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Vishwakarma Institute of Technology: An Internship Project Report On
Vishwakarma Institute of Technology: An Internship Project Report On
SUBMITTED BY
OF
SHAILESH JAGTAP
ACADEMIC YEAR 2018 – 2019 (SEMESTER II)
Bansilal Ramnath Agarwal Charitable Trust’s
Certificate
This is to certify that the dissertation work entitled “ISSUE RESOLVING ON COLD
PILGER MACHINE LINE FOR BETTER PRODUCTIVITY” carried out by VEDANT
PRASHANT POHARKAR (G.R. Number - 131096, B.Tech. (Mech Engg) is an original
work done by the student in partial fulfilment of the requirements for the degree of Bachelor of
Technology in Mechanical Engineering, under my guidance and supervision during the
academic year 2018 – 19, semester I.
___________________ __________________
___________________ __________________
Prof Dr M B Chaudhari
Examiner, Head,
1
ACKNOWLEDGEMENT
in their machining shop and SSP Technologies staff members for their
guidance.
Dr. Mr. Shailesh Jagtap – MD, SSP Technologies India, Pune for their
help and suggestions for Productivity Improvement.
techniques in syllabus.
2
ABSTRACT
Productivity can have achieved by minimizing the losses and change in input
were conducted to increase the productivity of the machine and the component
(tube size). Modification in tooling, input material, lubrication oil is done and
By doing this, the productivity of the component (tube size) was increased.
Productivity improvement is for doing right things better and makes it a part of
men, material, machine, time, space and capital, etc. It can be expressed as
human effort to produce more and more with less and less inputs of resources so
people.
3
carried out with the help of cross functional team from manufacturing, tool
room, maintenance, quality and the design team effectively. Identified various
elements affecting the growth of the productivity of the component (tube size)
and decide the action to reduce the same. On completion of this Productivity
4
CONTENTS
Contents
ACKNOWLEDGEMENT......................................................................................................................2
LIST OF FIGURE.........................................................................................................................................8
NOMENCLATURE......................................................................................................................................9
Following abbreviations are used during project,.................................................................................9
CHAPTER-1 PREAMBLE..................................................................................................10
INTRODUCTION..............................................................................................................................10
PROBLEM IN HAND:........................................................................................................................11
IMPORTANCE OF THE PROBLEM :...................................................................................................11
SCOPE OF THE PROJECT:.................................................................................................................11
CHAPTER – 2...........................................................................................................................................12
INTRODUCTION:-............................................................................................................................12
THE ORGANIZATION........................................................................................................................14
PROCESSES.....................................................................................................................................17
FACILITIES.......................................................................................................................................19
Patent for ‘Cold Pilegring’ technology:...........................................................................................19
Inspection and test facilities:..........................................................................................................20
In-house Calibration facility:..........................................................................................................20
In-house tool room:........................................................................................................................20
Material handling and packing facility:..........................................................................................20
BUSINESS RELEVENT INFORMATION....................................................................................21
CONCLUSION..............................................................................................................................21
CHAPTER – 3........................................................................................................................................22
THE PROBLEM IN HAND...................................................................................................................22
INTRODUCTION:.........................................................................................................................22
DESCRIPTION OF THE PROBLEM:...........................................................................................24
DETAILS OF PROBLEM:.............................................................................................................24
HISTORICAL PERSPECTIVE......................................................................................................28
CAUSE AND EFFECT RELATIONSHIPS...................................................................................28
CRITICALITY OF THE PROBLEM.............................................................................................28
CONCLUSION :............................................................................................................................28
5
CHAPTER - 4.......................................................................................................................................30
INTRODUCTION..........................................................................................................................30
PRODUCTIVITY..........................................................................................................................30
LITERATURE RESEARC.............................................................................................................31
CONCLUSION..............................................................................................................................34
TYPE OF DATA NEEDED............................................................................................................35
THE SOURCES FOR THE COLLECTION OF DATA.............................................................................36
