Quality & Consistency through Automation in Metal · PDF fileQuality & Consistency through...

12th April 2007, Mumbai12th April 2007, Mumbai

Manufacturing Excellence Through

A U T O M A T I O N

01

Quality & Consistency through Automation in Metal Finishing Lines

Anuj R. MiglaniDy. Managing DirectorUttam Galva Steels Limited

Sharad G. TudekarDirector (Works)

Uttam Galva Steels Limited


Manufacturing Excellence Through

A U T O M A T I O N

01

12th April 2007, Mumbai12th April 2007, Mumbai02

Automation is welcomed most where it contributes to profit.

Automation is effectively used for improving:Productivity

Product Quality

In turn it leads toProfit

Customer satisfaction.


Automation Leads to

More Goods produced per manufacturing floor area, machines installed & total human work force.

Reduces ‘Rework’ and wastages.

Competitive position through high volumes.

Customer’s delight.

Inventory levels come down sharply.

Reduction in accidents.

Less dependence on high skilled work force.


Earlier there were limitations in introducing automation in the Industry due to:

ν High Cost.

ν Low flexibility of the system.

ν Vulnerability to down time.

Now with the many advanced Technology in metal industry, Automation has become “Necessity” & “Way of Life”.

Design & Manufacturing cost of Automation has come down

User has become more friendly to Automation.Cont….

Earlier & Now


Earlier Customers were accepting whatever Manufacturer produces.With increasing Globalisation, Customers demand better and better Quality.Stringent Specifications have become order of the day.

For example:Normal Thickness Tolerance +/- 25 micronGuaranteed Tolerance : ½ Speci I.e. +/- 12.5 micronExpected by Customer : +/- 10 micronWith Automation : +/- 3 micron

Manufacturers must keep pace with recent developments in Automation to achieve more stringent results or else“They will be out in the Competitive Market.”

Earlier & Now


To transform the organization into an efficiently managed one through:

ν Productivity.

ν Quality.

ν Cost effectiveness.

ν Better profit.

To achieve above “Implementing Automation” in the any Industry is ‘Must’.

To take full advantage of recent development in Automation, Implement the same in the processing units and achieve ‘Excellence’ in the Industrial field.

Duty of ‘Technocrat’


Entire Range from Energy Management

To

Assets Management

To

Programme Management

To

Information Management

The nature of Automation depends upon the Type of Industry.

Automation Technology Covers


Automation is to be provided:

Know the process parameters of any line.

(To hear the voice of process through Automation)

Automatic correction to achieve desired technical parameter by feeding the data of finishing section to starting section.

To save the products before they are damaged during processing without depending on ‘Human factor’ or doing postmortem after damage is done.

To improve the quality required for further processing and/or to fulfill stringent demand of Customers.

Cont..

Achieving Excellence through Automation


To improve the yield by reducing the wastages.

To guide the operator for keeping minimum inventory and to avertany accident during operation.

To keep pace with the modern developments so that products can be competitive in World Market.

To flourish the industry keeping in view the future.

Achieving Excellence through Automation


Can be achieved through:

Machines

Men

Material

Support of “AUTOMATION TECHNOLOGY IS MUST”

Excellence through Automation


PROFILE OF UTTAM GALVA STEELS LIMITED

11


UttamGalva Steels

Limited

Producing CR Coils from HR Coils by Rolling in 20Hi, 6Hi, 4Hi & Twin Stand 6 Hi Mill.

Producing GP Coils by processing CR Coils in three Galvanizing Lines (now) while 4th Line(1650mm wide) will be commissioned in July 2007.

An ISO 9001 / IS 16949 Company.

Awarded Highest Export Awards consecutively for 7 years.

Producing Colour Coated Coils by processing GP / Skin Passed coils in Colour Coated Line.

12


CapacityCRFH / CRCA : 0.30 Million Tonne per annum.

Colour Coated Line : 80,000 Tonne per annum.

80% of Production to 120 different countries.

For Automobile, White Goods, Oil Industries, Electrical Industries etc.

CR Coils : 1 Million Tonne per annum.

GP Coils : 0.70 Million Tonne per annum.

Products Coil form, Sheet form, Slit coil form in various International grades.

OEM

EXPORT

13


Case Study Twin Stand Rolling Mill

14

Schematic Diagram of Twin Stand Mill


Technical Specification of 6Hi Twin Stand(Unique in INDIA)

15

Capacity: 350,000 Mt./Year

Strip Thickness: `Input – 1.50mm to 4.50mmOutput – 0.25mm to 1.60mm

Strip Width: 700 mm to 1650 mm

Coil ID / OD: 610 mm / 2100 mm

Coil Weight: 32 Mt. Max.

