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REDUCTION OF PLATE SCRAP OF A BATTERY BY USING MECHANICAL METHODS
ByP.Satyanarayana 06191A0310D.Sudhakar Reddy 06191A0325D.Dinesh Kumar 06191A0314P.Sravani 06191A0304P.Anusha 06191A0321
Company Introduction
ARBL is one of the biggest plant in Asia (area of 165 acres), most
advanced microprocessor controlled and fully integrated state of the art
manufacturing facility located at Tirupati, Andhra Pradesh with capital outlay of
Rs.180 crores.
Amara Raja is a public limited company whose scip is a joint venture between
Amara Raja group and Johnson Control Inc., USA. As of now 26% equity is with
JCI & Amara Raja group each and the rest 48% is with the public.
Amara Raja is the tenth largest MF-VRLA battery manufacturer in the world.
Amara Raja is also the largest supplier of VRLA batteries for various applications to
Indian Railways such as Train Lighting, Air Conditioning, Signal and Telecom
Batteries & AC Loco Batteries
Oxide Plant
Grid Casting
Paste Mixing & Pasting
Plate
Curing
Plate Cleaning
StackingGroup
Burning
Insertion
Heat sealing
Post Burning
Leak Testing
Cell Packing
Acid Filling
Cell Forming
Cell Cleaning & Insertion
FinishingPacking & Dispatch
Process flow for LVRLA
Process flow for MVRLA
Heat sealing
Post Burning
Leak Testing
Cell Packing
Acid Filling
Cell Forming
Cell Cleaning & Insertion
FinishingPacking & Dispatch
Oxide Plant
Grid Casting
Paste Mixing & Pasting
Plate
Curing
Plate Cleaning
EnvolopStackin
g
Cast on Strap
Insertion
Inter cell welding
Manufacturing Section
PlatePreparation
Assembly
Formation
Finishing
Industrial Battery
Industrial Battery Division (IBD) - LVRLA
Oxide Plant
Grid Casting
Pasting
Manufacturing Sections of IBD - LVRLA
Sub-Section
Busbar Casting
Plate curingPlate cleaning
Dispatch
Plate Preparation
Oxide Plant Grid casting Pasting
Oxide Plant
Grid Casting
Pasting
Oxide Powder
Pbo2+H2So4 + Dm Water+Chemicals = PasteGrid + Paste=Plate
+
Pure Lead (99.97 %)
MFX & LCALead Alloys
Paste
Section/Process Input Output
Oxide Plant
Pasting
Grid Casting
POS & NEG Plate
POS & NEG Grid
Grid
Lead Oxide Manufacturing
Process Flow Diagram
Lead Ingot
Lead Ingot Melting
Reaction
Oxide Powder Filtering
Quality Check Points:1. % Free Lead2. Apparent Density3. Acid Absorption
Transfer to Silos
Oxide Storage in Silos
1. Molten Lead2. Water3. Air
Balox & Eagle Oxide plants
SilosHammer Milling
Additional activityFor MVRLA
Lead Oxide Plant – Input & Out put Diagram
Oxide Preparation
Exothermic reaction
Pure Lead(Pb) Ingots 99.97 %
Lead Oxide(PbO)
Pb + ½ O2 PboH2O
Pasting
Process Flow Diagram
Plate cleaning
Quality Check Points:1. Free Lead %2. Dry plate Moisture3. Vibration loss%
Curing & Drying
Dry Plates Storage
1. Wet plates 2. Boiler
Cleaned Plates
Curing Ovens
Lead oxide powder stored in silo for min of 18hr. Then it is used to produce paste mix.
Composition used: For Positive Paste:
Lead oxide 1000kgBinder 0.5KgSPTH 2KgDM water 126ltSulfuric acid 110kg(Sp. gravity 1.4)
For Negative Paste:
Lead oxide 1000kgBinder 0.5KgBarium Sulphate 20KgVanisperse 2KgCarbon Black 2KgDM water 116ltSulfuric acid 110kg(Sp. gravity 1.4)
PASTE PREPARATION:
Plate Curing – Input & Out put Diagram – LVRLA &
MVRLA
CuringWet pasted
platesDry
plates
PROBLEM: Plate scrap in pasting
OBJECTIVE:
To reduce the plate scrap in pasting.
