CHAPTER 2

TRAINING EXPERIENCE

2.1. Training at Loadstar

2.1.1. My work sites

I was assigned to Casting Production Division (CPD) for the first 4 weeks (From 08 th of

February to 07th of March). I was monitored by Mr. Aravinda Gamage who was the electrical

engineer in Casting Production Division. Then I was assigned to Jinasena Industrial Park

(JIP) for the last 8 weeks (From 08th of March to 02nd of May). I was monitored by Mr.

R.D.S.S. Wickramasinghe who was a electrical engineer in Jinasena Industrial Park.

2.1.2. Duties & functions

2.1.2.1. Projects

I successfully completed my project under the title of “Analysis for further improvement of

CNC machines efficiency in the factory and investigation to any breakdown occur in CNC

machines”

Refer Annex D

2.1.2.2. Electrically operated machine maintenance

I worked with the maintenance crew of Casting Production Division since the beginning of

my training program. I was to be with the electricians to learn technical details. While I was

with them I participate mainly in repairing panel boards and re-wiring them, finishing the

break downs, etc. Apart from that I studied about the machines, their panel boards (control

and power circuits) and about the production process.

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2.1.2.3. Preventive and electrical breakdown maintenance of a factory

I worked with the maintenance crew of Casting Production Division to get knowledge about

Preventive and electrical breakdown maintenance of a factory. Also I learned about Buck and

Boost method implementation

2.1.2.4. Single phase & three phase motor winding & motor selecting for various applications

During the training period I wound one fan motor, one single phase motor & one three-phase

motor.

Fig. 2.1. Preparing fan motor winding Fig. 2.2. Finished Fan Motor

Fig. 2.3. Preparing 3-phase motor to wind Fig. 2.4. Preparing 3-phase motor to wind

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These were the steps I followed to wind a single phase motor,

Confirmed that the Motor supplied to us was burnt.

Checked it with a Multi meter.

Identified whether it was single phase or three phase Motor.

Removed the Condenser & get its details.

Removed the back cover of the motor & then front cover of it.

Got the sizes of the Bearings.

Identified the rotor type & gauge of the coil (if it’s only a wound rotor).

Identified the gauge of the stator coil, no of turns in a coil & pitch of the coils.

Prepared a “former” according to the “pitch” of the coil.

Pitch was the distance between two slots which a coil lays when we place it in the

stator. Former was a simple mechanism that uses to form coils according to the

relevant pitch, no of turns & to the relevant shape.

Formed the Stating & Running windings separately for the required gauge.(If it’s only

a single phase motor)

Replaced the slots with the insulators called Milinex or Atamax. Size of the Milinex

or Atamax depends on the capacity of the motor & the sizes of the coils.

If it’s a single phase motor first starting coil had to be place because, always running

coil had to be place near to the rotor.

After place the coils checked the coils with a Multi meter

Checked it with again for the short circuits.

Insulations were good place slag on the coils to up the insulations. Then placed it in a

oven to bake it.

After baking it removed extra slag on the inside of the stator, replaced the bearings

then re assembled the unit.

Fixed the condenser to the unit. (If it’s only a single phase motor)

Did a test run.

Also I learnt Motor Controlling using invertors.

2.1.2.5. Capacitor Bank Designing for Industrial Environments

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I was involved in preparing a capacitor bank to improve efficiency of the factory and to

reduce the cost of production.

2.1.2.6. Panel Board Designing

During the training period I got involved to design many panel boards. Therefore I got

knowledge about designing panel boards & safety procedures.

Fig. 2.5. Panel Board Designing Fig. 2.6. Panel Board Designing

2.1.2.7. PLC Programming for Siemens and Hitachi

In my training period I programmed the T-10 machine of OREX factory. T-10 machine is a

solid tire machine. It consists of 15 presses and hydraulic unit. Each press can invent one tire

at once. This machine is operated by a Program Logic Controller (PLC). T-10 system is

operated by SIEMENS PLC program.

Three tire presses are operated by 1 PLC. So there are 5 PLCs connected to this system. The

1st PLC is called “MASTER PLC”. All the other PLCs are connected with this.

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Fig. 2.7. Master PLC Fig. 2.8. Tire Press Machine

Also I programmed the PLC of heat treatment plant of Casting Production Division

Fig. 2.9 Heat Treatment Plant Fig. 2.10 Control Panel of the Heat

Treatment plant

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Fig. 2.11 Sample Code Fig. 2.12 Configuration Settings

Also during the training period I was involved in HMI Developing (Touch Panel) using

WinCC flexible Advanced, ADP 6 and Network PLC through RS485 Serial Data Bus.

