overview of bhushan power and steel
Post on 14-Apr-2018
341 Views
Preview:
TRANSCRIPT
-
7/30/2019 Overview of Bhushan power and steel
1/18
MID-TERM EVALUATION REPORT OF
6 MONTHS INTERNSHIP AT
BHUSHAN POWER
& STEEL LTD.
Submitted byAbhishek Dhawan
b.e.(Mechanical)4
thyear
Sg 9904
-
7/30/2019 Overview of Bhushan power and steel
2/18
CONTENTSS.No Description Pages
1 ACKNOWLEDGEMENT 3
2 COMPANY PROFILE 4
3 MISSIONS AND VALUES 5-6
3 PRODUCTS 7-8
4 DESCRIPTION OF TUBE MILL 9
5 PROCESSES 10-11
6 PROJECT/ CASE STUDY 12
7 SIX SIGMA ANALYSIS 13-18
-
7/30/2019 Overview of Bhushan power and steel
3/18
ACKNOWLEDGMENT
I deem it as my proud privilege to express my sincerest regards and
gratitude to Mr. Goyal , GM , Bhushan Power And Steel Limited (BPSL) for
providing this valuable opportunity to pursue this work .
I would like to record with in deep sense of gratitude to:
Mr. Harkamal Preet Singh
H.O.D of B.E. (MECHANICAL) , PUSSGRC , Hoshiarpur.
My humble and sincere thanks to all the technicians and workers for
their unstilted guidance and direction , which helped in increasing my
practical knowledge.
I wish to express my thanks to all staff members of BPSL for their
cooperative attitude and valuable suggestions during the course of the
project work .
COMPANY PROFILE
-
7/30/2019 Overview of Bhushan power and steel
4/18
Bhushan Power & Steel Limited (BPSL), is a fully integrated 2.8 Million TPA
Steel Making Company having turnover of INR 5020 Crores (USD 1000
Million) FY11.
The Company is certified to ISO 9001:2008 & TS-16949 Quality Standards
and ISO 14001:2004 Environment Management Standards.
BPSL is a leading manufacturer of flat and long products and have state-of
the-art plants at Chandigarh, Derabassi, Kolkata and Orissa in India. These
plants manufacture value added products covering entire steel value chain
right from Coal Mining to manufacturing Pig Iron, DRI, Billets, HR Coils,
CR Coils, GP/GC Sheets, Precision Tubes, Black Pipe/GI Pipe, Cable Tapes,
Tor Steel, Carbon and Special Alloy Steel Wire Rods and Rounds conformingto IS and international standards.
The Company have successfully commissioned a 2.8 Million TPA Greenfield
Steel and Power Plant in Orissa with HR Coil making facility - First in
Private Sector in the State of Orissa. For this plant, technology and equipment
were sourced from leading world-renowned companies viz., Lurgi, ABB Ltd.,
SMS Siemag, SMS Meer Danieli, LOI Tenova, Kocks etc. BPSL has a wide
marketing network in both India (comprising 35 sales offices) and abroad for
selling its value added product range.
The rock-solid foundation combined with continuous up gradation and
innovation has enabled the Company to surpass its goals constantly. BPSL's
end-to-end portfolio has enabled it to offer a wide spectrum of products at
superior quality consistently surpassing customers' specifications. In addition
to export thrust, BPSL cater to the domestic steel requirements of fast-
growing sectors like automotive, white goods, construction / infrastructure,
furniture, fasteners, telecommunication, power etc. With a view to make its
presence in a big way in Special Alloy Steel Long Product business, BPSL has
commissioned a most modern state of the art Wire Rod-cum-Bar Mill and iscommissioning a host of downstream finishing facilities viz., Heat Treatment
facilities, Bright Bar manufacture etc.
MISSIONS AND VALUES
-
7/30/2019 Overview of Bhushan power and steel
5/18
Our Mission is to achieve clear identity and leadership globally in Steel
production and distribution by integration of complete chain of production
starting from captive iron ore to end user Steel products.
