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The plant is the oldest establishment of the company, responsible for the production copper brass products
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Copper Brass Plant
Copper Brass Plant
1.1Introduction
The plant is the oldest establishment of the company, responsible for the production copper brass products.
The product range is extensive, having a large number of OE and Northern products.
The plant follows a batch type manufacturing system.
Most of the components used in the manufacturing process are produced within the plant.
The work force consists of both permanent and contractual workers.
1.2Zones of the Shop Floor
Press Shop: The press shop produces tanks, header plates for copper brass products & header plates for aluminium products. All operations required for producing these components are carried out here, which are blank cutting, drawing, trimming & punching. The press shop has seven press machines, having a capacity range of 10 to 100 tons. The press shop employs 14-17 workers, depending on the demand. All the dies are labeled, colour coded & placed on racks. All the components produced here are heat treated in the stress relieving oven. Inventory is maintained for production period of about five days.
Side frame & Cowl Storage: The side frame and the cowl are outsourced. The numbers of items stored are for a production period of two days. The side frames are stored on racks and the cowls are stored in stacks. The side frame is welded to the main assembly.
Painting and Packing: The painting machine is a dominant feature on the shop floor; it performs drying & painting operations. It has two painting booths and two drying zones. The radiators are attached to a slow moving overhead rail which moves throughout the machine, first through the drying zone then to painting and again through drying. The painted radiators are then fitted with accessories and packed. This zone employs two workers for painting & four to five workers for packing.
Fin and Tube Shop: The fin tube shop produces heat transfer tubes and air fins. It has two square fin machines, one Z fin machine, and one straight fin machine. The pre tinning machine, tube cutting machines & the straight fin machine are located on an elevated platform. A hoist is present for transferring the produce down. The pre tinning machine applies a coating of tin on brass foil, which in turn is machined into heat transfer tubes. The heat transfer tubes produced are washed in the ultrasonic washing machine and stored in bins. The straight fins & part of the heat transfer tubes produced are sent elsewhere for straight fin core assembly. The fin tube shop employs seven to eight workers.
Core Assembly: The core assembly primarily deals with two types of cores, namely the fin& tube type & the straight fin core. The straight fin core is outsourced; the fin & tube type is assembled on three manual jigs. Then the header plates are fitted, fins leveling & combing operations are performed. The core assembly employs four workers.
Core Baking: This work zone is responsible for fluxing and baking of the assembled cores. This zone has one furnace, three flux immersion tanks. The core is immersed in flux; post fluxing the cores are placed on frames and baked for four minutes. The baking zone employs three workers.
Welding shop: The welding shop primarily performs three functions: which are, welding of inlet & outlet pipes to the tank, tank to header plate welding and side frame welding. The pipe welding is performed on four work stations, the header plate-tank welding is done on six workstations, and the side frame welding is done on five workstations. Rework is performed on two workstations. The weld shop employs fourteen workers.
Leak Test: This zone is responsible for hydro testing the welded radiator assembly. The zone has two bays, both having two testing tanks each. The test rig is bolted onto the inlet and outlet pipe of the radiator, subjected to the test pressure and checked for leaks. Faulty radiators are sent for rework. The leak test employs four people.
Maintenance: The maintenance departments responsibility is to ensure the operation of all the machines in the plant. The maintenance department performs preventive as well break down maintenance.
Store: The store stocks all spares, outsourced components and raw materials.
