Reduction of manufacturing time of wagon-tippler

1. Reduction of manufacturing time of wagon-tippler Tanmoy Das 08IM6020 Industrial Engg. And Mgmt.

2. Company profile • TRF Limited, a TATA Enterprise, originally TATA-ROBINS-FRASER Limited was promoted in 1962. • TRF, is a pioneer in India to provide solutions in bulk material handling/processing systems and equipments and Port and Yard equipments. • It provides engineering solutions in the processing plants for core industries like power, mines, ports, steel, cement and fertilizers, dam construction, chemicals/ processes etc.

3. PRODUCT RANGE OF TRF • Vibrating Equipment -Mechanical • Vibrating Equipment-Electromagnetic • Crushers • Underground Mining Vehicles • Wagon Tippers • Apron Feeders • Plough Feeders • Rotary Table Feeders etc.

4. Some of the noteworthy projects executed by TRF LTD. includes:- • Downhill regenerative conveyor system for an iron ore mine at Bailadilla. • Coal Handling Plant for India’s first super thermal power station at Singrauli. • High speed vibrating screen for iron ore concentrators of Kudremukh Iron Ore Company. • Automatic mobile wagon loader for coal and iron ore for Tata Steel. • Circular stock piling, blending and reclaiming system for cement factory. • Coal washery. • Coal dust injection system for blast furnace. • Stamping-charging-pushing machine for coke oven.

5. Some big customers of TRF LTD. • TATA POWER • TATA STEEL • N.T.P.C • B.H.E.L • JINDAL STEEL

6. Stages of Manufacturing: • Order from the customer: The customer requiring a certain number of certain types of products issues the order to TRF. • Issue of SODS (Sales Order Data-Sheet): The marketing department of the company releases SODS and sends it to the departments of Planning and Design. • Drawing of the product: The design department makes a detailed drawing of the product to be made and sends APL (Advanced Procurement List) along with it to the Planning department. • Purchase Requisition: The above is sent to MMD (Material Management Division) and a Purchase Requisition (PR) is prepared involving the details of the materials to be purchased keeping in view of the inventory already existing, and the capacity of it. • Instruction– Sheet: Planning department sends an IS (Instruction Sheet) to the work-shop, which involves the details of the various units to be assembled in the final product, and acts as a guide to the Shop Engineers to manufacture the required product. • Purchase Order: The MMD then releases a PO (Purchase Order) which is sent to the various raw-material making companies. After the procurement of the raw-goods, the manufacturing is started in the work-shop.

8. Main cause of high production time • To reduce high cycle time • To reduce high non-productive time • Identify and reduce the unnecessary work elements • Identify and standardize the items with high production volume and manufacture in a lot. • Increase the shop floor space

9. Main time consuming areas • Design of equipments • Production planning • Procurement of items from outside. • Manufacturing (non-productive time) • Assembly

10. Main parts of wagon tippler • Cradle • End ring • Side beam • Top clamping arrangement • Drive assembly

11. TOP CLAMP SIDE BEAM END RING WAGON MOTOR CRADLE WAGON TIPPLER

12. TOP CLAMP SIDE BEAM END RING WAGON CRADLE MOTOR PARTS OF WAGON TIPPLER

13. Major time components