SCRAP MANAGEMENT AND REDESIGNING PLANT LAYOUT · chip Briquettes. This process consists of Hinged...

SCRAP MANAGEMENT AND REDESIGNING PLANT LAYOUT 1Saurav Samrendukumar,

2Piyush Pulukool,

3Mitul Chovatiya,

4Bhavinkumar Prajapati

Student, Mechanical department, Laxmi institute of Technology, Sarigam-Valsad. Gujarat

Corresponding Author Detail:

Saurav Samrendukumar

Student, Mechanical department,

Laxmi institute of Technology,

Sarigam-Valsad, Gujarat.

Internal Guide Detail:

Mr. Jignesh Chaudhri

Assistant Professor, Mechanical department,

Laxmi institute of Technology,

Sarigam-Valsad. Gujarat.

ABSTRACT

This Paper focus on the study of machine manufacturing company in Vapi. The Company ‗s

main business is to design, develop and deliver the all range of Textile machines. The main

problem observed in the company is Scrap in almost parts of company, and it need of Scrap

reduction and Plant layout improvement. The reduction of chip can be done by making metal

chip Briquettes. This process consists of Hinged steel belt conveyor, shredder machine (metal

Chips crusher), Screw conveyor, Briquetting machine. These systems are designed as per the

chips capacity of the company so the system is fit to the small scale industries. Now by

coming on the Plant layout. Due to high numbers of customer orders, the current production

layout has to improve. The objective of this study was to improve the current layout in order

to minimize Material handling cost, increase operator safety, improve flexibility for

operation, minimize the overall cost and utilize the available area.

KEYWORD:

Chips, Scrap reduction, conveyors, shredder machine, Briquettes, Plant layout.

INTRODUCTION

A manufacturing company must have an efficient production system to accomplish its

operation. The systems consist of people, equipment and procedure designed for the

combination of materials and processes that steer the company‘s operations [1] . In today‘s

business, controlling scrap is one factor that companies focus on in order to remain

competitive and maximize benefit. Scrap consists of recyclable materials left over from

product manufacturing and consumption, such as parts of vehicles, building supplies, and

surplus materials. Unlike waste, scrap has monetary value, especially recovered metal from

unwanted products and materials [2]. Non metallic materials are also recovered for recycling.

Here, we would only concentrate on the metallic scraps produced in the machining and

fabrication industries. Day by day, the volume of metallic scrap is increasing due to poor

management of manufacturing system and lack of acknowledgement in recycling of metals in

the industries [3]. As we all know, in the machining processes, the unwanted material is

removed from the work piece to get required product shape. The material is removed using a

suitable machine tool for the process. The unwanted materials removed are called as chips

International Journal of Scientific Research in Engineering (IJSRE) Vol. 1 (3), March, 2017

IJSRE Vol. 1 (3), March, 2017 www.ijsre.in 84

(Swarf). These chips are not used again for other purposes. Therefore, it is one type of

Metallic Scrap.

In many machining plant, lots of chips are produced on the daily basis. These chips get

collected in the plant without any further use, occupying valuable floor area of the plant. The

Industry then either sells the metal scrap/chips to a third party consumer for low price or will

dump the chips into the environment [4]. In the latter scenario, the chips will cause accidents

and major environmental problem such as pollution, etc. The discarding of waste materials

has a negative environmental impact and is a waste of time and money for the manufacturer.

And similarly, in the former situation, the company acquires less profit by selling the metallic

chips at low cost (by surveying in local markets we get the row M.S. Chips price of per Kg. is

about 14 INR.) to the third party consumers.

Therefore, by looking at both the scenarios, a scrap recycling combined with proper scrap

management technique has been developed to eliminate the ill effects of both scenarios [6]. A

recycling plant is designed which can be used to recycle the metallic chips produced in the

industry by itself. There are many methods to recycle the metal scrap but here we choose to

make metal chip Briquettes which the industries can sell them to other consumers with huge

profit(the price of the briquettes is 3 times more of metal chips).

In manufacturing system, facility layout is considered as one of the important criteria which

has a significant effect towards manufacturing productivity in terms of cost and time [8]. The

objectives of layout are to minimize the material handling cost, improve flexibility for

arrangement and operation, utilize the available area and minimize overall production time.

