1. SCRAP MANAGEMENT IN PUNCHING STATION OF SHEET METAL INDUSTRY
Guided by : Dr. Gukan Rajaram
MISAA 2015
Department of mechanical Engineering
P S G T E C H
KANNAN P
E-mail : Kanna1140@gmail.com

2. PLANT DETAIL
• Plant name - Madras Radiators & Pressings ltd.
• Manufacturing type - Job shop production
• Product - Sheet metal product
• Major customer - L & T, Gilbarco India, Bull India and Tafe.
• Production capacity - 60 tons per month
Department of mechanical Engineering
P S G T E C H
MISAA 2015

3. PROBLEM STATEMENT
• In the current method there is no system to track the scrapped sheet coming out
of the punching station which leads to increased scrap inventory in the shop floor
and reduced utilization of scrap sheets for further production.
Department of mechanical Engineering
P S G T E C H
MISAA 2015

4. LITERATURE REVIEW
• Taner Arsan, Emrah Bas_kan, Emrah Ar and Zeki Bozkus [1] have developed the
“Inventory Management System” to replace the traditional paper work based
inventory records. In their project they have designed the front end application
which have an interface with the SQL database for storage and retrieval of data.
The developed application has the ability to track, to keep history, to give detailed
reporting for each inventory with reduced human intervention.
• Winston Rey S. Aguirre and Jayson P. Bartolome [2] have developed the
“Laboratory inventory system” for the engineering college. They have develop the
Bar code for each component in the laboratory and information of those
components is stored in the database. Then they have installed the bar code
scanner to identify the information of the particular component.
Department of mechanical Engineering
P S G T E C H
MISAA 2015

5. LITERATURE REVIEW
• Arulogun O. T., Olatunbosun, A., Fakolujo O. A., and Olaniyi, O. M. [3] have
developed the “RF id based student attendance management system” to
eliminate the time waste in the manual collection of attendance. RF id technology
facilitate the automatic wireless identification using electronic passive and active
tags with suitable readers. RF id tag information along with student detail is
stored in the database. The receiver captures the signal from the tag and marked
the arrival and departure time of the particular student.
• Chitresh.S. and Amit.K [4] have developed the “Automatic Attendance System”
using “Fingerprint Reconstruction technique”. Here they designed a system such
that attendance report is generated using the thumb impression of student or
staff. Hence by implementing this system they try to reduce the false data in the
attendance record.
Department of mechanical Engineering
P S G T E C H
MISAA 2015

6. OBJECTIVE
• To Increase the utilization of resource by availing the suitable scrap sheets for
Punching operation.
• To develop the Scrap tracking and management system to track the scrap
sheets formed in the punching station of sheet metal industry.
• To Store and retrieve the particular sheet in the inventory without any confusion.
• To Track the scrapped material from the punching process without extra effort.
• To Reduce the requirement of measuring the scrapped inventory each time for
reusing the scraps.
Department of mechanical Engineering
P S G T E C H
MISAA 2015

7. METHODOLOGY
Department of mechanical Engineering
P S G T E C H
Implementation
Testing the software
Linking database with front end
Database design
Front end design
Software architecture and functional architecture design
Determination of Requirements
MISAA 2015

8. PRODUCT SELECTION
• Product name - CE Carrier Assembly
• Customer - Gilbargo
• Average demand - 500 products
• Lead time to delivery - 15 days
• Application - Fuel dispensing pump
Department of mechanical Engineering
P S G T E C H
MISAA 2015

9. CATIA DIAGRAM OF PRODUCT
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P S G T E C H
CE Carrier Assembly
MISAA 2015

10. PROCESS MAP
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P S G T E C H
Punching Part removal Filing
Deburring
Pressing operation
Welding/
fabrication
Pre-treatment Powder coating Drilling process
Packing Inspection process Paint touch up
MISAA 2015

11. CATIA MODEL OF PUNCHED SHEET
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P S G T E C H
MISAA 2015

12. EXISTING METHOD
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P S G T E C H
MISAA 2015

13. PROPOSED METHOD
Department of mechanical Engineering
P S G T E C H
MISAA 2015
SCRAP
MANAGEMENT
APPLICATION
DATABASE
PLANNING
COMMITTE

14. NEED OF SCRAP MANAGEMENT SYSTEM
• To reduce the time required to track the information of particular material in the
inventory.
• To locate the required material in the storage without any confusion.
• To eliminate the measurement activity to identify the dimensional information of
the material.
Department of mechanical Engineering
P S G T E C H
MISAA 2015

15. FUNCTIONAL REQUIREMENT
• The application should allow only authorized user to use the application.
• It should have the database in the back end to store the information about
scrapped sheets.
• There should be an option in front end to add and update the database by
entering the required information in the front end.
• There should be an option in the front end window to check whether the particular
record is available in the database or not.
• There should be an option in front end to check current stock status of scrapped
inventory.
Department of mechanical Engineering
P S G T E C H
MISAA 2015

