1) Snowman formation occurs when dusty clinker blows back from the cooler into the kiln, creating a cycle that increases dust levels.
2) High secondary air velocities above 5m/s can carry finer dust from the kiln into the burning zone, stealing liquid and creating stickier clinker dust.
3) This dust builds up on the cooler surfaces, forming snowman-like structures, worsened by the presence of alkalis or sulfur that increase melting. Maintaining a short, radiant flame with oxidizing conditions and optimizing air flow can help control clinker dust levels.
The document discusses maintenance procedures for rotary kilns, including checking and adjusting the kiln alignment using benchmarks, ensuring proper contact between rollers and riding rings, addressing issues like shell warping, and inspecting the gear and pinion alignment. Key steps include establishing an offset centerline to check alignment, adjusting rollers as needed to align the shell centerline, checking for riding ring runout, adjusting rollers to avoid excessive thrust, and maintaining proper mesh between the main gear and pinion. Regular maintenance is important to prevent problems and excessive wear.
This document provides details on the final project assignment to design a stair-climbing wheelchair. It includes an introduction that identifies the problem of limited wheelchair mobility on stairs and describes potential solutions. Working drawings and analyses are presented, including assembly drawings, part drawings adhering to GD&T standards, a design analysis considering real-world constraints, and a finite element analysis of stresses on climber wheels.
The kiln was running normally except for a period in February when it was shut down due to an issue. Inspections found diesel oil in the main burner's gas inlet and increased wear on support rollers at station 3. Temperature measurements of bearings and pinions were within acceptable limits and the spray pattern for lubrication systems was good. Recommendations included grinding support rollers at station 3 and repairing the kiln shovel during the next shutdown.
1. The experiment aimed to prepare a mud with a known density and then increase its density by adding barite. Barite has a high specific gravity of 4.2, which allows mud density to be increased up to 21 pounds per gallon.
2. Procedures involved mixing bentonite and water to form a mud, then weighing and adding barite while stirring. The mud balance measured the initial and final mud densities.
3. Barite is the most common weighting agent due to its ability to significantly increase mud density up to 21 ppg, control formation pressures, and stability. It is also inert, readily available, and not classified as hazardous.
Skew refers to the position of a kiln roller axis relative to the rotating drum axis. If the axes are parallel, there is zero skew; if not parallel, skew is present and creates axial thrust. Skew is a small pivoting adjustment of 0.004-0.040 inches that changes the roller-drum relationship without significantly moving the drum position. Proper skew adjustment is important for optimum kiln operation and minimizing wear.
The three sentence summary is:
The document is a table of characteristics of domestic wastewater that is dedicated to the author's loving wife and daughters, as well as the Environment, Research and Development Agency of Samosir Regency Government of North Sumatera Province and the people of Samosir Regency. It thanks all readers and notes the author's alumni status from PSMIL at Universitas Padjadjaran in Bandung.
This document analyzes the tire tightening system of a cement kiln through analytical and numerical methods. It aims to evaluate the mechanical strength of shims, which transmit rotational drive to the kiln drum and are subject to stresses. The study uses mechanical theory and finite element analysis to determine stresses on shims under operating conditions. Results provide guidance on accurately predicting optimal preventative maintenance intervals for rotary cement kiln drive elements.
1) Snowman formation occurs when dusty clinker blows back from the cooler into the kiln, creating a cycle that increases dust levels.
2) High secondary air velocities above 5m/s can carry finer dust from the kiln into the burning zone, stealing liquid and creating stickier clinker dust.
3) This dust builds up on the cooler surfaces, forming snowman-like structures, worsened by the presence of alkalis or sulfur that increase melting. Maintaining a short, radiant flame with oxidizing conditions and optimizing air flow can help control clinker dust levels.
The document discusses maintenance procedures for rotary kilns, including checking and adjusting the kiln alignment using benchmarks, ensuring proper contact between rollers and riding rings, addressing issues like shell warping, and inspecting the gear and pinion alignment. Key steps include establishing an offset centerline to check alignment, adjusting rollers as needed to align the shell centerline, checking for riding ring runout, adjusting rollers to avoid excessive thrust, and maintaining proper mesh between the main gear and pinion. Regular maintenance is important to prevent problems and excessive wear.
This document provides details on the final project assignment to design a stair-climbing wheelchair. It includes an introduction that identifies the problem of limited wheelchair mobility on stairs and describes potential solutions. Working drawings and analyses are presented, including assembly drawings, part drawings adhering to GD&T standards, a design analysis considering real-world constraints, and a finite element analysis of stresses on climber wheels.
