LEAN TOOLS IMPLEMENTATION IN MINING PLANT

Jaiganesh S1, Dr D RAJENTHIRA KUMAR2

1M.E, Industrial Engineering, PSG College of Technology, Coimbatore
2Professor, Department of Mechanical Engineering, PSG College of Technology, Coimbatore
119MM04@psgtech.ac.in

Abstract- quality with lowest cost per ton production. AVC series cone
Stone Crushing Industry crushing plays an important crushers are enable to work efficiently in secondary, tertiary or
quaternary crushing applications.
role in reducing particle sizes of rocks and ores and it is an
important industrial sector in the country engaged in
producing crushed stone of various sizes depending upon the Cone Crushers
requirement which acts as raw material for various Cone Crushers features a unique combination of crusher
construction activities such as construction. In industries speed, throw and cavity design. This combination has proved
supporting mining and crushing operations, to reach desirable revolutionary higher capacity and superior product quality.
end product size, the feed material endures a few crushing • Easy modification of throw setting for appropriate
stages that form a circuit. A crushing plant system consists of applications .
a combination of unit operations for storing, feeding, crushing, • Dual dust seal system protects the crusher internal system
screening, and conveying. from dust and dirt.
• User-friendly SMS System sends immediate information of
Crusher operating parameters.
• Bigger mantle diameter combined with effective speed,
Keywords—CRUSHER,KAIZAN,IMPLEMENTTON M enhances the production .
SAND • Availability of specially defined chambers (mantle/concave)
to crush coarse/fi ne feed materials and also to cover open/
closed circuit based on application requirement.
• The benefits of controlled CSS are: Biggest feed, Increased
INTRODUCTION capacity, Lowest maintenance cost, Quality products and
In India During the past years, clusters of the crushers are Increased liner life.
increased rapidly because of the significant expansion of the • Cone Crushers can be equipped with optional hydraulic CSS
construction industry including industrial buildings, hotels, setting system, ASP (Automatic Setting Process) which
residential houses as well as roads and other infrastructural improves performance.
works. The stone crusher is one such industry that exists near Vertical Shaft Impactor
almost all major cities/towns throughout the country in all
Vertical Shaft Impactor is an improved
the states because the construction activities go on
throughout the country. Therefore, the different sizes of the version of ‘Rock on Rock’ configuration, a way ahead of all
aggregates are required for the construction project. The conventional types available in the market. The VSI is
conventional process of stone crushing are viz. blasting, developed with various inputs available from aggregate
manual breaking i.e. primary crushing, manual loading, producers. The high velocity impact crusher in Propel VSI
handling of materials during the feeding at the hopper, enhances the shape of the aggregates and improves the surface
crushing, conveying, rotatory screening, reconvening, structure, resulting in superior shaped products at lower
crushing of material, and Transportation of the material to operating cost. Propel VSI is suitable for all type of materials,
the site, with this stone crusher runs with 65 % to 70% waste and recycling applications. Propel VSI rock-on rock
efficiency. The management and technical support gives the crushers have an established track record of cost savings,
proper solutions for the improvement in the efficiency of durability and unmatched performance in the variety of tasks to
stone crusher at every stage. Thus the improvement gives which they have been applied. These include the production of
speedy breaking, loading, smooth’s crushing process with quality aggregates & sand.
reduction in time, energy, maintains & labor cost, etc. Thus, • Specially built steel structure for smooth operation.
it has become an important task to develop the clusters of the • Simple inter-changeable cartridge type Rock Box for ‘Rock-
crusher sector. These findings have significant implications on-rock’ applications .
for the conventional crusher plant. It appears that this method • Hydraulic feed control Inbuilt device.
produces a best product to conventional plants, where it will • High productivity with excellent cubical shape (as per
be covered by studying and analyzing the crusher.
MORTH)
• Parallel flow system provides increased capacity and.
• Quick and easy installation. Crushers require minimum
Jaw crusher support structure and are also ideal as portables and mobiles.
Single toggle jaw crusher offers the maximum possible • More tolerant than conventional crushers to
fatigue strength and best reliability with various mounting difficult feed conditions.
possibilities. The fully welded sturdy construction, combined • Quick balance rotor which is easy to use and service.
with high graded cast steel components, large spherical roller • Simple, reliable grease lubrication.
bearings and forged steel special alloy shaft gives high crusher • Due to better shaping, the voids are taken care resulting in the
availability, efficient crushing resulting in lowering the less consumption of cement.
production cost per ton Jaw Crushers range from smaller to • Propel VSI produces shaping confirming to Ministry of
large size, specially designed for the most demanding crushing Surface Transport (MORTH) Standards.
applications. Propel series Jaw Crushers offer complete
crushing solutions for hard and abrasive rocks.
Crusher offers the highest crushing efficiency and end product
• Crusher impact combined with speed gives the unique shape
resulting in production of high quality manufactured sand
confirming to C 144 standards with improved surface texture
as like natural sand, which enhance the strength of the
concrete / mortar.

