Modification and Optimization of IVD 800 - Final Review
MODIFICATION AND OPTIMIZATION OFINVERT VERTICAL DRAWING MACHINE IVD 800 PROJECT REVIEW DATE: 16-04-2012GUIDED BY MEMBERSMR. S. BOOPATHI KARTHICK S -98608114017M.E, (PH.D) GOWTHAM A B -98608114011ASST PROFESSOR VIMAL RAJ K -98608114059
ABOUT THE INDUSTRY Project done at TVS Sundram Fasteners Ltd, Krishnapuram, Madurai Company specializes in manufacturing Fasteners using Cold Forging and also manufacture some powder metallurgy parts. Gives lot of importance for quality and has implemented lot of quality tools like TPM, Kaizen, etc. Has consistently got awards for quality like Deming Award, TPM award, etc
ABOUT THE PROCESS Raw material coming to the plant is checked for quality and then it is treated by means of annealing, phosphating, acid bath to remove rust and soften the metal for Cold Forging. Then the Raw Material is wire drawn using wire drawing machines including IVD 800. The drawn wires are taken to the Bolt Modules where bolts are manufactured using automated machines. The bolts are hardened, tempered and then packed for delivery.
ABOUT IVD 800 Invert Vertical Drawing Machine IVD 800 has been imported from Chengi Machine Co. Ltd, Taiwan. The main purpose of the machine is to draw the raw material to the standard dimensions using roller dyes. The wires are sent through rollers which reduce the dimension and after that they are pressed against cylinder by means of rollers.
PROBLEM FACED The machine is not able to support wires of larger diameter. The actual speed of the motor is 110 m/min. But it is currently run at 60-70 m/min due to the danger of wire getting out of the machine. The rollers are not able to support wires of diameter greater than 14.6 mm, though the machine is actually capable of supporting wires up to 18 mm diameter.
PROBLEM SOLVING METHODOLOGY In order to solve the problem, two management tools were considered. They are Fishbone diagram (Cause and Effect Analysis) and Forced Field Diagram. Fishbone diagram is done in order to find out the major cause of the problem. Forced Field Analysis is done after deciding a solution. It is done in order to find out whether the solution is suitable or not.
FISHBONE DIAGRAM Fishbone diagram also called as Cause and Effect diagram is a management tool invented by Prof. Kauro Ishikawa. In the diagram the causes for the problem and the sub causes are described like the bones of a fish. In IVD 800, the major causes found are workers, rollers, process, prior processing and motor.
FORCED FIELD ANALYSIS After discussing the solutions, we decided to do a Forced Field Analysis to find out the optimum solution. Forced Field Analysis is a new Management Technique in which we assign a score or mark to each parameter that supports the change and oppose the change. The score is assigned after consultation with experienced staffs and labors. If the supporting change has higher value then we can decide that the solution will be effective.
FORCED FIELD ANALYSIS FORINTRODUCING THIRD ROLLER
SOLUTION Based on the management tools, it is decided to introduce a new roller. The first roller is kept undisturbed. The second roller is turned anticlockwise and the length of the horizontal support is decreased in order to make the angle 120º The third roller is introduced by drawing a circle with 45.5 cm radius, which is the length of second roller support that is going to be used for the third roller. At a suitable point we fix the support.
AMOUNT OF WIRE PROCESSED – BEFORE AND AFTER If the machine is run at 65 m/min, then the amount of wire processed per hour is approximately 3900 m. By introducing the third roller, we can run the machine at 110 m/min and let us consider that the machine is run at 90 m/min. The amount of wire processed in an hour will be 60 min *90 m/min = 5400m We will be able to process an additional 1500 m of raw material per hour.
IMPROVEMENT IN THE MACHINE Expected Improvement in Efficiency =(New Length – Old Length)/ Old Length = (5400-3900)/ 3900 = 38.46% Be introducing the third roller, we would be able to process wires nearly 1.38 times the wires that are currently processed.
CONCLUSION Thus the model generated will used to introduce a third roller in the existing machine. The third roller will enhance safety for the workers, improve the speed of the machine and will ensure wires of higher diameter are run. It will increase the amount of Raw Material supplied to the Bolt manufacturing Modules in the industry.
REFERENCES Operating Manual of Invert Vertical Type Drawing Machine – Chi Ning Company Ltd. http://www.mindtools.com/pages/article/newTED _06.htm http://www.mindtools.com/pages/article/newTMC _03.htm http://en.wikipedia.org/wiki/Ishikawa_diagram http://www.accel- team.com/techniques/force_field_analysis.html https://forum.solidworks.com/thread/51997