Our revolution in Steel production has helped us to carve a niche unique only
to a market leader. Every year passes by with new value additions and more
accolades from our customers - Locally and Globally. Our rising chart in
respect of all-important parameters of production and finance is a testimony
to our claim.
In pursuing our mission, we at Bhushan Power & Steel Ltd. are guided by the
following values
Quality - To be the best in quality. We aim and achieve excellence.
Technology - State of the art technology and product enrichment by
continuous Research and Development.
Customer Friendly - Our products are world class and more and more clients
are appreciating and using our products. We also undertake customized
products with values addition and enhancement.
Corporate Governance - We comply with all applicable laws and regulations.
We believe in maintaining clean environment and conservation of natural
resources. We contribute towards betterment of our staff and provide them
with best of facilities.
Environment Protection and Practice - We are adopting and implementing
pollution control measures as a matter of policy. (All our efforts are in
accordance with the laid down norms of Central Pollution Control Board for
Industrial and Mixed use areas).
OUR COMMITMENTS
To improve the quality of our products and complete integration of
various stages of production.
-
7/30/2019 Overview of Bhushan power and steel
6/18
To be conscious towards quality and pricing of our products. We strive
by continuous research and development to make our products world
class, having distinct identity and uniqueness. Our customers get best
value for their money.
To run the company profitably year after year.
A workforce motivated, skilled and well looked after.
A workplace safe, secure and hygienic.
To make our Environment Clean, Healthy and Hospitable.
productsFLAT PRODUCTS
-
7/30/2019 Overview of Bhushan power and steel
7/18
These Tubes are widely used for Power and Industrial boilers, Transformers,
Super heaters, Automobiles and Bicycles, Railway Electrification, Furniture and
General Engineering Applications etc.
Cable Tapes
GP Coils
Steel Coils
GP coil sheets
Corrugated sheets
Cold Rolled Sheets
Narrow CR coils
Galvanised Pipes
Black PipesPrecision Tubes
LONG PRODUCTS
With the introduction of most technologically advanced special and alloy steel
long product rolling complex for manufacture of value added bars and coils, a new
dimension has been added in BPSL's long history in the steel business. The Long
Product Rolling Complex consists of a most modern 0.5 million TPA multiproduct
-
7/30/2019 Overview of Bhushan power and steel
8/18
Wire Rod and Bar Mill (18 pass Horizontal & Vertical Continuous Mill) supplied
by Danieli Morgardshammar, Italy and KOCKS, Germany (4 pass mill).
Wire rod bar and mill
Mill Product RangeRaw and Finished Products
Dimensions and Quality
Plant facility
Mill Special Features
SPRING IRON
Sponge iron is a basic raw material for making primary steel products. Production
is at our Orissa Project.
PIG IRON
A product in solid (lumpy) form obtained upon solidification of hot metal in pigcasting machine. Pig Iron is used for production of cast iron casting and steel. PigIron is manufactured at our Orissa Plant.
POWERPLANT
376 MW Power Plant is operational at our Orissa Plant. The excess power
generated is being sold through state power grid.
DESCRIPTION OF TUBE MILL
RAW MATERIAL
Cold rolled steel coils
-
7/30/2019 Overview of Bhushan power and steel
9/18
PARAMETERS
Thickness (mm) 0.10-4.00
Width (mm) 10-1700 (Max)
Coil Weight (MT) Upto 30 MT (7-18 Kg/mm width)
Surface finish Super bright, Bright, Dull and Matte
Grades Specifications- As per
JIS/BIS/ASTM/EN standards
ERW TUBES CEW TUBES
OUTER DIAMETER
(MM)
6.00 TO 127.00 MM 09.00 TO 110.00 MM
THICKNESS(MM) 0.40. TO 6.00 0.80 TO 6.00
LENGTH UPTO 12 MTRS. UPTO 12 MTRS.
APPLICATIONS Automotive, Boiler & Heat
Exchangers ,Air Heater, GEN. EGG.,
Bicycle & Propeller Shafts
Automotive, Boiler, Shock Absorbers, Textiles, Gener
Engg. Propeller Shafts, Cylinder bore tubes for specia
applications & front fork tube for two wheeler.