Bucket type sand washing machine –

Bucket type sand washing machine water type sand making
(M-Sand & P-Sand) equipment. It can improve the sand
quality by wash out the tiny stone powder and impurities
mixed in the sand getting from natural sources or from sand
making machine like sand cone or VSI. Propel Sand Washers
adopting advanced technology for high efficient sand washing,
developed according to practical conditions of sand industries
to meet out the IS standard for construction requirements of
gradation in the final output sand.
• Cartridge type bucket wheel and spiral arrangement, bucket
speed controlled by VFD to control percentage of fines.
• High tech planetary gear reducer is used in all propel sand
washers for better and efficient maintenance free running.
• Spiral wheels empowered with Hardox Liners for wear
resistant and long life.
• Total water trough is protected by anti-corrosive special
coating . fig 1
• In the weir system, the higher the water velocity, more fines
are washed away to the settling pond. Lower the water
velocity, more fines saved in the product. DATA COLLECTION FOR
MACHINING PROCESS-CURRENT
Problem Statement STATE MAP

1. crusher plant, huge time was wasted during an JAW CRUSHER

activity of process and it takes nearly 10 to 15
minutes / hr normally.
2. In order, to reduce wastages there is need to effective Time (in
method to reduce time while doing it manually.
minutes)
3. Thus, this project proposed some lean techniques to
overcome this problem. Cycle Time
Objectives 40
(CT) /HR
.To carry out the following analysis- machine specification
Analysis Changeover
20
- current Value Analysis Time(CO) /HR
- requirement Value Analysis
Available time
1650
1. Identify Invisible Losses. (AT)/DAY
2. To use Value Stream Mapping to identify the
table 1
non value added activities. Uptime(UT) 66%
3. To use lean tools to check the Feasibility of the Number of
solution proposed. 1
Workers
4. To increase the plant productions.

Time (in minutes)

Cycle Time (CT)/hr 43

Changeover
17
Time(CO)/hr

Available time (AT)/day 1650

Uptime(UT) 71.6%
fig 2
Number of Workers 1
CONE CRUSHER VERTICAL SHAFT IMPACTOR

table 2 table 3

fig 4
fig 3

SAND WASHER
 Time (in minutes)

Cycle Time (CT)/hr 58

Changeover Time(CO)/ HR 2

Available time (AT)/DAY 1650

Uptime(UT) 96%

Number of Workers 1

table 4

fig6

Kaizen – 1 ( Objectives and Problem

Identification)

Objectives:
 Continuous raw material feeding in jaw crusher.

 To eliminate of ideal running of jaw crusher.

fig 5
Problem Identifications:
 Over feeding when there machines is trip.

 To give an input raw material to semi water sate to

ABOUT VSM SOFTWARE
control the pollutions.
Software: iGrafx
Lean Value Stream Mapping using iGrafx:
iGrafx accelerate the drawing of the map and do some of the
‘math’ for you. iGrafx will automatically build a timeline for Kaizen – 1 ( solutions)
you, and can calculate Takt, overall lead time, Value-Added
(VA) vs. Non-Value-Added (NVA) time, Inventory impacts,  Develop and implement a solution. The possible
suggestions were given for the problem identified.

1. To avoid the raw send to feed the material.

.
2. To increase the one transportation vehicles.

3. Give an proper maintenance grease feeding daily ,v-

CURRENT STATE VALUE MAPPING
belt tensions checking.

 While doing the plant start lag of raw material is the

most problem.
  To eliminate of ideal running of jaw crusher.
After implementing this proposals we are efficiency getting a
 The machine electrical push buttons are can be upcoming output level due.
damaged due to on /off.

