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OPTIMIZATION OF MATERIAL HANDLING IN ROOF
SHEET ASSEMBLY FOR RAILWAY COACHES
A PROJECT REPORT
Submitted By
ABINESH MARAN. T 20061401
VASANTHI. R 20061436
VENKATRAJ. N 20061438
VIGNESH. M 20061439
in partial fulfillment for the award of the degree
of
BACHELOR OF ENGINEERING
in
MANUFACTURING ENGINEERING
DEPARTMENT OF MANUFACTURING ENGINEERING
COLLEGE OF ENGINEERING, GUINDY
ANNA UNIVERSITY CHENNAI::CHENNAI 600 025
MAY 2010
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ANNA UNIVERSITY CHENNAI::CHENNAI 600 025
BONAFIDE CERTIFICATE
Certified that this project report on OPTIMIZATION OF MATERIAL
HANDLING IN ROOF SHEET ASSEMBLYFOR RAILWAY COACHES
is the bonafide work of
ABINESH MARAN. T 20061401
VASANTHI. R 20061436
VENKATRAJ. N 20061438
VIGNESH. M 20061439
who carried out the project work under my supervision.
Dr.T.V.MOORTHY Dr. M. OMKUMAR
PROFESSOR AND HEAD SENIOR LECTURER
Department of Manufacturing Engg. Department of Manufacturing Engg.
College of Engineering, Guindy College of Engineering, Guindy
Anna University Chennai Anna University Chennai
Chennai 600025 Chennai 600025
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ABSTRACT
Degree : Bachelor of Engineering
Branch : Manufacturing Engineering
Month and year of submission : May 2010
Course : MN483 Project Work
Title of the project : Optimization of Material Handling in roof
sheet assembly for Railway coaches
Name of the students : Abinesh Maran. T 20061401
Vasanthi. R 20061436
Venkatraj. N 20061438
Vignesh. M 20061439
Name and Designation of guide : Dr. M.Omkumar
Senior Lecturer,
Dept. Of Manufacturing Engineering,
College Of Engineering, Guindy
Anna University, Chennai
Chennai 600 025
The topic deliberated here mainly deals with the optimization of the production
process at the Integral Coach Factory, Chennai. The crux of the topic here is that
the amount of material handled in the shop floor is generally 9 times more than that
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is actually used to produce the final product. Hence this project is aimed at
reducing the work in progress inventory to the least. Also, to device a method to
store the work in progress inventory (steel sheets). This project includes optimizing
algorithms, facility planning for efficient production and systematic study on
various storage techniques for steel sheets to finally zero in on the most
economical way of storage not compromising on quality and safety, therefore
helping the organization in increasing the productivity, reducing the cost and
reducing scrap in the form of rust.
Date:
Place: Chennai
ABINESH MARAN. T
20061401
VASANTHI. R
20061436
VENKATRAJ. N
20061438
VIGNESH. M
20061439
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ACKNOWLEDGEMENT
We would like to sincerely thank Dr.M.OMKUMAR, senior
lecturer , Department of Manufacturing Engineering for his invaluable guidance,
support, encouragement and keen interest, which helped us in the successful
completion of our project.
We wish to thank Dr.T.V.MOORTHY, professor and head,
Department of Manufacturing Engineering, for providing support towards the
completion of the project.
We solemnly thankDr.S.GOWRI, Professor, project coordinator and
Mr.G.SHAKTHINATHAN, Lecturer, Department of Manufacturing Engineering,
for their valuable suggestions.
We are very much thankful to Mr.RAMAKRISHNAN, sectional
engineer, ICF, for his immense care and guidance from the start of the project and
till the completion of it.
We also wish to express our hearty thanks to all the faculty members
of Department of Manufacturing Engineering for their time being help and
encouragements towards the successful completion of our project.
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TABLE OF CONTENTS
CHAPTER NO. TITLE PAGE NO.
ABSTRACT iii
LIST OF FIGURES ix
LIST OF TABLE x
1. INTRODUCTION1.1 Integral Coach Factory- A Short Presentation 1
2. CRUX OF THE CONUNDRUM
2.1 Current Scenario 2
2.2 Problems
2.3 Objective of the Project
2.4 Aim of the Project
3. OPTIMIZATION OF PLANT LAYOUT
3.1 Plant layout
3.2 Objective of Plant Layout
3.3 Factors Affecting Plant Layout
3.4 Types of Plant Layout and Function
3.4.1 Process Layout
3.4.2 Product Layout
3.4.3 Combination Layout
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3.4.4 Fixed Position Layout
3.4.5 Cell Layout
3.5 Procedure for Design of Plant Layout
3.6 Process Flow
4 AUTOMATED LAYOUT DESIGN PROGRAM
4.1 Relationship Chart
4.2 Steps of ALDEP
4.3 Data Collected
4.4 Relationship Chart for Data collected
4.5 Filling The Cells
5 MATERIAL HANDLING
5.1 Material Handling Equipment
5.1.1 Transport Equipment
5.1.2 Positioning Equipment
5.1.3 Unit Load Formation Equipment
5.1.4 Storage Equipment
5.1.5 Identification and Control Equipment
5.2 Principles of MHE
5.3 Automatic Guided Vehicles
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5.3.1 Navigation
5.3.2 Wired Sensor
5.3.3 Guide Tape
5.3.4 Steering Control
5.3.5 Path Decision
5.3.6 Frequency Select Mode
5.3.7 Path Select Mode
5.3.8 Magnetic Tape Mode
5.3.9 Vehicle Types
5.3.10 Common AGV Applications
6 GALVINIZING PROCESS
6.1 Types of Surface Protection
6.2 Elements of Galvinizing Process
6.2.1 Surface Prepartion
6.2.2 Galvinizing
6.2.3 Inspection
6.3 Benefits of Galvinizing Process
7 CONCLUSION
REFERENCE
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LIST OF FIGURES
FIGURE No. TITLE PAGE No.
2.1 Stack of materials
2.2 Assembly fixture
4.1 Existing layout
4.2 Proposed machine cell layout
5.1 Transport equipment
5.2 AGV moving in shop floor
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LIST OF TABLES
TABLE No. TITLE PAGE No.
