CHAPTER -1

1
INTRODUCTION TO COMPANY

Fig.no-1:-Company Photo

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 In the year 1997, Godrej & Boyce celebrated their centenary year.
This dynamic organization has progressed tremendously since its inception and
has been gaining strength consistently. Quality is the hallmark of all the Godrej
products and any product with the 'Godrej' mark represent quality,
dependability & satisfaction to its customers. What now is a gainful industrial
organization was a brainchild of Mr. Ardeshir GODREJ, which through the
help dedicated men with tremendous foresight and finely honed engineering
and marketing skills, has become one of the biggest houses in India.

Godrej also made a significant contribution to self-reliance of the

century by building the engine for the PSLRU locker launched by India. In the
year 1978 Godrej diversified in to the field of chemicals by starting the
manufacturing of soaps and further diversified into production of chemicals for
various industries like textile mills, pharmacies, confectioneries, etc.

The most recent achievement by Godrej was made when it acquired the
ISO 9000, ISO 9001 and ISO 14000 certificate, which former reinforced the
rest of not only the Indian market but also the global market in the product of
Godrej Today Godrej employee over 15,000 people and has grown in to a
multi-core professionally managed group with far reaching service and
distribution network. "Economy and Services” are being the main motto of
Godrej they have already diversified in to field of Indian industry thus helping
in the economic growth of the country.

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 Century old brand name, 'Godrej', it now also provides electronic
security systems products and is angered with the supply and installation of the
electronics safes, electronics security alarm systems, access control systems,
closed circuit television systems and very highly sophisticated advanced
electronic surveillance systems.

1.1 VAROUS PLANTS IN GODREJ

GODREJ & BOYCE MFG. CO LTD.:-

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 It is truly a mullet-faceted company. This is the major collaboration of
Godrej with Boyce Company. The maximum of the business of Godrej is
known by this name. At present all the divisions mentioned below come under
this company.

 OFFICE EQUIPMENT (O.E.) DIVISION: -

The manufacturing activities in this division are distributed in the

following plants:

➢ Plant 1: Steel processing plant

➢ Plant 4 & 14: Furniture systems plant

➢ Plant 13: Industrial storage system

➢ Plant 17: Security equipment

➢ LOCKS DIVISION: -Plant 18 A

➢ TYPEWRITER DIVISION: – Plant 18 B
➢ MATERIAL HANDLING DIVISION: -Plant 16

➢ MACHINE TOOL DIVISION: -Plant 9 & 19

➢ TOOL ROOM DIVISION: -Plant 7

➢ OFFICE AUTOMATION DIVISION: -Plant 19 A

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 ➢ PROCESS EQUIPMENT DIVISION: -Plant 15

This division is located in Plant 15 and it designs and fabricates a large

range of custom-made sophisticated equipment for chemicals, petrochemicals
and fertiliser industries such as heat exchangers, boiler shells, tower internals,
etc., as well as equipment for nuclear and aerospace applications such as parts
of atomic reactor, cryogenic engines and projects of ISRO (Indian Space
Research Organisation).

Fig.no-2:-Heat Exchanger

The process equipment division consists of five main production

departments as follows:

♦ Columns.

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♦ Heat exchanger.

♦ Reactors & Vessels.

♦ Aerospace Division.

♦ Trays & tower internals.

Product range –

• Heavy Walled Reactors

• Equipment Internals
• Fractionating / Distillation Columns
• High Pressure Shell & Tube Heat Exchangers
Custom built Equipment

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 Fig.no-4:-High Pressure Vessels

Fig.no-3:-Heavy Walled Reactor

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1.2 INTRODUCTION TO MACHINE SHOP DEPARTMENT

Machine shop department is one of the vital departments in the ‘Process

Equipment Division’. It possesses machines that are required for machining
the various components of the pressure vessel assembly. The department
produces components that are related to the heat exchanger of the pressure
vessel assembly. The machine shop department is a service department and
works in tandem with other departments of the plant.The components
produced in machine shop department can be given as follows: -