CONCLUSION..............................................................................................................................38
CHAAPTER - 5
ANALYSIS OF DATA...........................................................................................................................39
CHOICE OF TECHNIQUES.........................................................................................................39
CHAPTER - 7 RECOMMENDATIONS.....................................................................................................43
BRIEF DESCRIPTION OF RECOMMENDATIONS :...............................................................43
EVALUATION OF RECOMMENDATIONS...........................................................................................44
PAIRED COMPARISON & DECISION TAKING.......................................................................45
SUGGESTED SCHEME OF IMPLMENTATION....................................................................................47
CHAPTER – 8........................................................................................................................................48
INTRODUCTION..........................................................................................................................48
a. OVERALL EXPECTED BENEFITS.....................................................................................48
Manufacturing cost :.......................................................................................................................49
Machines :..............................................................................................................................49
Manpower :.............................................................................................................................49
Production :............................................................................................................................49
Quality :..................................................................................................................................50
Delivery :................................................................................................................................50
SUGGESTED SCHEME OF IMPLEMENTATION...............................................................................50
CONCLUSION..............................................................................................................................50
CHAPTER – 9........................................................................................................................................51
SUMMARY...................................................................................................................................51
GAINS OF THE STUDY...............................................................................................................51
LIMITATIONS OF STUDY...........................................................................................................51
SCOPE FOR FURTHER WORK...................................................................................................51
REFERENCES:..............................................................................................................................52
APPENDIX....................................................................................................................................53
6
LIST OF TABLES
7
LIST OF FIGURE
8
NOMENCLATURE
Abbreviation Details
B Basic function
MIN Minutes
9
S Secondary function
CHAPTER-1
PREAMBLE
INTRODUCTION
It can be expressed as human efforts to produce more and more with lesser
inputs of resources so that there will be maximum distribution of benefits
among maximum number of people. Productivity denotes relation between
output and relationship between output and one or all associates inputs.
European productivity Council states that Productivity is an attitude of mind.
10
Therefore, improved productivity means more is produced with the same
expenditure of resources i.e.at the same cost in terms of material, machine
,time or labor, alternatively , it means same amount is produced at the less
cost in terms of material machine time or labor that is utilized.
PROBLEM IN HAND:
One of the cew pilger tube size was consistently failed to meet export
customer monthly schedules due to low productivity. Due to fail in customer
schedule achievement customer was facing problem like frequent line
stoppages, material inventory shortage etc. Losses details has been collected
for one quarter to identify problems of failing customer schedule.
Result of this problem directly affects the customer. Due to this problem,
customer deliveries can not be achieved 100%. Delivery schedule adherence
which leads frequent customer line stoppage and dis-satisfaction. The importance
of this problem is to make 100% delivery schedule adherence with reduction in
mean time losses, improvement in tooling , minimum investment and effective
utilization of available resources. To achieve this, productivity improvement
techniques are the most effective techniques.
11
CHAPTER – 2
INTRODUCTION:-
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manufacturing 2000MT Tubes to supply Automotive Industries in domestic
and overseas market.
Handling of large volumes and different types of parts with various types
of materials.
Short product development time and concurrent engineering with
customers.
Welded tubes for automotive and process industry equipment for customers
like Bajaj Auto Ltd., Tata Motors Ltd., Mahindra & Mahindra and Mahindra
Tenneco, American Axle & Manufacturing (AAM), John Deere, Salem steel
13
Hydraulic and pneumatic system manufacturers.
THE ORGANIZATION
PRODUCTS
These are mainly used by automobile and farm equipment manufacturers. These
14
Figure No. 2 : Machined & press parts
The customer of SSP’s Component Division include industry leaders like Bajaj,
Tata Motors, Volkswagen and Salem steels in USA. Main products in this sector
go into
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1. Swing arm assembly
7. Brace fender
1. Propeller Shaft
3. Drag Linkages
4. Stabilizer Bars
5. Hydraulic Cylinders
6. Gas Spring
16
Figure No 2.2 Propeller Shaft
PROCESSES
Pilger is a cold working process that greatly improves the material grain
structure by reducing large amount of the outside diameter and inside
diameter of pre-existing tube
17
very quickly. Reduction percentage is high. Cold pilger machines
benefit,
2) In cold pilgering process, tube drawn in single pass where as in cold drawn
process
it requires 3-4 passes.
8) Improved microstructure.
Cold pilgering include a number of forming steps, located inside the tube is
stationary mandrel which taper in rolling direction .This is attached to a long
mandrel bar which is secured in, and rotated by a thrust block. Two dies form the
tubular stock in the same that the rolling pin rolls out pastry. The two dies are
mounted in a reciprocating saddle.
