rating System (ISRS) and the elite 'Sword of Honour', the highest award from the British Safety Council. A second plant was established in Hazira Essar Steel in 2005 with a capacity of 500 MW.
  9. 9. IMAGE OF ESSAR STEEL POWER PLANT INTRODUCTION TO CMD What is 'Maintenance'? Maintenance can be defined as a constant effort to continue to work with same efficiency. Maintenance can be classified as below: Based on Suitable for Type Advantages Disadvantages Preventive large capacity plants at regular intervals No degradation No loss of productivity The high cost because it employs more manpower and machinery
  10. 10. Medium to large installations predictive based on observation No loss of productivity cost is high (but less than preventive) Distribution small plants ventilation / full stop maintenance cost of production is relatively less critical loss of productivity. THE IMPORTANCE OF MAINTENANCEEXECUTION Good maintenance is good security -No new legislative requirements increased monitoring of stakeholders safety performance -No risk management strategies zero injuries Good safety is good business MAINTENANCE EXECUTION What is the execution of the maintenance? - Integrated process covering: - Selection of candidates (including the risks and priority) - No scope (what to do) - Planning (how to) - Scheduling (when) -Execution (how) -Close-out JOB SCREENING -Identify the required work -CMMS (SAP Notifications) -Can be raised by "person" -No review notifications -Made by someone who understands the business of "risk" -Determine business risk
  11. 11. -No Consequence and likelihood -No people, property, environment, and reputation -Converting business risk the priority -Determine required end date for the work and performing maintenance player to achieve this end date -Assign staff to scope and work plan DIAGNOSIS -What will you do? -Replace -Repair -No patch -No work Defer -Do nothing -Identify duplicate jobs (or similar work) -Developed by experts -No cost considerations must be accounted for -No operational constraints (production requirements, regulatory requirements, availability of resources, etc.) PLANNING -How will you do the job? -No basic requirements:tasks, milestones, duration and sequence -Resources -People -Materials -No Tools -Equipment
  12. 12. -Cost Estimate -No risk assessment (PPA) -Safety requirements (JSA / JHA) PROGRAMMING -When you do the job? -Planning involves several key stakeholders vegetable -Supervisors (have the manpower resources and equipment) -operations (factory owners) -Scheduler (built calendar) -Warehouse (owner of materials) -Someone has to "own" Annex (Lead) -No cyclical process (usually weekly) -No distinct roles for planning and scheduling EXECUTION -Do the work -Do the work you say you'll do -Do it when you say you will do -Like taking your car to a service -Measure performance by KPI -Schedule of education -Compliance PM -No orders filled by required end date -No Ownership of the KPI is to the appropriate speaker -NOTthe planner (or Scheduler) -Schedule Achievement supervisor
  13. 13. -Compliance PM Maintenance Technician -Orders by End Date Maintenance Technician CLOSE-OUT -Often forgotten part of the process the completion of recording of each step -Gather hours worked -Collect history (damage, cause, activities) -Identify costs -Continuous learning MAINTENANCE WORK FLOW -Types of Work -No PM (preventive maintenance) -No corrective work -Failures -Renovation -Each will have a workflow process
  14. 14. MAINTENANCE EVENTS - GP -If you do a job, then there is a 80% probability that you'll do it again in the next two years -What jobs can be converted to a calendar? No store in the CMMS system -Two major improvements -Increased reliability -The efficiency of planning increased -Identify resources in advance -Automate and consolidate the resource procurement process -No less waste SHOOTING -If you do a job, then there is a 80% probability that you'll do it again in the next two years -This applies to failures and -Some initiatives that can be implemented -APL (application parts lists) - Lists of documents that might be required for a job -No BOM (BOM) - Lists of parts that make up a piece of equipment -Plans Library - If a fault occurs, then you already have a model available -Remedial work -A LIST - Ask your list in a CMMS system should include the following: Project Work -Major Maintenance -Re-Engineering -Summary list of work to be done -Can be conflicts between work and project maintenance works
  15. 15. -Four arrest management phases Initiation JUDGMENT OF MANAGEMENT GROUP -Manage upwards or downwards management of a large program requires input from various stakeholders -Stop Steering Group strategic direction -Cup executive must have a charter (avoid micro-management) Planning and Preparation The stop criteria must justify why a job is done in the judgment REVIEW LIST OF WORKS -No Jobs to be reviewed for their operational impact if not done -Risk Matrix probability and consequences is high GANTT DEVELOPMENT CHART -A Gantt chart is necessary -Develop a critical path -Time is prime to prime have a schedule -The duration of each step is as to be easily tracked -Under the reporting period (target <12 hours) -Large jobs have milestones or other methods to track progress -Create a base and track progress against the baseline
  16. 16. RISK ANALYSIS -Use a risk management process -Kepner Tregoe n PPA (Potential Problem Analysis) PPP Criteria -No critical quality work -Reliability critical work -Security -Critical Path tasks with earlier problems -New and / or unusual tasks -Working Group Implications -No work again if critical changes criteria -Execution STRUCTURE OF MEETING -Schedule Updates -7:00 AM Update for the Morning Meeting -3:00 p.m. Update for Night Shift -No consistent meeting times -Morning 10:00 Meeting Space
