Annexure 4 - Study 2
Annexure 4 - Study 2
bars after hot rolling process. Cooling beds are to be steel, low alloy steel, and tool steel etc. Shears which are used
specifically designed considering the smallest and maximum in rolling mills before the cooling bed are called hot shears
size of bars being rolled in a particular rolling mill. They are while the shears which are used after the cooling bed are cold
designed for receiving, transferring, and cooling of the rolled shears. Hot shears cut desired length and as well as cut front
material. They are sized so that the product cools within a and tail ends of the rolling stock. These shears also cut the bar
particular cycle time. The length of the cooling bed is being rolled in case of cobble in the rolling mill. Hot shears
determined by the maximum run-out bar length, optimized by are designed to cut the rolling stock at the rolling temperature.
the selling lengths to minimize crop losses. The width of a Cold shears are used to cut the rolled product in to desired
cooling bed is determined on the basis of mill productivity saleable lengths. The type of shears normally used in rolling
(tons/hour) and the time required for cooling. Cooling beds mills are (i) crop and cobble shear, (ii) cooling bed dividing
normally have natural air cooling. However, for achieving shear, The crop and cobble shear is used in hot rolling mills
faster cooling of the bars, blowers can be installed for is to crop front end, tail end, as well as to segment cutting in
blowing air from the bottom of the hot bars. The rolled bars case of eventualities. These shears are usually of start/stop
after their rolling in the rolling mill are generally above 700 type and are driven either with flywheel mounted pneumatic
deg C and are to be cooled to below 150 deg C for subsequent clutch/brake or with direct DC (direct current) Motor driven.
finishing process. The cooling bed is located in the rolling These shears are controlled through PLC (programmable
mill after the rolling of steel material is completed. It logic control) system and provide very close tolerance of the
supports and permits hot rolled bars from last stand of the cut length. The cooling bed dividing shear is used to cut
mill to cool. In acooling bed the temperature of the entire cooling bed lengths. This shear is usually designed for low
length of the bar is to be cooled at the same time. If not, it surface temperatures. This shear is generally installed before
develops stresses in the bar. After the last stand of the rolling entry to cooling bed. The cooling bed shear is generally
mill, a shear arrangement is used to cut the bar which is stop/start and continuous operating type and is driven by the
moving to the cooling bed. This shear is normally a dual direct DC motor drive. Hot shears are usually flying shears.
ratio crop and dividing shear. The lengths cut are to suit the Flying shears are those shears which cur the material while it
length of the cooling bed and is based on the multiples of the is moving in the rolling mill at the rolling speed. Flying shears
finished saleable lengths. The cut length optimization are used for cutting applications, where endless material to be
software adjusts the primary cut lengths to the cooling bed to cut to length, cannot be stopped during the cutting process
minimize yield losses. The bar delivery system to the cooling and the cut is required to be effected ‘on the fly’. The
bed is to enable the bars to be transported onto the cooling mechanical construction provides a shear system mounted on
bed at a speed matching with the speed of the rolling in the a carriage, which follows the material with synchronous
rolling mill. There need to have a soft braking system for the speed whilecutting is in progress, and then returns to a home
bars so that the surface of the bars remains in a perfect position to wait for the next cut. The system is generally
condition despite the high delivery speed. The mechanical designed for the special requirements of flying shears under
type of cooling bed is used in which rake type cooling bed consideration of maximum efficiency and accuracy at
has a saw tooth pattern which is why it is also known as a minimum stress for all mechanical parts. Cold shear are for
rake type cooling bed. The purpose of the cooling bed of a cutting of cooling bed lengths into saleable lengths. They are
movable rake design is to uniformly air-cool rolled bars. The installed downstream of the cooling bed exit roller table after
rolled bar as it enters the cooling bed slides onto the first the straightener.
notch on the rakes. The initial notches provide continuous
support for the bar on a casting called a grid casting. Long II. LITERATURE REVIEW
plates with notches set at some distance apart, support the bar Sabiya. K, M. Shilpa, S. Appaiah, Scrap Reduction in TMT
after it moves beyond the grid castings. The bar moves across Reinforced Bar Production by the Application of Lean
the cooling bed by the movement of alternative plates moving Techniques, (IJRTE) ISSN: 2277-3878, Volume-8 Issue-2,
in a cycle of lift, move, and retract, by the action of eccentric July 2019, During the shear cut operation performed on the
cams. Repeating of this cycle moves the bars as they are billet, a large amount of scrap was being generated. The
delivered from the mill. A fixed number of cooled rolled bars overall scrap generation was 6% which is more than any
are sent for final length cutting by cold shear for subsequent industry. Eliminating this non value adding activity the rate
bundling or piling. Cooling beds can also use a chain transfer of scrap production was reduced. Based on this concept the
as the traversing method. Shearing is a simple process used overall percentage of scrap production was reduced to 4%
for the cutting of metals. It is basically a metal fabrication which is important for any leading company in the steel
process and is being used in rolling mills at several places for sector. This concept of wastage elimination is the MUDA
hot cutting of the steel material. Shears can be used to cut concept of lean technique.
steel and other materials of any size or shape. The shearing Tejas Chaudhari and Niyati Raut, Waste Elimination
force is appliedby two blades, one above and the other below by Lean Manufacturing, (IJISET) Vol. 4 Issue 5, May 2017
the material (upper blade and lower blade). These blades are ISSN (Online) 2348 – 7968, This Paper details the use of lean
positioned at an angle relative to each other. These two blades manufacturing Techniques in reducing waste in Nut Bolt
are forced past each other with the space between them Manufacturing Company. The reduction in Through-Put
determined by a required offset. Normally, one of the blades Time is achieved to increases the productivity. This Case
remains stationary. The shearing blades used in the shearing Study addresses the application of lean manufacturing
process typically have a square edge rather than a knife-edge
and are available in different materials, such as high carbon
conceptsto the continuous production sector with a focus on of elimination of waste in the form of under-utilized potential
the Pump manufacturing industry. of employees.