PROCESSESFORMING
Entry pass Edge Forming
The most common and most simple roll design to form tubing is known as Simple
Radius. In this process a cylinder is formed in a series of rolls having single radius
contours in which the radius decrease progressively.
-
7/30/2019 Overview of Bhushan power and steel
10/18
WELDING
Precision welded tubes are manufactured by high frequency induction welding
process. Welding is done continuously by passing of electric current of high
frequency that is 4,50,000 cycles/second across the butting edges. The outside bead
is trimmed off by Tungsten carbide tool.
SIZING
After the welding station is usually a scarfing stand with or without an
accompanying iron pass following by an overlying guide to guide the tube into the
first sizing pass with three driven passes and idlers between each. After the sizing
is the single ordouble Turks head for straightening.
CUTTING
The clod saw flying cutting machine has the capacity to cut the tubes to desired
lengths with tolerance of +/- 1.55 mm. The tube ends generated by the flying saw
machine are absolutely straight (90 degree) and do not require any de-dimpling.
INSPECTION AND QUALITY CONTROL
The tube division is fully equipped with advanced integrated quality control system
to produce tube matching the national and international standards. The quality
control system is backed by an advanced testing laboratory for advanced physical
and chemical tests. Laboratory is equipped with:
Spectrometer
Universal testing machine
Vickering hardness tester
Rockwell hardness tester
Carbon Sulphur determination apparatus
-
7/30/2019 Overview of Bhushan power and steel
11/18
Microscope
Eddy current tester
Hydraulic press for weld ability test
Flattening test
PROJECT STUDYTIME STUDY DURING OPERATIONS AND CHANGOVERS
Time study is a direct and continuous observation of a task, using a timekeeping
device (e.g., decimal minute stopwatch, computer-assisted electronic stopwatch,
and videotape camera) to record the time taken to accomplish a task .Here we facethe problem of lost mill time during operations and changeovers. A lot of time is
lost during the loading and unloading of the coil. Despite the use of accumulator,
still a major fraction of time is lost during loading and unloading, tool
changeovers. During my study here a lot of reasons have been found out during the
time study of tube mill which lead to excessive downtime which are:
-
7/30/2019 Overview of Bhushan power and steel
12/18
There are no written procedures for setup. All mills should have fixed
written procedures for operators to follow. It is important to control the timeof the process
There is no setup chart. Tweaking the mill during setup loses valuable setup
time. Operators must work the tooling as required. Hence setup chart shouldbe there.
There is lack of formal training. Training helps operators performprocedures for tube mill in the same way.
If the tube mill has been setup according to the written procedures and setupchart, the operator can write down numbers from the digital readout on the
single point adjustment unit (SPA) allowing the next operator to setup from
where the first left. It saves about 75% of the total setup time. If the mill is in poor condition it costs valuable time and scrap during setup
and operation.
Tube misalignment, inaccurate setup accounts for 95% of all problems facedduring tube production.
If tooling is in poor condition, much time is wasted. Running the tool until it
cannot produce more tubing that is beyond its tool life wastes valuable time.
Hence measures are needed to be undertaken to reduce this time duringloading/unloading and changeovers so that the efficiency of mill is
increased. To improve all these factors, study is being done.
-
7/30/2019 Overview of Bhushan power and steel
13/18
PROJECT ON
ACHIEVING SIX
SIGMA QUALITY
-
7/30/2019 Overview of Bhushan power and steel
14/18
SIX SIGMA INTRODUCTIONSix Sigma is a business process improvement strategy, which essentiallychecks that a business is doing what its customers require, that the process
employed is the most effective known and that variation is removed from that
process to provide significantly improved consistency. Much of the initial
success in the application of Six Sigma was based on manufacturing
applications; however, Six Sigma can also be applied in the services and also
banking industries. As clients place a high value on consistent business
processes, which have been proven to be efficient, Six Sigma would meet their
requirements as it is a proven methodology for delivering consistentincremental improvement.
By reducing process variation, Six Sigma allows the organization to focus on
improving process capability and as Sigma levels increase, the cost of poor
quality decreases and profitability increases. The principal purpose of this
project is to review the Six Sigma implementation process and emphasize the
importance of this methodology in the quality area. For this reason, its main
framework is based on the description of the Six Sigma process.