  17. 17. -Meeting 3:00 p.m. managers EARNED VALUE -No tools for tracking progress report of schedule -Put immediately if you fall behind -No expected costs to complete the work STOP COMMUNICATIONS -E-mail is a problem -No Reply All -No mass distribution lists -Not everyone has email access not very effective scoreboards -Tool Box Talks are very effective -No meetings are working well -Large mass meetings do not work well -No signs work well for operators -No flashing signs work extremely well -No jury is still Intranet -Your audience is not homogeneous -Public will generally not spread rumors that they believe are not true -Close-out
  18. 18. POST SHUTDOWN REVIEW -Perform SWOT Analysis -Consolidate issues -Back in the future judgments Management Plan -Some problem that came out stop manufacturing site -No Need two managers of the night shift -No Need to update the schedule of twice daily -Supply Department was very happy -No computer problems -Site Security not up -Steering Group has worked well -Site wide coordination worked well (the regular meeting of the forum) -Communication needs a lot of work -Fix phones CMS A brief introduction to the central maintenance shop The CMS is concerned at Essar mechanical maintenance and electrical maintenance does not. Hierarchy of CMS In addition there are two other departments CMS: Store: Retains all the tools / equipment and other spare parts stores Self-service: concerned with maintenance (electric + mechanical) CMS machine itself.
  19. 19. The planning department is CMS dept chief who is ordered other plants and fabrication, machining and inspection are the dept that work under defined set of operations as given by the planning team. The maintenance and store departments operate independently CMS. Manufacturing dept Manufacturing is essentially defined as a manufacturing process in which an item is made from raw or semi place ready to be assembled parts. In CMS workshop is primarily concerned with cutting (removal of damaged parts) and welding (adding new parts, hardware b / up, etc.). CMS Cutting methods: Gas cutting CMS uses cutting oxy-acetylene gas for most manufacturing work. It uses a gas mixture of acetylene oxygen which is ignited to produce a flame providing a temperature of 3100-3200 ° C. This is sufficient to oxidize the metal (formation of a metal oxide of low melting point). After that an oxygen jet at very high pressure blows off the field to the area and we get a cut. These cut edges then go for grinding or machining based on the requirement. Acetylene can not be stored at high pressures (it is unstable at pressures> 200 kPa), so that they are absorbed in acetone and then stored in high pressure cylinders. A gas cutting apparatus comprises: Storage Bottles -Oxygen Storage-acetone (absorbed in acetone) of the storage cylinder {The two cylinders have two flashback arresters that restricts or arrest the flame up into the cylinder.) -Hose -Gas Torch
  20. 20. Welding CMS uses mainly arc welding. Sometimes they can use the oxyacetylene welding fuel. In arc welding, they have the manual metal arc welding and inert gas welding arc (argon inert gas). Welding inert gas (argon) is used for high-precision work and are usually used to thin where accuracy requirement is high. Manual arc welding has low accuracy but is used for most high average thickness of jobs. It is relatively cheaper than the inert gas welding. Main characteristics: Power supply: DC Electrodes: Based on the requirement Temperature: 5000 ° C For a thickness of> 20 mm preheating is by oxy-LPG flame. Before welding the surface is cleaned by brushing. After welding, in some cases, stress is also performed via a heat treatment. Welding defects: There are two main welding defects: Crack and Porosity
  21. 21. If there are cracks on the surface and then grinding is done until it disappears. In some critical cases it may even require machining. The porosity is avoided in maximum extent. It is usually due to moisture in the electrode. In the case of mild steel, it is not so important. However, it is common cast iron. CMS uses good quality electrodes for the prevention of porous welds. In addition, they Preheat oven electrodes () or using stored empty electrodes to prevent defects in the welds. Planning dept. He is the head dept. CMS whose function is to receive the order to other units (repair and renovation) and define a set of series of operations to accomplish the task. For this, the team may require all the necessary details of the job, including its design (drawing) and the bill of materials (BOM) that may be needed to repair / rehabilitation. Sometimes the planning team itself provides a BOM. This nomenclature includes materials / spare parts to be organized by the customer himself. Another aspect of any maintenance work is its urgency (or the time planned to be spent at work), on the basis of which priority is decided. For example, if maintenance has to be done down price then those jobs are of high priority. The team also gives a predicted ratio estimate the cost of maintenance based on time, manpower and machinery invested. At the end of the team's work relates actual cost. The order given by the customer / user (HSM, CRM, etc. HBI) is called to great. And order (set of operations) as provided by the planning team was called up Operation / work. As a super control, there is a sub-order / work order of the planning team, but it can be to multiple suborders / work also according to the requirement. maintenance dept. The CMS Dept.of maintenance is entirely dedicated to maintenance machinery CMS only. It manages both mechanical and electrical problems that come one day or the other. The operation of the maintenance department. that is independent planning team is not doing good work for them. The Department. directly manages the problem and keeps their own records. Department Inspection