According to [10] ―a facility layout is an arrangement of everything needed for production of

goods or delivery of services‖. A facility layout is an entity that provides the performance of

any task that include a machine tool, a work centre, a manufacturing cell, a machine shop, a

department and a warehouse. Here we had change the machine shops layout by using 5S

Techniques, (5S Check sheet) according to the Briquetting processes setup.

FISH BONE DIAGRAM

Scrap production

Plant Layout Machining

Manpower

Metal chip production during metal cutting

Inaccurate machining

Untidy workplace

No proper sorting of machines

Human error

Lack of discipline and motivation

Management

No proper disposal of Metal scrap

No proper scrap management

No proper supervision

Figure-1 Fish bone Diagram


IJSRE Vol. 1 (3), March, 2017 www.ijsre.in Page 185

SCRAP MANAGEMENT SYSTEM

It is the system used for recycling the metal chips produced during machining. It mainly

consists of following components: Scrap collector, metal separators, metal compactor, and a

furnace. The system is designed to be as cheap and simple as possible considering the

affordability of the Industry and also considering the skill level of workers available at the

area of the plant.

The different components of the systems are:

HINGED BELT CONVEYORS

Operating

Metallic belt conveyors are used for the transport of chips and metal waste. The liquid and

chips flows on the horizontal part of the carpet. The liquid is recovered at the bottom of the

conveyor, and the chips are taken along by bars in the bucket. The liquid is recovered by

openings on the side or at the bottom of the conveyor. The belt conveyors can be also used in

other fields (ex: sheet falls, parts).

There are various sizes of pitch

• Pitch 25.4: Due to the small direction-change radius especially suited for installation

underneath stamping tool to transport parts and punching.

• Pitch 38.1: For the removal of metal chips, waste material, transport of small parts

and different tasks in the field of material conveyance.

• Pitch 63: For disposal of chips and stamping scrap, transportation of parts and

different transportation problems.

• Pitch 100: For central disposal of chips and stamping scrap and for transport of heavy

loads.

Thus Pitch 63mm is recommended to carry loose metal chips from different machines to

shredder machine.

COMPOSITION

The structure is folded sheet steel and welded bars. For safety, a bonnet cover is placed on the

inclined part of the conveyor and a chute of exit is bolted on the head of the conveyor.

The metallic belt is composed of two chains with metal rollers connected by plates, the whole

assembled by axes pinned at the ends.

A motor gear, with torque limiter, ensures the drive of the carpet

The conveyors can be equipped with:

• adjustable foot support

• chute on horizontal part

• electric safety

• mechanical safety

• tank of liquids recovery



Specifications

• BELT LENGTH: 25m (25000mm)

• BELT WIDTH: 8" - 36" [25"] (635mm)

• BEGINNING ELEVATION: 8" - 48" [35"] (900mm)

• ENDING ELEVATION: 36" - 126" [80"] (2032mm)

• SPEED: 10 - 45 FPM (2m/min-6m/min)

• INCLINED ANGLE: 30°, 45°, 60° [45°]

• FEEDER LENGTH: 150" - 850" [788"] (20000mm)

• LENGTH OF INCLINE: 52" - 324" [160"] (4047mm)

• NOSEOVER LENGTH: 15" - 120" [61"] (1500mm)

• PIN CHAIN PITCH: 25.4, 38.1, 63, 100 in mm [63mm]

• DRIVE: Standard drive is end drive, overhead, right hand side.

• MOTOR: 1/2 HP through 2 HP. Energy efficient, inverter duty and brake motors also

available. Voltages include 120/1/60, 230/3/60, 460/3/60 and 575/3/60 & DC Voltage.

• SUPPORT CENTERS: Standard supports are on nominal 10‘ centers.

• FRAME FINISH: Standard finish is OSHA safety blue powder. Optional colors

include green, beige, gray, orange, black and yellow.

Figure: 2



Figure: 3 End Drive, Overhead, Right Hand Side Shbz - Steel Hinged Belt Conveyor, Z shape

SHRADDER MACHINE

This machine is used for shredding (Crushing) long bushy chips into smaller and finer chips.