2.1.2.8. Experienced with ANDON Board Project

I involved developing the ANDON Board for OREX factory. It will help to increase the

efficiency of the factory through quickness of the communication. Also I developed the

software using Java & got a very good knowledge about Xml file handling using Visual

Basic6.0 for Client Server Applications.

2.1.3. Problems & Difficulties

Most of the time employees are hot on their work. Therefore, it was quite difficult to get

some explanations and we have to wait for them to call us because we cannot urge them.

Self-studying cannot be done fully because of the lack of manuals on some areas.

Sometimes no attention on trainees, so we had to wait for days for them to call.

Went for the sites to carry out same type of work repeated.

Sometimes they do not like to join us for their visits, because they do not have enough

facilities to give safe travel for us.

But maintaining the mental wellbeing of their employees is not given much priority in this

company. Every one of us is a human being, and being that we have necessities. Even

though Loadstar provides its workers with excellent welfare facilities and numerous other

benefits, the prime and most overlooked weakness is the fact that employees do not have

enough time-off. People get tired of working around the clock and not having enough time

to spend with their families. Even within the establishment there is no time for a rest.

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2.1.4. Information of Production Processes of JIP & CPD

Raw materials needed for other factories are distributed from here .Rubber and chemicals

which are needed to first stage and second stage mixings are weighted and prepared to take

the composition required and then packed them according to the required amounts of the

batch .Central stores also has been located at JIP. All machine components, spare parts used

in other factories are mainly distributed from here. Engineering manufacturing division gives

good contribution by producing most of machines and maintaining them used in other

factories

Casting Production Division (CPD) is producing metal pieces for tracks & steel wheels.

Casting Production Division is newly constructed factory with latest technology & good

safety procedures

2.1.5. Safety Procedure

Their aim is provide and maintain a safe and healthy working condition for all employees. To

achieve this objective, they provide safe equipment, system of work, information, training,

and supervision. They also accept that is our responsibility to ensure the health and safety

other people who may affected by our activities.

They take responsibility of marking all at Loadstar aware of the importance of environmental

protection and conservation, thus obtaining their full commitment and cooperation towards

ensuring that environmental protection and conservation; practices are adhered to at all levels

within Loadstar (Pvt) Ltd.

In recognizing of the fact that the provision of safety at work place is a joint responsibility,

we call upon all at Loadstar to take responsibility for health and safety of themselves and

others by activity implementing the safety policy of Loadstar.

The individual’s and group duties and responsibilities of loadstar members to ensure safe and

healthy work place are set forth in the safety manual. We at loadstar undertake the

responsibility to regularly update and annually review the safe policies and procedures so that

they are in line with the growth of our organization and meet the requirements of all statutory

requirements.

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2.1.5.1. Industrial Safety

Safety is a very important factor that should be considered within an organization. Especially

manufacturing firms because there are many machinery that are used in those companies.

Accidents can occur every moment at every place. If there is no good safety procedure then

these incidents can’t be avoided. It is a bad effect to the goodwill of a company.

2.1.5.2. Notification and recording of accident

Accidents are classified as,

Major accidents - Fatal, permanent, Disabilities, loss of body part or disaster.

Serious accidents - Temporary disabilities and not reporting for duty more than 3 days,

due to an accident and hospitalization for treatment.

Minor accidents - Local treatment handled by the first aid center.

Incidental accidents - Property damaged. No personnel injury.

Near miss - No injured or property damaged. But may lead to injury or property

damage.

2.1.5.3. General statement of safety at Loadstar

The company maintains a health & safety system under the control of a safety manager. The

safety manager is responsible for the implementation of safety systems at all the company

sites in Sri Lanka.

The company seeks to minimize the extent of hazardous occurrences & accidents through a

series of pro-active measures.

1. Risk assessment during the design & development stage of machinery,

plant & equipment.

2. Risk assessment prior to, during & after the installation of machinery,

plant & equipment.

3. Pre planned risk assessment audit of all work areas.

4. The reviews & analysis of any hazard areas highlighted by the safety

audits, actions with the agreed preventive measures being implemented &

recorded.