There drive pinions mesh with two stationary racks, thus the die rotates back and
forth in synchronization with the reciprocating saddle. The saddle is traversed
back and forth by a crank drive in the same way as a piston in the engine of a
motor car. The groove cross-section decreases across the circumference and are
virtually circular. This tapering cross section between the dies and mandrel
reduces both the diameter and wall thickness simultaneously. In the area of two
18
the two dead center position, The dies briefly disengage from the shell within
these end of stroke periods, the shell is advances and rotated.
Figure No 2.7 Tooling for process Figure No 2.8 Die For Process
19
FACILITIES
State of the art manufacturing facility plant located in chakan MIDC area along
with following facilities,
SSP Technology has patented its ‘Low Carbon Welded Tube and Process of
Manufacture’ (Here after ‘Cold Pilgering’ technology). This inventive ‘Cold
Pilgering’ technology developed by the Company to manufacture novel
CEW/DOM tubes leads to quality tubes with enhanced characteristics in a
most energy efficient and cost effective manner.
20
Inspection and test facilities:
Inspection is carried out in three stages like raw material receipt stage, in-
process stage and pre dispatch stage. For inspection and testing of machined
parts instruments like Micrometer, Vernier Caliper, radius gauge, feeler gauge,
dial gauges and attribute inspection by Snap Gauges, Plain plug gauges, are
Profile inspection
Metallography
Spectrometer
Compression Testing
21
Material handling and packing facility:
Machined parts and assemblies are handled equipment’s like conveyor
systems, trolleys& forklifts for in process handling, loading / unloading of
raw material, semi finished & finished products so as to prevent damage &
scratch marks. Most care is taken in packing, transportations product.
Metal to metal contact of parts are avoided. Material are packed as per
customer requirement in plastic bags, corrugated boxes, wooden boxes,
plastic crates, trollies etc. all material are identified by tags and locations.
& CEW Tubes and Auto Component to major OEM’s of Automotive and
SSP Technology was opened in year 2000. At that time, it was a private ltd
increased.
CONCLUSION
From above information, it was seen that SSP Technology is a leading
sectors.
22
CHAPTER – 3
INTRODUCTION:
Pilger is a cold working process that greatly improves the material grain
structure by reducing large amount of the out side diameter and inside diameter
23
7) Excellent surface condition.
8) Improved microstructure.
Cold pilgering include a number of forming steps, Located inside the tube
long mandrel bar which is secured in, and rotated by a thrust block. Two
dies form the tubular stock in the same that the rolling pin rolls out pastry.
Their drive pinions mesh with two stationary racks, thus the die rotates back
traversed back and forth by a crank drive in the the same way as a piston in
the engine of a motor car. The groove cross-section decreases across the
circumference and are virtually circular. This tapering cross section between
the dies and mandrel reduces both the diameter and wall thickness
simultaneously. In the area of two the two dead center position, The dies
briefly disengage from the shell. Within these end of stroke periods, the shell
is advances and rotated. Both the forward and return stroke are thus utilized
for the forming process. The feed increment and turn angle in two dead Centre
positions can be set according to the tube material and quality requirement.
24
Figure No 3.1 Pilgering Process Figure No 3.2 Pilger Mach
additional 1 machines required. But another machine of this series was not
DETAILS OF PROBLEM:
LG/50 is a cold pilgering machine. Technical specification of the machine
25
7mm/stroke. Export Customer requirement of cew pilger tube 38.mm(od) x
1) Cycle time is high, unable to increase the speed and feed of the machine:
Currently, unable to increase speed and feed of the machine due to high cross
sectional
reduction percentage. Currently input material used for this size is 57.15mm
(od) x 6.5mm(thk) x 3.5mtrs (length) based on this input material, more than
40% cross-sectional reduction percentage come for the process. And hence,
And due to this, company is not able to meet the customer monthly
requirement of 60mt.
26
2) Id marking inside the finish tube:
Currently mandrel (tool) material used is of D2 grade
(carbon 1.5%, Si
0.3%,Cr 12%,Mo 0.8% and V 0.9%). Due to this material grade, if the speed
and feed of machine increases some foreign material deposited on mandrel
(tooling) and id marking come on the tube. Due to this we are unable to
reduce the cycle time of the machine. Also, die (tooling) used is of 57.15mm
x 38.1mm.
Currently lubrication oil used is Asian oil AOC 335 having the
viscosity 125 Cst at the temp
of 40degree Celsius.
27
75kw. For increasing the productivity of the machine following thinks will
required to do.
deposited on the material during the processing time and speed and feed of
the machine increased.
