The objective of the project was to study about the generation of dross and how to reduce the dross through different processes .

1. TataAutoComp GY Batteries Pvt. Ltd.
Project report on Dross Generation in the Casting Section
Project by-
Abhishek Roy
Project Head-
Mr. Suvrajit Banerjee
Under the supervision of
Mr. Mohit Bhakal

2. TataAutoComp GY Batteries Pvt. Ltd.
Acknowledgement
I have taken efforts in this project. However, it would not
have been possible without the kind support and help of
many individuals and organizations. I would like to extend
my sincere thanks to all of them. I am highly indebted to Mr.
Suvrajit Banerjee, Mr. Mohit Bhakal for their guidance and
constant supervision as well as for providing necessary
information regarding the project & also for their support in
completing the project. I would like to express my gratitude
towards operators of Casting section of TATA AutoComp
GY Batteries Pvt. Ltd for their kind co-operation and
encouragement which help me in completion of this project
and for giving me such attention and time.

3. TataAutoComp GY Batteries Pvt. Ltd.
Company Profile
Tata AutoComp Systems Limited, promoted by the
Tata Group, provides products and services in the
automotive industry to Indian and global customers,
including Ashok Leyland, BMW India, Mercedes-Benz
India, EicherMotors, Fiat, Force Motors, Ford India,
General Motors India, Hero Honda, Hindustan Motors,
Honda Scooters, Honda Siel Cars India Ltd,
International Tractors John Deere India, Mahindra and
Mahindra, Mahindra Renault, Man-Force Trucks, New
Holland, Piaggio, Punjab Tractors, Royal Enfield,
Skoda, Swaraj Mazda, Tata Motors, Toyota Kirloskar
Motor Pvt. Ltd., Tractors and Farm Equipment Limited.

4. TataAutoComp GY Batteries Pvt. Ltd.
Company Profile (TATA AutoComp GY Batteries)
TATA Green Batteries are a product of
TATA AutoComp GY Batteries Pvt.
Ltd. (TGY), a joint venture between
TATA AutoComp Systems Ltd,
India's leading auto component
manufacturer and GS Yuasa
International, Japan, one of the
world's largest automotive battery
manufacturers. These batteries are
a combination of TATA AutoComp’s
extensive experience in the
Automotive Industry and GS Yuasa
International’s superior
technological know-how. With a low
top-up requirement and being 90%
recyclable, Tata Green Batteries
allow a hassle free battery running
experience

5. TataAutoComp GY Batteries Pvt. Ltd.
Different Sections In the Plant
CASTING
Pasting
Assembly
Charging
Dispatch
*The project is undergone under this section

6. TataAutoComp GY Batteries Pvt. Ltd.
Way to the
PASTING
section
Raw Material Section
Calcium –ve Alloy
Antimony Alloy
Calcium +ve Alloy
Sb+ve
Emergency
Exit
Ca+ve
Ca-ve
CASTING SECTION
Ca+ve
CorkPreparation
Area
CASTING
SectionEntry
Office
Dross
dumping
area
B1 B2 B3 B4 B5 B6 B7 B8
A1 A2 C6 C5 C4 C3 C2 C1C10 C9 C8 C7
Ca-ve
Ca-ve
Ca-ve
Ca-ve
Ca-ve
Ca-ve
Ca-ve
Ca-ve
Ca-ve
Sb+ve
Sb+ve
Sb+ve
Sb+ve
Sb+ve
Sb+ve
Sb+ve

7. TataAutoComp GY Batteries Pvt. Ltd.
Gravity Casting Machine

8. TataAutoComp GY Batteries Pvt. Ltd.
Working Of the machine
1
2
6
5
4
3
7

9. TataAutoComp GY Batteries Pvt. Ltd.
Process
POT (Where
The molten
lead is present)
FEEDLINE(which
transfer the
molten lead)
LADDLE
TRIM DIE
SECTION
(to cut excess
part of the panel)
COLLECTING
AREA (The final
product is kept
here )
MOULD(which
give shape to the
molten lead)
ROLLER
1 2
6
5
4
3
7
The excess part is send back
to the Pot

