Manufacturing Excellence Through A U T O M A T I O N Quality & Consistency through Automation in Metal Finishing Lines Sharad G. Tudekar Director (Works) Uttam Galva Steels Limited Anuj R. Miglani Dy. Managing Director Uttam Galva Steels Limited 01
Manufacturing Excellence Through A U T O M A T I O N 01
Automation is welcomed most where it contributes to profit. Automation is effectively used for improving: Productivity Product Quality In turn it leads to Profit Customer satisfaction. 02
More Goods produced per manufacturing floor area, machines installed & total human work force. Reduces Rework and wastages. Automation Leads to Competitive position through high volumes. Customer s delight. Inventory levels come down sharply. Reduction in accidents. Less dependence on high skilled work force. 03
Earlier & Now Earlier there were limitations in introducing automation in the Industry due to: ν ν ν High Cost. Low flexibility of the system. 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. 04
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 micron Guaranteed Tolerance : ½ Speci I.e. +/- 12.5 micron Expected by Customer : +/- 10 micron With 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. 12 2 th th April April 2007, Mumbai 05
Duty of Technocrat To transform the organization into an efficiently managed one through: ν ν ν ν Productivity. Quality. Cost effectiveness. 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. 06
Automation Technology Covers Entire Range from Energy Management To Assets Management To Programme Management To Information Management The nature of Automation depends upon the Type of Industry. 07
Achieving Excellence through Automation 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.. 08
Achieving Excellence through Automation To improve the yield by reducing the wastages. To guide the operator for keeping minimum inventory and to avert any 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. 09
Excellence through Automation Can be achieved through: Machines Men Material Support of AUTOMATION TECHNOLOGY IS MUST 10
PROFILE OF UTTAM GALVA STEELS LIMITED 11
Producing CR Coils from HR Coils by Rolling in 20Hi, 6Hi, 4Hi & Twin Stand 6 Hi Mill. Uttam Galva Steels Limited Producing GP Coils by processing CR Coils in three Galvanizing Lines (now) while 4 th Line(1650mm wide) will be commissioned in July 2007. Producing Colour Coated Coils by processing GP / Skin Passed coils in Colour Coated Line. An ISO 9001 / IS 16949 Company. Awarded Highest Export Awards consecutively for 7 years. 12
CR Coils : 1 Million Tonne per annum. Capacity GP Coils : 0.70 Million Tonne per annum. CRFH / CRCA : 0.30 Million Tonne per annum. Colour Coated Line : 80,000 Tonne per annum. Products Coil form, Sheet form, Slit coil form in various International grades. EXPORT 80% of Production to 120 different countries. OEM For Automobile, White Goods, Oil Industries, Electrical Industries etc. 13
Case Study Twin Stand Rolling Mill Schematic Diagram of Twin Stand Mill 14
Technical Specification of 6Hi Twin Stand (Unique in INDIA) Capacity: 350,000 Mt./Year Strip Thickness: `Input 1.50mm to 4.50mm Output 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. 15
Case Study Twin Stand Rolling Mill 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) 16
Twin Stand 6Hi Automatic Gauge Control (AGC) Objective To Control the thickness (+/-) within the limit desired by the Customers throughout the length of the coil Operator used to measure thickness by micrometer. Earlier Stops the mill. Correct Roll force manually. Not confident. Now Thickness is measured automatically on line while rolling with Radioactive non contact thickness gauge. No stoppage of the mill. Corrected by automatic gauge control system with: a) Feed back control. b) Feed forward control. c) Mass flow control. 17
Twin Stand 6Hi Automatic Gauge Control (AGC) Thickness control became easy. Results Thickness accuracy was +/- 6 microns ( 95% of HR Coil as against +/- 12.5 microns desired by the Customers & +/- 25 microns as per specification. Innovations implemented in Twin Stand Advance mass flow control added apart from (a), (b) & ( c ) controls. Stringent inter stand Tension Control added. Results Accuracy is achieved +/- 3 microns ( 98% of HR Coils. Beyond expectations of any Customer. Customers are delighted.) 18
Shape Control Objective To achieve better shape of CR Coils ( in terms of flatness throughout the coil & measured in I units ) Operator used to feel the shape by Bamboo Stick (Crude method) Earlier Correction by adjusting roll bending force & tilting. Correction is done manually in High Tension. Never correct. Results Adjustment by Fluke I Unit varies from 25 to 50 ( as against 22 I max as per specifications) 19