28
After certain modification in input material, tooling (mandrel),
reduction percentage during processing the current goes down to
150amp.And due to this, load on motor decreases and motor will not trip.
HISTORICAL PERSPECTIVE
tried out, but some are partially successes and some trials are failed.
technique. We identified all major causes / losses and their effect on this
product.
29
CRITICALITY OF THE PROBLEM
Because of this problem we are unable to achieve 100% delivery schedule
which directly results customer’s line stoppage and zero inventory also we
are going to loose business. The importance of this problem is to make 100%
CONCLUSION :
Productivity Improvement Techniques exercise will be conducted in
30
CHAPTER - 4
RELEVANT LITERATURE REVIEW
INTRODUCTION
31
current literature available on this subject and explained what we are going to
PROBLEM FORMULATION
PRODUCTIVITY
or better goods from the same resources, or the same goods from fewer
resources used.
despite the difficulty that even such definition imposes for the measurement
32
Productivity is closely related to the use and availability of resources as well
as to
qualitative changes take place when relative quantities and relative prices of
LITERATURE RESEARC
Productivity measurement
33
be given the sort of shorthand definition as the ratio between output and input,
the same vein, the problem of how to aggregate the different types of inputs
into a well-defined composite unit remains a critical one on the side of input
(kuruppu, 1994).
apparel factories. The dependence on past time standards must give way to
34
Initiate supervisor and manager training:
as well as work culture, so that the operators are made aware of how to
and finishing areas. It is important that the factories draw up a strategic plan
measurement and comparison systems. This will help the factory to record,
CONCLUSION
36
CHAPTER – 5
DATA COLLECTION AND ANALYSIS
knowledge and expertise in the technical field of study and a solid background
These are reviewed with the help of Vice President. Team members selected
from all relevant functions like operation, quality, tooling, purchase, drawing
Loss details : First team decided to collect All the facts. Hence all present
losses available in the production of tube size are collected. From supporting
details team identified due to following major reasons / losses production stop.
37
THE SOURCES FOR THE COLLECTION OF DATA
As decided data needed above team decided following sources for collection
of data, Table No. 5.2 : The sources for the collection of data
and HR Mgr.
4. Tooling data
38
THE DETAILS OF THE DATA COLLECTED
Productivity Improvement.
Productivity Improvement Team used above source and taken concern person’s
help to collect data for analysis, during this data collection lot of data received
high. area
Refer above details major constrain is Cycle time High hence team decide to
following details found, Input material used for the size is 57.15 x 6.5 due to
this cross sectional reduction percentage high 45%. Tooling Used as per the
raw material size is die size 57.15 x 38.10 and mandrel used is 42.15 x 25.34
39
mm. Existing Oil used as lubrication is AOC 335. Existing Mandrel (tooling)
5.5 CONCLUSION
All data collected like loss details, list of functions, are discussed within team
40
CHAPTER – 6
ANALYSIS OF DATA
CHOICE OF TECHNIQUES
During this phase we decided to use step by step phase wise job plan approach
defined in a highly potent and powerful management technique created to effect
IMPROVEMENTS i.e. Productivity Improvement hence, we have gone
following phases throughout the study and problem solve.
IMPLEMENTATION PHASE
required to do.
To change the current input material size. New input material required is of
cross sectional reduction percentage come for the process. And hence the
machine run on Speed 60 stroke/min and feed 4mm/stroke and based on this
41
Mandrel will be use of the M2 (carbon 0.78-1.05 %,chromium 3.75-
Due to this material foreign material is not deposited on the material during the
in circulation comes in contact with the soap coating and gets contaminated, this
continuous process increased the viscosity of the oil. The original oil viscosity is
viscosity of the oil from the machine it was found to be 190-200 CST at 400 C.
42
Coefficient of friction 0.062 0.031
Corrosion @100C for 3hrs 1A 1B
Dosage of EP additives Mild Heavy
Four ball load test ASTM
D2783
weld at 315kg load no welding at 400kg load
Table No. 6.6 : Oil Details.
Both oils are free from sulphur and chlorine. Trial of new pilger
oil was started on pilger machine and oil tested periodically fot its
viscosity. Specific gravity and depletion of additives through load test
per the ASTM D2783.
Sample Test-Comparison Statement of Improved Pilger Oil.
2nd 3rd
sample sample
Parameter Fresh Oil Ist sample
weld weld
point. point.
