By,
ESAB - GET 2012 Review I 26th July, 2012
Vivek Sengupta
Departments Visited
S.No. Departments Visited
1. 2. 3. 4. 5. 6.
R&D - Consumables
No 1 2 3 4 5 6 7 8 Group Metal powders Ferro alloys Complex alloys Minerals Composite oxides Clays Carbonates Fluorides Silicates Wires
Page no 3
WEIGHING
ESAB - GET 2012 Review I 26th July, 2012
DRY MIXING
9 10
WET MIXING
Electrode Arc stability Slag flow Spatter level LH/LHLA Good, initiation difficult Good Good Good
EXTRUSION
Slag release Bead appearance Good Less compared to Good MSGP More spatter Almost nil Good Good
Good Good
Page no 4
Short Circuiting
SS (Root Gap) 6.5-7 mm 12-13 mm 12-13 mm
Production
Extrusion process
Covering Capacity
Crack free elec. If not done, cracks will come at baking Remove moisture Moisture will be source of H2 Lead to Hydrogen cracking
Page no 11
SAWF Process
Maintenance
Types of maintenanceBreakdown, preventive, corrective, predictive Downtime of machines MTBF & MTTR calculations Condition based maintenance & problems in following that Mean Time between Failures (MTBF) MTBF = (Production Time Line Stop Time)/No. of Breakdown Mean Time to Repair MTTR = Equipment Stop Time/No. of Breakdown
Supply Chain
Purchase
Based on forecasting & inventory PO is generated. SupplierMaterialTrucksWeighingQAGRNmovexstock Cut wires MSGP (TATA/SAIL)->Drawn & cut by 3rd party-> BINS For SS coils first coil test is done for same heat no. by QA->cutting Packing material->locally purchased; shrink film->north india MSGP-TATA,SAIL SS-Advance metal powders alloyed wires-usha martin Rutile ukraine; others Kamman Corporation, Super smelt. Silicates Na, K (50-80 tonnes)
Transport, receivables
Payment modes: to be billed, to be paid Agreement signed with transporter-discipline, traffic rules, license etc Outside Destination Area (ODA) charges are applicable if the order has to be delivered to a place which is more than 70km (to and fro) from the nearest branch in the city. In case of equipment damages: Debit fixed damage cost for each type of machine (it is beyond 20,000). Or, debit actual repairing cost. ESAB India Ltd works on cash carry concept with the dealers so 100% advance payment is done Everyday cheque register has to be maintained. Based on the outstanding values, the amount is entered in the cheque.
ESAB - GET 2012 Review I 26th July, 2012 Page no 18
Production Planning
For the production department is drafted weekly (consumables), monthly for equipments ORD-38 report is generated from the MIS-excel sheet (convert) The excel format consists details about the stock, age of the stock, quantity, value. There are three classes of products A, B and C. Stock is maintained for A class. For B, marketing team gives forecast, for C no stock is maintained. Based on the stock on hand and forecasting quantity, logistics team gives the production plan to manufacturing team. The percent deviation of the production department from the plan given to them for the week is monitored.
ESAB - GET 2012 Review I 26th July, 2012 Page no 19
Quality
Inspection R/M: lab tests, dimension test (cut wires) In process(electrodes): VI, Dimensional, Concentricity, brushing, linishing In process SAWF: weights, mixing time, Mn content, blend chemistry, silicate quantity, chilling temperature, speed of angle bed, LT & HT temp, particle size, bulk density, grain strength Inspection & test (FG): VI, moisture content, 1000C moisture tester, coating strength SS (drop test), running performance, metal recovery for MSGP, Chemical analysis, Diffusible H2, ferrite test, tensile, impact, fillet, radiography tests.
Tests
Cut wires visual inspection Sieve analysis (to observe particle size distribution) XRF (Chemical composition of raw materials) Oxygen & Nitrogen analyzer Carbon & sulphur analyzer Tests for silicates (pH, viscosity) Mn test for blend powders Moisture test Packing material tests Diffusible H2 test Mechanical tests
ESAB - GET 2012 Review I 26th July, 2012 Page no 21
EHS
Introduction to EHS Awareness & ESAB group EHS education Non conformity reporting List of legal and other requirements documents
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