The kiln was running normally except for a period in February when it was shut down due to an issue. Inspections found diesel oil in the main burner's gas inlet and increased wear on support rollers at station 3. Temperature measurements of bearings and pinions were within acceptable limits and the spray pattern for lubrication systems was good. Recommendations included grinding support rollers at station 3 and repairing the kiln shovel during the next shutdown.
1. The experiment aimed to prepare a mud with a known density and then increase its density by adding barite. Barite has a high specific gravity of 4.2, which allows mud density to be increased up to 21 pounds per gallon.
2. Procedures involved mixing bentonite and water to form a mud, then weighing and adding barite while stirring. The mud balance measured the initial and final mud densities.
3. Barite is the most common weighting agent due to its ability to significantly increase mud density up to 21 ppg, control formation pressures, and stability. It is also inert, readily available, and not classified as hazardous.
Skew refers to the position of a kiln roller axis relative to the rotating drum axis. If the axes are parallel, there is zero skew; if not parallel, skew is present and creates axial thrust. Skew is a small pivoting adjustment of 0.004-0.040 inches that changes the roller-drum relationship without significantly moving the drum position. Proper skew adjustment is important for optimum kiln operation and minimizing wear.
The three sentence summary is:
The document is a table of characteristics of domestic wastewater that is dedicated to the author's loving wife and daughters, as well as the Environment, Research and Development Agency of Samosir Regency Government of North Sumatera Province and the people of Samosir Regency. It thanks all readers and notes the author's alumni status from PSMIL at Universitas Padjadjaran in Bandung.
This document analyzes the tire tightening system of a cement kiln through analytical and numerical methods. It aims to evaluate the mechanical strength of shims, which transmit rotational drive to the kiln drum and are subject to stresses. The study uses mechanical theory and finite element analysis to determine stresses on shims under operating conditions. Results provide guidance on accurately predicting optimal preventative maintenance intervals for rotary cement kiln drive elements.
Cement industry : grinding process of ball millPankaj Verma
this is the presrntation which i made when i was in traning in ultratech cement hirmi , i got project on studying the process and operations of grinding process of ball mill in the cement industry , after the clincker formation.
1) Skew is the position of the roller axis with respect to the rotating drum axis. If they are parallel there is zero skew, if not parallel the roller is skewed and creates axial thrust on the drum.
2) Skewed rollers can accelerate wear by creating uneven load distribution, loss of contact and high stress points, and slipping/skidding between the roller and drum.
3) Understanding the bearing style is key to determining the axial position and direction of skew for each roller. Fixed plain sleeve bearings with thrust buttons can be checked by striking the end caps to identify which end has thrust.
The document discusses mass balance reconciliation theory, which involves reconciling measured values with estimated values to account for measurement errors. It describes single-component balancing, material balancing equations, reconciliation equations that estimate true values based on measured values and errors, and the use of redundancy, observability, and least squares error minimization to solve reconciliation problems involving multiple measured and unmeasured flows.
CBL was firstly design in 1960’s .
In the beginning only single transmitter and single receiver is used for amplitude measurement .
Then after evolution occurred , just like openhole acoustic log , new design introduced , which measured signal amplitude near receiver .
Eventually borehole compensated device , using dual transmitter and dual receiver were introduced in 1980’s .
THE EFFECTS OF GEL STRENGHT ON THE OVERALLfelix aladetan
This document discusses gel strength, which is a measurement of the shear stress in drilling mud after it has been static for a period of time. It represents the mud's ability to suspend solids and cuttings when circulation is stopped. The document defines gel strength, describes how it is measured over 10 seconds, 10 minutes and 30 minutes, and identifies the factors that affect gel strength in water-based and oil-based muds. Both excessive and weak gel strengths can cause problems like stuck pipe or inadequate cutting suspension, so maintaining the proper gel strength is important for effective hole cleaning and drilling operations.
O documento discute as fontes não renováveis de energia, com foco nos petróleos ultra-pesados. Apresenta as seguintes informações essenciais:
1) Petróleos ultra-pesados têm densidade menor que 10°API e são encontrados em depósitos no Canadá, Venezuela, Rússia e outros países.
2) Na Venezuela, a faixa do Orinoco contém os 2o maiores depósitos de petróleo ultra-pesado do mundo, com estimativas de reservas entre 60-500 bilhões de barris.
3) A
6 Aspek Teknis dan Operasional Sanitasiinfosanitasi
Dokumen tersebut memberikan informasi mengenai aspek teknis dalam menyusun profil sanitasi suatu daerah, termasuk sumber data sekunder yang dibutuhkan, metode penetapan area berisiko sanitasi, dan cara membuat peta area berisiko awal.