16. REAL TIME DATA TRACKING SYSTEM-SOFTWARE
ARCHITECTURE
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P S G T E C H
Data base
Scrap
management
application
End user
MISAA 2015

17. REAL TIME DATA TRACKING SYSTEM-FUCTIONAL ARCHITECTURE
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P S G T E C H
MISAA 2015

18. REAL TIME DATA TRACKING SYSTEM-FRONT END
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P S G T E C H
MISAA 2015

19. REAL TIME DATA TRACKING SYSTEM-ADD DIALOG BOX
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P S G T E C H
Login
Valid
User
Invalid User
No
Yes
Display
Menu bar
MISAA 2015

20. REAL TIME DATA TRACKING SYSTEM-MDI WINDOW
Department of mechanical Engineering
P S G T E C H
MISAA 2015

21. REAL TIME DATA TRACKING SYSTEM-ADD DIALOG BOX
Department of mechanical Engineering
P S G T E C H
MISAA 2015

22. REAL TIME DATA TRACKING SYSTEM-ADD DIALOG BOX
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P S G T E C H
ADD
Data
missing
Required
data are
missing
Yes
Duplicate
data
No
Sheet id
already
exist
Yes
No
Database
updated
MISAA 2015

23. REAL TIME DATA TRACKING SYSTEM-UPDATE DIALOG BOX
Department of mechanical Engineering
P S G T E C H
MISAA 2015

24. REAL TIME DATA TRACKING SYSTEM-ADD DIALOG BOX
Department of mechanical Engineering
P S G T E C H
Update
Data
missing
Required
data are
missing
Yes
Duplicate
data
No
Sheet id
doesn’t
exist
Yes
No
Database
updated
MISAA 2015

25. REAL TIME DATA TRACKING SYSTEM-SEARCH DIALOG BOX
Department of mechanical Engineering
P S G T E C H
MISAA 2015

26. REAL TIME DATA TRACKING SYSTEM-ADD DIALOG BOX
Department of mechanical Engineering
P S G T E C H
Search
Valid
sheet id
Invalid
sheet id
No
Yes
Display
the data
MISAA 2015

27. REAL TIME DATA TRACKING SYSTEM-STOCK STATUS DIALOG
BOX
Department of mechanical Engineering
P S G T E C H
MISAA 2015

28. REAL TIME DATA TRACKING SYSTEM-BACK END
Department of mechanical Engineering
P S G T E C H
MISAA 2015

29. CREATION OF SCRAP TAG
• Sheet id must be unique to prevent the duplicate data
• Length of sheet id must be in 6 digit
• 1st and 2nd digit = Length of sheet
• 3rd and 4th digit = Width of sheet
• 5th and 6th digit = Thickness of sheet
• [E-x] Sheet id = 803015 represent the sheet having length of 8ft width of 3ft and
thickness of 1.5mm
Department of mechanical Engineering
P S G T E C H
MISAA 2015

30. SYSTEM REQUIREMENT
Following software should be installed before installing the scrap tracking and
management system
1. Microsoft access database
2. Microsoft .NET Framework 4 client profile(x86 and x64)
3. SQL server compact 3.5 SP2
4. Windows installer 3.1
Department of mechanical Engineering
P S G T E C H
MISAA 2015

31. BENEFITS
• Scrap management and tracking system is development and implemented for
trial run.
• Traditional manual tracking and retrieving of information is replaced with the Real
time data tracking system.
• Requirement of measuring the sheet each time to identify the dimensional
information is eliminated by introducing the scrap tag.
• Manual searching by labor to check the availability of particular sheet is
eliminated.
• The database file containing the information of scrapped material is saved in the
local disk(D) as shown in figure.
Department of mechanical Engineering
P S G T E C H
MISAA 2015

32. REFERENCE
1. Taner Arsan, Emrah Baskan, Emrah Ar and Zeki Bozkus, A Software Archiecture
for Inventory Managemnt System Innovation and Advances in Computer,
Information, System Sciences and Engineering, vol. 4, Issue 12, 2013.
2. Winston Rey S. Aguirre, Jayson P.Bartolome, John Erick T.De Torres, and Mark
Joseph P. Fajilan, Automated Laboratory Item-Inventory System With Bar Code
IJETAE, vol. 3, Issue 12, December 2013.
3. Arulogun O.T., Olatunbosun, A., Fakolujo O.A., and Olaniyi O.M, RF ID Based
Student Management System International Journal of Scientific And Engineering
Research, vol. 4, Issue 2, Feburary 2013.
4. Chitresh. S and Amit K (2010), An efficient Automatic Attendance Using
Fingerprint Verification Technique International Journal on Computer Science
and Engineering, Vol. 2. Pp 264-269
5. Jams Foxall, Teach yourself Visual C# 2008, John Wiley & Sons, Nov 2012.
Department of mechanical Engineering
P S G T E C H
MISAA 2015

33. THANK YOU
Department of mechanical Engineering
P S G T E C H
MISAA 2015