ABOUT THE COMPANY 1

TRF Limited
The Tata Group, founded in the last quarter of the 19th century, at a time when India had just embarked
on the road to independence, is committed to aligning its business opportunities with nation building
activities.
TRF Limited, established in 1962, is part of the Tata Group of Companies which consists of more than
90 enterprises operating in seven business sectors, in over 80 countries. .
The combined competencies of three companies, the erstwhile Tata Robins Fraser (established in
1962), Tata Material Handling Systems (formerly Tata Man. Ghh., established in 1978), and Tata
Techno dyne (established in 1996), resulted in the formation of TRF Ltd
The company has evolved into one of the most comprehensive sources of engineering equipment,
systems and services. It manufactures bulk material handling and processing equipment, bulk material
handling systems, coke oven equipment, coal dust injection systems for blast furnaces, coal
beneficiation systems, and port and yard equipment. It's Port and Yard Division is also equipped with
the technology; EPC and EPCM services for mini blast furnace technology. TRF Ltd caters to diverse
industries including power, metallurgy, chemical, mining and cement.
Over the last five decades, TRF has emerged as a pioneer in solutions for material handling equipment
and processing systems required in the infrastructure development. In quest of rapid growth, TRF has
also diversified into automotive applications business. It envisages growing five times in five years
and becoming a Rs 2500 Crores Company by 2013 by enhancing focus on material handling business
and auto applications business.

1.1 TRF Group Companies

The Companys subsidiary, York Transport Equipment (Asia)Pvt Limited, Singapore is engaged in the
business of trailer under gear, which includes axles, suspension and other components, with market
presence in 27 countries. York Transport Equipment (Asia) Pte Ltd has manufacturing facilities in
Singapore, Australia, China and India. TRF has also set up Adithya Automotive Applications Limited,
an automotive applications unit for a fixed body truck application in India. The objective of this
venture is to engage in automotive applications and provide end-to-end solutions through fabrication
and machining for tippers, load bodies, refrigerated bodies, etc. TRF acquired the Dutch Lanka Trailer
(DLT) Manufacturers Limited, Sri Lanka. DLT is a world class trailer manufacturing company and has
manufacturing facilities in Sri Lanka, Oman and India. It exports trailers to as many as 30 countries.
More recently TRF has acquired Hewitt Robins International Ltd (HRIL) London which has a world
class reputation in bulk material handling and processing equipment. Hewitt Robins is engaged in
design, manufacture of Mobile Crushing plants and Screens, and related products in the quarrying,
mining, recycling, iron and steel industries. It's proven screen and crusher brands, including the
Container Classic' and the Super Jaw', are all setting standards by which competitors' equipment is
judged.
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1.2 TRF Business Units

The Company has five business units which cater to the material handling requirements of customers
in the core infrastructure sectors of the economy. TRF Limited undertakes turnkey projects for
infrastructure development industries such as power and steel plants, cement, ports, fertilisers and
mining. TRF's material handling products and systems are well known in the market, in India and
overseas, for their reliability, productivity and longevity. The Company been constantly upgrading and
developing new products and systems with the help of internationally reputed enterprises having
cutting edge technical expertise.

BMHE
BMHS
PORT & YARD
O & MS
BOP
1.2.1 Bulk Material Handling Equipment(BMHE) Division:-

FIG 1:- BMHE DIVISION

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The Bulk Material Handling Equipment Division specialises in the design and manufacture of a wide
range of material handling equipment used in the infrastructure industries, such as wagon tipplers,
stacker reclaimers, ship loaders and unloaders, travelling wagon loaders, etc.

1.2.2 Bulk Material Handling Systems(BMHS) Division:-

FIG 2:- BMHS DIVISION

The Bulk Material Handling Systems Division offers a complete package of material handling and
allied systems and services on a turnkey basis.

1.2.3 Port & Yard Equipment :-

FIG 3:- PORT & YARD DIVISION

TRF Ltd specialises in engineering and manufacturing of unit and bulk material handling equipment
for ports, ship-yards, power plants and metallurgical units, while also providing consultancy and
maintenance to those sectors.The company has carved a niche for itself in the global market, as a
leading supplier to ports in India, having the potential to compete with global players. In fact, the
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largest luffing grab cranes and ship unloaders in India, have been supplied by TRF Ltd.

PRODUCTION PROGRAMME
Maritime Technology
Level luffing cranes unit handling
Level luffing cranes grab duty
Ship and barge unloaders
Ship and barge loaders
Shipyard gantry cranes
Rail mounted quay container cranes
Rail mounted gantry container cranes
- Rubber tyred gantry container cranes
Bulk Handling
Stackers
Bucket wheel on boom reclaimers
Combined stacker reclaimers
Bridge type reclaimers
Metallurgical Cranes
Ladle cranes
Special purpose cranes.
Operations
Development
Engineering
Supplying
Erection and
Commissioning of the above equipment as well as related consultancy and maintenance.
The equipments are customised to the customers requirements and also to the unique locational
characteristics, to enhance performance. The state -of-the-art technology coupled with TRFs
invaluable experience in this field, ascertains a smooth operation with minimum operator fatigue.
For the customers, this feature translates into uninterrupted higher output giving it a competitive
advantage.

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TRF Ltd. has set-up the Operations and Maintenance Services (O&MS) division to serve the end
customer for an operational plant. This service is aims to lower total cost of maintenance and asset
upkeep for the customer.
Apart from direct financial benefits, O&MS strives to provide customer with a safe and green plant,
guarantee performance levels and develop trust amongst the customer of the service provided.

1.2.5 BOP:TRF is exploring various possibilities to diversify into new areas of growth and BoP business is one of
such opportunity. With this intent TRF has launched a new strategic business unit as BOP Division at
Kolkata. This Strategic Business Unit undertakes complete execution of BOP facilities for power
generation projects on turnkey basis. TRF has many strategic advantages which have made it a
frontrunner in this arena.
The BOP or Balance of Plant system comprises of all the system and utilities which are required to run
thermal power plants starting from raw material input to waste output apart from the power island
which includes the generator, turbine and boiler with its auxiliaries.