1.3Machines in Each zone
1.3.1Press Shop
Ruby Shearing machine
Cut to length machine
Ultrasonic Washing machine
Stress relieving Oven
Bemco Hydraulic Press
Russell Jewelform 100T Press
Godrej 25T Mechanical Press
Rigimax 25T Mechanical Press
10T Hydraulic Press
Isteco Jewel form 100T Press
Ambika 100T
Ambika 100T Mechanical Press
Number Punching Machine
1.3.2Core Assembly
Vibronics Ultrasonic Washing Machine
Fin and Tube Assembly Jig (3 No.s)
1.3.3Fin and Tube Shop
Pre Tinning Machine
Tube Re Cut Machine (New)
Tube Re Cut Machine (Old)
Straight Fin Machine
Electrical Hoist
Square Fin Machine (2 No.s)
Z Fin Machine
1.3.4 Core Baking & End Dipping Baking Oven
Gas Operated End Dipping Bath (2 No.s)
1.3.5Weld Shop & Painting
Gas Oerated Welding Torch (17 No.s)
Thermax Painting Machine
1.3.6Maintenance Generator 180 KVA ( Caterpillar )
Generator 250 KVA ( Caterpillar )
Compressor 360 360 CFM ( IR )
1.3.7Store
Macneil Fork Lift
Sayaji Electrical Hoist
1.4Machines Specifications
SR NO.Machine DescriptionSpecificationsProduction Capacity/ Shift
1Rigimax 25 T PressCapacity: 25 tons, Press Cushion Capacity: 3. 15 tons, Motor: 2.2 KW, 1500 rpm, 56 Strokes/min3750 pcs
2Jewelform 100 T PressMotor: 20 hp, Power: 2900 KW, Voltage:380/420 V AC, Current: 26 A, Working pressure:140 Kg/cm2.Setup time: 6.5 hrs,25 pcs/hr
3Suresh Seal 25T Press (H.P Trimming)Capacity: 25 tons, Press Cushion Capacity: 3. 15 tons, Motor: 2.2 KW, 1500 rpm, 56 Strokes/min5200 pcs
410 T Hydraulic Press (Fluid Dynamics Pvt Ltd.)Size: 2150mm*1250mm*530mm(h*l*w), Weight:1150 Kg, System Pressure: 199 Kg/cm2, Motor: 5 HP, 1500 rpm, Voltage:415 V AC .1920 pcs
5Godrej 25 T PressCapacity: 25 tons, Press Cushion Capacity: 3. 15 tons, Motor: 2.2 KW, 1500 rpm, 56 Strokes/min2500 pcs
6Pre- Tinning Machine (F.Gustav Siegmund)1 V Belt 1300*13, 2 Receiving rings,10 scrapers of filt,6 Scrappers of Rubber, 20 Coal fins, 8 Heating Elements.-
7Ruby Shearing MachineCapacity:3*610mm, Strokes/min:70
Motor: 2.2 KW, 1440 rpm. -
8Bemco Hydraulic PressMotor:25HP, 1470 rpm, Voltage: 415 V AC.350 pcs
9Vibronics Ultrasonic Washing MachineType VS 2 KW- 2 Stage, Voltage: 230V AC, 16V DC, Current: 3.7 A, Frequency: 22 KHz.-
10Imeco Washing MachinePower:6000W, No. of Chambers:4, Size: 900mm*700mm*400mm(l*b*h), Capacity/tank:252 l, Power Output:3500 W, Voltage:415 V AC.-
11Isteco Jewel form 100T PressMotor: 20 hp, Power: 2900 KW, Voltage:380/420 V AC, Current: 26 A, Working pressure:140 Kg/cm2.Setup time: 6.5 hrs,25 pcs/hr
12Tube Machine Old (F. Gustav Siegmund)Capacity:40 m/min, Cut Lengths: 200- 1000mm&1500mm, Max. Wall Thickness: 0.20 mm,Weight: 1250 Kg.-
13Gas Operated Solder Bath( End Dipping)Voltage:230 V AC, Operating Gas Pressure: 0.5 psi, V-800 naturally aspirated burner.-
14Flameless Stress Relieving FurnaceChamber Size:1300mm*1400mm*1900mm(w*h*l), Trolley size: 1100mm*1100*1800mm, Operating Pressure: 0.5 psi, Max. Temp: 400 C, Working Temperature:250 C, Operation time: 1hr, Voltage: 415 V AC.1400 pcs
15Trimming MachineMotor: 5 HP Induction Motor, 1430 rpm, Air Pressure: 4.5- 5 Kg/cm2400 pcs
1.5Types of Products
1.5.1Straight Fin Type
ESC-440
Eicher S-325
ESC-335
Farmtrac-50
FT-45
Escort Construction
Terex Vectra
ACE (Radiator Assembly)
Bulls Backhoe
TT-55HP
FT1104D-44T
Eicher 5510
New Holland 55
1.5.2Fin & Tube Type
1.5.2.1
Z Fin
TMTL Genset
FT-60
Izuzu Cross Flow
Eicher 9mm
1.5.2.2
Square Fin TT-70
TT-70- FSC
1.6Observations
1.6.1Safety
1.6.1.1
General Observations
Lacks a loud speaker system for emergency announcements.
No dress code. Different jobs should have different uniforms.
Low visibility through out the plant, windows to the right is blocked by the air duct.
Floor Plan is confusing.