This document discusses the design and selection of V-belt drives. It describes the different types of V-belts and provides details on their cross-section. The advantages of V-belt drives are listed, such as smooth operation, ability to transmit power around corners, long service life, and acting as a safety fuse. The procedure for selecting a V-belt drive includes choosing the belt section, standard pulleys, center distance, nominal pitch length, modification factors, maximum power capacity, number of belts, and pulley dimensions. An example problem is provided to demonstrate the selection process. Key differences between flat belt drives and V-belt drives are also outlined.
This document discusses the primary causes of premature rotating machinery failures due to misalignment. It finds that 50-70% of such failures are misalignment-related. While alignment methods and tools have improved, misalignment still frequently occurs due to a lack of understanding machine concepts, misconceptions about coupling flexibility, and failure to address all potential sources of misalignment beyond just achieving tolerance specifications. These sources include issues like pipe strain, thermal growth, bent shafts, soft foot, poor foundations, and excessive coupling runout. Addressing misalignment requires analyzing its various potential root causes.
The document analyzes the thermal behavior of solid and ventilated disc brakes made from three materials - aluminum, grey cast iron, and structural steel - when subjected to braking forces through finite element analysis. Thermal simulations show that ventilated discs have better heat dissipation than solid discs, with maximum temperatures up to 8°F lower in ventilated models. Grey cast iron performed best overall with maximum temperatures under 150°F and was determined to meet strength and stability requirements for the application.
1. Vibration is a periodic motion where the motion repeats itself after an interval of time. Energy is converted between potential and kinetic forms during vibration.
2. Forced vibration occurs when an external force causes an object to vibrate, while free vibration happens when an object vibrates on its own accord after an initial disturbance.
3. Resonance is a phenomenon where the frequency of an external force matches the natural frequency of a vibrating system, causing the amplitude of vibrations to become very high.
The document discusses various causes of stuck pipe that fall under three main categories: 1) packing off and bridging, 2) differential sticking, and 3) wellbore geometry issues. Under the first category of packing off and bridging, the document describes seven specific cases that can lead to stuck pipe, such as cutting settling in vertical or deviated wells, shale instability, unconsolidated formations, and cement blocks. Preventive actions and procedures for addressing each stuck pipe scenario are provided.
This experiment will explain a procedure to get drilling mud with a range of density that requires for maintaining the borehole pressure as drilling goes dipper, the objective is generating a drilling mud; then it requires to rise the density by 0.1ppg and getting a drilling mud that is more dens.
This document provides the results of a technical inspection of a rotary kiln. Key findings include:
- Significant misalignment of the kiln axis in both horizontal and vertical planes requiring adjustment.
- Mechanical wear on most rollers requiring resurfacing or replacement of some rollers.
- Vibration observed at the drive station likely due to worn gear teeth and improper pitch line offset.
- Minor shell eccentricity and deformation observed except at a few cross sections requiring monitoring.
- Recommendations provided for adjustment, maintenance and improvement of kiln operation.
Rotary kiln design is a complex process, with a variety of factors and material characteristics influencing the sizing and design. This presentation gives an overview of the sizing and design process, including the many factors that will need to be considered during the design stage.
The document discusses the benefits of meditation for reducing stress and anxiety. Regular meditation practice can help calm the mind and body by lowering heart rate and blood pressure. Making meditation a part of a daily routine, even if just 10-15 minutes per day, can offer improvements to mood, focus, and overall well-being over time.
The document provides technical specifications and design details for an ATV vehicle called Zephyr. It includes parameters such as dimensions, weight distribution, suspension geometry, braking calculations, and analysis of components like the roll cage, suspension, steering, powertrain, and brakes. Diagrams and CAD models illustrate and validate aspects of the design. Charts break down the vehicle's weight and costs by subsystem. The team composition allocates members to work on different vehicle systems.
This document summarizes a project at Sohar Aluminium to handle hazardous aluminum dross generated at the casthouse. It discusses how dross is formed, its composition, and initial challenges with accumulation. The project implemented internal dross processing by cooling it with inert gas to stop combustion, then feeding it into the bath plant for separation and metal recovery. These improvements addressed dross issues, reduced waste, and allowed for complete recycling and cost benefits.
This document discusses different types of fluxes used in aluminum casting processes. It describes fluxes as mixtures that facilitate removing impurities from molten aluminum alloys. The main types are covering fluxes to prevent oxidation, cleaning fluxes to remove oxides, drossing fluxes to promote separating trapped aluminum from dross, and degassing fluxes containing chlorine and fluorine salts to remove hydrogen by forming gas bubbles. Each flux is designed for a specific purpose based on its chemical composition and reactions with impurities in the molten alloy.
Cement industry : grinding process of ball millPankaj Verma
this is the presrntation which i made when i was in traning in ultratech cement hirmi , i got project on studying the process and operations of grinding process of ball mill in the cement industry , after the clincker formation.