• Frequently metal chips are bushy and do not satisfy the short category necessary for

briquetting.

• Shredding reduces the space taken by metal chips.

• Long bushy chips may jam the briquetting machine components.

• Shredding increases the bulk density of the metal which is needed to be briquetted.

Figure 4



Technical Data

Table : 1

WORKING

• The type of shredder in above figure is called rotary metal chip shear shredder.

• This shredder uses shear blades to cut the long bushy metal chips.

• Shear forces act on the metal chips which will exceed the shear strength of the chips.

When the shear forces exceed the ultimate value, the metal fibers break and the shear

action takes place.

• The parameters of shredding depends on the type of material to be shredded, quantity

of shredded metals to be processed, type of feeding given to the shredder, the size of

shredded metal chip required.

SCREW CONVEYOR

A screw conveyor or auger conveyor is a mechanism that uses a rotating helical screw blade,

called a "flighting", usually within a tube, to move granular materials. They are used in many

bulk handling industries. Screw conveyors in modern industry are often used horizontally or

at a slight incline as an efficient way to move semi-solid materials.

They usually consist of a trough or tube containing either a spiral blade coiled around a shaft,

driven at one end and held at the other, or a "shaftless spiral", driven at one end and free at

the other. The rate of volume transfer is proportional to the rotation rate of the shaft. In

industrial control applications the device is often used as a variable rate feeder by varying the

rotation rate of the shaft to deliver a measured rate or quantity of material into a process.

Figure:5



https://en.wikipedia.org/wiki/Screw_(simple_machine)

https://en.wikipedia.org/wiki/Variable_rate_feeder

Selection of Conveyor Size and Speed

In order to determine the size and speed of a screw conveyor, it is necessary first to

establish the material code number. This Code number controls the cross-sectional

loading that should be used.

The capacity table (below) gives the capacities in ft3/hour at one revolution per

minutes for various sized and various cross-sectional loading.

The basis for the Capacity Table is as follows

Where:

C : Capacity [ft3/hour.rpm]

Ds : Diameter of screw [inches]

Dp : Diameter of pipe [inches]

P : pitch of screw, [inches]

K : percent trough loading

In order to determine the conveyor speed can be calculated by the formula:

Where:

N : Conveyor speed [rpm],

(≤ recommended max. Rpm)

Q : Required capacity [ft3/h]

C1 : Conv. Capacity at one rpm (see table below)

CFo : Overload capacity factor [110% - 120%]

CF1 : Conveyor pitch factor

CF2 : Type of flight factor

CF3 : Mixing paddle factor

BRIQUETTING MACHINE

Briquetting is the process in which densification of loose particles occurs. Briquetting process

was mainly started to compress agricultural waste. These wastes were compressed using high

pressure to increase their density and reduce their storage volume. This reduces their storage

volume and cost.



METAL BRIQUETTING TECHNOLOGY

Metal briquetting is the process of compressing shredded metal chips into small blocks using

high pressure to form briquettes of desired shape. Conventional briquetting processes are

mainly of three types:

1. High pressure compaction

2. Medium pressure compaction assisted by a heating device and

3. Low pressure compaction with a binding agent.

Mainly the selection of the process depends upon the pressure needed to be applied and the

type of material to form briquettes. Here, the material we are dealing with is shredded mild

steel chips. High pressure is required to convert these chips into briquette form of required

shape. Therefore the first method, i.e. High pressure compaction method is selected for metal

briquetting process.

High pressure compaction is of three types:

1. Piston Press briquetting machine

2. Screw type briquetting machine

In piston press briquetting machine, piston is used to apply necessary pressure on the metal

chips to form briquettes. The piston may be mechanically operated or hydraulically operated.

The piston reciprocates in a cylinder and applies pressure using suitable ram design. The ram

forces the material through a die shaped as required.

Advantages of Hydraulically operated piston press over mechanically operated piston press

are:

i. Hydraulic systems can be easily automated.

ii. Ergonomics and aesthetics of hydraulic system is more compared to mechanically

operated system.

iii. More flexible during operation.

iv. Does not require big bulky flywheel technology.