Helmets are not in use.
Area under the Fin tube section is a low visibility zone. High visibility jackets should be provided.
Emergency plan hasnt been displayed.
Emergency doors exist, but are blocked.
Emergency equipment is sparsely located. Places of worship are present but no safety equipment.
Rubber mats are not present in the press shop. Card board has been used instead.
No safety briefing given to me, a new employee.
The air circulation system is not adequate.
Most machines have an emergency kill switch.
Both entry and exit of the plant are located at the far ends of the factory, no exits in near the center of the shop floor.
1.6.1.2
Machine Specific Observations
Slippery surface near the baking furnace.
Exposed motor belts above the furnace,located right under the fin tube shop.
Hoist alarm is not loud enough.
Proper gas masks for the workers in the painting booth are required.
Gas masks and safety glasses not in use, the worker working on the furnace, washing machine, welding need to wear safety equipment. All these work stations are potential hazard zones due the presence of hot gases, chemicals and toxic fumes.
Worker at the End Dipping station needs a mask; currently using a piece of cloth, the hot solder emits fumes.
Better fitting gloves should be provided to workers at the furnace.
Some of the machines are leaking hydraulic fluid. Slippery surface around these presses has been covered by card boards.
Godrej 25 T doesnt have an emergency stop button.
Old fin cutting machines have exposed moving parts.
The pre tinning machine emits fumes, the operator should use a mask.
1.6.2Ergonomics
A short study of man machine relations.
1.6.2.1
General Observations
Most of the tasks performed on the shop floor require the operator to stand.
Task of the operator is to operate the designated machine, visually inspect the input and the output.
The working conditions with respect to productivity as well as ease of operation are different in different sections of the shop floor.
Most of the machines have been provided with the necessary auxiliary systems so as to enable the operator to work efficiently.
1.6.2.2
Machine Specific Observations
Operations such as tank welding , painting , core assembly ,baking, pre tinning, tube cutting, tube washing, end dipping, annealing, air leak testing require the person to operate the machine in an erect position.
The press shop work can be performed while sitting on a high rotating stool, given that the input material & output bins are located in the correct location.
Some of the press shop workers do have stools for easy and efficient operation of the machines.
The tools and dies are located on racks near the machine, all the tools, dies have been coded for easy identification, and proper lifting mechanism is also provided.
The CTL machine is easy to operate, but the operator could use a stool.
The straight fin core assembly section feeds the baking furnace, the assembly is done at one end of the furnace, the worker working on the other end has to carry the core from this location to the flux bath and then to the furnace. This setup makes it hard for the operators to work to their maximum efficiency.
The welding station basically performs three operations, welding of necks and tubes to the tank, welding the tanks to the core and welding the side frame to the radiator assembly. All these jobs are done in an erect posture. The workstation is located in a well lit area of the plant, fans are also provided. The fixtures provided for welding are swiveling for all direction access to the radiator assembly. The flux is located in tray next to the worker; the welding filler lead is conveniently located either in roll or cylindrical container.
The test tank area has two tanks, and receives welded the radiators from one end. As the radiators are heavy the operation becomes a difficult task for the worker working at the second bay. Also the person working at the second bay is old. Otherwise, the workstation is effective, the gauges and the test equipment is easy to read and operate.
Painting booth has been equipped with auxiliary lighting, a small fan; the painting booth is not crammed and allows free movement of the radiator as well as the painter.
The finished radiators arrive on conveyor belt which makes it easy to add the caps and covers to the finished product, the belt moves at suitable speed i.e in sync with the time taken to perform the finishing operations. The product is the packed in card board box with thermacol packing and loaded onto push carts.
1.7Process Flow Chart
The various operations involved in the production were studied, the result is the following process flow chart.
SHAPE
Aluminium Plant
2.1Introduction
The aluminium plant is responsible for the production of a wide range of heat exchangers cores.
It is relatively a new establishment. The machinery in the plant is modern.
Various types of heat exchangers cores are manufactured in this plant. These are radiators, air coolers, combi coolers, oil coolers & inter coolers.
It also follows a batch type production system.
The workforce is employed on a contract basis.
2.2Zones of the Shop Floor
Component Production Zone: This zone produces the components required for the products. The various components produced are short bar, long bar, separator sheet, heat transfer tubes, air fins, oil fins. All of the machines require one operator each. The operations performed in this work zone are cutting, shearing, fin forming, slitting, deburring and washing. The inventory level is maintained for a production period of one day. This zone employs eight workers.