The second chapter describes the significance of Six Sigma, its statistical
interpretation, the team members and their responsibilities and some of the
benefits and limitations of this methodology. The third chapter illustrates the
implementation process and the tools, which can be used in order to achieve
high-quality results. The fourth chapter is centered on showing the benefits
and difficulties that can occur in the implementation process in some
published case studies. In order to show that Six Sigma can be used in
different sectors, the last chapter presents the application of Six Sigma in the
financial services industry, with a focus on banking.
-
7/30/2019 Overview of Bhushan power and steel
15/18
SIX SIGMA DEFINEDIn order to introduce a Six Sigma definition it is necessary first to state the
meaning of sigma:For a manufacturing process, the sigma capability is a metric, which indicates
how well the process is performing. Sigma capability measures the capacity of
a process to develop without defects. A defect means an unsatisfied customer.
The quality scale of Six Sigma measures the number of sigmas between the
interval defined by the specification limits. The greater the number of Sigmas
between the specification limits the smaller will be the value of Sigma and the
lower the number of defects. The difference between the Upper Specification
Limit (USL) and the Lower Specification Limit (LSL) is divided by the
standard deviation to give the Sigma Level, z.The capability of a process for a Six Sigma Level is two, obtained by dividing
the difference between the USL and the LSL by Six Sigma.
Figure 1. Relationship between sigma, DPM, yield and the number of sigma.
Figure 1(a) shows a line with negative slope representing the relationship
between the standard deviation (sigma) and the number of sigmas between the
-
7/30/2019 Overview of Bhushan power and steel
16/18
specification limits. As the sigma value increases, the number of sigmas
reduces and vice versa.
The relationship between the number of sigmas and the yield (%) is shown in
Figure 1(b). It has a positive slope indicating that as the sigma level increases
the process yield also increases.
Figure 1(c) shows the relationship between the value of sigma and the
number of defects per million. It also has a positive slope, indicating that when
sigma increases, the number of defects per million also increases.
Figure 1(d) displays a line with a negative slope, which indicates that the
number of defects per million decreases, when the yield (%) Z increases.
Sigma measures demand a clear definition of what the customer
requirements are. This helps the company to realize what is important and
what need to be improved. With their focus on defects and defect
opportunities, sigma measure can be used to analyses and compare different
process inside an organization or between organizations. Once that have beenidentified the opportunity area and the requirement, the organization can
define the defect and the sigma level which wants to reach. Table 1 lists the
sigma level against the number of defects per million of opportunities, it shows
that the number of defects decreases exponentially as the sigma level
increases.
TOOLS OF SIX SIGMA
-
7/30/2019 Overview of Bhushan power and steel
17/18
Six Sigma statistical tools work like magic to uncover what you dont know.
Yet you dont have to be a statistician to use them:
You focus on selecting tools, using them, and analyzing data and let the
specific software do the calculations. The five-phase process of DMAIC,described earlier in this chapter, uses a collection of tools and is a logic filter
to lead you to the vital few factors affecting your process outcomes:
DefineDetermines the project goals and deliverables to customers (internal and
external).
MeasureIdentifies one or more product or service characteristics, maps the process,evaluates measurement systems, and estimates baseline capability.
AnalyzeEvaluates and reduces the variables with graphical analysis and hypothesis
testing and identifies the vital few factors for process improvement.
ImproveDiscovers variable relationships among the vital few, establishes operatingtolerances, and validates measurements.
ControlDetermines the ability to control the vital few factors and implementsprocess control systems.
Process for the study
-
7/30/2019 Overview of Bhushan power and steel
18/18
Till date, the following steps of the study have been completed :
Process Study
This includes the study of the overall process of manufacturing of tubes
and pipes.
Component Study
Each component of the study has been analyzed and studied separately.
Thorough study has been done on each component.
Data Collection
This step includes the collection of various data and the parameterswhich are required for the further process. This step has been followed
with fixed time intervals.
In the further study, following steps will be completed :
Data Study
Six Sigma Application
top related