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In the event of a dangerous occurrence or accident the company safety system requires the

following reactive measures to operate efficiently.

1. Trained, certified first aid providers are placed strategically through out the work

areas.

2. First aid centers, manned by qualified staff are maintained on every site.

3. A system of accident, dangerous occurrence, investigation and reporting

is established, together with a subsequent review procedure.

States are compiled in order to evaluate the overall safety system & also to identify the

nature of any trends in the types of accident that occur throughout the work place, so that

preventive measures can be taken. All safety procedures & documents require the approval of

the assistant safety manager before implementation into the system.

2.1.6. Maintenance Management

2.1.6.1. Introduction

Maintenance Management applies the management functions to keep a company’s physical

plants in sound and safe condition and to keep machinery and equipment in good operating

order. The basic process of maintenance might be seen as the front line in a long-standing

battle between two forces. On the one side, time and constant use tend wear down facilities

and equipment. Roofs begin to leak; railings become loose; bearing become worn and loose;

engines fail; hydraulic presses begin to leak; mixture’s become break downs est. On the other

side the battle are the efforts of the maintenance function. Workers renew parts of buildings;

they replace worn parts; they lubricate and adjust to reduce wear; they tighten bolts; replace

belt and chains; renew containers and do whatever else is needed to hold off the effects of

wear and time.

Several specific duties and objectives are in maintenance.

Keeping machinery, equipment etc. in good condition efficiently and cost

effectively.

Providing utilities and energy sources and waste disposal without interruption and

at the lowest cost possible.

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Administrating the maintenance, keeping good records of work orders, and

controlling employee efficiency, cost and schedules.

Maintaining an efficient supply of replacement parts and maintenance material

and controlling the inventory of these.

Providing assistance in process flow design to improve maintenance

characteristics.

Improving employee consciousness of an ability in using procedures that will

cause the fewest breakdowns and bring about the lowest maintenance costs.

2.1.6.2. Organization of maintenance

A maintenance manager or supervisor of maintenance reports either to the plant engineer or

to the plant manager. A separate maintenance department is there which reports directly to

the plant manager. This kind of organization reflects a realization of the importance of good

maintenance to efficient production.

The maintenance department has direct responsibility for performing the duties outlined

above. In the Loadstar (Pvt) Ltd JIP factory has situated separate maintenance department

under a senior maintenance engineer.

2.1.6.3. Types Of Maintenance

1. Improvement Maintenance

2. Corrective Maintenance

3. Preventive Maintenance

2.1.6.3.1. Improvement Maintenance

Is an attempt to reduce or eliminate the needs for maintenance. This aim at taking issue at the

source itself. Continues improvement of technology and fair amount of research and

development are involved in searching for technologies, which require very little no

maintenance. Example for permanent lubricates, bearings, self-adjusting bearings,

introducing PLC system.

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2.1.6.3.2. Corrective Maintenance

Corrective maintenance is the result of the reactive response to emergency or breakdown of

plant and equipment. Is a type of unscheduled activity where an attempt is made to repair a

machine only after it has broken? Also it was called running maintenance.

2.1.6.3.3. Preventive Maintenance

Preventive maintenance looks from a different angle at the problem of keeping equipment

running. Its goal is to prevent breakdowns by taking the time regularly to inspect machines,

to replace parts that threaten to fail, and keep lubricants, packing, bearings and other points

under continual watch.

Preventive maintenance schedules in advance regular periods when each piece of equipment

will be taken out of production of servicing.

It is easy for production managers and others to say; “ The Machinery’s working fine; why

should we give up hours of production for maintenance when there’s nothing wrong with the

equipment is the first place? Giving up some production time for regularly scheduled

maintenance has many benefits, though, to outweigh the costs of the lost production time.

Emergency shutdowns cost money; unexpected work stoppages spoil materials, disrupt

schedules and can set off a chain of expensive delays. Once a machine fails, the problem is

often more costly to repair than it would have been to prevent. If emergency breakdowns can

be reduced, it may be possible to eliminate equipment that has been kept for standby use.

Equipment that is not in good condition is dangerous; preventive maintenance reduces

accidents. Preventive maintenance requires a smaller maintenance crew since the work is

orderly and scheduled in advance. It is easier to manage because routine work is far easier to

estimate, control and evaluate than emergency calls.

In the common workshops done two types of preventive maintenance.

1. Electrical Preventive Maintenance

2. Mechanical Preventive Maintenance

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