2.1 Assembly time
4.1 Closeness value
4.2 Area of each machine cell
4.3 Relationship chart
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CHAPTER 1
INTRODUCTION
1.1 INTEGRAL COACH FACTORY: A SHORT PRESENTATION
Started in 1952, the Integral Coach Factory (ICF) is located in suburbs of Chennai,
India. Its primary products are rail coaches. Most of the coaches manufactured are supplied to the
Indian Railways, but it has also manufactured coaches for railway companies in other countries,
including Thailand, Burma, Taiwan, Zambia, Philippines, Tanzania, Uganda, Vietnam, Nigeria,
Mozambique and Bangladesh. Recently, ICF exports coaches to Angola and Sri Lanka. The coach
factory provides a number of different coaches primarily for the Indian Railways, primarily first
and second class coaches, pantry and kitchen cars, luggage and brake vans, self propelled
coaches, electric, diesel and mainline electric multiple units (EMU, DMU, MEMU), metro
coaches and Diesel Electric Tower Cars (DETC), Accident Relief Medical Vans (ARMV),
Inspection Cars (RA), Fuel Test Cars, Track Recording Cars, the latest coaches are for the Deccan
Odyssey (a luxury train of the Indian Railways), and coaches for MRVC (world class coaches).
An organization of such a potential is only able to make a profit of approximately Rs.
20,00,000 a year. This is mainly because of huge work-in-progress (WIP) inventories and huge
loss due to scrap caused by corrosion of the sheet metals. Thus need of the hour is to prevent the
above two problems as far as possible.
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CHAPTER 2
CRUX OF THE CONUNDRUM
2.1 CURRENT SCENARIO
It takes three shifts to produce the roof for one bogie. The roof is totally made of 7 sets of
sheet metal and each set contains 3 sheet metals profiled and welded together. A deeper
investigation reveals that the roof sheet assembly requires not only the sheets but a skeleton to
provide structure to it and an L stiffener and U stiffener for support and strength. Hence the
skeleton assembly alone takes one full shift and the grinding and hammering of the final
assembly requires another shift, which leaves the roof sheet assembly with only a shift.
In the single shift the sheet metal must be straightened, cut to length, bent to the required
profile, seam welded, bent at the edges and with all this process it must be routed to various
machines and if anyone of the machines is not in a state to process the WIP inventory then it
piles up quiet next to the machine causing the material to get exposed to the environmental
conditions leading to corrosion as shown in fig 2.1.
Fig 2.1 Stack of materials
Another problem is that work in process is not routed progressively, which means the
machines required for processing are not sequentially placed that leads to multiple transactions of
the same material back and forth. Hence there is a huge loss of time in this process. So, the
Overall production rate is 1400 coaches per year. The number of shifts taken, hrs per shift and the
number of laborers for different types of coaches is given in table 2.1.
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Type of coach Hrs per shift No. of shifts No. of laborers
BG 6.7 3 10
SCN 7.0 3 10
SLR 7.2 3 10
DC/DMU 7.5 3 10
Table 2.1 Assembly time
The following calculation quantifies the above:
Consider BG (Broad Gauge):
No. of sheets required = 7*3 = 21
Total hrs = 20.1
Laborers: 4 fitters and 6 welders
20.1hrs distributed for structure building, handling, and welding, hammering and finishing
operations.
The above quantification is only for the assembly and prior to each part of the assembly, the
respective forming and fabrication must be done within the scheduled time. The assembly fixture
for the roof sheet is shown in fig 2.2.
Fig 2.2 Assembly fixture
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2.2 PROBLEMS
The efficiency of material handling system at present, in the existing shop floor layout is
less than 10% i.e., the material handled is nine times the material being processed. A lot of human
effort is being exploited in the handling of the WIP. This leads to huge lead times and at a point of
time either the machine or the WIP is Idle within the shop floor.
2.3 OBJECTIVE OF THE PROJECT
The main aim of this project is to optimize the material handling by reducing the number
of trips in which the material is being handled. Also to suggest a method to protect the Work-in-
Progress (WIP) inventory from getting corroded. Finally reducing the lead time in the production
process and increasing the productivity.
2.4 AIM OF THE PROJECT
To increasethe rate of production. This can be achieved by reducing the WIP which
in turn is brought about by optimizing the process layout.
To reduce the number of accidentswhich is possible by devising a proper material
handling equipment which carries the material from the start till the end progressively
and reducing the manual handling
To reducethe level of inventories.
To reducethe overall material handling time.
Implement a newmaterial handling systemfor hand ling roof sheets.
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2.5 SUMMARY
This chapter explains the current existing scenario in the shop floor for the manufacture of roof
sheets and also lists out the various problems faced by the workers, both directly as well as
indirectly during the manufacturing process. The main aim and objective of this project is also
discussed in detail in this chapter.
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CHAPTER 3
OPTIMIZATION OF PLANT LAYOUT
3.1 PLANT LAYOUT
Plant Layout means the physical arrangement of the various Industrial facilities
(equipment, material, manpower, etc.) within the plant. This arrangement includes the spaces
needed for material movement, storage, indirect laborers and all other supporting activities or
services as well as operating equipment and Personnel. Plant Layout is the basis of industrial
activity since it determines the efficiency. Generally what is being achieved is arrangement of
work areas and equipment which is the most economical and at the same time safe and satisfying
employees.
Plant Layout is concerned with the analysis, planning, and design of the physical facilities
utilized in the production of goods and services. Material Handling deals with that phase of the
operations which involves the movements of the material used in carrying on the activities of the
enterprises. No two aspects of industrial activity are more closely related. Actually, Material
Handling is a Major part of nearly all Plant Layout work. This close relationship is emphasized in
the following definition of Plant Layout:
Plant Layout may be defined as planning and integrating the paths of the component
parts of a product to obtain the most effective and economical inter relationships between
men, equipment and the movement of material from receiving, through fabrication, to the
shipment of the finished product, (H.A.HARDING, 1997).
Plant layout planning includes decisions regarding the physical allocation of the economic
activity centers in a facility. An economic activity center is any entity occupying space. The
objective of plant layout planning is a more effective work flow at the facility, allowing workers
and equipment being more productive. Facility layout techniques apply to the case where several
physical means have to be located in a certain area, either industrial processes or services. The
objective of the chapter is not only plant layout but re-layout also (most common situation for a
company). To carry out an appropriate plant layout, its important to take into account the
business strategic and tactical objectives. Example: space requirements / cost per m2 in Malls;
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accessibility/ privacy in offices. To make a decision about layout planning, 4 different questions
must have an answer:
Which centers do we have to consider?