♦ Tube sheets

♦ Baffles

♦ Tie rods

♦ Spacers

♦ Flanges

The various machines used in the machine shop department can be

given as follows:

➢ CNC DRILLING MACHINES: -

♦ ARBOGA 1

♦ ARBOGA 2

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 ♦ HARTFORD 1

♦ HARTFORD 2

♦ BATLIBOI

♦ KOLB

➢ DRILLING MACHINES:- The Drilling machine is in tends fro

drilling medium to large and heavy work pieces. The machine consists of a
heavy round, vertical column mounted on a large base. The column
supports a radial arm which can be raised and lowered to accommodate
work pieces to different heights.

♦ RADIAL 1,2,3,4,5,6,7

➢ CNC LATHE MACHINE:-

➢ HMT LATHE

➢ HORIZONTAL LATHE MACHINES:- The Lathe has got all the

basic parts e.g. Bed, Headstock and Tailstock. The Headstock contains
mechanisms for driving a spindle at multiple speeds. Lathe can feed the tool
both in cross and longitudinal direction with reference to lathe axis. A lathe
receives its power from an individual motor known as motor driven lathe.

♦ BOMBAY LATHE

♦ THREE JAW LATHE

♦ MODULAR LATHE

♦ BECO LATHE

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 ♦ NEW LATHE

➢ VERTICAL LATHE MACHINES:- This type of boring

machine combines the advantages of vertical boring machine and turret
lathe. It has an indexable turret lathe mounted the cross rail above the table
for multiple tooling. A four station square turret side head which enables
facing, turning under cutting and many other operations.

♦ VTL1 SINGLE ARM (CNC)

♦ VTL5 DOUBLE ARM (CNC)

♦ VTL6 (FARREL)

➢ HORIZONTAL BORING MACHINE:- In a Horizontal Boring

machine, the work is supported on a table which is stationary and the tool
revolves in a horizontal axis. A Horizontal machine can perform boring,
reaming, turning, threading, facing, milling, milling, grooving, recessing
and any other operation with suitable tools.

➢ VERTICAL MILLING MACHINES:- A Milling machine is a

machine tool that removes metal as the work is fed against a rotating
multipoint cutter. In a vertical milling machine position of the spindle is
vertical or perpendicular to the work table. The spindle head can be
swivelled at an angle. This machine is adapted for machining grooves, slots
and flat surfaces.

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CHAPTER-2

6
INTRODUCTION TO PROJECT

“IMPROVING OVERALL EFFICIENCY OF THE

CUTTING MACHINES”

MACHINE 1: BEHRINGER BANDSAW

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 MACHINE 2: CNC GAS CUTTING MACHINE – SUAG

MACHINE DETAILS: (BEHRINGER BANDSAW)

Morgantown, PA (April 7, 2010) – A new line of bandsaws engineered to
accommodate and cut large diameter tubing quickly and efficiently is available from
Behringer Saws, Inc. HBP-800AXL Automatic and HBP-800XL Semi-Automatic Series
Bandsaws allow companies to save on upfront capital expenditures and avoid buying
more expensive bandsaws for everyday cutting while expanding their capability to
specifically cut large tubes when needed.
The HBP-800AXL Automatic and HBP-800XL Semi-Automatic Bandsaws
deliver all the performance and capabilities of “standard” HBP-800 Series Bandsaws
cutting solid bars and structurals up to 31.5”. In addition, these new bandsaws allow for

