1. B&H – Quarterly Opex Review 1
Project Title : Indigenous Development on Projection
welding machine to cater 7m finning length
Start Date :16th Nov 2015 End Date : 15th Feb 2016
Project Leader : Kiran Sirsath
Department : MED ( B & H )
Team Members:Vaibhav K. Shah , Sanjay Madhav, Tarak
Mankad, Ranba Waingade, Jagannath Kulkarni.
2. B&H – Quarterly Opex Review 2
Background of Project :
• Capability of Projection Fin welding machine is to weld upto
max 4.5m tube length.
• For recent order of Tata Steel & Nippon steel – as per design
engineering – Fin tube length is of 7m.
• In order to overcome the capability constraint , engineering
has put additional tube to tube butt joint for the same.
• Considering the volume of additional butt joints and its work
content , it is time consuming and laborious task. ( Appr. 7400
butt joints for both projects)
3. B&H – Quarterly Opex Review 3
Problem Definition :
• Requirement of finning for 7meter long tube.
• Increase in cycle time & work content to great extent for
finning of 7meter tube with additional butt joint.
• Existing Projection welding m/c is able to perform finning up
to 4.5 meter length because of constraint of bed length.
• Position of Electric motor on m/c restricting finning of tube
longer than 4.5meter.
• Old fixtures was not compatible for new requirement
because of following reasons
1) As per drawing, Finning starts at 110mm for bent tube.
2) Clamping of Tube was not possible in between finned
portion.
4. B&H – Quarterly Opex Review 4
Old Fixture photo ( 4.5 m length)
5. B&H – Quarterly Opex Review 5
Outcome Desired :
• Make 7meter long tube finning feasible on existing
projection welding m/c.
• Eliminate additional weld joint for finning 7meter long tube.
• Reduce cycle time & work content required for finning of
7meter long tube with additional butt joint i.e Tube cutting,
Tube chamfering, Tube set-up, Butt Joint welding,
correction after welding, RT, Ball Pass Test after welding.
6. B&H – Quarterly Opex Review 6
New Fixture photo ( 7 m length)
7. B&H – Quarterly Opex Review 7
Actions planned / implemented:
• New fixture designed to accommodate 7m Finning tube
length on existing bed length
• Servo motor for driving carriage was restricting additional
finning length so it was relocated on new fixture.
• Water cooling path was modified on the jaws to
accommodate minimum fin start position.
• PLC program was modified to cater 7m finning length
8. B&H – Quarterly Opex Review 8
Results Achieved :
• Successfully achieved 7m finning length on existing
machine of 4.5 meter bed.
• Successfully Eliminated additional weld joint for finning 7
meter long tube.
• Reduce cycle time & work content required for finning of
7meter long tube with additional butt joint i.e Tube cutting,
Tube chamfering, Tube set-up, Butt Joint welding,
correction after welding, RT, Ball Pass Test after welding.
• Total 3744 number of butt joint are eliminated
(Eco: 2944,Evap:800)
9. B&H – Quarterly Opex Review 9
Way Forward :
• This system works on two PLC programs to accommodate
7m finning length. Further this can be modified with bed
extension.
• Tube support system need to be modified to cater future
tube length requirement.
• Modification in servo motor & carriage mechanism to
withstand future finning length.
