We think you have liked this presentation. If you wish to download it, please recommend it to your friends in any social system. Share buttons are a little bit lower. Thank you!
Presentation is loading. Please wait.
Published byIrea Young
Modified over 3 years ago
1 © ARC Advisory Group Achieving excellence through IT and Automation a Bharat Forge Experience Ninth ARC India Forum, Pune August, 2011 Achieving Operational Excellence Through IT and Automation Solutions Mukund V Mavalankar Director Technical Bharat Forge Limited firstname.lastname@example.org Photograph of Speaker
2 © ARC Advisory Group. CHINAUSA INDIA Key Companies in the Group EUROPE Marsing, Denmark Hikal Chemicals Ltd Specialty Chemicals Kalyani Steels Ltd Kalyani Carpenter Special Steels Kalyani Gerdau Engineering Steel FAW Bharat Forge BF America CDP Bharat Forge GmbH, Germany Bharat Forge Daun GmbH, Germany Bharat Forge Aluminiumtechnik GmbH, Germany Bharat Forge Kilsta AB, Sweden Bharat Forge Ltd Kalyani Thermal Forgings Auto Components Automotive Axles Ltd Kalyani Lemmerz BF Utilities Kenersys India BF Alstom Khed Earth – The City Energy & Infrastructure Global Profile of Kalyani Group Kenersys GmbH, Germany
3 © ARC Advisory Group 4 6 5 31 2 BFL Bharat Forge – Global Profile Capacity over 750,000 Tons per annum Crankshaft machining capacity of over 1,200,000 nos. Capacity to machine 500,000 FAB & 750,000 steering knuckles CAPACITY 60,000 tons Strong Foray in the largest auto market USA Strong customer relationship Dual Shore manufacturing Manpower: 83 People CAPACITY 200,000 tons Production base close to the customer Proximity to large marquee Customers Dual Shore manufacturing Manpower: 1060 People CAPACITY 365,000 tons Worlds largest single location forging facility Technologically advanced, flexible forging & machining facility Proximity to fast growing Auto markets of China & india Dual Shore manufacturing Manpower: 4700 People BF AMERICA Lansing 4 6 BHARAT FORGE KILSTA, Sweden 5 CDP BHARAT FORGE Ennepetal, Germany 1 BF ALUMINIUMTECHNIK Dresden, Germany 3 CDP FORGE Daun, Germany 2 FAW BF (Changchun) Co. Ltd. Changchun, China CAPACITY 135,000 tons JV with FAW in China with 52% stake Foothold into fastest growing market Dual Shore Manufacturing Manpower: 1500 People
4 © ARC Advisory Group Objectives Till 1989 BFL was using manually operated pneumatic hammers for making forged parts. Under the technology up-gradation initiative investment in two large completely Automatic forging lines. The benefits envisaged Improvement in Quality Improvement in Productivity Reduction in costs Saving in Energy Saving in Raw material
5 © ARC Advisory Group Layout of First Fully Automatic forging line
6 © ARC Advisory Group Scheme Sequential control for forging line
7 © ARC Advisory Group Integration of diverse programmable controllers. Ease of sequential control and programming multiple part types. Ease of diagnostics. Ease of monitoring complete line. Consistent process parameters leading to consistent quality and higher OEE. Advantages of hierarchical control
8 © ARC Advisory Group Second wave of automation 1997 Automatic, programmable screw press with controlled energy for every blow and regenerative braking. Judicious use of combination of Fully programmable Hydraulic Robots First use of Electric robots, Dedicated manipulators Power and conveyors and walking beams. Complete line integration with Animated displays Single Console Operation First Use of Profibus Hierarchical PLC controls Use of Automatic application of Die lubricant
9 © ARC Advisory Group Up-gradation of Central Control 2011
10 © ARC Advisory Group Third wave of automation The Kurimoto line was set up in 2006. This has taken BFL to next level of Automation. The salient features are First Use of High speed Carbide saws First Use of Transfer Presses First fully integrated single flow line in BFL Power and free cooling conveyor and over head gantries. Robots 6 Axis all Electric Reduced cycle time 8 sec untwisted/ 12 sec twisted cranks Increased productivity Mass production of passenger car cranks.