Mill Speed: 1400 mpm Max.

12th April 2007, Mumbai12th April 2007, Mumbai 16

Automations Provided:

Automatic Gauge Control (AGC)

Shape Control

Level I, II (At present) III & IV (in Future)

Profiling gauge profile of HR Coils

Mill Management System (Level 2)

Case Study Twin Stand Rolling Mill


Objective

Operator used to measure thickness by micrometer.

Stops the mill.

Thickness is measured automatically on line while rolling with Radioactive non contact thickness gauge.

To Control the thickness (+/-) within the limit desired by the Customers throughout the length of the coil

EarlierCorrect Roll force manually.

Now

17

Twin Stand 6Hi –Automatic Gauge Control (AGC)

Not confident.

No stoppage of the mill.

Corrected by automatic gauge control system with:a) Feed back control.b) Feed forward control.c) Mass flow control.


Results Thickness accuracy was +/- 6 microns ( 95% of HR Coil as against +/-12.5 microns desired by the Customers & +/- 25 microns as per specification.

Advance mass flow control added apart from (a), (b) & ( c ) controls.

Thickness control became easy.

Innovations implemented in

Twin StandStringent inter stand Tension Control added.

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Accuracy is achieved +/- 3 microns ( 98% of HR Coils. Beyond expectations of any Customer. Customers are delighted.)Results

Twin Stand 6Hi –Automatic Gauge Control (AGC)


Objective

Operator used to feel the shape by “ Bamboo Stick “ (Crude method)

Never correct.

To achieve better shape of CR Coils ( in terms of flatness throughout the coil & measured in ‘I’ units )

EarlierCorrection by adjusting roll bending force & tilting.

Results

19

Shape Control

Correction is done manually in “ High Tension “.

Adjustment by Fluke

I Unit varies from 25 to 50 ( as against 22 I max as per specifications)


Now (in Twin Stand)

Shape measurement is processed through software & correction signals are given to hydraulic gap control system for :

a) Roll bending.b) Tiltingc) IMR (Intermediate Rolls shifting)

Faster acceleration to reach Top Speed can be achieved.

Shape is measured on line automatically with a flatness roll having piezoelectric transducers embedded inside the roll.

Results

Other benefits

20

Shape is control below 10 I units consistently.

Better quality of CR which helps in getting lower consumption of Zinc during Galvanizing.

Increased productivity due to lower number of coil breakages.

Shape Control


Level IV(Future)

Enterprise Resource Planning (ERP) System will be introduced with effect from Marketing Strategy, Production Planning & Operating Planning. ERP System will communicate to the Level II Computer.

21

Twin Stand (6 Hi)

Automation at

Production Planning will be transmitted to Level II System. Operator need not enter Input / Output products specification.

Level III(Future)

Input / Output products specifications are entered by operator and processed parameters are computed by Level II Computer through ‘ Mathematical Model ‘ and transferred to Level I System.

Level II

Level IInstrumentation, Programmable Logic Controller (PLC), Human Machine Interface (HMI) etc. Process parameters are set by operator manually but controlled automatically.


ObjectiveTo measure profile of HR Coil on line across the width & across the length and data to be utilized for precisely setting the roll gap in the first pass so higher speeds; and thereby higher productivity can be achieved.

Installed at Pickling Line & data transmitted to Mill to create Roll gap as per profile of HR Coil.

22

Profiling Gauge in Twin Stand Mill

In Process and

Results

Improves the yield.

Helps in controlling shape right from the beginning.

No damage to the rolls.

Higher speeds in first pass.


Mill Management

System (MMS) Level II

Through Mathematical Model, MMS System computes process parameters (required Roll force, Tension, Roll gap, thickness etc.) and transfers to Level I System.

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Benefits

Works as Level II System.

Consistency in operation and does not depend upon operators.

Consistency in Quality of CR Coils.

Operator enters Input / Output products specifications.

Twin Stand Mill


Case Study: Coating Thickness Gauge

for Galvanizing Lines


Case Study: Coating Thickness Gauge

for Galvanizing Lines

Automation

To control Coating thickness within the tolerance limit.To control Coating thickness within the tolerance limit.

With Semi Automatic, Operator gets display on XRF gauge coating thickness & he adjusts:

a) Nozzle distance / angle of nozzles.b) Air pressure

With Semi Automatic, Operator gets display on XRF gauge coating thickness & he adjusts:

a) Nozzle distance / angle of nozzles.b) Air pressure

Coating Thickness Gauge. (X-ray Fluorescent) - XRFCoating Thickness Gauge. (X-ray Fluorescent) - XRF

EarlierManual Control Variation (-) 5 gm/m2 to (+) 5 gm/m2.Manual Control Variation (-) 5 gm/m2 to (+) 5 gm/m2.