In screw type briquetting machine, a screw mechanism is used to push the feeding material

here, metal chips, into the die. The feeding is constant. The material to be briquetted is

trapped between the casing and the threading of the screw. The diameter of the casing

decreases which increases the pressure between the casing and the thread profile. This

increase in pressure is used for briquetting purposes. The pressure extrudes the metal chips

through the die of required shape.



PROS AND CONS OF BOTH THE METHODS

PROPERTIES Piston Press Screw Press

Flow of output Step by Step Continuous

Designing procedure Simple Complex

Energy Usage Low High

Maintenance High Low

Briquette Density 1.2 gram/cm3 1.4 gram/cm3

Initial Cost Low High

Wear Less More

Table : 2

Considering the application and cost, we need a mechanism which is less costly and easy to

use. Energy usage should be low enough.

We select the piston press because of its simple construction and design procedure. The main

reason being its less costly compared to screw press and has less energy usage. It is the most

cost effective technology currently used by the Indian market.

PARAMETERS OF A BRIQUETTING PROCESS:

1. Compacting Pressure: It is the most important factor which has to be taken In

consideration. Higher the compacting pressure, stronger will be the briquette generated.

The main advantage of correct pressure is that increase in interlocking forces and

adhesive bonding of the metal particles with each other. Other main advantage is that

briquettes generated with high pressure absorb less humidity from the atmosphere thus

reducing the risk of corrosion of the material due to moisture in the atmosphere.

2. Moisture Content: The moisture on the metal chips should be less than 5 percent.

During briquetting process the temperature of the same increases rapidly. This causes the

water to turn into steam. The steam generated has to escape, which is trapped between the

tightly packed particles after briquetting. This steam which is under high pressure will try

to escape to the surface of the briquette which induces cracks and roughness on the

surface of the briquette. So moisture is an important parameter and should be kept in

limits before briquetting.

3. Pressing Temperature: Optimal pressing temperature should be maintained while

making briquettes. If the temperature is very low, the briquette formed will be of very low

quality. The binding between the material may not be strong enough and the briquette

becomes brittle. When the temperature is higher than optimum value, the volatile

materials in the briquette tends to vaporize and may also burn destroying the quality of



the briquette. Therefore, by keeping the temperature at optimum value can increase the

quality, life and strength of the briquette.

STRUCTURE AND WORKING OF BRIQUETTING MACHINE

As stated above, we have selected to work with piston press briquetting machine. After

looking at the advantages offered by the hydraulic over mechanical piston press briquetting

machine, we decided to design the hydraulic system for hydraulic press briquetting machine.

The main components of hydraulic briquetting machine are:

i. Hydraulic equipments like hydraulic cylinders, rams, valves, hydraulic pumps and

hydraulic oil.

ii. Compression chambers

iii. Dies

iv. Screw feeders and hoppers

v. Motors for various mechanical power input.

Figure: 6 (a) Figure: 6 (b)

WORKING

The chips collected from the conveyor are dropped into a shear chip shredder. This shredder

cuts down the long and discontinuous chips into finer particles ranging from few millimeters

to 1 cm in length. These shredded chips are then carried to the hopper of the briquetting

machine. The shredded chips after falling into the hopper is needed to be conveyed to the pre

compression chamber. The feeding job is carried out using a screw feeding system as shown

in the figure. The screw feeder carries the shredded chips from the hopper in a uniform

manner. The screw feeder drops the metal chips into pre compression chamber.

In the pre compression, a hydraulic press which is operated using cylinder 1 applies force in

the range of 100KN and compresses the loose chips. This compression stage eliminates any

air trapped between the chips and compact the chips so that it can fit in the main compression

chamber. This initiates mechanical interlocking between the chips. After pre compression the

chips are then compressed using higher compression force in the range of 500 to 900 kN of



force. This is done using main hydraulic mechanism powered by cylinder 1 as shown in

figure. The chips are forced through a die of required shape using high hydraulic pressure.

The die should be designed to withstand huge temperature changes and pressures. After

pushing the chips through the die, both rams retract. When the ram reaches their TDC , the

screw feeder starts feeding the chips into pre compression chamber again. The same

procedure follows.