1.3 TRF JAMSHEDPUR :The TRF Works at Jamshedpur spreads over nearly 22 acres with and this includes six covered
manufacturing bays on nearly 21,250 square metres. TRFs skilled manpower meets the expectation of
its customers by continuously adapting new technology, upgrading skills and serving its customers on
time. They also use several process improvement tools and techniques like TOC-CCPM, quality
circles, cross functional teams, etc to attain the highest level of productivity.
TRF, with the help of advanced design and analysis software, constantly innovates, enhances
efficiency and improves reliability of its products and systems which enable it to maintain leadership
in the market.

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FIG 4:- MANUFACTURED PULLEY IN TRF

Vision

We will grow five times in five years and become a Rs. 2500 crore company by 2013, by enhancing
focus on material handling business and entering new businesses as necessary. We will expand our
business on a sustainable basis by building a team that is passionate about serving all its
stakeholders and is committed to makingTrust, Respect and Fellowship, a Way of life .

Mission

To be an internationl leader in material handling equipment, processes and systems.

TRF Values
Trust
Respect
Fellowship

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Excellence
Responsibility

Business Principles
Sense of urgency
Continuous improvement
Consistency and detail

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1.4 Vision - 2013

TRF Ltd Launches Vision 2013

TRF Lt d new vision was ceremoniously launched by its Chairman, Jamshed

J
Irani, along with Managing Director, MrSudhirDeoras and President of Tata
Robins Fraser Labour Union, MrRakeshwarPandey in the presence of its employees and external
stakeholders
in
a
function
held
on
April5,2008...
DrJamshed J Irani, Chairman, TRF Ltd said that while it is important to set a Vision, it was even more
important to achieve them within a given time frame as vision without action was just a dream. He
emphasized that the goals set in Vision-2013 must be achieved by the year 2013, if not earlier.
MrSudhirDeoras, Managing Director, TRF Ltd said that he was confident that TRF Ltd would achieve
the goals laid in Vision 2013. The Company is gradually raising the bar of its performance and this
indicated it had the potential to improve its performance. However, he said that the Company must
now work with a sense of urgency and execute its projects and orders with the customers interest in
mind.
The President of Tata Robins Fraser Labour Union, MrRakeshwarPandey, said that he believed that the
employees of TRF Ltd had the potential to achieve the goals laid in Vision-2013. This he said had been
demonstrated by them and the new vision would facilitate them to enhance their focus on and help to
achieve their targets on sustainable basis.

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1.5 Milestones
Pioneers & "Firsts"

It has been five decades of an uphill journey, at times easy and at times strewn with impediments. But
the fortitude to deliver in the most adverse of conditions, the team spirit and respect for each other and
the ability to dream and the courage to realise this dream has placed TRF in an enviable position.
Defined below are some historical moments in the TRF Ltd's voyage through these last 46 years....
1962-69

1970-79

1980-89

2000-09

2010-2011

2012 Onwards

1990-99

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1.6 TRF VALUES

Any organisation is identified by its corporation culture and the manner in which it conducts
business. The Tata group has since its inception been identified by its belief in responsible and
ethical business practices. These values were articulated by the Founder of the Group, Jamsetji
Tata. They have been reinforced and carried forward to every Tata Enterprise by successive
generations of leaders. At TRF, in all communication with employees and union office bearers,
MrSudhirDeoras, Managing Director, TRF continuously emphasises the need to demonstrate
certain Values.

Values

Appropriate Behavior

Trust

State of being responsible responsible behaviour wins trust

Respect

Due regards for feeling and for rights of others

Fellowship

Group of people meeting to pursue a shared interest or aim for larger benefit

Excellence

Possessing good qualities of a high degree

Responsibility

Ability to be responsible for our conduct and activities

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HISTORY 2
YEAR
1962 -

EVENTS
The company was incorporated on 20th November, at Jamshedpur. The company was
Ltd.,(ACC) in financial &technical collaboration with Hewitt-Robins,Inc.
of U.S.A.(now known as the Hewitt-Robins Division of Litton Systems Inc.,
Of U.S.A.) and the General.Electric Co., Ltd., U.K

1970 -

The main objective of the company is to manufacture of material Handling

equipment such idler rollers, vibrating screens, sectional and mine conveyors,
industrial chains, wire screen cloth, winders, tipplers, crushers, ore and coal
preparation equipment, and coal cutters and undertaking Systems Contracts for
such equipment including design, Manufacture,supply and installation of equipment.

1973 -

5,000 shares issued to ICICI upon conversion of loan.

1976 -

16,250 Bonus shares issued in prop. 1:3.

1978 -

Shares subdivided. 5,07,500 shares of Rs. 10 each issued at A prem. of Rs. 4

Company's Indian employees, directors, etc. and 4, 42,500 shares offered for public.
subscription during July

1985 .

6,90,000 No. of Equity shares issued at par in part conversion of 2,30,000-13.5% bonds
of Rs. 130 each

1986 -

The Company obtained foreign technical know-how for the manufacture of extensible
belt conveyors in collaboration with Kurimoto of Japan to expand the Company's range
of manufacture of various types of crushers.- 11,11,672 No. of equity shares allotted
(Prem. Rs. 5 per share)in part conversion of 12.5% debentures on 1.3.1989.

1987 -

A substantial portion of the Company's business comprises execution of turn-key

contracts which were executed over a period of two to three years depending upon
the magnitude of the project. The drop in turnover was due to the fact that there were
no major contracts which reached substantial completion during the year.

1988-

The Company also took up the manufacture of stamping charging pushing

machine and charging gas cleaning cars for Tata Steel.

1989 -

A repeat order was received from Tata Steel for a stamping charging pushing machine
and charging gas cleaning car forties coke oven battery No. 6
A portion of Rs. 60 of each debenture was to be compulsorily converted into
4 equity shares of Rs. 10 each at a premium of Rs. 5 per share as on 1st March.