To reduce the plates scrap from 2.4% to 1.35% per month
“12-STEPS” FOR PROBLEM SOLVING
STEP-1 IDENTIFICATION OF PROBLEMS
STEP-2 SELECTION OF THE PROBLEM
STEP-3 DEFINITION OF THE PROBLEM
STEP-4 ANALYSIS OF THE PROBLEM
STEP-5 IDENTIFICATION OF CAUSES
STEP-6 FINDING OUT THE ROOT CAUSE
STEP-7 DATA ANALYSIS
STEP-8 DEVELOPING SOLUTION
STEP-9 FORESEEING PROBABLE RESISTANCE
STEP-10 TRIAL IMPLEMENTATION & CHECK PERFORMANCE
STEP-11 REGULAR IMPLEMENTATION
STEP-12 FOLLOW UP/REVIEW
Step-1 Identification of Problems
Using Brainstorming
S.NO IDENTIFICATION OF PROBLEMS CAT:A\B\C
1 Plate Weight variation. A
2 Improper Filling of paste on grids A
3 Lug side over paste A
4 Filling problem of paste on grids A
5 Tool setting problem A
6 Flash Drier chain Vibration A
7 Parter timing problem A
8 Temp problem in Flash Drier B
9 Grid cutting problem A
10 Parter center chain sprocket problem B
11 Belt Nylon bed problem B
12 Heaters set fixing problem C
13 Feeder chain timing problem A
14 Grid feeding Rubber roller problem A
15 Knurling roller Bush problem B
16 Knurling roller Shaft problem B
17 Drive roller problem A
18 Drive roller Pins problem A
19 Drive roller Black bush problem B
20 Hopper Shaft bush problem B
Step-1 Identification of ProblemsUsing Brainstorming
21 Hopper Guard bush problem B22 Hopper Bottom shoe guard problem B23 Transfer roller bush problem B24 Lug cleaning brush problem A25 Parter Speed control Sensor problem B26 Oxide leakage (Near Oxmaster lids ) B27 Mixer Scrapers worn-out A28 Slide gate Sensor problem B29 Thermo couple problem in mixer B30 Thermo couple Sensor problem in mixer B31 Thermo couple cylinder problem B32 Mixer Dumping Door Sensor problem B33 Slide gate Water leakage problem B34 Air leakage in mixer B35 Acid leakage in mixer B36 Acid Valve (Filling and Dumping) problem B37 Mixer motor guard problem B38 Oxmaster cone gear box problem B39 Oxmaster cone Cylinder problem B40 Oil leakage in mixer B41 Plates scrap in pasting A42 Hydraulic oil leakage in Hydraulic unit B43 Hydraulic pressure problem B44 Plates pallet Down in Assembly A45 Plate Sagging problem A
Using Brainstorming
Step-1 Identification of Problems
46 Scissor lift problem at plate collecting area B47 Bottom paste Tray problem B48 Parter width Adjustment problem B49 Fresh Air not working properly (Pressure low ) B50 Pallet truck problem in pasting B51 Plate Cross cutting problem in parter A52 Heaters Failure in Flash drier B53 Hydraulic pressure gauge Oil leakage B54 Feeder center guide not working properly A55 Lifting plates problem B56 "D" Type Ovens Plates Moisture problem B57 Transfer roller Speed problem B58 Parter chain Bearing problem B59 Forklift problem B60 Oxide transfer problem to Day tank B61 Day tank bin vent problem B62 Day tank load cells problem B63 Silos load cells problem B64 Lighting problem in Grid feeder B65 Weighing scale problem B66 Plate storage Stands problem A67 PP sheets problem A68 High pressure pump problem B
PROBLEM CLASSIFICATION
ABC-ANALYSIS
CATEGERORY
NO
.OF
PR
OB
LEM
S
A-21
B-46
C-01
Problems solved by qc members
Where help is required from other departments