Shape Control Shape is measured on line automatically with a flatness roll having piezoelectric transducers embedded inside the roll. Now (in Twin Stand) Shape measurement is processed through software & correction signals are given to hydraulic gap control system for : a) Roll bending. b) Tilting c) IMR (Intermediate Rolls shifting) Results Shape is control below 10 I units consistently. Faster acceleration to reach Top Speed can be achieved. Other benefits Better quality of CR which helps in getting lower consumption of Zinc during Galvanizing. Increased productivity due to lower number of coil breakages. 20
Twin Stand (6 Hi) Automation at 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. Level III (Future) Production Planning will be transmitted to Level II System. Operator need not enter Input / Output products specification. Level II 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 I Instrumentation, Programmable Logic Controller (PLC), Human Machine Interface (HMI) etc. Process parameters are set by operator manually but controlled automatically. 21
Profiling Gauge in Twin Stand Mill Objective To 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. 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. 22
Twin Stand Mill Mill Management System (MMS) Level II Works as Level II System. Operator enters Input / Output products specifications. Through Mathematical Model, MMS System computes process parameters (required Roll force, Tension, Roll gap, thickness etc.) and transfers to Level I System. Benefits Consistency in operation and does not depend upon operators. Consistency in Quality of CR Coils. 23
Case Study: Coating Thickness Gauge for Galvanizing Lines
Case Study: Coating Thickness Gauge for Galvanizing Lines Automation Coating Thickness Gauge. (X-ray Fluorescent) - XRF Objective To control Coating thickness within the tolerance limit. Earlier Now Manual Control Variation (-) 5 gm/m 2 to (+) 5 gm/m 2. Control based on Laboratory Test (takes sampling to result 30 minutes) wastage of zinc. With Semi Automatic, Operator gets display on XRF gauge coating thickness & he adjusts: a) Nozzle distance / angle of nozzles. b) Air pressure Future to switchover to automatic to control above parameters. 12 2 th th April April 2007, Mumbai Even Zinc saving by 1 gm/m 2, Company can save about Rs. 25 Lakhs / month with a production level of 34,000 Mt/month. 24
Technical Specifications of Galvanizing Lines No.1(CGL) No.2(PRC) No.3(WGL) No.4(SGL) 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/m 2 90-275 gm/m 2 90-275 gm/m 2 100-600 gm/m 2 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 25
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. 12 2 th th April April 2007, 26 Mumbai
Conclusion At At the the end, end, I I would like like to to give give my my thoughts to to this this August Gathering. I I am am confident that that by by implementing these suggestions, it it will will make Breakthrough in in making further advancements in in the the field field of of Automation. a) a) There should be be more interaction amongst Automation Industries and and Metal Finishing Industries. b) b) Understand the the requirements of of Metal Finishing Industries. c) c) Make them as as Partner & not not only only as as Customers. d) d) Have full full transparency in in dealing with with Metal Finishing Industries with with respect to to Transfer and and Automation Technology. e) e) Develop the the Automation required by by Metal Finishing Industries in in various units keeping in in view view their their various requirements. 26
Conclusion f) f) Implement in in Metal Finishing Industries as as Joint Venture. g) g) If If successful at at first first attempt, make further improvement. If Ifnot, do do not not get get discouraged for for the the failure. You You are are going to to succeed in in next next attempt since your your will will is is very very strong. h) h) Indian Engineers both both in in Automation & Metal Finishing Industries have got got tremendous potential. Only Only we we have to to Tap it. it. i) i) If If higher management shows confidence in in them, they they can can do do miracles in in implementing Advance Automation in in Metal Finishing Industries keeping in in view view Quality, Consistency, Safety, Cost Cost effectivenessetc. etc. and and do do not not lag lag behind as as compared with with other parts of of the the World. 26
Thank you 27