8
the cutting of tubes up to 39" in diameter. Companies can now purchase a lower cost
bandsaw to handle day-to-day production cutting needs at the standard size range while
utilizing this additional feature to accept new projects requiring the cutting of large
diameter tubing.All HBP-800 Bandsaws are built with strong cast iron frame
construction and a twin column parallel down feed design for proper saw blade
tensioning to deliver quick, efficient and forceful low vibration cutting for smooth cuts.
These bandsaws also come with a heavy-duty roller conveyor for quick and efficient
handling of heavy materials pre- and post-cut.
HBP-800 Bandsaws feature a frequency controlled 14.7 horsepower main drive
motor with a variable speed range of between 55-393 Surface Feet Per Minute (SFM)
which is easily selected at the operator’s control panel. Hydraulic and hardened clamping
jaws on the bandsaw ensures steady and precise cuts at all speeds.
This bandsaw is available in both automatic and semi-automatic versions and
requires minimal operator intervention as it is controlled by a programmable logic
controller (PLC). It features an easy-to-use operator’s terminal with diagnostic display,
data entry and program storage. The speed is easily set, controlled and monitored before
and during the cutting process.
Behringer Saws, Inc. provides a full range of sawing and turnkey pre- and post-cut
material handling productivity-enhancing products. Behringer supplies world-class
quality automatic bandsaws to corporations, service centers, job shops and manufacturers
throughout the world. The company also offers the Behringer Eisele brand of manual,
semi-automatic and automatic miter circular cold saws, high performance circular cold
saws utilizing bi-metal or carbide saw blades and CNC miter circular sawing systems.
Also, the Vernet Behringer line of structural fabricating equipment includes high
performance drilling, punching, shearing, notching and marking machines along with
beam coping and drilling and sawing lines.

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 For more information on the HBP-800AXL and HBP-800XL Bandsaws, contact
Behringer Saws, Inc., 721 Hemlock Road, Morgantown, PA 19543. Call toll-free at 888-
234-7464.
Description of machine: -
Stainless steel and tool steel. Tempered steel, special alloys and aluminum. In
different thicknesses, shapes and diameters. Singly, in bundles of fixed lengths.
Whatever you aim to saw, our HBP, HBV and HBM high-performance and automatic
bandsaw series offer the solution you are looking for. In every cutting range. Despite
their outstanding performance, our machines are all designed to offer maximum
operating simplicity and space savings. And like everything from BEHRINGER, they are
unbeatable in terms of speed, precision and quality.

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 SPECIFICATION OF BEHRINGER BANDSAW:-

Model HBP 413A

Cutting range 90° round (inch) 16.1

90° flat (W x H) (inch) 19.7x15.7
90° square (W x H) (inch) 15.7x15.7
75° meter left dia. / flat (W x H) (inch) -
60° meter left dia. / flat (W x H) (inch) -
45° meter left dia. / flat (W x H) (inch) -
Working height (inch) 31.5
Single stroke of the feeding gripper (inch) 15.7
Drive motor (H.P.) – frequency controlled 5.4
Cutting speed (FPM) 65-459
Cutting capacities 47.2" x 31.5"
Saw blade dimensions 19’0”x1-1/2”x .050”
Weight (lbs) 5,170
Space requirement (inch) 116x77
Large dual column - parallel down-feed design
Solid cast bow frame
Cast Meehanite band wheels
Fully automatic hydraulic blade tensioning & carbide blade guides

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MACHINE DETAILS: (CNC GAS CUTTING MACHINE - SUAG)
The RUM is the latest generation of CNC profile cutting machine that combines
the quality of construction of the MAXI machine with the advantages of the price/output
ratio of RUR machine. Standard equipment of the RUM includes all available
automation facilities.
 Basic equipment

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  fully welded beam without bolted joints
 linear bearing in cross axis
 AC servomotors
 digital synchronization in longitudinal axis
 BURNY 10 LCD Plus control system with touch screen
 membrane keyboard
 floating cutting heads
 electric ignition
 capacitive height control of oxy-fuel torch
 automatic gas console
 torch selection from control panel
 automatic initial height sensing of plasma torch
 arc voltage height sensing of plasma torch
 parking facility for heads out of cutting area
 limit switch in each axis
 Optional equipment
 plasma system by customer request
 pneumatic anti-collision system
 pneumatic, plasma or inkjet marker
 air cooling of portal frame
 control system heating (for winter operation)