Core Assembly: This zone assembles the cores of basically three type of heat exchangers, namely plastic tank radiators , charged air coolers and plate & bar type hear exchangers. The various operations performed in this work zone are core assembly, leveling, fluxing, tube flaring and brazing. This work zone employs fifteen workers.
2.3Machines in Each Zone
2.3.1Component Production Zone
Kawa Shearing Machine
10.2 mm Fin Forming Machine
Sahyog Bar Cutting Machine
Ramani Tube Re Cut Machine
Slitting Machine
Oil Fin Cutting Machine ( 8 pitch )
Square Fin Machine
Paint Flux Conveyor
Component Washing Master Handler
2.3.2Core Assembly
Plate & Bar Jig ( 3 No.s )
Sellecan Brazing Furnace
Drying Oven
Spray Fluxing Machine
PTR Header Setter ( 3 No.s )
9mm Ecko Fin Machine
7.55mm Ecko Fin Machine
Square Fin Machine
Oil Fin Cutting Machine
Tube Flaring Machine
CAC Header Jig ( 2 No.s )
2.4 Machine Specifications
SR NoMachine DescriptionSpecificationsProduction capacity/Shift
1Sahyog Bar Cutting MachineMotor:1.5 HP, 1440 rpm, Carbide saw, Speed:35mm/min, Max spindle speed:2100rpmShort Bar:
3000 pcs, Long Bar: 1500pcs.
210.2 mm Fin MachineMax fin Width:140mm,Cutting speed:25-30 m/min,Max coil diameter:1200mm, Min coil diameter: 300mm-
3Ecko 9mm fin Machine.Size: 1352mm*660.4mm*1651mm(l*w*h),Material width range:12.7mm to114.3mm, FPI:6- 25 fpi, Input speed: upto 500ft/min, Motor:2 HP, Voltage:240 V AC.-
4Kawa Shearing MachineSize: 2000mm*2000mm*1400mm(l*w*h) , Motor: 2 HP, 1400 rpm, Voltage 400/440 V AC.1800 pcs
5Ramani Tube Re Cut MachineLoading Height 1300mm, Operating Pressure: 6Kg/cm2, Power: 0.5 KW, Voltage: 415 V AC, 24 V DC.5000 pcs
6PTR Head Setter
(3 no.s)Pneumatic, Accepted Core Length: 400-500mm, Core width:400-500mm, Core thickness: 28-48mm, Fin width: 28,48,49.120 cores
7Paint Flux Machine (Ramani Automation)Sheet size: 40-220 mm, Sheet thickness: 0.8-1.6mm, Width of Spray zone: 600mm, Power: 10 KW, Operation Temperature:120-150 C, Voltage: 415 V AC.57mm sheet: 4000 pcs
8CAC Assembly Jig
( 2 no.s)Manual operation.140 cores
2.5Types of Products
2.5.1PTR (Plastic Tank Radiators)
E 440
(9mm Louvered Z Fin)
NH 55
(7.55mm 14 Square Wavy)
Piaggio
(7.55mm Louvered Z Fin)
Swaraj Mazda
(7.55mm Louvered Z Fin)
2.5.2P&B (Plate and Bar)
Bulls
(10.2mm, Non Louvered Z Fin)
KPCL 57
(10.2mm Louvered Z Fin)
Axxiom 30KW
(10.2mm Louvered Z Fin)
IR 11KW
(7.55mm Louvered Z Fin)
IR 22 KW
(7.55mm Louvered Z Fin)
IR 37KW
(10.2mm Louvered Z Fin)
Cumitas HOC
(10.2mm, Non Louvered Z Fin)
HP 140
(7.55mm 14 Square Wavy)
Elgie 45
(10.2mm Louvered Z Fin)
2.5.3CAC ( Charge Air Cooler )
Eicher 483
(9mm, Louvered Z Fin)
Eicher 683
(9mm, Louvered Z Fin)
Avtec
(9mm, Louvered Z Fin)
2.6Observations
2.6.1Safety
2.6.1.1
General Observations
Visibility is good.
Floor plan is clearly marked out.
All the machines and equipment are in their respective locations.
Lack of loud speaker system, fire alarm etc.
No marked out evacuation plan.
Emergency exits are not present.
Fire fighting equipment is not adequate.
The space between the degreasing machine and the wall may be an issue in an emergency.
