process plant working

1. Seminar report
Implementation of
Industry 4.0
at
Tega industries Dahej(Gujarat)
Submitted to
Dr Arun maity
Instructor in charge-
Department of Mechanical engineering
Bits pilani
Submitted by
Shubham pareta
ID no-2018H1410159P
ME –Design engineering
Bits pilani (Rajasthan)

2. Tega industries established in 1976. It is a global leader in the
design and production of consumables for the mineral
beneficiation, mining, bulk solid handling industry. Headquartered
in Kolkata, India. Tega offers a range of abrasion and wear resistant
products and services required for mining and mineral processing,
grinding, material handling industry.
Tega offers a range of rubber, polyurethane, abrasion resistant
steel and ceramic based lining products which have been
incubated in our R&D centers. The company offers value added
consultancy services and solution in areas of mineral beneficiation
and material handling industries.
Tega industries at glance

3. How a product is made in Tega industries
• Fabrication shop- Basic raw material hardox ,mild steel, cast iron ,aluminum is process by cutting ,
welding, grinding. Material is send to blasting shop.
• Blasting & painting shop-High velocity steel grit of suitable hardness make impact on metal
surface to improve surface finish of metal. Blasting is done to remove impurities and improve
bond quality between metal and rubber. It is a surface finishing operation. Metal is send for paint
shop to obtain high quality surface.
• Banburry shop- In the banburry mixing of natural rubber with suitable chemicals such as carbon
black took place at suitable pressure and temperature in spiral mixer called banburry to make
rubber ply .
• Blank shop-In the blank shop rubber ply output from banburry works as a input to make rubber
blank of suitable shape, size and dimensions. Machine used is cold feed extruder.
• Press shop-The output of blasting shop i.e. reinforcement and output of blank shop i.e. blank is
input to press shop . In the press shop blank and reinforcement at placed carefully in heated
mould at suitable temperature. After curing time is over product is ready for quality test and
dispatch.

4. RAW MATERIAL 1
INSPECTION
REJECTED
ACCEPTED
FABRICATION
INSPECTION
REJECTED
BLASTING
INSPECTION
REBLAST
PRIMARY COAT
FINAL COAT
INSPECTION
REBLAST
REPAINT
RAW MATERIAL 2
INSPECTION
BANBURRY
BASE STOCK
READY STOCK
BLANK SHOP
BLANK
PREPARATION
INSPECTION
ELASTIC PROPERTY
VISCOSITY
RHEOMETRE
ABRASION
DENSITY
COLD FEED EXTRUDER
MIXING MILL
BLANK CORE TEMP
BLANK WEIGHT
CHARGING TIME
PRESS SHOP
LABELING
REINFORCEMENT
FINAL PRODUCT
INSPECTION
REJECT
ACCEPT
REWORK
PACKING &DISPATCH
HARDNESS
UT
CUTTING
WELDING
GRINDING
HARDNESS
UT
BOILER
STEAM
7.5KG/CM^
2
PRV
HANDLINING
AUTOCLAVE
FINISHED
PRODUCT
PACKING
DISPATCH
SIMPLE
SHAPE
INSPECTION
STEEL GRIT
SIEVE TEST
3 ROLL
CALENDER
DFT
DFT
COMPLETE
FLOW CHART

5. COMPOUND
READY STOCK
BLANK
SHOP
PRESS
SHOP
MOULD SHOP
BLASTING
&PAINTIN
G
FABRICATION
Aluminum
FINISHED
PRODUCT
PACKING DESPATCH
BANBURRY
PHASE 1
PHASE 1
PHASE 1 PHASE 2
PHASE 2
PHASE 1
PHASE 3
PHASE 2
PHASE 3
PHASE 3
DAILY MONITORING
PLANT LEVEL MONITORING
DIRECTOR LEVEL MONITORING
CHAIRMAN DASHBOARD
IOT PLATFORM

6. Long-term vision by implementing industry
4.0
• It would be big milestone in era of Smart factories.
• The overall operational efficiency will increase.
• Better Control on performance measurement system.
• Better control over SOP (Systematic operating procedure).
• Per product cost will be less.
• Better control over quality of product

7. List of activities performed
• Study the plant and process from end to end carefully.
• Detailed study of each process –press shop ,banburry , blank shop, blasting shop.
• Collect the critical parameters from each process and find the way to capture
them by sensors and electronic devices.
• Design the blank ordering system as apart of industry 4.0.
• Design the reinforcement ordering system as part of industry 4.0.
• Time study of blasting machine to improve its utilisation.
• Study safety issues in Tega industries and suggest preventive actions.
• Design a disaster management system for comman hazard.
• Review paper writing on industry 4.0
• Post covid 19 lockdown strategy in Indian manufacturing sector.