SPECIFICATION OF CNC GAS CUTTING MACHINE - SUAG:-

RUM 3500 4000 4500
max. number of torches 6
rail span 3500 mm 4000 mm 4500 mm
cutting width * - 1 torch 3100 mm 3600 mm 4100 mm

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cutting width * - 2 torches 3100 mm 3600 mm 4100 mm
cutting width * - 3 torches 3100 mm 3600 mm 4100 mm
cutting width * - 4 torches 3080 mm 3580 mm 4080 mm
cutting width * - 5 torches 2945 mm 3445 mm 3945 mm
cutting width * - 6 torches 2810 mm 3310 mm 3810 mm
cutting length by customer request
min. parallel cut 90 mm
cutting speed 0 - 20000 mm/min.
standard cutting thickness 200 mm
machine width 4100 mm 4600 mm 5100 mm
machine length 1200 mm
machine height incl. rails 1700 mm
cutting table height 700 mm
plasma system by customer request
supply voltage 230V/50Hz
Plate widths 1,000 to 2,000mm
Speed 0 to 8,000mm/min
Track 2,000mm (standard) 1,000mm (optional)
Drives: Longitudinal Rack and pinion Transverse Rack and pinion
Plasma: Upto 200amp plasma system. Full height sense and heavy duty head
Gas and heads: Hi Lo preheat (standard) 2 stage pierce (optional)
Cutters: 2 Maximum
Controller: C.N.C. controller mounted on a pedestal

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Key features:
 Burny 1250 control system includes a fully-integrated Burny 2.5 CNC Shape
Cutting Control, Plasma process controls and a servopak 120 watt pulse with
modulated drive
 CNC Width 2000mm
 Track length to be advised
 Maximum Cutting Speed 6000mm/min
 Maximum Cutting Thickness with gas 300mm
 Single sided drive
 Combined gas and plasma post with ESAB Cool jet Cutting Post
 Operational Manuals
 Mains input would require 240 volts single phase
 Photographs taken on site PRIOR to any work commencing.

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CHAPTER-3

LITERATURE REVIEW

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Literature Review:
1. METHODS:
 Time to process Raw-material.
 Lack of proper understanding.
1. PEOPLE:
 Lack of availability of designers.
 Conflicting mindsets of designers.
 Inadequate skill-mapping.
 Lack of motivation & understanding.
1. MANPOWER:
 Dedicated personnel for planning.
 Lesser no. of designers involved.
 Dynamics of self-help groups.
1. POLICIES:
 Government oriented(Time-consuming) paper work.
 Lack of finance to create larger SHG’s.
 Investment.
1. PLACE:
 Time & cost incurred.
 Proximity to large markets slightly less.
1. SURROUNDING:
 Traditional barriers & mind-sets.
 Linguistic barriers(biggest issues).
1. PROCEDURES:
 Material constraints.
 Requires fine tuning of mind towards market.
 Requires deeper market understandings by designers.

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1. SKILLS:
 Newer skills not impaired.
 Imbalance in skills.

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19
CUTTING TORCH:
A cutting torch head is used to cut metal. It is similar to a welding torch, but can
be identified by having three pipes that go to a 90 degree nozzle and by the oxygen-blast
trigger.

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 Only iron and steel can be cut using this method. The metal is first heated by the
flame until it is cherry red. Once this temperature is attained, oxygen is supplied to the
heated parts by pressing the "oxygen-blast trigger". This oxygen reacts with the metal,
forming iron oxide and producing heat. It is this heat which continues the cutting
process. The cutting torch only heats the metal to start the process; further heat is
provided by the burning metal.

Cutting
Torch for CNC Gas Cutting Machine

Acetylene is the primary fuel for oxy-fuel welding and is the fuel of choice for
repair work and general cutting and welding. Acetylene gas is shipped in special
cylinders designed to keep the gas dissolved.
Oxygen is not the fuel: It is what chemically combines with the fuel to produce the
heat for welding. This is called 'oxidation', but the more general and more commonly
used term is 'combustion'.

