24-09-2014, 02:40 PM
ABSTRACT The principal objective of this paper is to demonstrate the importance of time saving and achievement of maximum production of product in a given time in industry. This project is about the how the scrap will manage in industry for improve the productivity rate or we say �SCRAP REDUCTION MANAGEMENT IN INDUSTRY� at Bhushan Power & Steel Limited, where I was under training, in which I found the losses which were affecting the company production and give remedies of those losses. Basically in Scrap management I learnt that in industry required lots of raw material, The raw material coming from the various sources should be analyzed as some sources that�s raw material is input medium, after machining the output is come ,with this outcome the scrap is also induced that scrap will minimized in this project. So this project is �how to control the scrap during the input and output�. Firstly Scrap management is of two types �Trimming and end scrap, where trimming scrap is planned scrap and end scrap is unplanned scr
PROJECT REPORT
SCRAP MANAGEMENT
Scrap reduction \ management
There are two types of scraps available:-
· trimming scrap
· end scrap
Trimming scrap is a planned scrap. It is due to in proper operation. Its projected are:-
· reduce scrap
· Increase productivity and yield.
SCRAP YARD
1 Action plan:-
· Formation of sub group area wise.
· Therotitical scrap generation calculation.
· Education plan for workman.
· Suggestion from peoples.
· Evaluation of suggestions.
· Implementation of suggestions.
COILS SCRAP
.2 SCRAPS TARGETS (IN tons):-
SrNo. MACHINE AVG SCRAP TARGET
1 HR SLITTER 1.00 0.85
2 CB LINE 0.30 0.20
3 MILL (403) 0.50 0.45
4 MILL (408) 0.45 0.40
5 CR SLITTER 1 1.00 0.90
6 CR SLITTER 2 0.90 0.80
TOTAL 4.15 3.60
.3. THEROTICAL SCRAP
MACHINE
AVG. WIDTH
SCRAP WT.(KG)
SCRAP %
COIL WT.(MT)
4 HI MILL
485.5
131
1.30
7.5
CR SLITTER 1
501
113
1.00
7.09
CR SLITTER 2
490
111
0.90
6.81
CR SLITTER3
609
118
.80
9
STEEL STRIPS
4 OBSERVATIONS:-
1.1 Raw material
The raw material coming from the various sources must be analyzed as some sources. Give face end cut, some give tail end cut, some give both and some don’t give any sort of cut.
The face end cut is given at front and tail end cut of the coil, this saves a lot of scrap while cutting for example if 1410 mm of coil the comes and 10 mm scrap which is planned by PPC dept. because of machine limitations.
The total scrap amounts to loss. On the other hand if the initial scrap is avoided to large extent as the length which comes is fixed and the finished materials length is not bought to get decreases at the end of the processes, which can lead to entire wastage of coil. This type of analysis will help in checking the scrap at the supplier end.
The planned width which is based on actual width must be controlled in order to decrease the scrap as planned width should remain same at each at stage and every stage.
Storages of width at any stage can lead to the wastage of coil while the process is going on.
Basically in this the PPC dept. is asked stringently to plan the scrap in the coil keeping in view the initial scrap of coil so that the scrap is minimum at the end.
1.2Maximum input coil width:
It should be noted that coil that is planned by PPC dept. should be maximum as possible.
· Mandrel shape to be rectified:
Mandrel edges some times goes blunt and the inside edges of the coil become bent & this would spoilt he shape of coil there by leading to discarding of that particular amount of coil as scrap. The shape of the mandrel can be rectified with the help of hand grinder.
· Leader end & tail rolling with load:
The tail end which is cut from the coil due to its damaged appearance was going wasted as it was not being rolled properly, so it was advised that the cut portion should be welded with the existing coil at the coil build up line so that the length that is welded with the coil is saved from going into scrap.
Actually when the coil is fed in the mill some 2-3 wraps are wasted in jogging & load seating & that much length is not rolled properly. So it is advised that leader and tail end should be rolled with load