10. TataAutoComp GY Batteries Pvt. Ltd.
Type Pot Temp. Ladle Temp. Moving mould Temp. Fixed Mould Temp. Feed Line Temp.
Sb +ve 420±30 600±30 200±30 200±30 490±30
Ca -ve 420±30 600±30 200±30 200±30 490±30
Ca +ve 420±30 600±30 200±30 200±30 490±30
Grid information

11. TataAutoComp GY Batteries Pvt. Ltd.
Grid Nomenclature
Y M 83A
Plate thickness (100-83)/10=1.7±0.1mm
Grid thickness ((100-83)/10)-0.2=1.7±0.1mm
Small
Calcium
OTHER NOTATIONS:-
C Antimony
G Big
In case of
Plate thickness
=(100- )/10=2.1±0.1mm
Grid thickness
=((100- )/10)-
0.2=1.8±0.1mm
C G 80A 79
79
80

12. TataAutoComp GY Batteries Pvt. Ltd.
Dross
Dross is a mass of solid impurities floating
on a molten metal or dispersed in the metal,
such as in wrought iron. It forms on the
surface of low-melting-point metals such as
tin lead zinc or aluminium or alloys by
oxidation of metals
as tin, lead, zinc or aluminium or alloys by ox
idation of the metal(s). Dross, as a solid, is
distinguished from slag, which is a liquid.
Dross product is not entirely waste material;
for example, aluminium dross can be
recycled and is used in
secondary steelmaking for slag deoxidation.
Dross

13. TataAutoComp GY Batteries Pvt. Ltd.
16 Major Losses In a Company
8 Availability
Losses
Machine Loss
Setup & adjusting
Tool change
Start-up losses
Minor stoppage
Speed loss
Defect and
rework
Shutdown
5 Productivity
losses
Management
losses
Operating Motion
Line organisation
Logistics
Adjustments
3 Production
losses
•Loss of energy
•Die-tool losses
•Yield loss

14. TataAutoComp GY Batteries Pvt. Ltd.
Time Study of the Machine (B3-B4)
Total sample time for the production- 180 minutes
No of panels to be produced– 3690 panels
Actual Time taken for production- 144 minutes
No of grids produced- 3168 panels
Major losses occurred during the process-
• Shut Down Loss/Defect and rework- 20 min
• Setup Loss-5 min
• Die/Tool Loss- 5 min
• Line organisational loss-6 min

15. TataAutoComp GY Batteries Pvt. Ltd.
Date April'16 May'16
1st 237 0
2nd 432 409
3rd 385 341
4th 427 285
5th 426 321
6th 471 323
7th 373 407
8th 0 394
9th 457 412
10th 379 342
11th 431 425
12th 292 557
13th 341 444
14th 397 497
15th 324 299
16th 431 493
17th 418 266
18th 300 464
19th 206 428
20th 289 511
21st 436 515
22nd 300 442
23rd 430 459
24th 304 451
25th 366 363
26th 417 0
27th 455 0
28th 398 0
29th 367 89
30th 323 452
31st n/a 470
possible reasons-
- temperature variations
-manpower variation
-Impurities in the ingot
highest
amount of
dross
generated

16. TataAutoComp GY Batteries Pvt. Ltd.
Dross Generation Data
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th 16th 17th 18th 19th 20th 21st 22nd 23rd 24th 25th 26th 27th 28th 29th 30th 31st
April'16 237 432 385 427 426 471 373 0 457 379 431 292 341 397 324 431 418 300 206 289 436 300 430 304 366 417 455 398 367 323 0
May'16 0 409 341 285 321 323 407 394 412 342 425 557 444 497 299 493 266 464 428 511 515 442 459 451 363 0 0 0 89 452 470
0
100
200
300
400
500
600
Dross(inkg)
highest
amount of
dross
generated

17. TataAutoComp GY Batteries Pvt. Ltd.
Action Plan
There are ways by which we can reduce the
generation of dross-
• By induction heating- induction heating helps in
reducing dross generation and also helps in energy
saving. The idea is being proposed and is in a
prototype position.
• By minimising the surface area of the opening of
the pot- The opening present in the pot is the
reason for the generation of dross as more amount
of air can enter through it to oxidise with the lead. If
the conveyor length is increased so that it ends at
the inside the opening and the opening is made
small enough so as to make the dross removal
easier for the operator and putting a cover on it, the
dross generation can be reduced by 5%.