1990 -

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19911992 -

The non-convertible portion of Rs. 100 of each debenture would be redeemed at par after
the expiry of 7 years from the date of allotment of the debentures.
Drop in Company's turnover was due to the fact that there were no major contracts
Which reached substantial completion during the year.

1993 -

As a part of its diversification plans, the first phase of the steel service centre was
implemented. - 15, 60,108 shares allotted on rights basis.

1994 -

Company has been awarded Iso 9001 certification during the year.

1995-

1996 1997-

During February the Company made a Rights Issue of 15,60,836 equity shares
of Rs. 10 each at a premium of Rs. 15 per share in the ratio of 1:2 (only 15,60,
148 shares were taken up). The remaining 688 shares were reserved for allotment
as per approval of Regional Stock Exchange, Patna
The expansion plans for putting up a composite steel service centre at Bara near Agnrio
Jamshedpur made satisfactory progress.
Tata-Ryerson Ltd. was formed to provide value added steel service centre
Facilities throughout the country. In addition, the company's steel service centre at
Bara with all its plants machineries and buildings etc. were to be sold by negotiation to
Tata Ryerson Ltd.

1998 -

The Company had sold its steel service centre assets and Barafora consideration of
Rs. 14 cores to Tata-Ryerson Ltd.

1999 -

As a part of its ongoing technology up gradation and innovation programme the

company has signed an MOU with M/s. Tip-TopSaarGmbH, Germany for acquiring
state-of-the-art know-how for conveyor belt reconditioning plant.

2000 -

The Company successfully commissioned the projects of Stamp Charging machine for
Tata Steel's Battery No.8, Coal Dust Injection Systems for SAIL, Coal Handling Plant for
Rajasthan and Andhra Pradesh.

1999 -

Amalgamation of M/s. Tata Material Handling Systems Ltd.,(TMHS) and Tata

Techno dyne Ltd. (TTDL), with the Company effective1stApril was approved in
The Board Meeting held on 30th March, 1990.

2007 -

TRF Ltd has appointed Mr. Sudhir L Deoras as an Additional Director of the
Company with effect from January 22, 2007.

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TRF Ltd products have established their own brand and a demand for themselves in the Indian
infrastructure sector, such as power, steel, mining, cement and port, to mention a few.
Among its other activities are, implementation of projects on an EPC (engineering, procurement and
construction) basis or providing EPCM (engineering, procurement, construction management) services
towards the setting up of small and medium size plants, such as blast furnaces, sinter plants and coal
washeries.

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PRODUCTS MANUFUCTURE 3
3.1 The products manufactured in TRF LTD. can be listed as follows: Wagon Tippler & Side Arm Charger
Rotary Breakers
Ring Granulators
Screens: Vibro Pulse, Truflo, Ultra flo, Unbalanced Motor, Washery Screens
Impactors, Jaw Crushers, Roll Crushers, Cone Crushers & Hammer Wheel
Rotary Plough Feeders, Belt Feeders
Vibrating Feeders
Shuttle Conveyors
Apron Feeders
Stacker & Barrel Reclaimers
Level Lufffing Cranes & Ladle Cranes
Side Discharge Loaders
Travelling Tippers
Idlers & Pulley

3.1 Some of the noteworthy projects executed by TRF LTD. includes:

Downhill regenerative conveyor systemfor an iron ore mine at Bailadilla.

Coal Handling Plant for Indias first super thermal power station at Singrauli.
High speed vibrating screen for iron ore concentrators of Kudremukh Iron Ore Company.
Automatic mobile wagon loader for coal and iron ore for Tata Steel.
Circular stock piling, blending and reclaiming system for cement factory.
Coal washery.
Coal dust injection system for blast furnace.
Stamping-charging-pushing machine for coke oven.

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3.3 Some big customers of TRF LTD. are:

Tata Power
Tata Steel
National Thermal Power Corporation
Bharat Heavy Engineering Limited
Jindal Steel & Power Limited
Damodar Vailey Corporation
Indian Iron and Steel Company Limited
Shaheed Iron and Steel Limited
South Thermal Power Corporation Limited
Rajasthan Rajya Utpadan Nigam Limited
Aravali Power
Tata Project Bhuwal
M.P. Power

3.4 Name of the competitor:Those companies which are producing the same products as TRF Ltd. and are giving healthy
competition in the world market are:

THYSSEN KRUPP
BEEKAY ENGG
LARSEN AND TOUBRO
ELECON
MCNALLY BHARAT
MECON
HEC
PROMAC
TECPRO

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INTRODUCTION OF PULLEY 4

4.1 INTRODUCTION
Pulleys are the heart of the Belt Conveyor Systems, which hardly can be resisted by an industry to use
them. TRF Ltd. Is one among the prime manufacturers of pulley in India.
Pulleys are generally specified by their types (as drive or non-drive), type of fit, and their purpose and
area of use and these are also important in the decision of the type of manufacturing processes to be
employed.
In the following report, an effort has been implied to reduce the manufacturing time of the pulley.
A pulley can be considered to be made of four main parts namely shaft, hub, flange and shell. This
proves helpful in the study of the manufacturing process of pulley and generating the idea of parallel
machining of each part.
The observation of time involved in machining, transportation, loading, unloading etc. and their
application to the operation tools such as Gantt chart, reveals the scope of reduction of manufacturing
time. The deductions from the chart are then used to establish relationship between different cells using
the concept of Activity-Relationship chart & activity relationship diagram. This concept is then
combined with quantitative techniques, like CRAFT to develop the layouts for manufacturing of
pulley. The possible layouts are then checked for minimum transportation distance between different
cells, using from-to chart.
The report concludes by list of some suggestions related to design of pulley, these when employed may
improve the life of the pulley.

FIG 5:- MANUFACTURED PULLEY

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4.2Types of Pulleys:
I.