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BAND-SAW CUTTING BLADE:

Band-saw Cutting Blade

The typical metal cutting bandsaw machine is used for simple cutting of solid
steel, tubing, and odd shaped material. The material to be cut is mounted in a vise
attached to the bed of the machine.
An electric motor drives the bandsaw blade through a belt and pulley arrangement
from which three speeds may be obtained. The sawing machine frame, upon which the
drive wheel, idler wheel, bandsaw blade, and motor are mounted, pivots from one corner
of the sawing machine bed. The frame is counterbalanced by a tension spring between
the frame and the bed.
Feed is controlled by positioning a sliding weight along a bar fixed to the top side
of the sawing machine frame. A dashpot is positioned between the frame and bed to
stabilize the feed movement and prevent any quick movement of the frame that could
cause damage to the bandsaw blade.

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 The vise used to hold the material being cut is a quick-positioning type and can be
adjusted easily to any angle. An adjustable work piece stop is provided for rapid
positioning of production work pieces.

CHAPTER-4

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ANALYSIS

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25
Time study on Behringer Band Saw Cutting M/C

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27
TIME STUDY ON BEHRINGER BAND SAW CUTTING M/C
LOSSES

SR.NO. ACTIVITY TIME in min %

1. Setting if JOB 115 19.79

2. Measurement 83 14.28
3. Operator non availability 35 4.30
4. Crane waiting time 15 2.58

5. M/C down time 313 53.87

6. Tool changing time 30 5.16

TOTAL 581 100

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TIME STUDY ON CNC GAS CUTTING M/C - SUAG

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30
31
 CNC
SUAG CUTTING M/C LOSSES

SR.NO. ACTIVITY TIME in min %

1. Scheduled/Planned Stoppages 698 49.75
2. Setting Time 17 1.22
3. Start-up Losses[mock-up] 288 20.52

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4. Minor Stoppage[Time Loss] 20 1.42
5. Non Availability of Material 340 24.24
6. Non Availability of Operator 40 2.85
TOTAL 1403 100

CHAPTER -5

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34
 SUGGESTION

SUGGESTIONS BEHRINGER BAND SAW CUTTING M/C:-

Three Major Losses in Behringer:-

1. M/C Down Time.

2. Setting Time.
3. Measurement.

1. M/C Down Time

REASON

Break-down maintenance

SOLUTION

Preventive Maintenance of M/C to be done on time to avoid maintenance while M/C

is in production.

2. Setting time

REASON

Fatigue to Operator in Setting the Job.

SOLUTION

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 Sensors are to be employ on machine.

3. Measurement

REASON

1. Presently measurement is done manually by operator.

2. New measurement type equipment must be procured to minimize measurement time.
SOLUTION

Sensors assembly has to be done near to the machine blade so measurement time will
be minimum.

SUGGESTIONS CNC SUAG CUTTING M/C:-

Three Major Losses in CNC Suag:-

1. Scheduled/Planned Stoppages.
2. Non Availability of Material.
3. Start up Loss[mock-up].

1. Scheduled/Planned Stoppages

REASON

1. Loading Time Of Plate Is Too High.

2. Time consumed for Setting the Job Plate.

SOLUTIONS

1. Loading Time Should Be Minimized By Offline Setting Of Plate.

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2. Special fixture to be Designed for Quick Setting of Job Plate.

2. Non Availability of Material

REASON

Improper & Unplanned Stacking of Plates.

SOLUTIONS

1. Proper stacking of plates as per priority.

2. Proper proactive planning to feed the m/c as per plan.

2. Start up Loss[mock-up]

REASON

1. No cleaning before Operator reports the machine.

2. Major time consumed in Test Run.

SOLUTIONS

1. Special Cleaning staff to be provided for cleaning of the m/c before operator reports
on the m/c during each shift.
2. Special Fixture to be made to avoid Test Run.

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CHAPTER -6

38
PRO E

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40
41
42
CHAPTER -7

43
CONCLUSIONS

44
REFERENCES

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