1) Skew is the position of the roller axis with respect to the rotating drum axis. If they are parallel there is zero skew, if not parallel the roller is skewed and creates axial thrust on the drum.
2) Skewed rollers can accelerate wear by creating uneven load distribution, loss of contact and high stress points, and slipping/skidding between the roller and drum.
3) Understanding the bearing style is key to determining the axial position and direction of skew for each roller. Fixed plain sleeve bearings with thrust buttons can be checked by striking the end caps to identify which end has thrust.
The document discusses mass balance reconciliation theory, which involves reconciling measured values with estimated values to account for measurement errors. It describes single-component balancing, material balancing equations, reconciliation equations that estimate true values based on measured values and errors, and the use of redundancy, observability, and least squares error minimization to solve reconciliation problems involving multiple measured and unmeasured flows.
CBL was firstly design in 1960’s .
In the beginning only single transmitter and single receiver is used for amplitude measurement .
Then after evolution occurred , just like openhole acoustic log , new design introduced , which measured signal amplitude near receiver .
Eventually borehole compensated device , using dual transmitter and dual receiver were introduced in 1980’s .
THE EFFECTS OF GEL STRENGHT ON THE OVERALLfelix aladetan
This document discusses gel strength, which is a measurement of the shear stress in drilling mud after it has been static for a period of time. It represents the mud's ability to suspend solids and cuttings when circulation is stopped. The document defines gel strength, describes how it is measured over 10 seconds, 10 minutes and 30 minutes, and identifies the factors that affect gel strength in water-based and oil-based muds. Both excessive and weak gel strengths can cause problems like stuck pipe or inadequate cutting suspension, so maintaining the proper gel strength is important for effective hole cleaning and drilling operations.
O documento discute as fontes não renováveis de energia, com foco nos petróleos ultra-pesados. Apresenta as seguintes informações essenciais:
1) Petróleos ultra-pesados têm densidade menor que 10°API e são encontrados em depósitos no Canadá, Venezuela, Rússia e outros países.
2) Na Venezuela, a faixa do Orinoco contém os 2o maiores depósitos de petróleo ultra-pesado do mundo, com estimativas de reservas entre 60-500 bilhões de barris.
3) A
6 Aspek Teknis dan Operasional Sanitasiinfosanitasi
Dokumen tersebut memberikan informasi mengenai aspek teknis dalam menyusun profil sanitasi suatu daerah, termasuk sumber data sekunder yang dibutuhkan, metode penetapan area berisiko sanitasi, dan cara membuat peta area berisiko awal.
This document discusses the design and selection of V-belt drives. It describes the different types of V-belts and provides details on their cross-section. The advantages of V-belt drives are listed, such as smooth operation, ability to transmit power around corners, long service life, and acting as a safety fuse. The procedure for selecting a V-belt drive includes choosing the belt section, standard pulleys, center distance, nominal pitch length, modification factors, maximum power capacity, number of belts, and pulley dimensions. An example problem is provided to demonstrate the selection process. Key differences between flat belt drives and V-belt drives are also outlined.
This document discusses the primary causes of premature rotating machinery failures due to misalignment. It finds that 50-70% of such failures are misalignment-related. While alignment methods and tools have improved, misalignment still frequently occurs due to a lack of understanding machine concepts, misconceptions about coupling flexibility, and failure to address all potential sources of misalignment beyond just achieving tolerance specifications. These sources include issues like pipe strain, thermal growth, bent shafts, soft foot, poor foundations, and excessive coupling runout. Addressing misalignment requires analyzing its various potential root causes.
The document analyzes the thermal behavior of solid and ventilated disc brakes made from three materials - aluminum, grey cast iron, and structural steel - when subjected to braking forces through finite element analysis. Thermal simulations show that ventilated discs have better heat dissipation than solid discs, with maximum temperatures up to 8°F lower in ventilated models. Grey cast iron performed best overall with maximum temperatures under 150°F and was determined to meet strength and stability requirements for the application.
1. Vibration is a periodic motion where the motion repeats itself after an interval of time. Energy is converted between potential and kinetic forms during vibration.
2. Forced vibration occurs when an external force causes an object to vibrate, while free vibration happens when an object vibrates on its own accord after an initial disturbance.
3. Resonance is a phenomenon where the frequency of an external force matches the natural frequency of a vibrating system, causing the amplitude of vibrations to become very high.
The document discusses various causes of stuck pipe that fall under three main categories: 1) packing off and bridging, 2) differential sticking, and 3) wellbore geometry issues. Under the first category of packing off and bridging, the document describes seven specific cases that can lead to stuck pipe, such as cutting settling in vertical or deviated wells, shale instability, unconsolidated formations, and cement blocks. Preventive actions and procedures for addressing each stuck pipe scenario are provided.
