B&H – Quarterly Opex Review 1

Project Title : Indigenous Development on Projection welding machine to cater 7m finning length

Start Date :16th Nov 2015 End Date : 15th Feb 2016

Project Leader : Kiran Sirsath

Department : MED ( B & H )

Team Members:Vaibhav K. Shah , Sanjay Madhav, Tarak Mankad, Ranba Waingade, Jagannath Kulkarni.

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Background of Project :• Capability of Projection Fin welding machine is to weld upto

max 4.5m tube length.

• For recent order of Tata Steel & Nippon steel – as per design engineering – Fin tube length is of 7m.

• In order to overcome the capability constraint , engineering has put additional tube to tube butt joint for the same.

• Considering the volume of additional butt joints and its work content , it is time consuming and laborious task. ( Appr. 7400 butt joints for both projects)

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Problem Definition :• Requirement of finning for 7meter long tube.• Increase in cycle time & work content to great extent for

finning of 7meter tube with additional butt joint.• Existing Projection welding m/c is able to perform finning up

to 4.5 meter length because of constraint of bed length.• Position of Electric motor on m/c restricting finning of tube

longer than 4.5meter.• Old fixtures was not compatible for new requirement

because of following reasons

1) As per drawing, Finning starts at 110mm for bent tube.

2) Clamping of Tube was not possible in between finned

portion.

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Old Fixture photo ( 4.5 m length)

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Outcome Desired :

• Make 7meter long tube finning feasible on existing projection welding m/c.

• Eliminate additional weld joint for finning 7meter long tube.

• Reduce cycle time & work content required for finning of 7meter long tube with additional butt joint i.e Tube cutting, Tube chamfering, Tube set-up, Butt Joint welding, correction after welding, RT, Ball Pass Test after welding.

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New Fixture photo ( 7 m length)

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Actions planned / implemented:

• New fixture designed to accommodate 7m Finning tube length on existing bed length

• Servo motor for driving carriage was restricting additional finning length so it was relocated on new fixture.

• Water cooling path was modified on the jaws to accommodate minimum fin start position.

• PLC program was modified to cater 7m finning length

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Results Achieved :

• Successfully achieved 7m finning length on existing machine of 4.5 meter bed.

• Successfully Eliminated additional weld joint for finning 7 meter long tube.

• Reduce cycle time & work content required for finning of 7meter long tube with additional butt joint i.e Tube cutting, Tube chamfering, Tube set-up, Butt Joint welding, correction after welding, RT, Ball Pass Test after welding.

• Total 3744 number of butt joint are eliminated (Eco: 2944,Evap:800)

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Way Forward :

• This system works on two PLC programs to accommodate 7m finning length. Further this can be modified with bed extension.

• Tube support system need to be modified to cater future tube length requirement.

• Modification in servo motor & carriage mechanism to withstand future finning length.

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Thank You