Where management help is required
Using Brainstorming
VICTORY
Step-2 Selection of the Problem
Ranking method
Ranking 01 - Low 05 - Moderate 10 - High
Sl No Problems V.R.R K.V D.S G.G Y.M Total
1 Plate Weight variation. 6 7 5 8 6 32
2 Improper Filling of paste on grids 5 6 4 5 4 24
3 Lug side over paste 9 9 10 9 10 47
4 Filling problem of paste on grids 5 6 2 4 5 22
5 Tool setting problem 5 6 4 3 6 24
6 Flash Drier chain Vibration 5 5 5 5 5 25
7 Parter timing problem 6 6 6 6 6 30
8 Temp problem in Flash Drier 6 4 4 4 4 22
9 Grid cutting problem 5 6 6 6 7 30
10 Parter center chain sprocket problem 4 5 5 5 5 24
11 Belt Nylon bed problem 5 7 5 4 5 26
12 Heaters set fixing problem 6 5 6 5 4 26
13 Feeder chain timing problem 5 5 7 7 6 30
14 Grid feeding Rubber roller problem 6 8 6 7 3 30
15 Knurling roller Bush problem 5 4 7 2 5 23
16 Knurling roller Shaft problem 6 6 4 5 4 25
17 Drive roller problem 5 5 5 4 5 24
18 Drive roller Pins problem 7 4 5 6 3 25
19 Drive roller Black bush problem 5 6 6 4 6 27
20 Hopper Shaft bush problem 6 7 7 3 8 31
21 Hopper Guard bush problem 8 4 6 4 4 26
22 Hopper Bottom shoe guard problem 5 6 7 5 6 29
23 Transfer roller bush problem 8 5 4 6 5 28
24 Lug cleaning brush problem 6 7 6 4 7 30
25 Parter Speed control Sensor problem 7 6 5 5 2 25
26 Oxide leakage (Near Oxmaster lids ) 6 8 4 7 4 29
27 Mixer Scrapers worn-out 6 5 8 8 6 33
28 Slide gate Sensor problem 6 6 6 4 5 27
29 Thermo couple problem in mixer 5 8 7 5 4 29
30 Thermo couple Sensor problem in mixer 4 7 6 4 7 28
31 Thermo couple cylinder problem 5 6 8 5 5 29
32 Mixer Dumping Door Sensor problem 6 5 2 6 6 25
33 Slide gate Water leakage problem 5 8 4 5 4 26
34 Air leakage in mixer 4 6 6 6 3 25
35 Acid leakage in mixer 5 5 4 7 4 25
36 Acid Valve (Filling and Dumping) problem 6 7 6 6 4 29
37 Mixer motor guard problem 5 4 5 5 5 24
38 Oxmaster cone gear box problem 4 5 5 4 5 23
39 Oxmaster cone Cylinder problem 6 4 7 6 6 29
40 Oil leakage in mixer 7 5 6 5 4 27
Ranking method
Step-2 Selection of the Problem
Ranking 01 - Low 05 - Moderate 10 - High
41 Plates scrap in pasting 10 9 9 10 9 4742 Hydraulic oil leakage in Hydraulic unit 5 5 6 6 4 2643 Hydraulic pressure problem 5 7 5 5 7 2944 Plates pallet Down in Assembly 10 9 9 10 9 4745 Plate Sagging problem 5 6 4 6 4 2546 Scissor lift problem at plate collecting area 2 6 6 8 6 2847 Bottom paste Tray problem 5 5 5 5 5 2548 Parter width Adjustment problem 4 4 4 6 4 2249 Fresh Air not working properly (Pressure low ) 6 4 5 5 5 2550 Pallet truck problem in pasting 3 5 7 6 4 2551 Plate Cross cutting problem in parter 5 5 6 7 6 2952 Heaters Failure in Flash drier 4 5 4 5 4 2253 Hydraulic pressure gauge Oil leakage 3 5 6 6 7 2754 Feeder center guide not working properly 4 7 5 5 5 2655 Lifting plates problem 6 6 4 6 8 3056 "D" Type Ovens Plates Moisture problem 2 4 6 7 4 2357 Transfer roller Speed problem 6 5 5 4 5 2558 Parter chain Bearing problem 5 4 5 6 6 2659 Forklift problem 5 3 4 5 4 2160 Oxide transfer problem to Day tank 4 5 3 4 4 2061 Day tank bin vent problem 5 4 4 2 2 1762 Day tank load cells problem 4 5 4 4 3 2063 Silos load cells problem 5 4 2 3 4 1864 Lighting problem in Grid feeder 4 3 3 5 2 1765 Weighing scale problem 4 4 2 2 5 1766 Plate storage Stands problem 5 5 4 4 2 2067 PP sheets problem 4 3 5 3 4 1968 High pressure pump problem 5 2 2 2 5 16