How much space and capacity is required for each center?
If there is not enough space, productivity may be reduced.
Too much space is expensive and may also reduce productivity.
How must the space be configured at each center?
Space quantity, shape and the elements of the work center are related
to each other.
Where should each center be located at within the facility?
The allocation of the different centers may affect productivity.
The plant layout process starts at an aggregate level, taking into account the different
departments. As soon as we get into the details, the different issues arise, ant the original
configuration may be changed through a feedback process. Most (if not all of them) layouts are
designed properly for the initial conditions of the business, although as long as the company
grows and has to be adapted to internal and external changes, a re-layout is necessary.
The reasons for a re-layout are based on 3 types of changes:
Changes in production volumes
Changes in processes and technology
Changes in the product
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3.2OBJECTIVES OF PLANT LAYOUTThese main objectives are reached through the attainment of the following facts:
Congestion reduction
Elimination of unnecessary occupied areas
Reduction of administrative and indirect work
Improvement on control and supervision
Better adjustment to changing conditions
Better utilization of the workforce, equipment and services
Reduction of material handling activities and stock in process
Reduction on parts and quality risks
Reduction on health risks and increase on workers safety
Moral and workers satisfaction increase
Reduction on delays and manufacturing time, as well as increase in production capacity
All these factors will not be reached simultaneously, so the best solution will be a balance
among them.
3.3FACTORS AFFECTING PLANT LAYOUTThe final solution for a plant layout has to take into account a balance among the
characteristics and considerations of all factors affecting plant layout, in order to get the
maximum advantages.
The factors affecting plant layout can be grouped into 8 categories:
Materials
Machinery
Labor
Material handling
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Waiting time
Auxiliary services
The building
Future changes
3.4 TYPES OF PLANT LAYOUT AND FUNCTION
There are five different types of plant layouts each serving a particular purpose and has its own
advantages as explained below.
3.4.1 PROCESS LAYOUT OR FUNCTIONAL LAYOUTIt is characterized by keeping similar machine or similar operations at one location
(Place). In other words, all lathes will be at one place, all milling machine at another and so on
that is machine are to be arranged according to their function. Process layout for two products is
shown in the fig 3.1. This type of layout is generally employed for industries engaged in job order
production and non-repetitive kind of maintenance or manufacturing activities.
Drilling Planning Grinding
(1) (2) (5) (5)
(2) (3)
Milling Welding Assembly
(1)
(3) (4) (4) (6) (6)
Product A:
Product B:
Fig 3.1 Process Layout
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Advantages of Process Layout
1) Better Machine utilization allows lower investment on equipment.
2) It is better to maintain continuity of production in event of
(a) Machine breakdown
(b) Storage of Raw material
(c) Absence of workers
3) It comes up with varying production schedules.
4) It is adopted to a variety of products and to frequent changes in sequence of operations.
3.4.2 PRODUCT LAYOUT OR LINE TYPE LAYOUT
It implies that various operations on a product are performed in a sequence and the
machines are placed along the product flow line, i.e., machines are arranged in the sequence in
which a given product will be operated upon. This type of layout is preferred for continuous
production, i.e. involving a continuous flow of in-process material towards the finishing product
stage. A line layout for two products is given below in fig 3.2.
Lathe Drill Grinder Assembly Paint shop
Product A (1) (2) (3) (4) (5)
Planer Grinder Miler Lathe Welding
Product B (1) (2) (3) (4) (5)
Fig 3.2 Product or Line Layout
Advantages of Product Layout
1) Less Handling of Material.
2) Less material in process allows lower investment in materials.
3) More effective use of labor
(a) Through greater job specialization
(b) Through ease of training
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(c) Through wider of labor supply
4) Easier control
(a) Of production allows less paper work.
(b) Over workers allows easier supervision
3.4.3 COMBINATION LAYOUT
A combination of process and product layout combines the advantages of the both types of
layouts. A combination layout is possible where an item is being made in different shape and
sizes. In such cases machinery is arranged in a Process Layout but the process grouping is than
arranged in a sequence to manufacture various types and sizes of product. The point to note here
is that, no matter the product varies in size and type, the sequence of operations remain same or
similar.
3.4.4 FIXED POSITION LAYOUT
In other types of Layouts discussed earlier, the product moves past stationary
Production Equipment, whereas in these cases the reverse applies; men and equipment are moved
to the material, which remains at one place and the product is completed at that place where the
material lies. For e.g., aircraft manufacture, ship building, big pressure vessel fabrication. Fixed
position layout for ship building industry is shown in fig 3.3
Ship building yard
inputs
Fig 3.3 Fixed Position Layout
Finished products
(ship)
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3.4.5 GROUP OR CELL LAYOUT
In a group or Cell Layout, the layout design is in not according to functional
characteristics of machine, but rather by group of different machines (called Cells) that are
necessary for the production of families of parts.
3.5 PROCEDURE FOR DESIGN OF PLANT LAYOUT
The ideal procedure for a plant layout is to build the layout around the productive process
and then design the building around the layout. This may not be possible always, because the
plant building may already be existing or the shape of plant site may not permit the construction
of building to house the productive process, etc. Ultimately, one has to strike to balance between
the two approaches. However various procedural steps involved in plant layout have been listed
below:
a. Accumulate basic data
b. Analyze and coordinate basic data
c. Decide the Equipment and Machinery required
d. Select the material handling system
e. Sketch plan of plot for making factory building
f. Determine a general flow pattern
g. Design the individual work stations
h. Assemble the individual layout into the total layout
i. Calculate the storage space required.
j. Make flow diagram for workstations and allocate them to areas on plot plan,
k. Plan and locate service areas,
l. Make master layout,
m. Check final layout, and
n. Install the approved layout.
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3.6 PROCESS FLOW
Fig 3.4 Process Flow Chart
Sheet metal
cutting
Seam welding to join
the sheet metals
Bending along the
sides for the flow of
rain water
Alignment over the roof
jig and welding
Finishing operations
hammering and buffing
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3.7 SUMMARY:
This chapter gives the basic definition for plant layout and explains the various types of plant
layouts in detail along with their pictorial representations and advantages. This chapter also
explains the procedure and the relevant data required in order to design a new plant layout or even
to modify the existing plant layout in order to overcome the disadvantages in the existing layout.