Exhaust fans are effective in dispelling gases produced by the drying oven.
The Nitrogen tank has been properly secured outside with proper fencing.
The portion of the building housing the RO plant is crammed, might be problem area in case of an emergency.
2.6.1.2
Machine Specific Observations
10mm Fin forming machine: external cover is present, but moving gears are exposed.
Control panels for most machines are suitably located suitably located for both operation & emergency.
Some work areas need to have a mat for better grip.(10mm fin machine, Bar cutting machine)
The equipment is well designed
Flux machines produce particulate matter, operators should wear masks.
The shearing machine needs better lighting.
The PTR jigs retract back their original position in the case of power loss, operators hand might get injured.
The Nitrogen tank has been secured properly.
2.6.2Ergonomics
2.6.2.1
Machine Specific Observations
Almost all operations are performed in an erect position.
Fin forming: There a total of six fin forming machine, all of them are linear in operation; the operator has to visually inspect the fin for defects. All the machines are easy to operate. The control panel is located at suitable height so that operator of any size can operate the machine without discomfort. The 9mm Ecko fin machine and the CAC assembly line behaves as a small cellular manufacturing system. Such a sequence in operation results in higher productivity in this line.
Tube re cut machine: The input material, control unit are suitably placed, the output is delivered to the box automatically, and no inspection is required.
Core Assembly jigs: The operator is required to stand to perform the job, the input materials are located in bins on both sides of the machine, and adequate light is present. The assembly of the cores is efficiently achieved with minimum loss of energy.
Par and Bar type leveling station: Lighting is essential for this job, workers require more lighting to perform their jobs efficiently, also the work space requires have better tooling solutions
Paint Flux Station: This machine is operated by two workers, location of the machine leads to rise in particulate matter when door next to machine is opened,
Brazing furnace: This machine requires the operator to load the machine and start the brazing operation, the process take a long time during which the person can perform other jobs.
PTR tube flaring station requires better tooling solutions
2.7Process Flow Chart
The various operations involved in the production were studied, the result is the following process flow charts.
Charge Air Cooler
Plastic Tank Radiator
Plate & Bar Type
SHAPE
SHAPE
SHAPE
Wigman Center & Laboratory
3.1Introduction
The Wigman center is responsible for the finishing operations on the heat exchanger cores produced by the aluminium plant.
It is relatively new establishment.
Tanks for all aluminium cores are welded in this establishment.
All new products and prototypes of prospective products are tested in the lab.
The establishment has modern TIG welding machines.
All heat exchangers produced are sent for powder coating to another company.
3.2Zones of the Shop Floor
Fin & Tube Shop/CAC Shop: The fin & tube shop is responsible for welding of tanks to the CAC cores. The tanks are outsourced; they undergo stress relieving and hydro testing before they are welded to the core. The various operations performed in this zone are cleaning, welding, inspection and packing. Welding is performed on four workstations. This work zone employs nine workers.
Plate & Bar Shop: The plate & bar shop is responsible for welding of C channel tanks to cores. The tanks are cut from C section channels, inlet-outlet holes are drilled at the development center. The operations performed here are welding, grinding, brushing, inspection and packing. This work zone employs nine workers.
Plastic Tank Radiator Shop: The PTR Shop is responsible for the fitting of plastic tanks to the fin and tube type radiators. The plastic tanks are outsourced. The operations performed in this work zone are pipe fitting, clinching, crimping, side frame fitting, accessory fitting, dry testing and packing. The PTR shop employs ten workers.
Laboratory: All new products and prototypes undergo various tests at the laboratory. The tests are heat dissipation test, vibration test, thermal cycle test, corrosion test, internal cleanliness test and hydraulic pressure test.
3.3 Machines on the Shop Floor
Kemppi TIG Welding Machine (8 No.s)
Dry leak Test Machine (2 No.s)
Top Crimping Machine
Hot Water Generator
Thermic Fluid Heater
Combined Vibration & Pulsation Test Rig
Thermal Cycle Test Rig
Hydraulic Test Machine
Electro Dynamic Vibration Shaker
Corrosion Test Chamber
Internal Corrosion Test
Tensometer
Hydro Test tanks (3 No.s) and Hoist.