8. Collect key performance indicators/critical
parameter in phase 1
•Blank shop KPI
•Press shop KPI
•Blasting shop KPI
•Painting shop KPI

9. Phase 1 Industry 4.0 Objectives
1) The blank should be charged within 30 minutes of making else press should not charge the blank.
2) We should ensure blank is going to charge on right press so bar code system should be implemented on blank.
3) Reinforcement should also be charged with in 30 min of placing it in cavity.
4) Reinforcement should arrive at right press so some barcode system requires.
5) Complete digital form of job card which is issued at each press for new order.
6) Mould temp should be 150 degree for SOP CP 21 and 170 degree for SOP CP 09.
7) Blasting shop operator should have clear picture of real time inventory of reinforcement on press machine via
computerised work order. If any press is falling short of reinforcement alarm should be generated until press is
supplied with required reinforcement.
8) Alarm should be generated if parameters cross limit.
9) Energy meters where necessary.
10) Plan vs actual - real time report
11) Integration of data with SAP.
12) Traceability of product .

10. PRESS LOADING CHART
DAILY PRODUCTION
SCHEDULE
PRESS SHOP
JOB CARD
PRESS MACHINE
MOULD
SHOP
BLASTING SHOP
HEATED MOULD
TEMP <140
DEGREE CELSIUS
CURING &FINISHED PRODUCT FPIR QUALITY
PACKIN
G
&DISPA
TCH
BREAK DOWN
BLANK
SHOP
1-BLANK CORE TEMP
T=95 DEGREE
2-BLANK WEIGHT
AS PER BLANK JOB CARD
3-SOP-CP-09
CHARGING TIME<60 MIN
SOP-CP-21
CHARGING TIME<40 MIN
BLANK JOB
CARD
1-TIME<3 DAYS HARDOX
2-TIME<7 DAYS MS & AL
3-TEMP <65 DEGREE
OR CHARGING TIME
LESS THAN 30 MIN
MOULD INSPECTION REPORT
REINFORCEMENT
1-STEAM PRESSURE
2-PLATEN TEMPERATURE
3-HYDRAULIC PRESSURE
4-OIL TEMPERATURE
5-CURING TIME
6-STEAM FLOR RATE
MCC
PANEL
REBLASTING
FABRICATION
PRESS SHOP MAPPING

11. JOB CARD
RECEIVE AT
PRESS SHOP
INFORMATION
INPUT
PRODUCT TYPE
SO. NO
PRODUCT CODE
AT PRESS SHOP
INFORMATION PASS
TO BLANK SHOP
DIGITALLY
REQUIREMENT GENERATED BY
PRESS OPERATOR REGARDING
BLANK WEIGHT,CAVITY AND
BLANK DRAWING
IF AT SAME TIME ANOTHER
PRESS REQUIRED BLANK THEN
ORDER WILL BE PLACED AFTER
PREVIOUS ORDER.
BLANK OPERATOR
SELECT FOR WHICH
PRESS BLANK NEED
TO BE FORMED AS
PER EMERGENCY
REQUIREMENT
TIME START
FROM ZERO
WHEN FIRST
BLANK FORM TO
COUNT 30 MIN.
BAR CODE
GENERATE
IF BLANK TAKES
MORE THAN 30
MIN THEN PRESS
WILL NOT CHARGE
THE BLANK
BAR CODE ON
EACH BLANK –
BLANK WILL GO
TO RIGHT PRESS
BAR CODE
SCANNING
IF BLANK GO TO
WRONG PRESS THEN
QR CODE UNABLE TO
SCAN
BLANK SHOP ORDERING SYSTEM

12. R1 R2 R5 R6 R7 R8 R9 R10 R11 R12 R13
R3 R4
Blasting & painting
shop
Fabrication shop
Just in time
KANBAN
DISPATCH TO PRESS SHOP
REINFORCEMENT ORDERING
SYSTEM
R1-REINFORCEMENT FOR PRESS 1

13. Blasting machine utilization (working in progress)
• The blasting machine utilization is less than 50% in tega dahej plant.
• It is a surface finishing operation in which high velocity metallic grit of high hardness
make impact on metal surface to improve surface quality.
• It becomes a bottleneck operation in tega dahej.
• We need to increase the effective utilization of blasting machine by time study and
motion study.
• During blasting of aluminum utilization is poor but casting and hardox utilization is better.
• Fatigue of operator is also a kind of reason for under utilization of blasting machine.
• Utilization also depends on complexity of part and material.
• Most of ideal time of machine goes in loading and unloading of reinforcement so
automatic conveyor based loading system could be used as apart of industry 4.0

14. Time study data –Blasting machine

15. Safety study in Tega industries ,Dahej
• Safety study of complete plant with main focus on banburry and
blasting shop.
• High accident prone area in tega industries are mixing mill, material
handling, boiler ,press machine.
• Most hazardous area in plant to work with is banburry because of
high carbon emission which is a health hazard.
• Boiler area is also accident prone area either due to fire, high
pressure etc.
• The safety rules are highly violated in banburry and paint shop.

16. Accident statistics Tega industries Dahej

17. Thank you