Finally this chapter explains the flow of operations in the shop floor for the manufacturing of roof
sheets.
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CHAPTER 4
AUTOMATED LAYOUT DESIGN PROGRAM
Automated Layout DEsign Program (ALDEP) is a construction type algorithm. This
algorithm uses basic data on facilities and builds a design by successively placing the department
in the layout. After placing all the departments in the layout a score is computed. This is nothing
but the sum of the closeness rating values of different neighboring department in the layout. This
algorithm is repeated for a prespecified number of times and the best layout is selected based on
the maximum layout score.
The basic data required for this algorithm are listed below
1. Total number of department
2. Area of each department
3. Length and width of layout
4. Closeness rating of various pairs of department in the form of Relation chart
5. Minimum department preference ( MDP) value.
6. Sweep width
7. Number of iterations to be performed
8. Location and size of each restricted area in the layout if present.
4.1 RELATIONSHIP CHART
This chart is a triangular matrix whose elements represent the closeness relationships
among the departments. The following notations as shown in table 4.1 are used to indicate the
various degrees of closeness.
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Closeness Notation Value
Absolutely necessary A 64
Especially important E 16
Important I 04
Ordinary closeness OK O 01
Unimportant U 00
Not desirable X -1024
Table 4.1 Closeness value
4.2 STEPS OF ALDEP:
The ALDEP procedure is explained as follows:
Step 0.Input:
1. Number of departments in the layout.
2. Area of each department.
3. Length and width of the layout.
4. REL-CHART (Relationship chart).
5. MDP value.
6. Sweep width.
7. Number of iterations to be carried (N).
8. Current iteration number (1), 1.
9. Locations and sizes of fixed departments if present.
10.Score of the current layout (It is assumed as a very high negative value before
performing the first iteration).
Step1. Select a department randomly and place it in the layout.
Step2. Scan the relationship (REL) - chart and classify the unselected departments into lists,
namely List A and List B.
List A contains the unselected departments whose relationship values in relation to the lastly
selected departments are less than the MDP value.
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List B contains the unselected departments whose relationship values in relation to the lastly
selected departments are greater than or equal to the MDP value.
Step3.Is the List B empty? If so, go to step 4; otherwise, go to step5.
Step4.Select a department randomly from List A and place it in the layout. Go to step 6.
Step5. Select a department from List B which has the maximum REL value in relation to the
lastly selected department and place it in the layout.
Step6. Whether all departments are placed in the layout? If not go to step2; if yes, go to step7.
Step7.Compute the score of the layout.
Step8.Is the score of the layout more than the score of the current best layout? If yes, update the
new layout as the current best layout and store the corresponding score. Otherwise, drop the new
layout.
Step9. Is the current iteration number I=N? I f yes, go to step 10; otherwise, increment the
iteration number by one (I=I+1) and go to step 1.
Step10.Print the current best layout and the corresponding score.
4.3 DATA COLLECTED:The distance between the various machine cells and the area occupied by them in the shop
floor is collected and presented in fig 4.1 and table 4.2. Also the process flow chart for the
manufacture of roof sheet is shown in fig 3.4.
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Fig 4.1 Proximity diagram for machine cells
DEPARTMENT NAME AREA in Sq.Ft NUMBER OF
SQUARES
Cut To length Machine 115 x 32 = 3680 ~ 3600 36
Profile Bending 25 x 40 = 1200 12
Seam Welding 30 x 52 = 780 ~ 800 8
Press Break 1 24 x 25 = 600 6
Press Break 2 24 x 25 = 600 6
Assembly 80x 40 = 3200 32
Table 4.2 Area of each machine cell
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4.4 RELATIONSHIP CHART FOR DATA COLLECTEDThe proximity relationship between the various machines are specified using the notations
A,E,I,O and U in table 4.3.
cut to
length
machine
Profile
Bending
Seam
Welding
Press
Break 1
Press
Break 2
Assembly
cut to length
machine
0 A E A A O
Profile Bending A 0 A U U I
Seam Welding E A 0 U U E
Press Break 1 A U U 0 I E
Press Break 2 A U U I 0 E
Assembly O I E E E 0
Table 4.3 Relationship Chart
Assumptions:
Each machine in the shop floor is assigned a number and this number is used to represent
the particular machine in the ALDEP table as shown in the iterations.
1 - Cut to length machine
2 - Profile bending
3 - Seam welding
4 - Press brake 1
5 - Press brake 2
6 -Assembly
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List:
There are two lists A and B. list A contains the machines having least proximity values
(o,u) and list B contains the machines having maximum proximity values (a,e,i).