The briquette form from the previous cycle may be loosely connected to the die, therefore,

the briquette formed in the current cycle pushes the briquette forward and the briquette comes

out of the die. This applies necessary axial on the die to maintain it‘s required shape.

Necessary support columns are used to support the hydraulic and feeding systems. This

prevents the machine from vibrating and prevents failure due to bending and tensile loading.

HYDRAULIC CIRCUIT USED AND ITS WORKING

The following figure shows the hydraulic circuit used in the briquetting machine. This circuit

uses the sequence valves to control two operations performed in a proper sequence in both

the direction of the DACs. In this example the circuit uses manually operated 4/3 DCV

(Direction Control Valve). This can be made solenoid operated if automation of the

mechanism is required.

Figure: 7

As shown in the figure, the briquetting machine consists of 2 Double Action Cylinders

(DACs). The main cylinder is numbered as 1 and the pre compression cylinder is numbered

as cylinder 2. The extension and retraction of these two cylinders should be in proper

sequence for the working of the briquetting process which is being carried out.

As we have seen, the pre compression takes place first, therefore, the Cylinder 2 should be

extended first and the main cylinder 1 should stay in retracted position. After that the cylinder

2 reaches its end of stroke, the cylinder 1 should extend with greater force so that it can push

the metal chips through the die. The second cylinder should still remain in extended position.

After that, in the third sequence, the main cylinder 1 should retract to it‘s initial position

meanwhile cylinder 2 should maintain its position. In the fourth step, after the full retraction

of the first cylinder, cylinder starts retracting to it‘s initial position.

Ladder diagram shows the proper sequence of the cylinders in an easy manner.



Here, the sequence valves are used for sequencing both the cylinders as described above. 4/3

valve is used for fluid direction control.

The working of the circuit is as follows:

i. When the DCV is in it‘s first position, the hydraulic fluid flows into cylinder 2. This

extends the ram in cylinder 1.

ii. When the cylinder 2 reaches it‘s end of stroke, the pressure inside this line increases.

The pilot of the first sequence valve V1 senses this change in pressure and connects

the line to cylinder 1. This moves the ram of cylinder 1.

iii. When the DCV is switched to position 2, the pressurized fluid from the pump first

flows into the main cylinder. Port 3. This retracts the ram of the cylinder 1.

iv. When cylinder one is fully retracted, the pressure in the line increases. The pilot of

sequence valve 2 senses this increase in pressure which switches the flow of fluid to

cylinder 2. Port 4. This step retracts the extended ram to its initial position.

v. Then the DCV is again switched to 1st position and the cycle continues.

PLANT LAYOUT REDESIGNING

We choose 5S techniques for Redesigning of existing machine shop layout.

The high chips produced machine ore arranged in a single row for convince of transfer of

chips to shredder machine.

5S TECHNIQUE FOR REDESIGNING THE LAYOUT OF MACHINE SHOP

5S is structured approach to achieving clean and orderly work place by fixing place for

everything in its place. 5s is an abbreviation for the Japanese words seiri, sieton, seiso,

seiketsu and shitsuke.

We have used this quality tool in the machine shop of Yamuna Machine work to improve the

environment and safety in the machine shop. We used 5s to redesign the layout to improve

the productivity and cleanliness of the machine shop.

Japanese words meanings are as follows:

i. Seiri – Getting rid of unnecessary items.

ii. Sieton – arranging items systematically for easy retrieval.

iii. Seiso – keeping work place clean and tidy.

iv. Seiketsu – scheduling regular clearing and clearing out operation.

v. Shitsuke – making all the above tasks meet agreed standard.



Figure : 8(A) Figure : 8(B)

LITERATURE REVIEW

This literature review will address a number of experimental studies, experimental

Correlations and data reduction publications which focused on the topic Scrap

recycling/reduction and proper scrap management.