Jorge Madias, Split Ends during Long Products Sanjay Kumar, Dr. S.S. Mantha and Dr. Arun
Rolling: Billet Quality or Rolling Process, during the Kumar, Scarp Reduction by using Total Quality
continuous process in rolling mill, in the long products end Management Tools, International Journal of Industrial
splitting (alligatoring defect) and central bursting occurs, Engineering, 16(4), 364-369 2009. This case study was
which effect on quality and productivity of the product and carried out in one of the leading Indian industries
the different aspects of defects are represented. manufacturing pre-stressed concrete steel strands (PC wire).
Alberto Simboli, Raffaella Taddeo and Anna It has major applications in bridges and construction industry.
Morgante, Value and Wastes in Manufacturing. An Overview During study, lot of scrap was observed. Reasons for scrap
and a New Perspective Based on Eco-Efficiency, ISSN 2076- were found out by using total quality management tools
3387, Adm. Sci. 2014, 4, 173–191; (TQM).
doi:10.3390/admsci4030173, Various studies have been
carried out to encourage companies in including the III. PROCESS DESCRIPTION:
environment in their strategic and operational decisions TMT bar production process involves Induction furnace,
making. This study presents an overview on the evolutionary Continuous casting machine, Reheating furnace, roughing
dynamics of manufacturing in the industrial age, and offers a mill operation, intermediate mill operation, finishing mill
discussion about the potential synergies in integrating IE operation, Quenching process, cooling bed and Cutting
approaches and tools in Lean Manufacturing, by introducing operation, the flow chart for TMT bar production is shown in
the environmental load as a further type of Muda; the figure 1. In the roughing mill, the billet size is increased from
systematic actions to reduce this waste can build up the basis 130*130 sq.mm Cross-sections to 150*150 sq.mm. This is
for improving competitiveness through the eco-efficiency. conducted by passing the billet through rollers in 6 stands.
Agnieszka Grzelczak and Karolina Werner- After this intermediate mill is carried out, in which shear cut
Lewandowska, Eliminating Muda (Waste) in Lean operation is performed. Here, the rod will be cut at its head
Management by Working Time Standardization, Arabian J and tail ends to eliminate the alligatoring defect. In the
Bus Manag Review 2016 and 6:3 DOI: 10.4172/2223- intermediate mill, the cross- section of 150*150 sq.mm rod
5833.1000216, The authors focused on just the last type of diameter is reduced to sizes of 6,8, 10, 12,16,20,25 and 32,
waste that is on the under-utilization of the potential of 36, 40 mm, according to requirements are sent to Pomini
employees. However, according to the author’s Quenching Process where it is quenched in water. These rods
interpretation, thinking of “muda” is not using the available are now quenched in water medium and their length is
working time of employees. In the opinion of the authors, this reduced to 60-Meter after the finishing mill. After this, the
loss is due to a lack of standardization of working time of rods are sending to the cooling bed, where they are cooled to
employees In order to eliminate wasted time at the workplace, atmospheric temperature. After this, depending on customer
the authors suggest using the techniques of work analysis and requirements the rod length is reduced to 12-Meter. These
standardization. The purpose of this article is to present the TMT bars are sent to bundling and ready to use.
methods mentioned and focus on the possibility of their
inclusion in the concept of Lean Management, in the context
Where, 46 are the number of bars obtained and 0.20% is the Weight /1mt length as per BIS for 12mm from table 1 =0.844
random rod generated. weight We would need length of 60 meter = weight * length
(60) = 0.844 * 60Weight for 12mm = 50.64 kg
C. Billet length calculation for 130*130 sq.mm cross section
Number of rods in 1 billet = 1587.85 /50.64 = 31.35
area & for 12mm diameter bar:
Where, 31 are the number of bars obtained and
Length = 9.150 meter, Weight of billet = 1213.88 kg 0.35% is the random rod generated.
Weight /1mt length as per BIS for 12mm from table 1 =0.844 Where, 46 are the number of bars obtained and
weightWe would need length of 60 meter = weight * length 0.20% is the random rod generated. With the revised
(60) = 0.844 * 60Weight for 12mm = 50.64 kg calculation,the % of random rods is reduced from 0.47% to
Number of rods in 1 billet = 1213.88/50.64 = 23.97 0.20% (for 10mm) & 31 are the number of bars obtained and
Where, 23 are the number of bars obtained and 0.35% is the random rod generated. With the revised
0.97% is the random rod generated. calculation,the % of random rods is reduced from 0.97% to
D. Billet length calculation for 150*150 sq.mm cross section 0.35% (for 12mm). The rectified billet calculation for 10mm
area & for 12mm diameter bar: and12mm is shown in table 2.
Length = 8.990 meter, Weight of billet = 1587.85 kg
TMT Bar Billet length in meter No. of Rods Billet length in meter for No. of Rods
Sr.no. Diameter in for cross section produced in 1 cross section 150*150 produced in 1
MM 130*130 billet (rectified) billet
1. 10 9.210 35 9.010 46
2. 12 9.150 23 8.990 31
Table 2: Rectified billet calculation for 10 and 12 mm diameter