List A {o,u}
List B a,e,i
Relationship values:
A - 64
E - 16
I - 04
O - 01
U - 00
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Fig 4.2 Existing layout
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4.5FILLING THE CELLSIteration 1 (Existing Layout):
For cell 1: list A {6}, List B {2, 3, 4, 5}
For cell 2: list A {4, 5}, List B {3, 6}
For cell 3: list A {6}, List B {4, 5}
For cell 4: list A {6}, List B {5}
1 1 2 2 2 2 6 6 6 6
1 1 2 2 2 2 6 6 6 6
1 1 1 1 2 2 6 6 6 6
1 1 1 1 2 2 6 6 6 6
1 1 1 1 3 3 6 6 6 6
1 1 1 1 3 3 6 6 6 6
1 1 1 1 3 3 5 5 6 6
1 1 1 1 3 3 5 5 6 6
1 1 1 1 4 4 5 5 6 6
1 1 1 1 4 4 4 4 6 6
Relationship
Score:
1 2 = 64
2 3 = 64
2 6 = 04
3 6 = 16
3 1 = 16
4 1 = 64
4 3 = 1
4 5 = 4
5 6 = 16
4 6 = 16
1 3 = 16
Total :281
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4.6 EXPLANATION:
Iteration 1 gives the existing distribution of the machine cells in the shop floor. The pictorial
representation of the existing shop floor is given in fig 4.2. The entire shop floor area and the area
occupied by each machine along with the area for material storage are measured. The common
factor from all the individual machine cell area is removed and tabular grids are drawn for the
remaining area. In our case, 100 sq feet is taken as the common area factor and the remaining total
are is calculated to be 100 sq feet. A 10x10 tabular grid is constructed, wherein each cell
represents 1 sq feet. The grid is now filled with numbers, which are used to represent each
machine cell as explained in assumption. The tabular grid is filled column wise taking two cells of
a row at a time and also the filling is done in a continuous way starting from the first two cells of
the first row and ending with the last two cells of the last row. The machines are then place in the
same order along the shop floor. The best layout can be identified by trying all possible iterations
and calculating the relationship score for each iteration. The maximum score corresponds to the
most optimized layout. The first machine cell is selected randomly and the area occupied is filled
along the tabular grid. Based on the closeness relationship between the filled machine cell and the
remaining machine cells, two lists are created. They are known as list A and list B. list A consists
of the machine cells having least closeness relationship with the previously filled machine celland list B consists of machine cells having the maximum closeness relationship with the
previously filled machine cell. For instance iteration 1 is started by filling the tabular grid with
number 1, which corresponds to the Cut to Length Machine. Now the list A for Cut to Length
machine contains the assembly cell and list B consists of the remaining machines. Now, among
the machine cells in list B, the one with maximum closeness value with machine cell 1 is selected
and filled along the tabular grid. In this way the tabular grid is filled completely with all the
machine cells. From the filled tabular grid, the machines which are in direct contact are identified
and the relationship values are added together in order to calculate the total score for example: in
iteration 1, machines 1 and 2 are in direct contact with each other and there corresponding
closeness notation is A, which corresponds to a value of 64. Similarly all the closeness values of
the machines which are in direct contact with each other are added and the final score is
computed. The final score for iteration 1 is 281. In this way all possible iterations score were
calculated and the highest score obtained was 313, which corresponds to iteration 3. Hence
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iteration 3 is considered to be the most optimized machine cell layout and its corresponding
machine locations are shown in fig 4.2.
Iteration 2: (Sample Iteration)
1 1 4 4 4 4 5 5 2 2
1 1 4 4 6 6 5 5 2 2
1 1 1 1 6 6 5 5 2 2
1 1 1 1 6 6 6 6 2 2
1 1 1 1 6 6 6 6 2 2
1 1 1 1 6 6 6 6 2 2
1 1 1 1 6 6 6 6 3 3
1 1 1 1 6 6 6 6 3 3
1 1 1 1 6 6 6 6 3 3
1 1 1 1 6 6 6 6 3 3
For cell 1: list A {6}, List B{2, 3, 4, 5}
For cell 4: list A {2, 3}, List B {5, 6}
For cell 6: list A {}, List B {2, 3, 5}
For cell 5: list A {2, 3}, List B {}
Relationship
Score
1 4 = 64
1 6 = 01
4 6 = 16
4 5 = 04
6 5 = 64
5 2 = 00
6 2 = 04
6 3 = 00
Total: 153
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Iteration 3 (Optimized Layout):
1 1 4 4 4 4 6 6 6 6
1 1 4 4 5 5 6 6 6 6
1 1 1 1 5 5 6 6 6 6
1 1 1 1 5 5 6 6 6 6
1 1 1 1 2 2 6 6 6 6
1 1 1 1 2 2 6 6 6 6
1 1 1 1 2 2 3 3 6 6
1 1 1 1 2 2 3 3 6 6
1 1 1 1 2 2 3 3 6 6
1 1 1 1 2 2 3 3 6 6
For cell 1: list A {6}, List B {2, 3, 4, 5}
For cell 4: list A {2, 3}, List B {5, 6}
For cell 5: list A {2,3}, List B {6}
For cell 2: list A {}, List B {3}
Relationship
Score
1 4 = 64
4 5 = 04
1 2 = 64
4 6 = 16
5 6 = 16
2 3 = 64
3 6 = 16
2 6 = 04
2 5 = 01
1 5 = 64
Total: 313
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Fig 4.2 Proposed machine cell layout
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4.7 SUMMARY:
This chapter deals with the algorithm used to modify the current layout into an optimized one.
This chapter gives a detailed introduction about the ALDEP algorithm and explains the step by
step procedure for using it. The various data collected from the shop floor, which are used as
input to the algorithm, are presented using figures and tables. A pictorial representation of the
existing and the suggested optimized layout along with its tabular grid diagram and explanation is
also given in this chapter.
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CHAPTER 5
MATERIAL HANDLING
Material Handling involves the movement of material, manually or mechanically in
batches or one item at a time within the Plant. The movement may be horizontal, vertical or
combination of horizontal or vertical. Material Handling is concerned with motion, time, quantity
and space. Basically Material Handling is the art of implementing movement-economically and
safely.
5.1 MATERIAL HANDLING EQUIPMENT
Material Handling Equipment (MHE) is all equipment that relates to the movement,
storage, control and protection of materials, goods and products throughout the process of
manufacturing, distribution, consumption and disposal. Material Handling Equipment is the
mechanical equipment involved in the complete system. Material Handling Equipment is
generally separated into four main categories: storage and handling equipment, engineered
systems, industrial trucks, and bulk material handling.
MHE is the most critical component of cargo ground handling; shortages will significantly
impact throughput capability. MHE is the primary platform for loading and unloading all DOD
general and special cargo, including outsized and oversized components. MHE is the one that
reduces manual material handling distances. Also MHE aims in reducing the WIP inventories
which affects the productivity and profitability of an Organization /Industry through increased
Lead time, Machining cycles etc. MHE is used for the movement and storage of material within a
facility or at a site. Every organization in this world is looking for a material handling equipmentsolutions to improve their productivity, while reducing the potential of workplace injury. MHE is
the mechanical equipment involved in the complete system. MHE is used for the movement and
storage of material within a facility or at a site.
MHE can be classified into the following five major categories:
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5.1.1. TRANSPORT EQUIPMENT
Equipment used to move material from one location to another (e.g., between workplaces,between a loading dock and a storage area, etc.). The major subcategories of transport equipment
are conveyors, cranes, and industrial trucks. The basic transportation equipments are shown in the
fig 5.1.
Fig.5.1 Transport Equipment
The major subcategories of transport equipment are:
Conveyors-Equipment used to move materials over a fixed path between specific points.