Based on use: The following gives an account of the types of Pulleys based on use
1. Drive Pulley It is one which has to drive the conveyor belt system and hence it
involves more Torque transmission.
2. Non-Drive Pulley It just facilitates supporting a belt conveyor system on the other
side of a drive pulley. Obviously, it involves less torque transmission.
3. Snub Pulley It is an idler pulley so mounted as to increase the arc of contact between
a belt and a drive pulley.
4. Bend Pulley It is an idler pulley that is used solely for the purpose of changing the
direction of travel of the belt other than at the terminals of the conveyor.
5. Take-Up Pulley It is an adjustable idler pulley to accommodate changes in the length
of a conveyor belt to maintain proper belt tension.
So, basically, pulleys are of just two types Drive and Non-Drive. Snub, bent, and take-up are
all Non-drive pulleys.

II.

Based on construction: The types of pulleys manufactured here in TRF Ltd. are 1. Non-Replaceable type Press Fit The shaft and the hole are press-fitted to each other,
and hence this is usually used with requirements of less torque transmission.
2. Non-Replaceable type Key-Fit Once fitted using key, the shaft cannot be taken out
from the system, hence called non-replaceable type.
3. Replaceable type Key-Fit It has different diameters of shaft at the two ends, and
hence it can be taken out of the hub at a later stage, hence replaceable. The fit used is
using a key.
4. Ring Feeder Type Ring feeders are used to employ the connection of shaft and hub.
Ring-feeders are heavy-duty locking elements and can be tightened as per the
requirements of the torque transmission. It is the most costly but the most advanced in
Pulley construction design as well.

Thus we see that there is a wide variety of Pulleys manufactured here in TRF Pvt. Ltd, and a particular
industry when ordering, orders all the different kinds of Pulleys needed to it, at different places in the
industry based on its use.

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PROCESS FOR MANUFUCTURING 5

5.1 Process chart:1. Planning :-

2. Preparation:3.
4.
5.
6.
7.
8.

Material
Instruction sheet
Process chart
Progress cum H/O sheet
Marking and cutting

Fabrication :Drilling, Bending, Rolling, Straightening

Fitting
Welding
Assembly (Dressing, Cleaning, Painting)
Inspection
Cost centre

5.2 Stages of Manufacturing:

For manufacturing of a certain product, the process takes the following route:
1. Order from the customer: The customer requiring a certain number of certain types of
products issues the order to TRF.
2. Issue of SODS (Sales Order Data-Sheet): The marketing department of the company releases
SODS and sends it to the departments of Planning and Design.
3. Drawing of the product: The design department makes a detailed drawing of the product to be
made and sends APL (Advanced Procurement List) along with it to the Planning department.
4. Purchase Requisition: The above is sent to MMD (Material Management Division) and a
Purchase Requisition (PR) is prepared involving the details of the materials to be purchased
keeping in view of the inventory already existing, and the capacity of it.
5. Instruction Sheet: Planning department sends an IS (Instruction Sheet) to the work-shop,
which involves the details of the various units to be assembled in the final product, and acts as
a guide to the Shop Engineers to manufacture the required product.
6. Purchase Order: The MMD then releases a PO (Purchase Order) which is sent to the various
raw-material making companies. After the procurement of the raw-goods, the manufacturing is
started in the work-shop.

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FLOW CHART OF PULLEY

PROCESS
Lagging

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FIG 6:- OVER ALL FLOW CHART

5.3 Details of the operations:

The manufacturing process of pulley can be subdivided into that of its main parts namely shaft, hub
and shell and then their assembly. Various operations involved require different machines and
equipments and finished or unfinished components are to be transferred to the respective. The required
transportation is executed by EOTC (Electric Overhead Travel Crane). The EOTC facilitates
movement of a work piece by hanging it by the means of iron-ropes and hooks. For the machines
placed closer, jib cranes are used for transportation. For transportation of smaller components, special
vehicles called Forklift are used more often.

SHAFT
1. Raw material for shaft can either be Forged Steel Bar/Blank or Rolled Steel bar, depending
upon the diameter of Pulley, applications, cost and preferences. (Typical Ultimate Tensile
Strength 60-65 N/mm2).
2. Centering: Centering of shaft is essential to eliminate any possible eccentricity (caused due to
eccentric turning of shaft on lathe) that can lead to appreciable amount of vibration in the
pulley. The purpose of centering is accomplished by the use of centering machine, incorporated
with the arrangements that easily locate the center of the shaft. Two V-jaws are employed for
locating centers. Centers are drilled into the ends of the shafts. (25 minutes)
3. Turning: Turning for the shaft of pulley under study is performed on Conventional lathe. At
first turning is performed on one side of the shaft as per the dimensions required, then the shaft
is reversed to turn the unmachined part of the shaft (part under the chuck) it is required that the
shaft be unloaded, the chuck be set according to the new diameter, the program required for the
machining of the other side be entered, etc. These all take some 200 minutes. (800 minutes)
4. Key way marking: After the turning of the shaft is finished, shaft is transferred to the marking
table.keyway is marked manually. (33 minutes)
5. Key way cutting: The marked keyway is transferred to the milling machine. Two different tools
are employed to cut the slots having round end. First the round end is machined using two flute
slot drill and then key slot is extended along the length by slot cutter.The keys are then fitted
into the two middle slots. (197 minutes)
This makes the shaft ready for assembly.

FLANGES
Flanges are disc-shaped structures made from weldable quality structural steel plate. In End-flanges,
OD is matching to Shell and ID is matching to Hub, to support the hub against shell, while in middle
flanges, OD is matching to shell and ID is kept with some clearance between it and shaft. End Flanges
are supported to the hub using ribs. Chamfer is provided at the inner periphery of the end
flange.Cutting of Flanges from Steel plates is performed using Super Plasma Cutting System, from
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Koike Sanso Kogyo Company Ltd., Japan. It is reputed to be the worlds fastest precision plasma
cutting system, with a maximum speed of 6000 mm/min.

HUB
1. The raw hubs are hollow round bar or Forged Steel blank or weld able steel casting,
depending upon quality and preferences.
2. Turning of the outside diameters of the Hub as well as boring of the inner diameter is
performed on CNC lathe. (185 minutes)
3. The Hub is marked for keyway cutting. (16 minutes)
4. The keyway is cut using Slotting Machine. (92 minutes)
5. Fitting End-Flange: Flanges are cut using Plasma Cutting Machine. End-flanges are fitted with
the hub using Tack-Welding. (89 minutes)
6. Welding End-Flange Then it is welded with the hub, using CO2 welding. (255 minutes)
Thus the hub with end-diaphragms is ready for assembly.