11 © ARC Advisory Group
12 © ARC Advisory Group Next level of automation with remote I/Os
13 © ARC Advisory Group Case Studies in machined components division Cooling tower Flow control through automation to achieve Energy Conservation. Automatic Monitoring of machine Parameters & pop up error messages on machine screen. Two case studies
14 © ARC Advisory Group Flow Control in Cooling tower Per Day Energy Consumption @ 3000 Units Sudden Starting tend to reduce Switch-gear life. Also Flow control adjustment required. No Control on Real Time Basis Before Implementation Before 3000 Cooling Tower is used for Cooling the Electrical switch- gear as well as quenching media. In MCD1 we have used single cooling tower for more than 15 machines.
15 © ARC Advisory Group DRIVE PANEL MOTOR CONTROL Drive PLC Interface M/C Temperature Sensor WATER IN WATER OUT COOLING TOWER Sense the number of machine running & decide the flow requirement Sense the Difference in Temperature of Incoming & outgoing lines & Decide the Flow & Exhaust Fan requirement On Real Time basis switch On & off the Cooling tower in Lunch / Dinner time Flow Control in Cooling tower
16 © ARC Advisory Group Sr NoParameterBeforeAfter* 1Power by the Cooling tower120 KW72 KW 2Power Factor0.8784>0.94 3Unit Consumption per month65000 Units35000 Units 4 Energy Cost (per Month) ` 325,000/- ` 175,000/- 5Savings in Energy cost46% Per Million Contribution reduced by ` 1000 for MCD1 Flow Control in Cooling tower After 1750
17 © ARC Advisory Group Manual monitoring of Machine Parameters Machine Parameters are monitored for Predictive / Preventive Maintenance Plan. This was done manually by the operator and relevant data was entered in the logbook. Action Plan is communicated manually by each operator. No interlock with machine Logic if any parameter is out of range.
18 © ARC Advisory Group Machine Pressure Temperature Oil Level Programmable Controller Machine CNC System Preventive Maintenance Machine Parameter Monitoring Machine CNC System (To generate Fault on machine screen) Separate Control System Designed & programmed for automatic monitoring of Machine Parameters
19 © ARC Advisory Group Summing up However we have challenges to overcome Challenging Environment for Automation products High Temperatures High level of Dust, Scale, Graphite and water High impacts and rough use We have huge scope to automate our forging lines by Automatic application of Die Lubricant Automatic control of Die Temperature Automatic monitoring of presses and motors Automatic inspection of Forged parts with Vision systems Automation of Post Forging operations We have consistently used Robots and automation effectively to be More Productive More cost Effective More Energy efficient More Environmental Friendly
March, 2010 OVERVIEW April, Scrap / Recycling Steel Mills Downstream Gerdau Ameristeel | Efficient vertical integration.
- 1 - ULTIMO-R4 © Dürr Assembly Products India Dürr Assembly Products India (A Division of SRIL) Roll Test Stand – ULTIMO- R4.
1 © ARC Advisory Group Latest trends in Automation for Automotive Industry - case studies Ninth ARC India Forum, Pune August, 2011 Achieving Operational.
FCX Performance, Inc.. The Power of One 2 World class flow control solutions built on over 100 years of experience FCX does not run businesses; we provide.
1 LITOSTROJ RAVNE IS A MEMBER OF LITOSTROJ GROUP TRADITION, POWER QUALITY, INNOVATION Litostroj Ravne Ltd. Koroška cesta Ravne na Koroškem Slovenia.
1 Adept PLC Server November 20, Introduction Adept is the largest robot manufacturing company in North America. We have been manufacturing robots.
Zeki Aydan / / 1 of 19 FIT FOR THE FUTURE ???
Electric cars: part of the problem or a solution for future grids? Frans Nieuwenhout, Energy research Centre of the Netherlands ECN Sustainable.
1. 2 5kW, 6kW, 8kW, 10kW, 14kW, 16kW model Domestic heat pump - Air to Water.
1 Heinrich Müller Maschinenfabrik GmbH HMP Umformtechnik GmbH 1 Heinrich Müller Maschinenfabrik GmbH HMP Umformtechnik GmbH Process forming.
MicroDot Softwares Welcome to the Presentation of MicroDot Deckle Planner.