Cranes-Equipment used to move materials over variable paths within a restricted area.
Industrial Trucks-Equipment used to move materials over variable paths, with no restrictions
on the area covered by the movement (i.e., unrestricted area).
5.1.2. POSITIONING EQUIPMENT
Equipment used to handle material at a single location so that it is in the correct position
for subsequent handling, machining, transport, or storage. Unlike transport equipment, positioning
equipment is usually used for handling at a single workplace. Material can also be positioned
manually using no equipment.
5.1.3. UNIT LOAD FORMATION EQUIPMENT
Equipment used to restrict materials so that they maintain their integrity when handled a
single load during transport and for storage. If materials are self-restraining (e.g., a single part or
interlocking parts), then they can be formed into a unit load with no equipment.
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5.1.4 STORAGE EQUIPMENT
Equipment used for holding or buffering materials over a period of time. Some storageequipment may include the transport of materials (e.g., the S/R machines of an AS/RS, or storage
carousels). If materials are block stacked directly on the floor, then no storage equipment is
required.
5.1.5. IDENTIFICATION AND CONTROL EQUIPMENT
Equipment used to collect and communicate the information that is used to coordinate the
flow of materials within a facility and between a facility and its suppliers and customers. The
identification of materials and associated control can be performed manually with no specialized
equipment.
5.2 PRINCIPLES OF MHE
The Seventeen MHE Principles remain constant.
1. Least handling is best handling. The greatest economy in moving materials is secured by
keeping handling to a minimum.
2. Standardization of methods and equipment results in the reduction of costs of operation.
Maintenance, repair, storage and issue procedures can be simplified.
3. MHE must be selected for a multiple number of applications. Flexibility is the key.
4. Specialized equipment should be kept to a minimum. Normally, first cost, cost of operations
and maintenance costs are greater for special equipment than for standard equipment.
5. Volume dictates the method of handling materials. The number of pieces to be moved
determines the method of handling.
6. The most essential phase of any program is planning. Material handling is no different.
Factors requiring advanced planning include protection against weather and breakage, legal
and physical restrictions in reference to transportation, the possibility of using unitized loads,
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the standardization of equipment and methods, the combination of material handling methods
and the consideration of safety hazards.
7. The length and number of moves of material should be kept to a minimum. Movement paths
should be studies for the possibility of reducing "backtracking" and length of moves, resulting
in better utilization of equipment and personnel.
8. Equipment capacities should never be exceeded. Overloading causes excessive wear of
equipment and creates accident potential.
9. All materials handling activities should be analyzed for improvement possibilities by
elimination, combination or simplification. Combination of operations may result in the
simplification and reduction of the number of times material must be handled.10.The selection of MHE is based on the economies of operation. Greater payloads for each
handling operation will result in less handling cost per piece.
11.The "physical state" of materials is a factor in determining MHE. The three physical states of
material - solid, liquid and gas - determine the method of containment (pack). This, in turn,
influences the selection of MHE.
12.The shortest distance between two given points is a straight line - utilize a straight line flow of
materials whenever possible. The time to move materials can be reduced by using a straight
line flow.
13.Materials should move continuously along any production line. Choppy or broken flow causes
confusion and delay. Most shipping and receiving operations should operate on the principle
of continuous flow.
14.All materials handling operations should follow a defined method. The standardization of the
method will provide a basis for determining handling requirements.
15.Short, irregular moves lend themselves to manual materials handling. When moves are short,
irregular and load capacity of people is not exceeded, it may be more economical to use
manpower.
16.Whenever practicable materials should be prepositioned for the handling operations.
Prepositioning places containers in position to facilitate picking up and/or moving and
materials so they do not obstruct other materials.
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17.Whenever practicable, materials should be moved in a horizontal plane or with the aid of
gravity. The ideal lifting position is at the waist. The nearer to the waist that a container or
part can be picked up and disposed, the greater will be the efficiency.
5.3 AUTOMATIC GUIDED VEHICLES
An automated guided vehicleor automatic guided vehicle(AGV) is a mobile robot that
follows markers or wires in the floor, or uses vision or lasers. They are most often used in
industrial applications to move materials around a manufacturing facility or a warehouse.
Application of the automatic guided vehicle has broadened during the late 20th century and they
are no longer restricted to industrial environments.
AGVs increase efficiency and reduce costs by helping to automate a manufacturing
facility or warehouse.
AGVs can carry loads or tow objects behind them in trailers to which they can
autonomously attach. The trailers can be used to move raw materials or finished product. The
AGV can also store objects on a bed. The objects can be placed on a set of motorized (conveyor)
and then pushed off by reversing them. Some AGVs use forklifts to lift objects for storage. AGVs
are employed in nearly every industry, including pulp, paper, metals, newspaper, and general
manufacturing. Transporting materials such as food, linen or medicine in hospitals is also done.
An AGV can also be called a self-guided vehicle (SGV). Lower cost versions of AVGs
are often called Automated Guided carts (AGCs) and are usually guided by magnetic tape. AGCs
are available in a variety of models and can be used to move products on an assembly line,
transport goods throughout a plant or warehouse, and deliver loads to and from stretch wrappers
and roller conveyors.
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5.3.1 NAVIGATION
AGVs in a FMS are used to transport an object from point A to point B. AGVs navigatemanufacturing areas with sensors. There are two main sensors AGVs use for navigation, a wired
and a wireless sensor.
5.3.2 WIRED SENSOR
The wired sensor is placed on the bottom of the robot and is placed facing the ground. A
slot is cut in the ground and a wire is placed approximately 1 inch below the ground. The sensor
detects the radio frequency being transmitted from the wire and follows it.
5.3.3 GUIDE TAPE
Many light duty AGVs (some known as automated guided carts or AGCs) use tape for the
guide path. The tapes can be one of two styles: magnetic or colored. Magnetic and colored types
have its own advantages and disadvantages respectively. The AGC is fitted with the appropriate
guide sensor to follow the path of the tape. One major advantage of tape over wired guidance is
that it can be easily removed and relocated if the course needs to change. It also does not involve
the expense of cutting the factory or warehouse floor for the entire travel route. Additionally, it is
considered a passive system since it does not require the guide medium to be energized as wire
does. Colored tape is initially less expensive, but lacks the advantage of being embedded in high
traffic areas where the tape may become damaged or dirty.