SHELL
1. Raw material for shell is large weldable quality structural Steel Plate.
2. The large plate is cut into smaller sheets of sizes corresponding to the dimension of the shell.
This cutting is executed by using Plasma Cutting machine.

Shell Cutting:150

Shell Rolling:350

Steel Plate

Rawmatl. for mid-fange

Steel plate

Machining:610

End Flange Cutting

Balancing:60

Middle-fange cutting

Shell Extra Matl. Cutting:100

Shell Fitting:80

Shell Welding:230

Re-rolling:170

Shell with middle fange welding:100

Pulley Manufactured

3. The plate is bent into cylindrical from using 3-Roll Bending Machine. (350 minutes). The three
rolls are so placed that their centers form the three corners of a triangle. Initially, one end of the
plate is inserted between first two rolls and the plate is then withdrawn spontaneously due to
rotating roll pressure. The bending of the sheet is obtained by the vertical translation of two
lower rolls required to increase the roll pressure. The open shell is obtained as a result of this
process.

Forge

Hub

Hub

Hub

Hub with fange ft

Hub with Flange w

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Shaft Centering:25

Forged Bar/Rolled Round

ning:180

Shaft Turning:700

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Blank/round Bar

rking:15

Pressing:180

Shaft Key ftting

Shaft Keyway Cutting:200

Keyway Marking:30

g:90

ding:250

Welding of Pulley:540

Fitting of Pulley:420

yway cutting:90

FIG 7:- MANUFACTURING OF SHELL

4. More commonly, the portion of the metal at the ends of the rolled sheet remain unrolled. This
makes it difficult to join the ends to form the shell. Thus, it is required to remove these portions
of the rolled sheet. This is executed by the gas cutting. In general, the width of this portion is
6mm approximately at both ends.
5. The shell is then fitted. Tack welding is performed at intermittent points. (81 minutes)
6. The two ends are then joined together by welding. The welding process used is submerged arc
welding. (231 minutes)
7. The welded shell is again processed by the 3-Roll Bending Machine to make it more uniform.
(173 minutes)
8. The Middle-flanges (also called Diaphragms) are welded in between the shell. This is done to
provide extra constraint to the shell expansion and keep the shell intact even in severe cases.(97
minutes)
9. The Shell is ready for assembly.

ASSEMBLY
After making all the parts ready, they are assembled through the following sequence of operations:
1. Pressing: One Hub with flange is pressed to one side of the shaft using the type of fit
incorporated (here, it is key fitting). The shaft is then carefully inserted into the shell to
properly match the central line of shaft and shell. The second hub is then pressed into the shell
using Horizontal Pressing machine. (180 minutes)
2. Fitting: It involves performing tack welding at areas where shell and end-flange join and
making the pulley ready for welding. The distance of shaft and shell is checked in four (or
eight) different radial directions, and made equal before tack welding is performed.
3. Welding: The above areas are now welded using CO 2 welding on both the sides of the pulley.
(537 minutes) Horizontal welding is employed by putting the assembly into a pit. First flange is
welded , assembly is reversed and then the second end is welded.(420 minutes)
4. Returning : Finally, pulley is machined by mounting it on its shaft centers. (612 minutes) this
is done to obtain more uniform cylindrical surface.

23 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

5. Balancing: It is performed to make the pulley balanced in terms of weight along all radial
directions. (60 minutes)
Method of checking: For checking, whether the pulley is balanced or not, it is mounted on the
Balancing Machine, and rolled to a particular direction. When it stops, it should not roll back
by more than 5o.
If the pulley is not balanced, counter-weights are welded to the outer periphery of end-flange
inside the shell at appropriate positions.
6. Lagging: It is the operation of providing Rubber Lagging on external face of the shell, which
comes in contact with the belt. It is performed due to following reasons:
(i)

To increase friction: The friction co-efficient between rubber and rubber is higher
compared to rubber and steel. Thus rubber lagging permits transmission of higher
tractive pull to belt, reduction in belt tensions and consequent economy.

(ii)

To prevent material build-up: Rubber lagging prevents wear of shell against wear by
abrasive and corrosive materials.

Lagging is not performed here in TRF, and Pulleys are sent outside for the same. It is done
using Hot Vulcanising Process. The Non-Drive pulleys usually have plain lagging, while two
types of lagging grooving patterns are usually provided on the Drive-Pulleys:
(a) Herring Bone pattern The grooves are inclined at approximately 60o to the belt-axis. This
type is ideal for unidirectional conveyor, and the groove apex allows escape of material
trapped between belt and pulley.
(b) Diamond pattern This is used for conveyors operating in both the directions.
In this way, a Pulley is manufactured.

24 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

5.4

FLOW CHARTS OF PROCESSES

FLOW CHART FOR MANUFACTURE OF SHAFT

START

TEMPORARY STROAGE

CENTERING
&
CUTTING

CM-1, SW-2

TURNING
& FACING

CL-1, 16, 18, 20,

CL-21, 22, 24

KEYWA-Y
YES/N0OOO
OO

YES

UM-2

KEY
PROCESS

NO
INSPECT
ION

SHAFT

25 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

FLOWCHART FOR MANUFACTURE OF DIAPHRM OR E.F

START

TEMPRORAY STORAGE

PC-2

CUTTING &
PREPRARIO
N OF E.F

BEVELLIN-G
OF E.F

PC-2

INSPECTI
ON

DIAPHRAM OR
E.F(2 NOS.)