3.4Machine Specifications
SR No.Machine DescriptionSpecification
1Kemppi 3500W TIG Welding Machine.Voltage: 400 V AC, Rated Power: 60% ED: 350A/11.7KVA, 100% ED 280A, Open Circuit Voltage: 70 V DC, Power: 18 W, Efficiency: 80% (350A/34V), Size: 690mm*260mm*870mm(l*w*h), Weight: 74 Kg, Max Pressure of Cooling Unit: 350 Kpa.
2Electro Dynamics Vibration ShakerVibration: Sine, sweep & random, Rated force: 1500 Kgf , Acceleration: 10g, Rated displacement: 35mm, Velocity: Upto1.5 m/sec, Frequency range: 5Hz to 3 KHz, Payload capacity: 300 Kg, 3D vibrations.
3 Hydraulic Pressure TestHydraulic Pressure: Upto 100 Kg/cm2, Fluid flow: Upto 10 lpm.
4External Corrosion Resistance TestSolution temperature: Ambient to 45-55 C, Air pressure: Upto 4 Kg/cm2, Fog rate: 10-20 Ml/hr per 80 cm2,Solution Type: Salt solution spray test( 5 % NaCl soln prepared in D.M water), Agricultural fertilizer test( 5% fertilizer soln in D.M water), SWAAT( 42g of synthetic sea salt + 10 ml of glacial acetic acid/l).
5Vibration TestAcceleration: 3g fixed, Amplitude: 3mm fixed, Frequency: Upto 16 Hz, Direction: Vertical, Max. payload: 20 Kg.
6Combined Vibration & Pressure Pulsation TestVibration Test (Acceleration: 3g max, Amplitude: 5mm max, Frequency: Upto to 25 Hz, Direction: Vertical, Max payload: 15 Kg.), Pressure Pulsation Test( Fluid Pressure: Upto to 2.0 bar, Fluid Temperature: Upto to 130 C, Frequency: Upto 25 CPM.
7Thermal Cycle TestCold fluid temperature: min 5 C, Hot fluid tempearature: max 130 C, Chamber temperature: 17-23 C, Cycle time: Computer control on spray time.
8Heat Dissipation TestAir Velocity: 1- 30 m/s, Coolant flow: 1.5-223 l/m, Coolant heating capacity 130C, Oil flow: 2-225 l/m, Oil Heating Capacity: 55 C, Test Range (size): 100*100mm to 1350*1350mm
3.5Observations3.5.1Safety
Work area is well marked out.
Lighting is good.
Lack of loud speaker system, fire alarm etc.
All the machines and equipment are in their respective locations.
Curtains have been provided for all welding stations. All workers use shields.
Fire fighting equipment is sparsely located.
No emergency exits or plans.
No uniforms.
Only one entry and one exit, both located at ends of the shop floor. Also, the exit doesnt lead to an open area.
3.5.2Ergonomics
All the operations performed here need the worker to be in an erect position.
TIG welding station: The operator has been provided with all the necessary equipment to enable him to work efficiently.
PTR assembly: Plastic tanks are provided next to the machine, the brazed core a conveniently located on a pallet, bolt guns, bolts, o rings etc are located in trays. Everything is organized and labeled.
The inspection and packing area is also well chalked out, the gauges are easy to read, and all the packing requirements have been provided. Packed good are placed onto a pallet next to the workstation.
Development Center
4.1
Introduction
The Development Center is responsible for the development of new machines, machining of tools & dies and other machining for maintenance purposes.
It is old part of the factory.
It has both new and old machinery.
Most of the workers are permanent employees of the company.
4.2Machines on the Shop Floor
HMT Surface Grinder
Surface Grinder
Lathe Machine
HMT Milling Machine
Shaping Machine
Power Hacksaw Machine
C Channel Cutting Machine
Radial Drilling Machine
Accumax Drilling Machine
4.3Machine Specification
SR NO.Machine DescriptionSpecification
1Surface Grinding Machine(small)Size:46*9(l*w), Working surface: 18*9, Motor: 1 HP, Spindle speed: 2800 rpm, Working pressure: 120psi, Longitudinal traverse: 19, Cross traverse: 7, Head Traverse: 11.
2Milling Machine(HMT)Main motor: 7.4 HP/5.5 KW, Rapid traverse motor: 2.0 HP/1.5 KW, Coolant pump motor: 0.13 HP/0.1KW, Spindle speeds: 68-1270, Max. payload: 315 Kg, Weight: 2900 Kg., Size: 2300mm*2000mm*1850mm(l*w*h)
3Accumax Drilling MachineDrill motor: 5 KW, Elevating motor: 0.55 KW, Coolant motor: 0.12 KW, Size: 1285mm*1880mm*1925mm(w*d*h)
4Kirloskar Hacksaw MachineMotor: 1 HP, 7200 RPM, Voltage: 400/440 V AC.