5.3.4 STEERING CONTROL
To help an AGV navigate it can use two different steer control systems. The differential
speed control is the most common. In this method there are two sets of wheels being driven. Each
set is connected to a common drive train. These drive trains are driven at different speeds in order
to turn or the same speed to allow the AGV to go forwards and/or backwards. The AGV turns in a
similar fashion to a tank. This method of steering is good in the sense that it is easy to maneuver
in small spaces. More often than not, this is seen on an AGV that is used to transport and turn in
tight spaces or when the AGV is working near machines. This setup for the wheels is not used in
towing applications because the AGV would cause the trailer to jackknife when it turned.
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The other type of steering used is steered wheel control AGV. This type of steering is
similar to a cars steering. It is more precise in following the wire program than the differential
speed controlled method. This type of AGV has smoother turning but cannot make sharp turns in
tight spots. Steered wheel control AGV can be used in all applications; unlike the differential
controlled. Steered wheel control is used for towing and can also at times have an operator control
it.
5.3.5 PATH DECISION
AGVs have to make decisions on path selection. This is done through different methods:
frequency select mode (wired navigation only), and path select mode (wireless navigation only)
or via a magnetic tape on the floor not only to guide the AGV but also to issue steering commands
and speed commands.
5.3.6 FREQUENCY SELECT MODE
Frequency select mode bases its decision on the frequencies being emitted from the floor.
When an AGV approaches a point on the wire which splits the AGV detects the two frequencies
and through a table stored in its memory decides on the best path. The different frequencies are
required only at the decision point for the AGV. The frequencies can change back to one set
signal after this point. This method is not easily expandable and requires extra guide cutting
meaning more money.
5.3.7 PATH SELECT MODE
An AGV using the path select mode chooses a path based on preprogrammed paths. It
uses the measurements taken from the sensors and compares them to values given to them by
programmers. An AGV used in shop floor is illustrated in figure 5.2. When an AGV approaches a
decision point it only has to decide whether to follow path 1, 2, 3, etc. This decision is rather
simple since it already knows its path from its programming. This method can increase the cost of
an AGV because it is required to have a team of programmers to program the AGV with the
correct paths and change the paths when necessary. This method is easy to change and set up.
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5.3.8 MAGNETIC TAPE MODE
The magnetic tape is laid on the surface of the floor or buried in a 10 mm channel, not
only does it provide the path for the AGV to follow but also sort strips of the tape in different
combos of the strip tell the AGV to change lane and also speed up slow down and stop with north
and south magnetic combos, this is used by TOYOTA USA and TOYOTA JAPAN.
5.3.9 VEHICLE TYPES
AGVS Towing Vehicleswere the first type introduced and are still a very popular type
today. Towing vehicles can pull a multitude of trailer types and have capacities ranging
from 8,000 pounds to 60,000 pounds.
AGVS Unit Load Vehicles are equipped with decks, which permit unit load
transportation and often automatic load transfer. The decks can either be lift and lower
type, powered or non-powered roller, chain or belt decks or custom decks with multiple
compartments.
AGVS Pallet Trucksare designed to transport palletized loads to and from floor level;
eliminating the need for fixed load stands.
AGVS Fork Truckhas the ability to service loads both at floor level and on stands. In
some cases these vehicles can also stack loads in rack.
Light Load AGVSare vehicles which have capacities in the neighborhood of 500 pounds
or less and are used to transport small parts, baskets, or other light loads though a light
manufacturing environment. They are designed to operate in areas with limited space.
5.3.10 Common AGV Applications
Automated Guided Vehicles can be used in a wide variety of applications to transport
many different types of material including pallets, rolls, racks, carts, and containers.
AGVs excel in applications with the following characteristics:
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Repetitive movement of materials over a distance
Regular delivery of stable loads
Medium throughput/volume
When on-time delivery is critical and late deliveries are causing inefficiency
Operations with at least two shifts
Processes where tracking material is important.
Fig 5.2 AGV moving in shopfloor.
A few examples of typical leasing costs for different size AGV systems:
1 vehicle CHEP forklift type AGV system with up to 20 load and unload positions and a
travel distance of up to 100 meters.
Monthly cost for 5 years, with no residual: Rs 2,09,500/month
3 vehicle CHEP forklift type AGV system with up to 50 load and unload
Positions and a travel distance of up to 200 meters.
Monthly cost for 5 years, with no residual: Rs 4,61,000/month
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5 vehicle CHEP forklift type AGV system with up to 100 load and unload positions and a
travel distance of up to 300 meters.
Monthly cost for 5 years, with no residual: Rs 7,12,250/month
5.3.11 SUGGESTED AGV SPECS:
Flexible magnet floor tape guidance
Travel speed 120 feet/min
Tow capacity 2,000 lbs.
Carry capacity 1,700 lbs
Auto charge
Roller decks
Towed carts
Remote call
5.3.12 AGV SET UP SPECIFICATIONS AND COST:
1 SavantCart Model 100 HD (tow or carrier style)
500 feet magnet floor tape
1 Battery set
1 Battery charge
2 Path branches
Savant installation
Savant training
1 year warranty
24/7 service hotline
TOTAL COST Rs. 26,56,500/-
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5.4 SUMMARY:
This chapter gives a basic definition for material handling and explains in detail the variousmeans of material handling inside shop floor. The main area of focus in this chapter is the AGV,
it explains the various types of AGVs their advantages and rent per month. Finally this chapter
concludes with the specifications and cost of the AGV proposed suiting the conditions of the
factory.
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CHAPTER 6
MATERIAL HANDLING MECHANISM
6.1 AUTOMATED TABLE ACTUATION
This mechanism is employed for the handling of roof sheets once they are seam welded. The roof
sheets are at present being handled manually by picking them and placing them over the trolleys
through human effort. This process involves the following steps which are:
1. Placing the roof sheet horizontally over the trolley once the seam weld is made.
2. Manual movement of the trolley to the assembly shop.
3. Changing the orientation of the roof sheet from horizontal to vertical while lifting it using
the crane.
4. Then placing the roof sheet over the roof jig horizontally, which involves another change
in the orientation.