Now

Control based on Laboratory Test (takes sampling to result 30 minutes) wastage of zinc.Control based on Laboratory Test (takes sampling to result 30 minutes) wastage of zinc.

Future to switchover to automatic to control above parameters.

Even Zinc saving by 1 gm/m2, Company can save about Rs. 25 Lakhs / month with a production level of 34,000 Mt/month.Even Zinc saving by 1 gm/m2, Company can save about Rs. 25 Lakhs / month with a production level of 34,000 Mt/month.

Objective


Technical Specifications of Galvanizing Lines

No.4(SGL)No.3(WGL)No.2(PRC)No.1(CGL)

Thickness: 0.27 to 1.0mm 0.19 to 0.80mm 0.14 to 0.50mm 0.30 to1.60mm

Width: 750 – 1250mm 750 – 1040mm 750 – 1320mm 914 – 1650mm

Coil Weight: (Mt./Max.) 12.00 Mt. 18.50 Mt. 18.50 Mt. 35.00 Mt.

Speed (mpm) 160 mpm 160 mpm 200 mpm 160 mpm

Coating (Min. / Max.) 90-275 gm/m2 90-275 gm/m2 90-275 gm/m2 100-600 gm/m2

Extra Provision in Line: TLL, Skin Pass, TLL ---- TLL, Skin Pass Electrostatic Oiler

Automation Provided: Coating Gauge Coating Gauge Coating Gauge Coating Gauge

Capacity: (LT/Yr.) 180,000 120,000 100,000 350,000

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Conclusion

Automation in Metal Industries has become “Necessity” to cater needs of Customers who are demanding more stringent quality.

Automation will only help in fast developing World (Going for higher speed & highly sophisticated quality)

Keeping pace with developments in Automation Technology is MUST to withstand in the competitive market.

Pay back period will be very fast due to increase in productivity.

Uttam Galva Steels Limited is not lagging behind. Adopting Automation from the BEST PLAYERS in the world to derive the real benefits and to achieve the excellence through Automation.


Conclusion

At the end, I would like to give my thoughts to this August Gathering. I am confident that by implementing these suggestions, it will make Breakthrough in making further advancements in the field of “Automation”.

a) There should be more interaction amongst Automation Industries and Metal Finishing Industries.

b) Understand the requirements of Metal Finishing Industries.

c) Make them as “Partner” & not only as “Customers”.

d) Have full transparency in dealing with Metal Finishing Industries with respect to Transfer and Automation Technology.

e) Develop the Automation required by Metal Finishing Industriesin various units keeping in view their various requirements.

At the end, I would like to give my thoughts to this August Gathering. I am confident that by implementing these suggestions, it will make Breakthrough in making further advancements in the field of “Automation”.

a) There should be more interaction amongst Automation Industries and Metal Finishing Industries.

b) Understand the requirements of Metal Finishing Industries.

c) Make them as “Partner” & not only as “Customers”.

d) Have full transparency in dealing with Metal Finishing Industries with respect to Transfer and Automation Technology.

e) Develop the Automation required by Metal Finishing Industriesin various units keeping in view their various requirements.


Conclusion

f) Implement in Metal Finishing Industries as Joint Venture.

g) If successful at first attempt, make further improvement. If not, do not get discouraged for the failure. You are going to succeed in next attempt since your “will” is very strong.

h) Indian Engineers both in ‘Automation ‘ & Metal Finishing Industries have got tremendous potential. Only we have to ‘Tap’ it.

i) If higher management shows ‘confidence’ in them, they can do miracles in implementing ‘Advance Automation’ in Metal Finishing Industries keeping in view Quality, Consistency, Safety, Cost effectiveness etc. and do not lag behind as compared with other parts of the World.

f) Implement in Metal Finishing Industries as Joint Venture.

g) If successful at first attempt, make further improvement. If not, do not get discouraged for the failure. You are going to succeed in next attempt since your “will” is very strong.

h) Indian Engineers both in ‘Automation ‘ & Metal Finishing Industries have got tremendous potential. Only we have to ‘Tap’ it.

i) If higher management shows ‘confidence’ in them, they can do miracles in implementing ‘Advance Automation’ in Metal Finishing Industries keeping in view Quality, Consistency, Safety, Cost effectiveness etc. and do not lag behind as compared with other parts of the World.


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