5Surface Grinding Machine(HMT)Grinding motor: 5.7 HP, 720 RPM, Speed: 2880 RPM, Max traverse of grinding wheel: 320mm, Longitudinal traverse: 1150mm, Grinding length: 1000mm.
4.4Observations
4.4.1Safety
Visibility is good.
Floor plan is clearly marked out.
All the machines and equipment are in their respective locations.
Lack of loud speaker system, fire alarm etc.
No marked out evacuation plan.
Fire fighting equipment is not adequate.
4.4.2Ergonomics
Machining is the primary operation of this work space, hence upright position is necessary to perform the job.
Platforms have been constructed for better visibility and access, stools are also available.
All the machines and tools are labeled for easy identification.
Equipment to lift and place the raw material has been provided.
Raw Material Storage
Raw Material Storage
Raw Material Storage
Storage
Fin Forming
Fin Forming
Blank Cutting
Blank Cutting
Outsourced Straight Fin Core
Drawing
Trimming
Hole punch
Pipe Seat Dimple Forming
1st Forming
Logo Embossing
2nd Forming
Trimming
Slot Punching
Stress Relieving
Fin Leveling & Combing
Stiffener Insertion
Core Fluxing & Baking
End Dipping
Tank, Side Frame Welding
Core Assembly
Air Fin
Z & Square
Air Fin
Straight Fin
Tank
Header Plate
Protection Cap & Packing
Copper Brass Plant
Inspection
Stress Relieving
Inspection
Temporary Storage
Header Plate Fitting
Raw Material Storage
Pre Tinning
Tube Forming
Tube
Washing
Temporary Storage
Gauging
Pipe Welding
Leak Test
Not OK
Rework
Leak Test
Not OK
Radiator Drying, PRC Application & Painting.
OK
Accessory Fitting
OK
Visual Inspection
Packing
Rejection
Raw Material Storage
Radiator Drying, PRC Application & Painting.
Raw Material Storage
Raw Material Storage
Storage
Raw Material Storage
Storage
Storage
Fin Forming
Washing
Tank Periphery Cleaning
Blank Cutting
Drying
Washing
Corner Cutting
Drying
Forming
Punching
Washing
Drying
Fluxing
Degreasing & Drying
Brazing
Tank Fitting
HP to Tank Welding
Core Assembly
Leak Test
Leak Test
Rework
Rejection
Accessory Fitting
Visual Inspection
Packing
Air Fin
Tube
End Plate
Header Plate
Tanks
Protection Cap & Packing
Charge Air Cooler
OK
Not OK
OK
Not OK
Header Plate Fitting
Washing
Inspection
Raw Material Storage
Raw Material Storage
Raw Material Storage
Raw Material Storage
Raw Material Storage
Raw Material Storage
Fin Forming
Fin Degreasing
Bar Cutting &
Deburring
Bar Washing
Fin Forming
Fin Degreasing
Bar Cutting & Deburring
Bar Washing
Sheet Cutting & Deburring
Sheet Washing
Drying
Sheet Cutting & Deburring
Sheet Washing
Drying
Core Assembly
Material Storage
Clamping
Leveling
Brazing
Visual Inspection
TIG Welding
Rework
Packing
Air Fins
Oil Fins
Long Bar
Short Bar
Separator Sheet
End Plate
Tank
Leak Test
Leak Test
OK
Not OK
OK
Not OK
Plate and Bar Type
Fluxing
Raw Material Storage
Raw Material Storage
Storage
Raw Material Storage
Storage
Storage
Fin Forming
Washing
Blank Cutting
Drying
Washing
Corner Cutting
Drying
Forming
Punching
Washing
Drying
Fluxing
Degreasing & Drying
Brazing
Gasket Fitting
Tank Crimping
Core Assembly
Leak Test
Leak Test
Rework
Rejection
Accessory Fitting
Visual Inspection
Packing
Air Fin
Tube
End Plate
Header Plate
Plastic Tank, Rubber Gasket
Protection Cap & Packing
Plastic Tank Radiator
OK
Not OK
OK
Not OK
Header Plate Fitting
Inspection
Recommended