Step-2 Selection of the ProblemRanking method
Ranking 01 - Low 05 - Moderate 10 - High
Step-2 Selection of the Problem
PRIORITY METHOD
S.NO Problem NOT URGENT(0) URGENT(2) VERY URGENT(5) TOTAL
1 Lug side over paste 1 2 2 14
2 Plates scrap in pasting …. 2 3 19
3 Plates pallet Down in Assembly 2 2 1 9
PLATES SCRAP IN PASTING HAS SCORED MAXIMUM MARKS AND IS SELECED FOR OUR PROJECT
Step-3 Definition of the Problem
Pasting Process Flow Chart
PASTING
GRID FEEDER
HOPPER PASTE MIXER
FLASH DRIER
PARTER
PASTE
STACKING
Step-4 Analysis of the Problem
Problem analysis was carried out through 4W 1H Technique
WHAT - Plates scrap in pasting
WHEN - During pasting
WHERE - In pasting section WHO - Pasting operators
HOW - By analysing the causes and developing solution
Step-4 Analysis of the Problem
Manufacturing cost ProductivityOperator stress
WEEKS PRODUCED SCRAP PLATE REJECTION
COST(Rs)
WEEK1 287130 1747 37300
WEEK2 357637 14363 30665
WEEK3 467330 8375 17881
WEEK4 406708 12813 27355
AVERAGE: 9324 No 28308 RS
Step-5 Identification of Causes
Men Machine
MethodMaterial
Lack of awareness
Lifting problem feeder
Feeder chain timing change
Driver roller bush and block worn out
Driver roller worn out
Oxide usage with out aging
Grids usage with out aging
Paste problem
Improper tool setting
Cause and effect diagram
Plates scrap
Conveyor chain vibration
Porter dog chain timing change
V belt worn out
Brush worn out
Pressure plate improper setting
First sample checking
Cross cutting
Improper pate filling
198400
55007
41956
3095820832 18024 15496
10109 7221 6376 5081 4116 3483 3445 2372 1384 672 600 500 118 28
46.6%
59.5%
69.3%
76.6%81.5%
85.7%89.3%
91.7% 93.4% 94.9% 96.1% 97.0% 97.9% 98.7% 99.2% 99.5% 99.7% 99.8% 100.0%100.0%100.0%
0
50000
100000
150000
200000
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
90.0%
100.0%
Pareto analysis
No
of
pla
tes
76% OF REJECTIONS OCCURING DUE TO VIBRATION LOSS,CROSS CUTTINGPARTER JAMMING,IMPROPER PASTE FILLING
Causes
Step-4 Analysis of the Problem
Step-6 Root Cause Analysis
Data collection
FROM DATA COLLECTION 76% OF REJECTIONS OCCRING DUE TO
1. VIBRATION LOSS2. CROSS CUTTING3. PARTER JAMMING,4. IMPROPER PASTE FILLING
Vibration losses Cross cutting Parter jamming Improper paste filling
Action (3W 1H)
Step-8 Development of Solutions
WHAT WHO WHEN HOW
P.Satyanarayana 24feb-20marFlash drier chain modification
do Increasing quantity of binder addition
D.Dinesh Kumar do Sprocket modification
do Giving awareness to the operator
do Changing freuency of cutter fixing
D.Sudhakar Reddy do Brush level modification
p.Anusha do Prater on/off switch near to operator
do Pressure plate adjustment
IMPROPER FILLING p.sravani do cone switch near to operator
VIBRATION LOSSES
CROSS CUTTING PLATES
PORTER JAMMMING
Step-8 Development of Solutions
Using Brainstorming
Vibration looses
Flash drier chain modification
Increasing quantity of binder addition
Cross cutting
Sprocket modification
