A presentation on wire industry!

1. A PRESENTATION ON
INDUSTRIAL ATTACHMENT AT
EVEREST WIRE INDUSTRIES
DEPARTMENT OF MECHANICAL AND AUTOMOBILE ENGINEERING
LAMACHAUR-16,POKHARA
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Roll no: 34

2. TABLE OF CONTENTS
1. Objectives
2. Introduction
3. Production System
4. Job Description
5. Problems and Solutions
6. Safety
7. Conclusion
8. References
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3. OBJECTIVES
• To Develop skills in warehouse optimization, maintenance,
production management and sales
• To study about various activities carried out within the company.
• To know about the role of a Mechanical Engineer in the company.
• To study and observe the equipment, machine and tool used.
• To be familiar with the human resources management.
• To evaluate and inspect the continuous production system.
• To observe the quantity of production
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4. INTRODUCTION
• Everest Wire Industries is sister company of Everest Group Nepal.
• Everest Group was established in 1981.
• Everest Wire Industries was licenced in 2069 B.S at Dhalkewar,
Dhanusha, Nepal.
• It produces copper wire, copper rods and super- enameled copper wire
from imported copper cathodes and copper rods of 99.97% of
minimum purity level.
• Everest Wire Industries imports copper scrap (ISRI Berry, BIRCH) and
SCR copper rods (8-10mm). The quantity varies from 100 tons to
megatons.
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6. MATERIALS PRODUCTION
•Cables
• Wires
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7. MATERIALS PRODUCTION
CONDUCTORS NAILS
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8. MATERIALS PRODUCTION
•Galvanized Iron wire Gabion Box
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9. MATERIALS PRODUCTION
•Ribbed Wire
•Copper rods
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10. PRODUCTION SYSTEM
• The production of copper wires and cables are done on automated
continuous production system.
• The production procedure are
• Crushing, mining, and grinding of copper
• Turning into copper cathode
• Drawing
• Annealing process
• Bunching process
• Tinning process
• Twisting and braiding of the wires
• Cabling and jacketing process
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12. DRAWING OF WIRE
• Wire Drawing is a metal working process in which the cross
sectional area of wire is reduced.
• At first wire is shrinking. This can be done by many ways like
rolling hammering or swaging. This helps in filling through the die.
• Then the pulling process is done either by mechanically or
hydraulically.
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13. • It requires more than one step to produce one type.
• In this process the cross section of wire is reduced gradually as to
be determined.
• Die angle has great influence on the drawing force and the quality
of the wire.
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14. MACHINES USED IN FACTORY
• Wire drawing machine
• Speed= 40rpm, max 45rpm
• Inlet cathode diameter= 8-10mm
• Drawn wire diameter= 1,1.5,2.5mm
• Coiling machine
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15. MACHINES USED IN FACTORY
• Gabion machine
• Extruder- PVC coating machine
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16. JOB DESCRIPTION
• Inspection of copper wire sample according to the cross sectional
sizes.
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17. JOB DESCRIPTION
•To test the copper cathodes sample in tensile testing machine.
For proper conductors the tensile strength must be between
(200-250 N/mm^2).
•To keep the record of quantity of raw materials inventory and
prepare inventory report.
•To keep track of different wire such as for households, industry,
transmission wire, etc.
• To check the quality of wire. For example 3/22 means 3
stranded with gauge 22
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18. PROBLEMS AND SOLUTIONS
•Problems
• Warehouse optimization and maintenance
•Breakdown of Drawing machine
•Breakage of wire during production
•Fluctuation of current and voltages of power supply
•Mixing of impurities of ferrous or other metals
•Oxidation
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19. PROBLEMS AND SOLUTIONS
•Solutions
• The use of wire drawing machine for wire or rod ready before pull-out test work,
wire if occurrence quality problem then timely replacement must be done or
reduce the pull-out rate according to actual condition, ensure the normal operation.
• Pay attention to the current situation of the wire drawing equipment, and whether
there will be too many transient current events. Special attention should be paid to
the change of return current, or to install a stabilizer, voltage stabilizer, etc. Ensure
the normal operation of wire drawing equipment.
• Pickling is metal surface treatment used to remove impurities like stains dust,
inorganic containment, rust or scale from ferrous metal, copper. A solution called
pickle liquor which usually contain acid is used to remove the surface impurities.
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20. SAFETY
• At high voltage fluctuation all the transmission line was shut
down.
• Fire extinguisher were available for fire hazards.
• Proper equipments for worker and technicians were provided
including helments, gloves and other.
• During Saturday maintenance no any other personnel were
allowed to enter the workshop.
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21. CONCLUSION
• During this internship I have learnt about the latest technology that
involves in high profile industry to produce the finished products.
• One of the production system that I have learnt about is
Continuous production system in curriculum which I was fortune to
observe in this internship. The system was fully automated with
little inspection needed. The operators and other technician were
just inspecting the final products. The workers were only involving
in transportation of raw materials and finished products with
industrial heavy equipments.
• I have also learnt about the property of copper and other metals
like brass. The copper is very fundamental for the conductors to
conduct electricity. The household wiring is one of the major
application of copper wires.
• For the transmission line Galvanized Iron is widely used. These
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22. REFERENCES
• everestgroup.com.np
• linkedin.com/in/ramesh-prasad-saraff-
7a708372/?originalSubdomain=np
• aksbaje.com/Janakpur/Electrical-Cable-Manufacturers/Everest-Wire-
Industries
• Prospects and annual magazines
• Slideshare.net
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