VISION- Leading from the front We visualize ourselves as one of the major and dedicated technology contributor to the country. Innovation and re-engineering.
1 The Metro Ethernet Forum Helping Define the Next Generation of Service and Transport Standards Ron Young Chairman of the Board
Striving to exceed customer demands by delivering the best.
A presentation by Werardt Systemss P Ltd An Online Machine Monitoring System.
1 An Introduction ppt - Saurabh Mehta Renewable Energy Technologies in Power Generation.
Addition 1’s to
CG Drives & Automation. Who are CG? A specialist: in the management and application of electrical energy focused on supporting the growing demand.
Company profile and competences August Company identity 2.Facts & figures 3.Company vision 4.Casting cell overview, new investments, layout.
Technology Management, Inc Lake Shore Blvd Cleveland, Ohio Technology Management, Inc Lake Shore Blvd Cleveland, Ohio 44108(216)
There is a difference.... Future Business, Why VEKA?
Www. otis.com. An Innovation for the New Millennium.
Delivering a real CDM Project The BP PRODEEM Rural Solar Project.
Flexible Manufacturing Systems (FMS). What Will Be Covered Flexible Manufacturing is Defined How “you” can use FMS Nuts and Bolts How FMS works.
11 Heinrich Müller Maschinenfabrik GmbH HMP Umformtechnik GmbH Process forming cylinder with concentric mandrel device 2segment chuck 3forming.
VISION STATEMENT To be a Leading, Dynamic, Result Oriented Company focused on providing Quality Solutions, Systems and Support To be consistent by improving.
Company presentation Die Produkte | StrikoMelter | Seite 2 Company Information.
Where You Turn The Timken Company 2006 Profile. The Timken Company Industrial technology company A leading provider of friction management and power.
Water Utility Business Applications. 2 Agenda Industry overview and trends Our application visionary solution Business values Wireless network components.
Recent trends in Automotive Pumps Market from 2015 to 2025 By FMI
Riga ; Latvia Vehicle “Off-Line” GPS and Fuel Monitoring System (post trip vehicle monitoring system)
Addition Facts = = =
DC-R/Copyright Festo Didactic GmbH&Co. KG Basics of Automation Technology Festo Didactic GmbH&Co. KG Copyright Festo Didactic 2007.
JAQUET Products for VG-Turbochargers and Turbobrakes.
HTS Wires for Energy and Magnet Technologies Superconductivity and the electricity supply industries November 27th, 2003.
Energy Management with the use of an Intelligent Building Management System.
1 Case Study of Demand Response: Con Edison Business Program by Eileen Egan-Annechino Consolidated Edison Company of New York, Inc.
Thailand Investment Opportunities In Machinery and Metal Working.
1 PredictiveOnLine PREDICTIVE SYSTEMS ENGINEERING Vintec Knowledge Ltd.
Energy Management Practices: Rolling Mills 1. Contents Introduction Energy Intensive Processes & Reduction in Energy Expenditure through Innovative Practices.
STEEL SMITH was established in the year of 1980 using extract gained by its promoter Lt. Sh. PRITHVI RAJ SHARMA during his dedicated services given to.
Global Heat Recovery Steam Generator Market Share, Global Trends, Analysis, Research, Report, Opportunities, Segmentation.
Mafijul Islam, PhD Software Systems, Electrical and Embedded Systems Advanced Technology & Research Research Issues in Computing Systems: An Automotive.
1 ECOMM 2010 moving people – bridging spaces How klima:aktiv mobil helps to move and bridge DI Robert Thaler Head of Division Transport,
1 PLC: Programmable Logical Controller CONTENTS 1. What is a PLC ? 2. Application examples 3. Inputs, Outputs and Commercial PLCs 4. Structure and Operating.
20/11/161 NEW E5 FINN-POWER e-technology - 14 years of excellence.
E6xPage 1 Finn-Power E6x The perfect Machine tool for your first FINN-POWER.
HT Series – High Temperature Technology 1 INTERPUMP GROUPS NEW PUMP LINE FOR CAR WASH AND INDUSTRIAL APPLICATIONS UP TO 85°C (185° F)
Lindbergh Field International Airport New Terminal Bill Mahoney LSW Engineers.
© 2017 SlidePlayer.com Inc. All rights reserved.