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Graduate Engineer Trainee Review - I

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 Production Maintenance Supply Chain Quality EHS

ESAB - GET 2012 Review I 26th July , 2012 Page no 2

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

MSGP SS ESAB - GET 2012 Review I 26th July, 2012

Good Good

Good Coloured bead

Page no 4

Transfer in GMAW; Chem & Mech pad


SPRAY GLOBULAR Spray Globular Pulse
MSGP (Root Gap) 13 mm 16 mm 20 mm

Short Circuiting
SS (Root Gap) 6.5-7 mm 12-13 mm 12-13 mm

Mechanical Pad root gaps for MSGP & SS


Core wire dia 3.15 mm 4.00 mm 5.00 mm

Chemical Pad Pad size used is 50x12x65 mm3


ESAB - GET 2012 Review I 26th July, 2012

Weld deposition of 16 mm is obtained using 3 electrodes.


Page no 5

MECHANICAL AND CHEMICAL TESTS


MECHANICAL Tensile test (Y.S., UTS, %elongation, %reduction area) Impact test (Toughness at low temperatures) Vickers micro hardness (hardness of sample) Ferrite Number (To find amount of ferrite in austenitic SS) CHEMICAL Spectroscopy (To obtain composition of weldment) Humidity & CO2 tester (humidity content & CO2 content) KF moisture testing (moisture content, more precise) Gas equipment (amount of gas evolved)
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Production

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Extrusion process

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Covering Capacity

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Air Drying & Baking


Static ovens LH, LHLA, SS & CC (5 nos.) Continuous ovens - MSGP & LH (3 nos.) HT oven-mostly for LH electrodes like 36H (1 no.) MSGP No air drying, Drying in oven from 60 C to 130 C gradually increasing temperature over pass (continuous oven). For LH 24 hrs air drying. Baking LH 60C(30mins)-120C(30mins)250C(30mins)-400C(60mins)-cooling at 1.58C/min. For LHLA 24 hrs air drying. Baking LA-60C(30mins)120C(30mins)-250C(30mins)-420C(90mins)-cooling at 1.58C/min For SS- 24hrs air drying. Baking SS same as LH except the 400C cycle is for 120mins. For CC-8 hrs air drying. Baking CC-35C-90C(30mins)-cooling at 0.61C/min.
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Process parameters, quality parameters


Area Batching Wet mixing Process Parameters Quality Parameters Effect of PP on QP Dry mixing time Homogeneity of If more, settling of dense particle (30 min) blend powder If less, not proper mixing Amt of silicates Bonding Silicate chilling Bonding Extrusion Extrusion Pr Die block chilling Air Drying Baking Drying time Baking tem Proper coating Good finish If more, moisture in flux(H2) If less, improper bonding Silicate will become hard & wont give proper bonding More, over extrusion Less, under extrusion If not done, s/f finish will be bad.

Crack free elec. If not done, cracks will come at baking Remove moisture Moisture will be source of H2 Lead to Hydrogen cracking
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ESAB - GET 2012 Review I 26th July, 2012

SAWF Process

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SAWF (process parameters & covering capacity)

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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

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Production & downtime of machines

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Supply Chain

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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)

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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.
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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.
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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.

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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
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EHS
Introduction to EHS Awareness & ESAB group EHS education Non conformity reporting List of legal and other requirements documents

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THANK YOU

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