315kg 2.24 1.94
43
Table Nos.6.6 .1: Trial Results
Both oils are free from sulphur and chlorine. Trial of new pilger oil was
started on pilger machine and oil tested periodically fot its viscosity.
Specific gravity and depletion of additives through load test per the
ASTM D2783.
Sample Test-Comparison Statement of Improved Pilger Oil.
Oil will not be contaminated due to soap coating and will not thicken up, Less
viscous oil will dissipate heat faster; thus improving tool life, Avoids damage
to the bearing due to lumps formation, Good surface finish of the tube, Less
percentage is less during processing and hence the current goes down to
150amp.
Conclusion:
44
45
CHAPTER - 7
RECOMMENDATIONS
As we decided to reduce the cycle time (increasing speed and feed ) of the
many basic root causes. Percentage cross sectional reduction during the
process is high, heat generation during the process is high. Here the CFT
team decided to work on this and reduced the reduction of the process and
which are high during the process due the current input material used.
Size Cross-sectional
Reduction
Proposed
Input 50.8 x 6.5 30%
46
Heat generation during the process is also high to reduce the heat generation
during the process. We provide the ID lubrication (see the fig.6.2) to reduce the
heat generation. Existing oil used during the process having high viscosity due to
this, I have taken the different trials of the oil. Existing oil used during the
material.
EVALUATION OF RECOMMENDATIONS
phases are judged, refined and combined as per requirement, to determine how
each of these ideas can be utilized to accomplish the needed function and
fulfill its criteria. To evaluate above three alternatives the team selected
C. Tooling material.
47
PAIRED COMPARISON & DECISION TAKING
In paired comparison ranking is simplest form of evaluation. Here it is
decided that criteria II is better than criteria .Cross sectional reduction
during the process is as follows
Cross-sectional
Size Reduction
Current Input
57.15 x 6.5 45%
material
Proposed Input
50.8 x 6.5 30%
material
Tooling Graph No. 7.3(a): Table Paired Comparison between Cross sectional
Area
48
Carbon Chromium Manages Molybdenum Phosphorous Tungsten Vanadium
D2 Grade
Material
M2 Grade
0.78-1.05 3.75-4.5 0.15-0.4 4.5-5.5 0.03 max 5.5-6.25 1.75-2.2
Material
Excessive heat generation during the process due to the pilger oil for this
different trial of pilger oil was conducted and finally AOC335P pilger oil is
49
SUGGESTED SCHEME OF IMPLMENTATION
The input material of size 50.8 x 6.5 mm, Tooling (mandrel) material used is
of M2 grade, ID lubrication should be provided during the process and for the
Due to above changes, cycle time of the process will be reduced and the
50
CHAPTER – 8
INTRODUCTION
In order to validate the expected results achieved, an audit of Productivity
51
Prod. before
Improvement
Prod After Improvement
Month Dec- Jan-19 Feb-19 Mar-19 Apr-19 May-
18 19
Production in MT 30 30 48 60 60
Results After
Previous
Improvement
50
Strokes 60 strokes/min
strokes/min
2
Cycle Time Feed 4 mm/strokes
mm/strokes
Machine
Out put 0.8 kg/min 1.6 kg/min
Monthly
30 MT 60 MT
Production
Values in
21,00,000 42,00,000
Rupees
Machines Req.
to complete
schedule 02 01
Manufacturing cost :
Before the improvement, monthly output of the machine was 30MT which
52
Machines:
Manpower:
Production:
Quality:
Delivery:
100% delivery performance achieved and sustained.
Morale:
53
CONCLUSION
Results are monitored in terms of P-Q-C-D-S-M and successively
achieved. Hence, team identified other parts from same part family
for horizontal deployment.
CHAPTER – 9
CONCLUDING REMARKS
SUMMARY
useful to overcome any problem during our day to day work, hence we use
2.3mt/day. Also the quality of the product improved, in the same way 100%
Initial investment for inserted tool is comparatively high, hence effective for
mass production parts.
REFERENCES:
doi:10.1080/0020754021000042391
55
Journal of Production Economics, Vol. 36, No. 2, 1994, pp. 69-183.
doi:10.1016/0925-5273(94)90022-1
262-272. doi:10.1016/j.intman.2008.12.004
APPENDIX
ii) Tool change time = actual tool change time x no. of times tool changed.
III : Total tool change time
x 100
56
57