STEEL WIRE MANUFACTURING

STEEL WIRE MANUFACTURINGWire drawing is a metalworking process used to reduce the cross-section of a wire by pulling the wire through a single, or series of, drawing die(s)Applications: Tension-loaded structural components Stringed musical instrumentsTypes Cold working At elevated temperaturesPROCESS OF WIRE DRAWINGPicklingThe wire is pulled through the die, its volume remains the same, so as the diameter decreases, the length increases.% of areal reduction

Single block wire drawing machinesA bracket standing up to hold the dieA vertical drum which rotates and by coiling the wire around its surface pulls it through the dieThe wire drum or "block" is provided with means for rapidly coupling or uncoupling The block is also taperedSnatchingContinuous wire drawing machinesA series of dies A block between each dieThe speeds of the blocks are increased successivelyStringing-upIntermediate anneals

Non-circular cross-section drawing

LubricationThe following are different methods of lubrication:Wet drawingDry drawingMetal coatingUltrasonic vibration

Copper sulphate solutionMechanical Properties

The strength-enhancing effectTensile strength can be as high as 3760 MPa

Drawing dies

Tungsten carbideDie angles usually range from 615 OPTIMIZATION OF OPERATIONS IN A STEEL WIRE MANUFACTURING COMPANY

Process flow chart :

The preliminary study at the plant Wire breakages and maintenance resulted in approximately 60% of the total idle time Downtime of any one of the KOCH machines will affect the productivity of BekeartNo specific schedule was prepared for preventive maintenanceThe time consumed and the frequency of each fault was not studiedNo specific task was taken to change or to revise subassemblies or machine members design which are giving trouble periodically.GOAL: NEED TO IMPROVE THE PRODUCTIVITYProductivity can be increased in numerous ways :By reducing the input for the same level of outputBy increasing the output with the same level of inputBy combining bothBy reducing down-time due to -Wire breakages, maintenance, reducing the material input, by using better quality of goods, improved utilization of resources, reduction in working capital

IDLE-TIME ANALYSISShift-to-shift detailed production chart of each machineReasoning for idle time occurrence per shiftWire breakages were basically due to defective raw material, improper pickling and weldingRare problems very high time consumptionRegular problems very less time consumptionDecision variablesThe number of arrivals of the entity at the stores.The number of resources requiredFrequency and time of breakdown maintenance of the KOCH machinesUtilization of the KOCH machines

FINDINGS AND CONCLUSIONSOptimum Lot SizeThe objective was to reduce the blocking of the coils in the processThe optimum arrival quantity 42

ThroughputIncreasing the arrival quantityAdding an extra forkliftVariables DecisionScenarios12345% down,KOCH16.61.45.71.81.6% down,KOCH28.62.68.22.52.5% down,KOCH38.82.88.63.82.9% down,KOCH49.13.19.13.43.0% Utilizationof forklift199.910079.879.980.0% Utilizationof forklift244.543.599.499.599.5Preventive Maintenance

FINDINGS AND CONCLUSIONSPAVANKUMAR D. WADHONKART. Y. PRODROLL NO. 20807066 (PE 03 46)THANK YOU