This experiment will explain a procedure to get drilling mud with a range of density that requires for maintaining the borehole pressure as drilling goes dipper, the objective is generating a drilling mud; then it requires to rise the density by 0.1ppg and getting a drilling mud that is more dens.
This document provides the results of a technical inspection of a rotary kiln. Key findings include:
- Significant misalignment of the kiln axis in both horizontal and vertical planes requiring adjustment.
- Mechanical wear on most rollers requiring resurfacing or replacement of some rollers.
- Vibration observed at the drive station likely due to worn gear teeth and improper pitch line offset.
- Minor shell eccentricity and deformation observed except at a few cross sections requiring monitoring.
- Recommendations provided for adjustment, maintenance and improvement of kiln operation.
Rotary kiln design is a complex process, with a variety of factors and material characteristics influencing the sizing and design. This presentation gives an overview of the sizing and design process, including the many factors that will need to be considered during the design stage.
The document discusses the benefits of meditation for reducing stress and anxiety. Regular meditation practice can help calm the mind and body by lowering heart rate and blood pressure. Making meditation a part of a daily routine, even if just 10-15 minutes per day, can offer improvements to mood, focus, and overall well-being over time.
The document provides technical specifications and design details for an ATV vehicle called Zephyr. It includes parameters such as dimensions, weight distribution, suspension geometry, braking calculations, and analysis of components like the roll cage, suspension, steering, powertrain, and brakes. Diagrams and CAD models illustrate and validate aspects of the design. Charts break down the vehicle's weight and costs by subsystem. The team composition allocates members to work on different vehicle systems.
This document summarizes a project at Sohar Aluminium to handle hazardous aluminum dross generated at the casthouse. It discusses how dross is formed, its composition, and initial challenges with accumulation. The project implemented internal dross processing by cooling it with inert gas to stop combustion, then feeding it into the bath plant for separation and metal recovery. These improvements addressed dross issues, reduced waste, and allowed for complete recycling and cost benefits.
This document discusses different types of fluxes used in aluminum casting processes. It describes fluxes as mixtures that facilitate removing impurities from molten aluminum alloys. The main types are covering fluxes to prevent oxidation, cleaning fluxes to remove oxides, drossing fluxes to promote separating trapped aluminum from dross, and degassing fluxes containing chlorine and fluorine salts to remove hydrogen by forming gas bubbles. Each flux is designed for a specific purpose based on its chemical composition and reactions with impurities in the molten alloy.
This document discusses weldability and defects in weldments. It covers various topics related to weld design, residual stresses, weld defects, and the weldability of different materials such as steels, aluminum alloys, copper alloys, titanium alloys, and magnesium alloys. The objectives are for students to understand causes of residual stresses and distortions, differentiate between weld defects, and suggest remedies. Weldability depends on factors like material composition and welding techniques. Some materials like steel are more weldable than others such as aluminum.
This document discusses common casting defects such as surface defects, internal defects, incorrect chemical composition, and unsatisfactory mechanical properties. It defines casting defects and explains how they reduce output and increase production costs. Specific defects covered include swell, fins, gas holes, shrinkage cavities, hot tears, and cold shuts. For each defect, the causes and remedies are described. Even in modern foundries, the rejection rate can be as high as 20% of total castings produced due to these defects.
The document discusses various types of casting defects including gas defects, shrinkage cavities, molding material defects, pouring metal defects, and metallurgical defects. It provides detailed descriptions and characteristics of different specific defects such as blowholes, pinhole porosity, cuts and washes, penetration, fusion, rattails, swell, washout, misruns, and cold shuts. The document emphasizes the importance of properly identifying and classifying defects in order to determine their causes and implement appropriate corrective actions to control quality.
The document discusses the process of sand casting. It begins by defining foundry and casting as the process of producing metal parts by pouring molten metal into a prepared mold. It then provides terminology used in casting such as flask, pattern, parting line, pouring basin, sprue, runner, riser, gate, core, and chaplets. The steps of sand casting are outlined as making the pattern, preparing sand mixtures, making the mold and cores, melting metal, pouring, cleaning, inspecting, and heat treating. Common casting materials and applications are also listed.
This document discusses efforts taken by Tata Motors to optimize manpower at its Integral Bus Factory in Lucknow, India. It begins with background on Tata Motors and the Integral Bus Factory. An analysis found disproportionate manpower distribution compared to volume contribution. Work measurement studies using MOST identified opportunities to reduce non-value added work, such as by reducing excessive operator motion. Implemented improvements cut standard man-hours by 25% and non-value added work by 9%. The document also examines issues around non-standard work from retrofits and modifications. Data collection helped establish time standards to better plan for irregular non-standard tasks.