Giving awareness to the operator
Fixing the changing frequency of cutter
Step-8 Development of Solutions
Using Brainstorming
Parter jamming Brush level modification
Parter on/off switch near to operator
Improper paste filling Pressure plate adjustment
Cone switch near to operator
BEFORE
Problem ImprovementDue to more length of chain, plates are getting vibrated
The length of the chain has decreased by removing six links
AFTER
Flash drier chain modification
Step-10 Trail Implementation & Check Performance
BEFORE
Problem ImprovementDue to frequent loosing of sprocket causing
Dog chains unlevel leading to cross cutting
Sprocket was fixed with supporting rod provide to prevent frequent loosing
AFTER
Sprocket Modification
Step-10 Trail Implementation & Check Performance
Step-10 Trail Implementation & Check Performance
BEFORE
Problem ImprovementDue to brush unlevel causing plates disturbance leading to cross cutting of plates
Brush level is fixed with supporting rod to avoid cross cutting
AFTER
Brush level modification
Step-10 Trail Implementation & Check Performance
BEFORE
Problem ImprovementDue to unlevel of pressure plate causing over paste on lugs leading to disturbance at the brushes
The springs in the pressure plate has modified.
AFTER
Pressure plate modification
Step-10 Trail Implementation & Check Performance
BEFORE
Problem Improvementswitch is near to cone due to this operator feeling difficult for frequent access
Cone switch provided near to operator so that he can frequently fill the paste in hopper
AFTER
Cone switch
Step-10 Trail Implementation & Check Performance
BEFORE
Problem Improvement Cross cutting occurring due to Parter on/off switch far from operator
Parter on/off switch provided near to operator
AFTER
Parter switch
STANDARDISATION
Step-11 Regular Implementation
To avoid vibration losses binder addition increased from 1kg to 1.25kgs for positive and 1kg to 2.5kg for negative.
Check list for Parter cutter changing for every 800000 plates STANDARDISATION
Step-11 Regular Implementation
Step-12 Follow Up & Review
12813
5342
1137 1297
0
20000
40000
60000
80000
100000
120000
140000
PLATE REJECTIONS
NO
.OF
PL
AT
ES
RE
JEC
TE
D
GOAL: To reduce the plates scrap from 2.4% to 1.35%
TANGIBLE BENIFITS
INTANGIBLE BENIFITS
1. Developed leader ship Qualities2. Pride in achievement3. Opportunity of learning4. Self motivation
Plates saved per week =4177 NoCost saved per week =89178 Rs/-
Before modify scrap%=(avg.scrap/produced plates)(9324/379701)=2.4%After modify scrap%=5147/379701=1.35
1. Brain Storming
2. Bar Graphs
3. Ranking Technique
4. Flow Diagrams
5. 4W&1H Method
6. Ishikawa Diagram
Application Segments / Costumers
Industrial Batteries Railways Power Generation Oil & Gas Process Industry Defence Motive Power DG Set- Auxiliary power Telecommunications
Plates scrap in pasting has played prominent role in reduction and wastage of huge amount , large amount of workers working hours so we have reduced by implementing some of the mechanical techniques.
As we had the goal to reduce the plates scrap from 2.4% to 1.35%, But we achieved 1% by implementing the all techniques and tools used.