In order to reduce the time consumption due to above steps, we have devised the following
material handling system. Which involves the usage of hydraulically actuated table and a mobile
bin for the vertical storage of root sheets that can be coupled with the AGVs mentioned above.
6.2 MECHANISM
The mechanism with which the hydraulically actuated table moves, such that the roof sheets are
stored vertically inside the mobile bin is explained below
6.2.1 MOBILE BIN
This is used to carry the roof sheets in vertical orientation. The main purpose for designing this
mobile bin is to save time in the handling of roof sheets. Since the roof sheets are stored in
vertical position there is no wastage of time in changing. the orientation of the roof sheet from
horizontal to vertical and then vice versa. This mobile bin can be coupled with the AGV for its
movement from the seam welding machine cell to the assembly area.
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6.2.2 HYDRAULICALLY ACTUATED TABLE
This table is designed in such a way that it can tilt itself to a maximum of 45 degrees. The purposeof this table is to automate the movement of the roof sheets after seam welding, to store them in
the mobile bin vertically. This table is hydraulically actuated with three links of which one is
stationary and the other two are extendable. The height of the table from the ground is 225 cms
which in turn is equal to the height of the stationary link and its outer diameter is 25cms. The first
extendable link which is in direct contact with the stationary link extends to a height of 200cms
and its outer diameter is 22cms. The second extendable link which is in direct contact with the
first extendable link extends to a height of 175 cms, whose outer diameter is 20 cms. When the
two extendable links are in their maximum extended position the table is lifted to a height of 600
cms from ground, thereby making an angle of 45 degrees with its stationary leg. The assembly of
the Table and Mobile bin is shown in fig 6.1.
Fig 6.1 Table and Bin
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6.3 SUMMARY:
This chapter discusses the storage mechanism for the automated vertical storage of the roof sheet
in order to reduce the handling time and automate the material handling. This includes the design,
construction and working of the mobile bin and the storage table mechanism.
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CHAPTER 7
GALVINIZING PROCESS
Hot dip galvanizing is the process of applying a zinc coating to fabricated iron or steel
material by immersing the material in a bath consisting primarily of molten zinc.
7.1 TYPES OF SURFACE PROTECTION
Barrier protection is perhaps the oldest and most widely used method of corrosion
protection. It acts by isolating the metal from the electrolytes in the environment. Two important
properties of barrier protection are adhesion to the base metal and abrasion resistance. Paint is one
example of a barrier protection system.
Cathodic protection is an equally important method for preventing corrosion. Cathodic
protection requires changing an element of the corrosion circuit, introducing a new corrosion
element, and ensuring that the base metal becomes the cathodic element of the circuit.
Hot dip galvanizing provides excellent barrier protection as well as cathodic
protection.
7.2 ELEMENTS OF GALVINIZING PROCESS
The galvanizing process consists of three basic elements:
Surface Preparation
Galvanizing
Inspection
7.2.1 SURFACE PREPARATION
Surface preparation is the most important step in the application of any coating. In most
instances where a coating fails before the end of its expected service life, it is due to incorrect or
inadequate surface preparation.
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The surface preparation step in the galvanizing process has its own built-in means of
quality control in that zinc simply will not react with a steel surface that is not perfectly clean.
Any failures or inadequacies in surface preparation will be immediately apparent when the steel is
withdrawn from the molten zinc because the unclean areas will remain uncoated. Immediate
corrective action is taken.
Surface preparation for galvanizing typically consists of three steps: caustic cleaning, acid
pickling, and fluxing.
1. Caustic Cleaning - A hot alkali solution often is used to remove organic contaminants
such as dirt, paint markings, grease, and oil from the metal surface. Epoxies, vinyl,
asphalt, or welding slag must be removed before galvanizing by grit blasting, sand
blasting, or other mechanical means.
2. Pickling - Scale and rust normally are removed from the steel surface by pickling in a
dilute solution of hot sulfuric acid or ambient temperature hydrochloric acid.
3. Fluxing- Fluxing is the final surface preparation step in the galvanizing process. Fluxing
removes oxides and prevents further oxides from forming on the surface ofthe metal prior
to galvanizing and promotes bonding of the zinc to the steel or iron surface.
7.2.2 GALVANIZING
In this step, the material is completely immersed in a bath consisting of a minimum of
98% pure molten zinc. The bath chemistry is specified by the American Society for Testing and
Materials (ASTM) in Specification B 6. The bath temperature is maintained at about 850 F (454
C).
Fabricated items are immersed in the bath long enough to reach bath temperature. The
articles are withdrawn slowly from the galvanizing bath and the excess zinc is removed by
draining, vibrating, and/or centrifuging.
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7.2.3 INSPECTION
The two properties of the hot dip galvanized coating that are closely scrutinized after
galvanizing are coating thickness and coating appearance. A variety of simple physical and
laboratory tests may be performed to determine thickness, uniformity, adherence, and appearance.
7.3 BENEFITS OF GALVANIZING PROCESS
Lowest first cost
Less maintenance/Lowest long term cost
Long life
Reliability
Toughest coating
Automatic protection for damaged areas.
Complete protection
Ease of inspection
Faster erection time
A full protective coating can be applied in minutes
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7.4 SUMMARY:
This chapter deals with the concept of galvanization in order to protect the roof sheets from the
effect of the atmosphere. This explains the various types and elements of galvanization process
and also covers the various advantages of this process..
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CONCLUSION
Through this project we were able to analyse the existing plant layout and various
material handling techniques present at the integral coach factory. The major areas addressed here
and solved were reduction in the WIP inventories, change in the existing plant layout thereby
reducing the operation and assembly time for the same number of roof sheet assemblies or for the
same time increase in the number being produced. Though the entire WIP inventory cannot be
brought down to zero, we have suggested a technique to protect them from the effect of
atmosphere thereby preventing corrosions. We have also suggested a new material handling
technique in order to reduce the overall material handling time thereby increasing the productivity
from 1400 coaches in the year 2009-2010 to more than 2000 post implementation. The significant
improvements made are:
Change in the plant layout, thereby decreasing the distance between the work centers,
using ALDEP algorithm
Increasing the overall productivity by 21.89%
Reducing the Idle time of the machines thereby decreasing the overall WIP inventory.
Devising a new material handling system bringing it close to automation.
Suggestion of Galvanization process for the protection of roof sheets from corrosion.
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