26 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

FLOWCHART FOR MANUFACTURE OF HUB

START

TEMPRORAY STORAGE

SB CNC CL-23(CL-22, 18, 21, 24)

TURNING
PROCESS

BORINGP
ROCES-S

SB CNC CL-23(CL-22, 18, 21, 24)

FACINGP
ROCES-S

SB CNC CL-23(CL-22, 18, 21, 24)

KEYWAY

KEYWAY OR
DRILLTA-PPING

DRILLTAPING

KEYWAY
YES/NO
YES

KEYWA-Y
PROCESS

DRILLIN-G
PROCESS
NO

INSPECTI
O-N

HUB

27 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

FLOWCHART FOR MANUFACTURE OF SHELL

START
TEMPORARY STORAGE

CUTTING &
PREPRATIO-N

PC-2

PR-3

BAY-3(SAAW-1)

ROLLING
OF SHELL

WELDING OF
SHELL
(INSIDE/OUTSIDE)

GRINDING(WE
LD SPOT UPON
SHELL

MIG-2/3

PR-3
REROLLING

MFWELDIN-G

INSPECTI
ON
SHELL

28 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

PULLEY LAGGING 6
Conveyor pulleys can be covered with some form of rubber fabrics or other material. One use of
lagging is to increase the coefficient of friction between belt and drive pulley. Another purpose is to
reduce wear on the pulley face and to effect a self cleaning action on surface pulley.
6.1 Lagging thickness and attachment:
Lagging thickness varies from a few thousandths of an inch as with a sprayed-on coating to a
considerable thickness as with some solid rubber vulcanized coatings.
The normal methods of attachment are bolting, painting, cementing and vulcanizing. Vulcanized
lagging is generally preferred for the heavy or severe service applications. Bolted-on lagging has the
advantage of being replaceable in the field. It can be obtained in various grooved and the specialized
surface finished types. Bolted lagging generally consists of a rubber cover reinforced with multiple ply
fabric construction similar to conveyor belting. The fabric insert is required to reinforce the bolt
holding strength. Painted-on and cemented lagging are generally limited to lighter conditions and are
normally not used where grooving and imbedability characteristics are needed.

6.2 Lagging hardness:

Rubber lagging used on drive pulleys normally has a durometer hardness of 55 to 65 shore A scale.
The lagging on snub or send pulley, which contacts the carrying side of belt, normally has a specified
hardness from 35-45 shore A scale. This cover rubber tends to the build up of material on the pulley
face and allows solid objects to imbed in the rubber lagging rather than to damage the belt.

6.3 Grooving of lagging:

Drive pulley which perform in wet or damp condition are often grooved, these grooves commonly
take the shape of herringbone or chevron shaped pattern cut into the lagging. Generally the dimensions
of the groove are in. wide X in. deep with 1/8 in. minimum thickness of material under the bottom
of the groove. These grooves are usually spaced on 5/4 to 7/4 in. centers. Their purpose is to improve
the traction between the belt and pulley by removing water from belt. The apex of pattern points is in
the direction of belt travel.

29 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

30 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

ssor

section

GATE

Security office

F.G.

Medical office

Transfor -mer 1

Transfor- mer2

Compre -

Diesel generator

Bay 1

Bay3

Storage

Idler section

Bay4

Bay 6

Garden

Canteen

Friction & water testing

Fabrication & Assembly

Storage of various parts

Path way

Material management division (MMD)

Bay 2

Finance

Fabrication & Assembly

Accounts Dept. &

CURRENT LAYOUT OF TRF 7

7.1 SUPPLY RANGE FOR TRF:

DIA.OF PULLEY(mm): 200,219,273,324,400,500,630,800,1000,1250,1600

BELT WIDTH(mm): 400,500,650,800,1000,1200,1460,1600&1800

TIME OF OPERATION 8
8.1 Time involved in each operation:

1
2
3
4
5
6

Centering
Turning one side
Set up time
Turning other side
Keyway Marking
Keyway Cutting

25
400
200
300
30
200

Total time for one piece

1155

BAY 5

M/C
Time(Min) used

Currentlayout of TRF LTD.

Component Name : Shaft

Op.
no.
Operation Name

Centering Machine
CNC Lathe
CNC Lathe
Manual
Milling Machine

Component Name : Hub (with

end flange)
Op.
no.
Operation Name
Time(Min) M/C used
Turning one side
Set up time
Turning other side
Keyway Marking

100
200
80
15

5
6
7

Keyway Cutting
Hub with flange fitting
Hub with flange welding

90
90
250

Total time for one piece

825

Work general ofce

1
2
3
4

CNC Lathe
CNC Lathe
Manual
Slotting
Machine
Welding
Welding

Component Name : Shell

Op.
no.
Operation Name

M/C
Time(Min) used

1
2
3
4
5
6
7

Shell Cutting
Shell Rolling
Extra Material Cutting
Shell Fitting
Shell Welding
Re-rolling
Middle-flange Welding

150
250
100
80
200
10 0
100

Total time for one piece

1180

Plasma Arc Cutting

Plate Bending Machine
Gas Cutting
Welding
Welding
Plate Bending Machine
Welding

31 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

CAPACITY ANALYSIS OF MACHINES

SHIFT

REST

MACHINE

REMAINING 75%
HOUR
(ACTUAL

CAPACITY
X

EFFICIENCY)

CM-1,SW-2

3hrs

21hrs

15.75hrs

350*3000mm

CL-21

2hrs

14hrs

10.5hrs

CL-22

3hrs

21hrs

15.75hrs

CL-24

3hrs

21hrs

15.75hrs

Hgt of center-260mm
Dist. Of center1500mm
Hgt of center-260mm
Dist. Of center1500mm
SHAFT SPEED1800MAX.