  22. 22. Inspection dept. CMS is concerned by the inspection and detection of specific problems that occur in any machine or its components. Any component offered at this department undergoes a series of tests, an account of which is given below Visual Inspection The visual inspection is performed to identify defects that are visible to the naked eye. It can be any kind of breakage, rust, etc., which is not recommended for the proper functioning of the component. Dimensional control Here, the dimensions of a component is checked with respect to a drawing that the reference component. For this, they use various measuring instruments some of which are given below: Caliper: ranges available: 0-300mm, 0-600mm, 0-1000mm: less Count: 0.02mm Caliper Outside: ranges available: 0-25mm, 25-50mm, 300-400mm, 400-500mm Inside Caliper: ranges available: 100-125mm, 50-300mm (with additional lengths 2075- 2100mm, 2025-2050mm): less Count: 0.01mm Bore dial: ranges available: 0-18mm, 18-35mm, 20-50mm, 50-100mm: less Count: .01mm Slip gauges: Available range: 1.00-60.95mm: less Count: 0.01mm Gauge Radius: Available range: up to 30mm Pitch Gauge: Available range: up to 4mm Other instruments: the level of the mind, depth gauge, height gauge, telescoping gauge, surface roughness tester, etc. CMS unannounced inspections calibration of all instruments once a year. NDTS (NDT) These tests are used to identify defects (cracks, voids, etc.) on the surface or in the bulk material. 1. Penetrant (DP) test:
  23. 23. This is the most common test for the detection of surface defects. It involves four steps: Pre-cleaning: Clean the surface so that it does not affect the dyeing process Dye / Dye spray: Apply dyeing or by spraying or by brushing or soaking. The dye goes into cracks, voids etc.via capillary action. Removal of excess dye: The excess dye is cleaned / wiped with a soft linen cloth. May also employ cleaner. Developer Application: The developer is in the voids, cracks strawberry being denser than the dye causes the dye to come to the surface and surface defects are evidenced by the dye color. Temperature range for testing: 5-52 degrees Celsius Any position is suitable for dye penetrant as it occurs via capillary action. The viscosity of the colorant is an important consideration. If the dye is highly viscous, so it can not penetrate in cracks especially the little ones. 2. Ultra sonic testing It uses ultrasonic waves to detect defects in the bulk of a material. It is based on the principle that the ultrasonic waves can not pass through so that it bounces off a crack or a defect when encountered in the mass. There is a special process known as ultrasonic flaw detector which includes a sensor (transmitter and receiver integrated) that sends waves and receives ultrasonic waves through the material. On the basis of elapsed time / b transmission and reception of the ultrasonic pulse from defects in the distance from the free surface can be calculated. Based on various tests / inspection team come to specific conclusions about what should be done. This award recognizes one of the 5 types of stickers for a different test component. * BLUE: Deleted Assembly * GREEN: OK * ORANGE: Cleared for new process * YELLOW: To be rectified * RED: Rejected When the green sticker is given by the inspection team, only this component or the assembly is ready to ship.
  24. 24. If the team gives a yellow sticker then it is supposed to give an inspection report for the tested component to the planning team that decides what should be done next. These stickers have other details like inspection report no., Work order no., Not the drawing. and the sign of the authority concerned. Assembly dept. Assembly Dept.of CMS is concerned about the disassembly and reassembly of components (including housing, fasteners, bearings, shafts, seals, etc.). some of the equipment / methodologies used in the assembly shop are: - Units of the Assembly: a device is a peripheral device or holding work support is used to hold the job specific orientation to facilitate disassembly / assembly. - Heat treatment unit: It is used to relieve stress or hardening or change by heat treatment properties. It includes the box furnace, quenching tank oil, pit furnace. - Cut through the electrodes CG100: cut through electrodes has principle identical to that of welding (arc generation). It generates considerable heat which simply burns off the material. Here unlike abusive, not compressed air or oxygen is necessary. It is used to break the small joints or welds or bolts and nuts trapped. - Blowers: For cleaning tight spaces, holes etc. - Key hydraulic torch: It is the hydraulic wrench for the opening of bolts. - Power supply: pressure taps that are used in combination with hydraulic pumps for lifting / pushing. - Welding: Although it is a part of the shop manufacturing, but it is done in assembly shop too. - Polishing: After dismantling of polishing components is done. This is to remove rust on the surface. It is also called truing operation. - Correction: the surface material removal. - Grease: To Eating fat in the holes that are difficult to be lubricated with grease otherwise. - Induction bearing heater: Temp 250 degrees Celsius, 1800 W (230V, 50 Hz) - In this shop using electrically controlled cranes can also been seen for handling and component position where the devices can not be used.
