Presentation on theme: "“Achieving excellence through IT and Automation a Bharat Forge Experience” Ninth ARC India Forum, Pune August, 2011 Achieving Operational Excellence Through."— Presentation transcript:
1 “Achieving excellence through IT and Automation a Bharat Forge Experience” Ninth ARC India Forum, Pune August, 2011 Achieving Operational Excellence Through IT and Automation SolutionsThis presentation is intended to provide a corporate overview of ARC and the services we provide to the Manufacturing and Supply Chain communities.Mukund V MavalankarDirector TechnicalBharat Forge LimitedPhotograph of Speaker
2 Global Profile of Kalyani Group Energy & Infrastructure .Key Companiesin the GroupINDIACHINAEUROPEUSAKalyani Steels LtdKalyani Carpenter Special SteelsKalyani GerdauEngineering SteelCDP Bharat Forge GmbH, GermanyBharat Forge Daun GmbH, GermanyBharat Forge Aluminiumtechnik GmbH, GermanyBharat Forge Kilsta AB, SwedenBharat Forge LtdKalyani ThermalFAW Bharat ForgeBF AmericaForgingsAutomotive Axles LtdKalyani LemmerzAuto ComponentsBF UtilitiesKenersys IndiaBF AlstomKhed Earth – The CityEnergy & InfrastructureKenersys GmbH, GermanySpecialty ChemicalsHikal Chemicals LtdMarsing, Denmark
3 Bharat Forge – Global Profile 51CDP BHARAT FORGEEnnepetal, Germany314CDP FORGEDaun, Germany226BF ALUMINIUMTECHNIKDresden, Germany3CAPACITY135,000 tonsJV with FAW in China with 52% stakeFoothold into fastest growing marketDual Shore ManufacturingManpower: 1500 PeopleBF AMERICALansing4BFLBHARAT FORGE KILSTA, Sweden56FAW BF (Changchun) Co. Ltd. Changchun, ChinaCAPACITY365,000 tonsWorlds largest single location forging facilityTechnologically advanced, flexible forging & machining facilityProximity to fast growing Auto markets of China & indiaDual Shore manufacturingManpower: 4700 PeopleCAPACITY200,000 tonsProduction base close to the customerProximity to large marquee CustomersDual Shore manufacturingManpower: 1060 PeopleCAPACITY60,000 tonsStrong Foray in the largest auto market USAStrong customer relationshipDual Shore manufacturingManpower: 83 PeopleCapacity over 750,000 Tons per annumCrankshaft machining capacity of over 1 ,200,000 nos.Capacity to machine 500,000 FAB & 750,000 steering knuckles
4 ObjectivesTill 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 envisagedImprovement in QualityImprovement in ProductivityReduction in costsSaving in EnergySaving in Raw material
7 Integration of diverse programmable controllers. Advantages of hierarchical controlIntegration 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.
8 Second wave of automation 1997 Automatic, programmable screw press with controlled energy for every blow and regenerative braking.Judicious use of combination ofFully programmable Hydraulic RobotsFirst use of Electric robots,Dedicated manipulatorsPower and conveyors and walking beams.Complete line integration withAnimated displaysSingle Console OperationFirst Use of ProfibusHierarchical PLC controlsUse of Automatic application of Die lubricant
10 Third wave of automation The Kurimoto line was set up in This has taken BFL to next level of Automation. The salient features areFirst Use of High speed Carbide sawsFirst Use of Transfer PressesFirst fully integrated single flow line in BFLPower and free cooling conveyor and over head gantries.Robots 6 Axis all ElectricReduced cycle time 8 sec untwisted/ 12 sec twisted cranksIncreased productivityMass production of passenger car cranks.
13 Case Studies in machined components division Two case studiesCooling tower Flow control through automation to achieve Energy Conservation.Automatic Monitoring of machine Parameters & pop up error messages on machine screen.
14 Flow Control in Cooling tower 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.Before ImplementationBefore3000Per Day Energy 3000 UnitsSudden Starting tend to reduce Switch-gear life. Also Flow control adjustment required.No Control on Real Time Basis
15 Sense the number of machine running & decide the flow requirement Flow Control in Cooling towerCOOLING TOWERM/CM/CM/CM/CM/CWATER INTemperature SensorM/CM/CM/CM/CM/CTemperature SensorM/CM/CM/CM/CM/CWATER OUTSense the Difference in Temperature of Incoming & outgoing lines & Decide the Flow & Exhaust Fan requirementSense the number of machine running & decide the flow requirementMOTOR CONTROLDRIVE PANELOn Real Time basis switch On & off the Cooling tower in Lunch / Dinner timeDrivePLCInterface
16 After Flow Control in Cooling tower Sr No Parameter Before After* 1 1750Sr NoParameterBeforeAfter*1Power by the Cooling tower120 KW72 KW2Power Factor0.8784>0.943Unit Consumption per month65000 Units35000 Units4Energy Cost (per Month)` 325,000/-` 175,000/-5Savings in Energy cost46%Per Million Contribution reduced by `1000 for MCD1
17 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 Machine CNC System (To generate Fault on machine screen) Machine Parameter MonitoringSeparate Control System Designed & programmed for automatic monitoring of Machine ParametersProgrammable ControllerMachine CNC SystemMachine CNC System (To generate Fault on machine screen)MachineOil LevelTemperaturePressurePreventive Maintenance
19 Summing up However we have challenges to overcome Challenging Environment for Automation productsHigh TemperaturesHigh level of Dust, Scale, Graphite and waterHigh impacts and rough useWe have huge scope to automate our forging lines byAutomatic application of Die LubricantAutomatic control of Die TemperatureAutomatic monitoring of presses and motorsAutomatic inspection of Forged parts with Vision systemsAutomation of Post Forging operationsWe have consistently used Robots and automation effectively to beMore ProductiveMore cost EffectiveMore Energy efficientMore Environmental Friendly