CL-18

3hrs

21hrs

15.75hrs

CL-1

3hrs

21hrs

15.75hrs

CL-20

3hrs

21hrs

15.75hrs

CL-16

3hrs

21hrs

15.75hrs

UM-2

3hrs

21hrs

15.75hrs

SL-1

3hrs

21hrs

15.75hrs

SL-2

3hrs

21hrs

15.75hrs

PC-2

3hrs

21hrs

15.75hrs

PR-3

2hrs

14hrs

10.5hrs

SAAW-1
(WELD)
MIG-2/3

2hrs

14hrs

10.5hrs

13hrs

1hr

12hrs

9hrs

HP-3

3hrs

21hrs

15.75hrs

CL-9

3hrs

21hrs

15.75hrs

600MIN.
Hgt of center-450mm
Dist. Of center900mm
Hgt of center-762mm
Dist. Of center812mm,RPM1800MAX.
Hgt of center-1m
Dist. Of center-7m
400*4000mm
630mm(width),
1410mm(long)
R.P.M-11.2
Length of stroke-7.3
R.P.M-18
Length of stroke-11.8
6 to 32mm(thick),
27m(long),3m(width)
3000mm(width)
25 to 32mm(bend
thickness) ,550 to
1200mm(dia.)
Man power=4
Man power=4
MAX. TONS OF
RAM-150
Hgt of center-825mm
Dist. Of center2700mm

32 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

8.2 Deduction from the Gantt chart:1. The time involved in machining of a shaft is maximum; therefore the machining of shaft
must not be delayed as this would delay the overall manufacturing time of the pulley.
2. During the time, a shaft is manufactured, the shell welded with mid-flanges, two hubs
and two end flanges have already been completed. Thus operation of assembly can be
started without losing any time in waiting for the parts.
3. Since, Plasma Arc Cutting Machine is employed for cutting both flanges and sheets for
shells, sheets are first to be cut since they involve longer operation time and then
flanges are cut. Delaying the operation on flange doesnt influences the overall
manufacturing time.
4. As there is sufficient time available for welding the middle flange with the shell, so it
can be transported to the welding section (assembly) and a common welding section can
be employed.
5. If, the machining time, loading, unloading, and setting time are kept constant, the total
manufacturing time is reduced by an hour approximately when new layout is employed.
6. In long run, when large numbers of pulley are to be manufactured, the manufacturing
time reduces significantly.

8.3 ACTIVITY- RELATIOSHIP CHART

B
C

33 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

Here, the symbols in italic form signify the different sections as:A

Plasma arc cutting m/c

Symbols

Meaning

Shaft section

Important

Shell section

Essentially important

Hub section

Absolutely necessary

Assembly section

Storage

Form of layout on the basis of activity relationship chart:

A
ACTIVITY RELATIONSHIP DIAGRAM

CLOSENESS RATING
A
E
I

INDICATION( NUMBER OF LINES)

4
2
1

34 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

8.4 BEST POSSIBLE LAYOUT

Probable cellular layouts of the pulley section can be obtained on the basis of the activity-relationship
chart. Here, some are some attempts to find the best possible layout:1.

9m

9m

PLASMA ARC
CUTTING M/C

13.5 m

PRESS
ROLL

STORAGE

4.5 m

CM

SAW

9m

BALANCING

9m

35 m

2m

8m

WELDING
SECTION

9m

E
HORIZONTAL
PRESS

SL

CNC LATHE

13.5 m

CL

UM +
MARKING
TABLE

9m

35 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

From-To chart for the above layout (assuming center to center transportation b/w cells) is:-

17.
5
X

B
C

X
X

16.5

12.4

3
12.
4
16

16

16.8

16.
8
19.
7

19.7

F
17.
5

61.7

19.7

98.9

Other alternative layout can be:9m

9m

PLASMA ARC
CUTTING
M/C

7m

PRES
S
ROLL

5m

CNC
LATHE

D
F
SL

STORAG
E

9m

B
UNIVERSAL
MILLING +
MARKING TABLE

C
L

19 m

CL

CENTERING M/C

M/C

BALANCING M/C

WELDIN
G

PRESSING

9m

35 m

SAW

36 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

37 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

From-To chart for the above layout (assuming center to center transportation b/w cells) is:A
A
B

B
X

C
1
X

18

C
D

1
1

X
X
X
14.7

36
9
18
1
6
14.
0

F
18

61

14.7

93.
7

Thus, from the above two alternatives for the layout of the pulley section designed as per the activityrelationship chart, it can be deduced that the transportation distance of the material is lesser for the
second layout and therefore involves less transport cost. Thus it can be concluded that the second
layout is better than the first one.
There can be more alternatives for these layouts for the same activity relationship chart. For each of
them From-To chart is prepared and total distance covered by the material during the manufacturing
process is calculated. The layout corresponding to the minimum value of the distance will be the best
layout.

38 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

CONCEPT OF SHAFT DESIGN & PULLEY 9

9.1 CONCEPT OF SHAFT DESIGN IN PULLEY

The basic concept of forces, torque and bending moment can be shown by a schematic representation
of pulley.

F
E

F
D

FIG 8:- DESIGN OF SHAFT

The above figure shows the schematic view of a drive pulley. Point B and point E are bearing support
centerlines. Point C and point D are the diaphragm centerlines. Torque T Qis applied at point A. Shaft
section AC will be transmitting this full value of torque. The portion of this torque T QCwill be absorbed
by diaphragm at C and the balance portion TQDis absorbed by the diaphragm at D such that TQC + TQD =
T. the shaft portion AC is carrying full value of torque and thus becomes the criterion for design of
shaft.The torque being applied has following characteristics: The torque during steady state operation is less, but is applicable for most of the time.
The torque at the starting phase is more but duration is short.
The torque is not alternating but remains unidirectional. Therefore, endurance strength is not
applicable.
Maximum torsion stress is at shaft periphery.
Other major force acting on the pulley shaft is in radial direction. Total radial force F= T1 + T2 +
weight of the pulley. The force F can be considered acting at the center. Thus force exerted by each
will be F/2. A multiplier 1.05 is included to compensate for the other factors.
Thus F = 1.05 X F/2. The bending moment has following characteristics: Bending moment is more during starting phase.
Bending moment is less during steady phase operation.
The shaft is rotating. Therefore, each element in the shaft will be subjected to alternating
compressive and tensile stress. Thus endurance strength is applicable here.
Maximum bending stress is at periphery.