Tata Nano was intended to be the world's cheapest car but faced challenges. It was originally planned for a plant in Singur, West Bengal, but political issues led Tata to shift production to a new plant in Sanand, Gujarat. The Nano's design and production processes were highly optimized for low-cost manufacturing, but issues with marketing strategy and positioning contributed to lower than expected sales volumes, making it a failure for Tata Motors.
Global solution for the overall fleet consumption reduction inside the Autmot...guestb741cc
The document discusses a global solution from MMCGroup to reduce fleet fuel consumption in the automotive sector. It presents three patents that could save over 5 billion euros and reduce material usage by over 1 million tons each. The patents could also apply to other industries and be implemented through various partnerships between OEMs, suppliers, governments, and investors.
The document provides information about Sanmati Group of Industries, which is an ISO certified manufacturer of grey cast iron and ductile iron machined castings located in Kolhapur, Maharashtra, India. It has 80,000 square feet of manufacturing area and produces intricate cast components weighing 6-70 kg for customers in volumes of 1,000-15,000 per month. The company aims to become a preferred supplier of precision castings and machined components through eco-friendly processes and committed teamwork.
This document provides an executive summary and details of NuStar Limited's GBar, GBolt, and GMat glass fiber reinforced polymer (GFRP) rebar manufacturing process. GFRP rebar offers benefits over steel rebar such as corrosion resistance, higher tensile strength, lower weight, and a projected service life over 100 years. NuStar plans to use pultrusion, an established manufacturing method, to produce the GFRP rebar in various diameters and shapes at competitive linear foot prices. Facility requirements, management plans, and production projections are also outlined.
Neel Auto Pvt. Ltd. Pantnagar Internship ReportPradeep Yadav
The JBM Group is an Indian automotive components manufacturer established in 1983. It has over 42 manufacturing plants globally and supplies components to major automakers. Neel Auto Pvt Ltd is one of JBM's companies and a supplier of components for two-wheelers. It has facilities for pressing, welding, painting and other operations. The document provides details about Neel Auto's departments, production processes like pressing and quality policies. It describes the press shop operations and types of presses used for manufacturing parts like fuel tanks, chains and swing arms.
1. The factors responsible for OEE calculation at the TML Engine Division assembly line are availability, performance, and quality.
2. The parameters for OEE measurement include good count, ideal cycle time, and planned production time.
3. The TML Engine Division assembly line OEE deviates from world and India standards, ranging from 70-90% versus the target of 85%.
4. Reasons for deviation include breakdowns, setup/adjustments, small stops, reduced speeds, and quality issues. Fitting machines in particular cause high losses.
5. Ways to increase OEE include addressing fitting machines, automating clamping, improving accessibility for repairs, focusing on permanent not temporary fixes
ASK Automotive is a leading manufacturer of friction products for two-wheelers in India founded in 1989. Over two decades, it has grown from a small manufacturer to a major supplier of brake assemblies, brake shoes, and other automotive parts to OEMs in India. The company aims to make its products the first choice of users. It manufactures brake shoes and other friction products through a process that includes melting aluminum alloy, die casting, trimming, lapping, inspection, and packaging. Quality is ensured through certifications and a JIT production system with zero PPM defects.
The document provides details about the production processes of U-bolts and spring pins at G.S. Auto International. It describes the raw material procurement process and quality checks. It then outlines the various steps for manufacturing U-bolts, including facing, turning, threading, bending, hardening, washing, auto-black coating, and packaging. A similar level of detail is provided about the spring pin production process. Some recommendations are made to improve productivity and capacity.
1. Advancements in CAE and manufacturing technologies are providing opportunities for diversification and improvement in the metal casting industry. This includes award-winning optimized designs from topology optimization and simulations.
2. Companies are using these technologies to improve existing automotive and sports components, reducing weight by up to 50% while maintaining strength. This allows compliance with emissions regulations.
3. The technologies also enable feasible smaller production runs and diversification into new industries like tooling, with 3D printed fixtures. Overall these advancements are driving lighter, smarter, and more efficient product design.
The document is a report submitted by Youraj G. Talwekar for his Bachelor of Engineering degree in partial fulfillment of requirements. It summarizes his in-plant training project at CEAT Tyre Ltd. The report includes an introduction to CEAT Tyre Ltd, the tyre manufacturing process, department profiles, the project work conducted, and conclusions. Key sections include descriptions of CEAT's history and products, the tyre components and manufacturing stages of blending, milling, building, curing, and quality control. Figures and tables illustrate the CEAT plant layout and products manufactured.