  25. 25. Store: CMS store is concerned about material planning, planning for manpower and infrastructure planning and management. - Planning for the material: it provides all the tools, equipment (including PPE), spare parts and stationery, electrical and electronic products to all other departments / stores. It keeps all records of the inventory, regenerates periodically. It also supports party providers (for control of new elements) and calibration parties (for the annual calibration of all measuring instruments). - The planning of the workforce: All staff provided the CMS is provided by various contractors. The store retains and maintains control of all the files too. - Infrastructure planning: All matters of CMS for related infrastructure are also processed by the store. For example, problems such as clogging of drains, roof damage, repair of windows, etc. should betaken over by the store. However, the material planning is the most important of all. The store has an inventory in which each product has a unique identification code. These elements may be issued from the store on two bases: 1. Temporary basis: when the article is supposed to be returned after a certain time interval. However, there is no trace of these issues on SAP. 2. Permanent basis: when the article is published permanently from the store. A bill of material delivery is made for each item that is then entered in SAP to update the inventory. Items issued permanently deplete the inventory and therefore has to be replenished. So stores orders for new articles that follow a certain procedure. ESSAR STEELS a central evil that provides products to all stores in his pants on which CMS is also one of them. Sometimes emission store items from the central store or they can contact suppliers directly to the article. But this must be received by the central store only. Any item can be ordered directly from the central store or an external supplier (if not available in the central store), which requires a "requisition" (PR). Purchase is of two types: - PR Service: includes infrastructure, workforce, equipment maintenance
  26. 26. - Purchase PR: includes ordering products from the main store or external supplier. PR is a kind of reserve that you do for a particular item available in the central store. Once the PR is accepted, we can take at any time from the store and is reserved exclusively for this clientele. But if this point has already been reserved by another unit / plant and there is no additional ore quantity, then we must take the permission of the controller of the original article. In some cases, when the very particular element is not available in the central store, so they may directly contact the other plants stores / units. It can happen the other way thus also may request another factory CMS store item. Articles can be of two types: - Common Element: used by all depts. like stationery - Particular: eg inventories inserts (m / c shop) or grinding wheel, abrasive (assembly shop) must be supported by the store because they are regularly consumed only and unique CMS. regarding central store plant A and plant B have separate buildings, but they are all interconnected by SAP. Provide from external suppliers: Do not place directly store for suppliers for any item, but an intermediate party / supplier takes first place in the order. It may be specific or specific requirements. Today, the party gives quotes from all suppliers of different brands that meet the requirements.The store, which then decides to accept quotation and reject reason. If the order is placed specific brand while receiving only the single quote mark. All funds in CMS CMS made by the Fund Center. The records and store inventories are maintained in SAP (MM module). At regular intervals, the inventory is as provided by SAP is checked by physical inventory. Sometimes there are small deviations are immediately corrected.
  27. 27. Reliability Centered Maintenance Reliability centered maintenance (RCM) is a CMS department that is concerned with the supervision of the state. It involves: - Vibration analysis - Oil Analysis - Thermography - Ultrasonic testing The team visits various plants / units at regular intervals of time for analysis. They collect data and back in CMS they analyze and report this. If there is a critical problem found in one of the M / C so he sent for maintenance. RCM is basically for predictive maintenance. - Vibration analysis: it is the analysis of data by the vibrations of the machine. All machines are working vibration. These vibrations are the combinations with all the vibrations introduced by the various components that make up a complex waveform. These individual waves are separated on a computer and analyzed. If a component to severe vibrations, they can be offered for maintenance. - Oil Analysis: Here the plant / unit is supposed to give the sample oil / coolant / lubricant which is then tested in the office of the MRC contamination ferrous / non-ferrous, contaminated water, change in viscosity and change in the chemistry. This not only gives the state of the oil / fat, but also the condition of the machine. - Thermography: thermal analysis is where a thermal image is taken by an infrared thermal camera. In this image, we can get the average temperature of the particular area and can analyze temperature anomalies of components / materials. For example refractory furnace linings - Ultrasonic: It uses ultrasonic waves that can detect very small cracks / defects that are then received by a microphone and its frequency is varied within the scope of the hearing. Any change model gives the fault in the machine. The duration of the conduct of the test on a machine depends on the criticality of the operation of this machine for the operation of the entire plant / unit. For critical work, tests are performed
  28. 28. frequently and less critical jobs of the tests are conducted over a relatively longer period of time or if the plant apply the analysis to be done.

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