S.N. A Rahim said that ―At present of the manufacturing sector, which is at the economic

level, must be made to sustain societies in the high living by industrial societies and able to

increase productivities so that they are able to achieve the same standard of living equally. It

will be a big issue because recycled materials have become very important to environmental.‖

Qiang Zhai view on scrap recycling ―Current manufacturing companies either landfill these

wastes or pay a third party to haul them away, causing both environmental and economic

issues. As widely recognized, recycling these metal chip wastes could enhance the economic

profit and reduce the environmental impact of manufacturing.‖

Many literatures are been observed over Briquettes making Process of different materials

such as Biomass, Saw Dust, Wood chips, Metal chips, etc.

Sr No. Author Conclusions/Findings

1. Roberto Lucci Theory on recycling or refining of metal chips obtained from

machining in automobile industry. Fusion techniques studied are

efficient since it allows obtaining a considerable percentage of

recovered metal. The values close to 90% recovery.

2 Ganapathi K. N.,

Kalathil

Ramachandran

DMAIC (Define, Measure, Analyze, Improve and Control.)

approach is used for scrap reduction in electronic industries.



3 Qiang Zhai,

Chris Yuan

In the scrap recycling system,

Recycling Metal Chips from Manufacturing Industry through a

Combined Hydrodynamic and Electromagnetic separator instead

of simple magnetic conveyor separator.

4 M. K. Khare Minimization of material and energy wastage also depends

mainly on conditions of material and machine tools. By choosing

proper parameters on the machining operation can reduce the

scrap output. Scrap recycling for metals is the best way to save

energy as well as materials. Chips Briquetting.

5 Sanjay Kumar Total quality management can be used for scrap reduction in a

manufacturing industry and also reduces the production of

unwanted materials during machining process. Stress on metal

recycling is reduced. 5S, Six sigma tools.

6 Sorin T. Teich Lean Management—The Journey from Toyota to Healthcare

7 Matja` Torkar The investigations confirmed that the compaction of the chips is

necessary for a better yield of material in the melting process and

that stainless steel is a valuable source of alloying elements.

8 Sean Dyer cost structure analysis of the recycling process.

Table : 3

PROFIT CALCULATION

The chips Produced per month in the machine shop in the Yamuna industry is about 2,200kg

to 2,800kg. The average taken is 2,500kg per month. The loose chips produced in the

industry is about 30,000kg per year. Loose chips sold to the third party Approx. at rupees 14

per kg.

Therefore, Price of loose chips sold to the third party per month is: 2,500 × 14 = Rs. 35,000/-

The Price of loose chips sold per year is : 35,000 × 12 = Rs. 4,20,000/-

The price of the metal Brequites in the market is about 3 times then the price of loose metal

chips Thus, price of the loose metal chips × 3 ⁞⁞⁞⁞ 14 × 3 = 42 Rupees.

Therefore, Price of Brequites per month is 42 × 2,500 = Rs. 1,05,000/-

Price of Brequites per year is 12 × 1,05,000 =Rs. 1,260,000/-

• Profit per month = Rs. 1,05,000 –Rs. 35,000 = Rs. 70,000/-

• Profit per year = Rs. 1,260,000 – Rs. 4,20,000 = Rs. 8,40,000/-



https://www.ncbi.nlm.nih.gov/pubmed/?term=Teich%20ST%5BAuthor%5D&cauthor=true&cauthor_uid=23908857

Figure : 9

CONCLUSION

As we have already seen that, in today‘s time, the production of large amount of scrap

materials is not only harmful for the industry but also to the environment we live in.

Therefore, by developing this techniques we can reduce the wastage of our valuable resources

(in this case metals like steel, iron, etc). By using metal chip reduction technique in the

Industry, there should not more scraps getting collected in manufacturing plant area.

• The briquette formed is of dimension 100X140 mm

• The volume reduction can be achieved from 10:1 to 15:1. This means that there would be

10 to 15 times less space required than the loose chips. Thereby, reducing storage cost by

10 to 15 times the Initial price.

• The density of the briquette will be 500kg per m^3. The density may be increased or

decreased by increasing or decreasing hydraulic power. This increases the yield of the

material and reduces oxidation of the bulk material. Thereby, the value of briquette is 3

times the value of loose chips.

• Transport cost is readily reduced. Due to volume reduction and definite shape, one can

easily ship these briquettes from one place to other. The number of transport will reduce,

thereby reducing transport cost.

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