1) Additive manufacturing (3D printing) allows for the production of complex, lightweight parts and is increasingly being used in the automotive industry.
2) It provides benefits like faster prototyping, supply chain transformation through on-demand production, and cost savings through lightweight materials.
3) Major automakers like Ford, BMW, Volkswagen, and McLaren are investing in 3D printing and have implemented the technology for prototyping, tools and fixtures, and some production parts.
Traditional manufacturing processes vs Advanced manufacturing processesSisubalan Selvan
The document discusses the manufacturing processes for a disc brake part. It begins by introducing the group members and their task to identify the material and processes for an engineered part they selected, which was a disc brake. It then provides details on the specific processes and material used to produce a disc brake part, including:
1) Disc brakes are typically made of gray cast iron due to its properties like thermal stability and cost effectiveness.
2) The production process for a ceramic composite disc brake involves steps like pouring carbon fiber into a mold and pressing the ceramic material into a die.
3) Essential properties like dimensional accuracy, surface finish, and weight distribution are considered to ensure proper performance.
4) Disc
A go-kart, also written as go-cart (often referred to as simply a kart), is a type of open-wheel car. Go-karts come in all shapes and forms, from motorless models to high-powered racing machines. Some, such as Superkarts, are able to beat racing cars or motorcycles on long circuits.
We have Produced the automated taping machine, automated box shaping machine, vending machine, semi-automated shaping machines, FA etc., and we will expert our efforts to enhance our productivity and to help the advanced packing process.
This document provides a case study on Tata Power's efforts to increase the sustainable use of bottom ash, a byproduct of coal combustion. It details the quality circle team's application of the PDCA (Plan-Do-Check-Act) process to address the problem of disposing 625 metric tons of bottom ash per month. Through root cause analysis, trials, and regular implementation, the team developed a solution to incorporate bottom ash into bricks, reducing monthly disposal to 300 metric tons. Tangible benefits included savings of over Rs. 4 lakhs in transportation costs and Rs. 18 lakhs in natural sand costs. Future plans aim to further reduce disposal and deploy the approach across Tata Power.
Jacob Peled, executive chairman of Pelmar Engineering Ltd, discusses his career path and views on the tire industry. After studying polymer science and business, he started Pelmar in 1966 and grew it into a renowned supplier of reconditioned tire machinery. While his entry into tires was partly coincidental, working in a tire plant sparked his fascination. Peled believes tire construction changes have been minimal, but automation improvements started 15 years ago. He envisions future plants outsourcing compounding and using faster tire building machines. Peled advises machinery buyers to thoroughly research references, capabilities, and prices when selecting equipment.
This document provides a vocational training report submitted by Prabhat Kumar, an undergraduate student at NIELIT Aurangabad, for their training at Tayo Rolls Ltd from June 8th to July 7th 2015. The report focuses on motor control through a variable frequency drive (VFD) used to control machines in the forge shop. It includes a certificate signed by the training and project supervisors, as well as sections on the company profile, introduction to lathe machines, what a VFD is and how it works, applications of VFDs, and a conclusion.
The document discusses several case studies of companies using 3D printing technologies for prototyping and manufacturing applications in automotive, footwear, architecture, and other industries. Specifically, it describes how automotive companies like Ford, Benteler, F1 Racing and Porsche use 3D printing for prototyping vehicle parts and testing designs. It also discusses how footwear companies like Adidas use 3D printing to quickly prototype new shoe designs.
1. TataAutoComp GY Batteries Pvt. Ltd.
Project report on Dross Generation in the Casting Section
Project by-
Abhishek Roy
Project Head-
Mr. Suvrajit Banerjee
Under the supervision of
Mr. Mohit Bhakal
2. TataAutoComp GY Batteries Pvt. Ltd.
Acknowledgement
I have taken efforts in this project. However, it would not
have been possible without the kind support and help of
many individuals and organizations. I would like to extend
my sincere thanks to all of them. I am highly indebted to Mr.
Suvrajit Banerjee, Mr. Mohit Bhakal for their guidance and
constant supervision as well as for providing necessary
information regarding the project & also for their support in
completing the project. I would like to express my gratitude
towards operators of Casting section of TATA AutoComp
GY Batteries Pvt. Ltd for their kind co-operation and
encouragement which help me in completion of this project
and for giving me such attention and time.