39 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

In addition, there will be radial compressive stress within hub due to fitting between shaft and
hub. This compressive force is uniformly spread across width when there is no tension in the
belt. However, in actual installation, a couple force acts on shaft at hub, which arises as a result
of the shaft deflection. The pulley assembly tends to prevent shaft deflection but shaft tends to
create deflection in pulley assembly.
Schematic view of the shaft under action of forces:A

Bending moment diagram of the shaft when free to deflect :-

Bending moment diagram of the shaft when shaft is constrained at hub:-

Pulley behavior under load:- Pulley is a composite structure, which is subjected to radial and tangential
forces. The source of the radial force is the belt and the tangential force originates at the end of the
drive pulley. Pulley composite structure deflects under these forces; creating certain value of deflection
in each component. The deflection of each component is dependent on its stiffness as well as rigidity
of its connection with other components.
The element in the shaft is subjected to usual bending stress, polar shear stress and radial compression
due to hub. It has been observed that the diaphragm joints at rim and particularly at hub are the zones
of stress concentration between hub and shaft. One side of the hub is hard pressed to the shaft whereas
the other side of the hub is less pressed to the shaft. This situation reverses in every revolution and is
critical for hub and shaft. The sudden change of load resisting area from hub to diaphragm and welded
joint at hub outer diameter and rim are prone to failure.

40 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

9.2 Suggestions for design of pulley:1. Use of simple taper bush at Hub:- The taper bush hub sheave is subjected to torque and radial
force but stress due to shaft deflection is virtually non-existent within Hub because it is free to
deflect within shaft. Simple taper bush when used for belt conveyor pulley, is subjected to
different kind of stress pattern due to widely spaced two rigid units subjected to shaft defletion.

Hub
Taper
bush
Shaft

FIG 9:- SCHEMATIC LAYOUT OF PULLEY

2. Shifting of hub joint radially outwards:- The sudden change of load resisting area from hub to
diaphragm and welded joint at hub outer dia. and rim are prone to failure. So, design can be
improved by shifting the hub joint radially outwards. This is economically possible by using
forged or cast steel hubs with extension on the hub outer radius.
3. Changing the position of the keyways in shaft: Keyways are one of the prime sources of
raising stress concentration. Here, there are four keyways machined in the same line in shaft.
This is certainly going to raise the stress concentration. Therefore, it may be suggested that two
of the keyways required for fitting hub should be in one line and other two should be machined
at angular offset of 900 to them. Although, it will increase the machining time and cost, it will
definitely enhance the quality and life of the product.
4. Removing the sharp edge in keyways:- Usually, this is taken care of by the engineers in their
design. But workers often used to neglect this important point. The sharp edge in the inner
surface of the keyways, experiences drastic rise in the stress. This can be avoided by
rounding /filleting the edge using the form tools after slot has been made using slot drill and
slot cutter.

41 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

ANNUAL REPORT 10
Rupees in lac
2013-14

2012-13

2011-12

2010-11

2009-10

Consolidated

Consolidated

Consolidated

Consolidated

Consolidated

117,453.39

111,482.43

132,740.63

111,355.70

86,591.86

Other Income

1,443.58

817.73

659.03

1,254.42

1,237.10

Exceptional Item

2,972.50

Employee Costs

10,889.36

11,787.43

10,306.89

8,302.18

6,914.10

Depreciation

1,233.98

1,214.57

1,077.89

849.17

611.60

Interest & brokerage

5,886.38

5,493.99

4,036.85

1,755.21

1,250.76

(5,644.35)

(8,778.03)

2,718.45

711.86

7,386.77

Provision for taxes (net)

149.01

355.11

1,375.99

522.84

2,509.91

Profit/(Loss) after taxes

(2,820.86)

(9,133.14)

1,342.46

189.02

4,876.86

40

20

75

Work Production

26,450.34

30,713.00

28037.00

24,910.00

20,009.86

Progress billings

50,522.96

59,952.88

65,612.31

64,014.87

54,046.79

As on

As on

As on

As on

As on

31.03.2014

31.03.2013

31.03.2012

31.03.2011

31.03.2010

10,973.75

11,151.99

11,166.11

8,390.78

6,170.29

Share Capital

1,100.44

1,100.44

1,100.44

1,100.44

1,100.44*

Reserves and Surplus

4,746.87

6,570.60

15,017.56

13,380.05

13,616.54

Net worth

5,647.31

7,671.04

16,118.00

14,480.49

14,716.98

59,907.76

57,561.64

50,315.02

32,776.87

21,661.95

53.14

69.71

146.47

131.59

133.74

10.61:1

7.50:1

3.12:1

2.26:1

1.47:1

1390

1579

1556

1336

Sales & Services (Net)

Profit/(Loss) before taxes

Dividend (%)

Net fixed assets

Borrowings
Net worth per share (Rs.)
Debt: Equity ratio
Number of employees

CONCLUSION 11
42 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

From the case study on the TRF LTD.,we got the brief knowledge about the company, its management,
its marketing stratergy etc. About the products which is manufactured in the TRF. Pulley is also one of
the product which is manufactured in this company. A basic idea is highlighted for the manufacturing
of the Pulley, its type, parts which is used in the pulley. There is also need of some improvement in the
process of manufacturing to reduce the time taken by the machines and to increase the the rate of
production. Basic design concept of shaft is essential to make a balanced pulley. After the completion
of the product.i.e- pulley, a process called lagging is needed to increase the life of the pulley, lagging
reduces the wear and tear of the pulley surface from the belt.

43 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING

REFERENCES.

1. http://www.tatasteel.com/UserNewsRoom/usershowcontent.aspx?
id=30&type=Awards&REFERER=http://www.tatasteel.com/media/awards-andrecognitions.asp

2. http://www.tatasteel.com/corporate/operations/indian-operations.asp
3. http://www.tatatinplate.com/hospital.shtm
4. http://www.telcon.co.in/html/SubIndex.asp?sMainPage=plants
5. http://www.tata.com/company/profile.aspx?sectid=4c4BdnkPpOQ
6. http://www.tatagrowthshop.com/corporate/profile.asp
7. http://www.myjamshedpur.com/iswp-launch-wire-unit-expansion-plans-jamshedpur
8. http://www.aiada.in/web/profile/facts.php

44 | R A D H A K R I S H N A I N S T I T U T E O F T E C H N O L O G Y A N D
ENGINEERING