 Also motor changing the star to delta connections its

IMPLEMENTATION RESULTS
get the over voltage and electrical consumptions are
more .
JAW CRUSHER
 120tph of cotton are fed into the machine per hr. In 1. To avoid the raw send to feed the material.
total, 200tph of wastage were removed every day in
2. To increase the one transportation vehicles.
three shifts.
3. Give an proper maintenance grease feeding daily ,v-
 The percentage of waste = 120 / 200 = 0.6 = 60%
belt tensions checking.
 40%waste per /hr.

Kaizen – 2 ( Objectives and Problem

Time (in minutes)
Identifications)
Cycle Time (CT) 45
Objectives: Changeover Time(CO) 15

 The objective is to minimize the pollutions . Available time (AT) 1650

Uptime(UT) 75%
 To balance the machine capacity and supply feed.
Number of Workers 1
 To utilize the machine full efficiency to feed the raw
material properly

 Skilled labor required .

table 5
problem Identifications:
 In which plant running air will be polluted.
CONE CRUSHER

To give an input raw material to semi water sate to control the

Kaizen – 3 ( Objectives and Problem pollutions.
Identifications) To utilize the machine full efficiency to feed the raw material
properly skilled labor required.
As there are implement in cone crusher we are get more
Objectives: effective performance and there arranged to implemented

 The primary objective of plant reduced there water

level
Time (in minutes)
 Conveyor maintained Cycle Time (CT) 45

Changeover Time(CO) 15

Available time (AT) 1650

Problem Identifications:
 To continuously check the machine and the clearance Uptime(UT) 75%
between conveyor and roller.
Number of Workers 1
 .4000 litres per/hr recycled water so we reduced the
water consumption level

 one of the most important is as water consumption

we are used to develop the minimum level of water
to reduced the water consuming level. table 6

Proper maintenance to conveyor set up to reduce the plant

breaks.
VERTICAL SHAFT IMPACTOR Reference
Abdulla, N. “Effect of Recycled Coarse Aggregate Type on
In Which machine we have regularly check there wear parts Concrete”. American Society of Civil Engineers, Journal of
and input material to given to required size we are get thereMaterials in Civil Engineering, Volume 2, Issue 10, October
good production in there arrangement. 2015-1061.
[2] Fernando, E., Button, J., and Crockford, W, “Rut
Susceptibility of Large Stone Mixtures”. American Society of
Time (in minutes) Civil Engineers, Journal of Environmental Engineering, Journal
of Transportation Engineering, Volume 123, Issue 1 January
Cycle Time (CT) 50 1997 ,51-59
Changeover Time(CO) 10 . [3] Hamid Karimpour, Poul V. Lade , “Time Effects Relate to
Crushing in Sand” .American Society of Civil Engineers,
Available time (AT) 1650 Journal of Geotechnical and Geo-environmental
Engineering ,Volume 136, Issue 9,September 2010,1209-1219.
Uptime(UT) 83%
[4] Jonathan Jingsheng Shi. “Mathematical Models for
Number of Workers 1 Maximizing Aggregate Plant Production” American Society of
Civil Engineers, Journal of construction Engineering and
management, Volume 125, Issue 1, January 199, 53-60.
5] R Bearman, S Munro and C M Everson. “Crushing
Efficiency- Factors” Met Plant, Conference, August 2011, 17.
[6] Sivacoumar, R., Jayabalou, R., Swarnalatha, S., and
table 7 Balakrishnan, K. “Particulate Matter from Stone Crushing
Industry: Size Distribution and Health Effects”. American
Society of Civil Engineers, Journal of Environmental
SAND WASHER Engineering, Volume 132, Issue 3, March 2006, 405-414.
Sand Washer we given as there following output we got in [7] S. P. Gautam, Shri R. C. Kataria . “An Overview of Stone
there machine efficiency. Crushing Sector In India”.Central Pollution Control Board,
February 2009, 2.

Time (in
minutes)

Cycle Time (CT) 60

Changeover Time(CO) 58

Available time (AT) 1350

Uptime(UT) 96.2%

Number of Workers 1

table 8

FUTURE PLAN

• To increase the Value Added Ratio.

• To reduced the environmental pollution.

• Increase the production in green way.

CONCLUSION
Hence it was an important aspect to improve working
efficiency of the system. In order to achieve objectives of
study whole process of crushing is divided in various stages
each stage is studied and analyzed for improvements. While
carrying this work of divination it is observed that the time &
energy was utilized to after implementation.