3. TataAutoComp GY Batteries Pvt. Ltd.
Company Profile
Tata AutoComp Systems Limited, promoted by the
Tata Group, provides products and services in the
automotive industry to Indian and global customers,
including Ashok Leyland, BMW India, Mercedes-Benz
India, EicherMotors, Fiat, Force Motors, Ford India,
General Motors India, Hero Honda, Hindustan Motors,
Honda Scooters, Honda Siel Cars India Ltd,
International Tractors John Deere India, Mahindra and
Mahindra, Mahindra Renault, Man-Force Trucks, New
Holland, Piaggio, Punjab Tractors, Royal Enfield,
Skoda, Swaraj Mazda, Tata Motors, Toyota Kirloskar
Motor Pvt. Ltd., Tractors and Farm Equipment Limited.
4. TataAutoComp GY Batteries Pvt. Ltd.
Company Profile (TATA AutoComp GY Batteries)
TATA Green Batteries are a product of
TATA AutoComp GY Batteries Pvt.
Ltd. (TGY), a joint venture between
TATA AutoComp Systems Ltd,
India's leading auto component
manufacturer and GS Yuasa
International, Japan, one of the
world's largest automotive battery
manufacturers. These batteries are
a combination of TATA AutoComp’s
extensive experience in the
Automotive Industry and GS Yuasa
International’s superior
technological know-how. With a low
top-up requirement and being 90%
recyclable, Tata Green Batteries
allow a hassle free battery running
experience
5. TataAutoComp GY Batteries Pvt. Ltd.
Different Sections In the Plant
CASTING
Pasting
Assembly
Charging
Dispatch
*The project is undergone under this section
9. TataAutoComp GY Batteries Pvt. Ltd.
Process
POT (Where
The molten
lead is present)
FEEDLINE(which
transfer the
molten lead)
LADDLE
TRIM DIE
SECTION
(to cut excess
part of the panel)
COLLECTING
AREA (The final
product is kept
here )
MOULD(which
give shape to the
molten lead)
ROLLER
1 2
6
5
4
3
7
The excess part is send back
to the Pot
10. TataAutoComp GY Batteries Pvt. Ltd.
Type Pot Temp. Ladle Temp. Moving mould Temp. Fixed Mould Temp. Feed Line Temp.
Sb +ve 420±30 600±30 200±30 200±30 490±30
Ca -ve 420±30 600±30 200±30 200±30 490±30
Ca +ve 420±30 600±30 200±30 200±30 490±30
Grid information
11. TataAutoComp GY Batteries Pvt. Ltd.
Grid Nomenclature
Y M 83A
Plate thickness (100-83)/10=1.7±0.1mm
Grid thickness ((100-83)/10)-0.2=1.7±0.1mm
Small
Calcium
OTHER NOTATIONS:-
C Antimony
G Big
In case of
Plate thickness
=(100- )/10=2.1±0.1mm
Grid thickness
=((100- )/10)-
0.2=1.8±0.1mm
C G 80A 79
79
80
12. TataAutoComp GY Batteries Pvt. Ltd.
Dross
Dross is a mass of solid impurities floating
on a molten metal or dispersed in the metal,
such as in wrought iron. It forms on the
surface of low-melting-point metals such as
tin lead zinc or aluminium or alloys by
oxidation of metals
as tin, lead, zinc or aluminium or alloys by ox
idation of the metal(s). Dross, as a solid, is
distinguished from slag, which is a liquid.
Dross product is not entirely waste material;
for example, aluminium dross can be
recycled and is used in
secondary steelmaking for slag deoxidation.
Dross
13. TataAutoComp GY Batteries Pvt. Ltd.
16 Major Losses In a Company
8 Availability
Losses
Machine Loss
Setup & adjusting
Tool change
Start-up losses
Minor stoppage
Speed loss
Defect and
rework
Shutdown
5 Productivity
losses
Management
losses
Operating Motion
Line organisation
Logistics
Adjustments
3 Production
losses
•Loss of energy
•Die-tool losses
•Yield loss
14. TataAutoComp GY Batteries Pvt. Ltd.
Time Study of the Machine (B3-B4)
Total sample time for the production- 180 minutes
No of panels to be produced– 3690 panels
Actual Time taken for production- 144 minutes
No of grids produced- 3168 panels
Major losses occurred during the process-
• Shut Down Loss/Defect and rework- 20 min
• Setup Loss-5 min
• Die/Tool Loss- 5 min
• Line organisational loss-6 min
17. TataAutoComp GY Batteries Pvt. Ltd.
Action Plan
There are ways by which we can reduce the
generation of dross-
• By induction heating- induction heating helps in
reducing dross generation and also helps in energy
saving. The idea is being proposed and is in a
prototype position.
• By minimising the surface area of the opening of
the pot- The opening present in the pot is the
reason for the generation of dross as more amount
of air can enter through it to oxidise with the lead. If
the conveyor length is increased so that it ends at
the inside the opening and the opening is made
small enough so as to make the dross removal
easier for the operator and putting a cover on it, the
dross generation can be reduced by 5%.