4. SUMMARY OF STANDARD COIL LINE ACTIVITIES
0, 0%
85%
(14694)
4%
(680)
10%
(1821),
1%
(205)
OPERATION
STORAGE
TRAVEL
INSPECTION
DELAY
5. Summary Of Actual Coil Line Activities
20332, 73%
1220, 4%
2825, 10%
265, 1%
3520, 12%
OPERATION
STORAGE
TRAVEL
INSPECTION
DELAY
6.
7. COIL LINE TPT
• C:Documents and
Settingslpujari1DesktopCopy of Coil
Plan pl-1.xls
8. VARIABILITY FOUND TO ACHIVE THE GOAL
1) Non Availability Of Tig welders
2) Non Availability Of bend Coils
3) Non Availability Of setup coils
4) Low output of tig welders
5) Non Availability Of chamfered tube’s for bending.
6) Taper chamfering tubes received from dolphin machine.
7) Rechamfering of coil.
8) Joint straightening after welding.
9) Non Availability Of scallop plate
10) Non Availability Of EOT crane.
11) More weld repair %.
12) Waiting for S.R.
13) Waiting for IBR stamp
9. MAJOR 4 VARIABILITY
1) Non Availability Of Tig welders:
a) Welder required- 12
b) Welder available – 07
c) Loss of hours Due to non availability of Tig welders = 16hrs (45
joints.)
2) Low output of tig welders:
a) Output req. for 8 RPD = 115 Joints. (for five welder)
b) Actual RPD of five welders = 4.31 ( 62 joints)
c) Loss of hours 19 hrs. ( 53 joints)
3) Non Availability Of EOT crane
Hours lost = 23 hours
4) More weld repair %
(6% WELD REPAIR)
Loss of hours16.16 hrs
TOTAL LOSS OF HOURS : 74.16
PRESENT RPD WILL IMPROVE FROM 4.93 TO 5.87 RPD
10. Action taken1) Self Improvements.
2) Requirement given to welding cell for recruiting the tig
welders.
3) Training, Retraining & Retraining schedule prepared in
consultation with welding cell.
4) Appreciation award proposed.
5) Video shooting done by IED to find out variability of
welder output.
6) EOT crane utilization implemented in lunch & tea time.
7) Advance plan done of chamfering.
8) Tube chamfering process improved to get chamfer in
right angle.
9) Joint distortion control fixture implemented for butt joint
welding.
