Final

Copper Brass Plant

Copper Brass Plant

1.1Introduction

The plant is the oldest establishment of the company, responsible for the production copper brass products.

The product range is extensive, having a large number of OE and Northern products.

The plant follows a batch type manufacturing system.

Most of the components used in the manufacturing process are produced within the plant.

The work force consists of both permanent and contractual workers.

1.2Zones of the Shop Floor

Press Shop: The press shop produces tanks, header plates for copper brass products & header plates for aluminium products. All operations required for producing these components are carried out here, which are blank cutting, drawing, trimming & punching. The press shop has seven press machines, having a capacity range of 10 to 100 tons. The press shop employs 14-17 workers, depending on the demand. All the dies are labeled, colour coded & placed on racks. All the components produced here are heat treated in the stress relieving oven. Inventory is maintained for production period of about five days.

Side frame & Cowl Storage: The side frame and the cowl are outsourced. The numbers of items stored are for a production period of two days. The side frames are stored on racks and the cowls are stored in stacks. The side frame is welded to the main assembly.

Painting and Packing: The painting machine is a dominant feature on the shop floor; it performs drying & painting operations. It has two painting booths and two drying zones. The radiators are attached to a slow moving overhead rail which moves throughout the machine, first through the drying zone then to painting and again through drying. The painted radiators are then fitted with accessories and packed. This zone employs two workers for painting & four to five workers for packing.

Fin and Tube Shop: The fin tube shop produces heat transfer tubes and air fins. It has two square fin machines, one Z fin machine, and one straight fin machine. The pre tinning machine, tube cutting machines & the straight fin machine are located on an elevated platform. A hoist is present for transferring the produce down. The pre tinning machine applies a coating of tin on brass foil, which in turn is machined into heat transfer tubes. The heat transfer tubes produced are washed in the ultrasonic washing machine and stored in bins. The straight fins & part of the heat transfer tubes produced are sent elsewhere for straight fin core assembly. The fin tube shop employs seven to eight workers.

Core Assembly: The core assembly primarily deals with two types of cores, namely the fin& tube type & the straight fin core. The straight fin core is outsourced; the fin & tube type is assembled on three manual jigs. Then the header plates are fitted, fins leveling & combing operations are performed. The core assembly employs four workers.

Core Baking: This work zone is responsible for fluxing and baking of the assembled cores. This zone has one furnace, three flux immersion tanks. The core is immersed in flux; post fluxing the cores are placed on frames and baked for four minutes. The baking zone employs three workers.

Welding shop: The welding shop primarily performs three functions: which are, welding of inlet & outlet pipes to the tank, tank to header plate welding and side frame welding. The pipe welding is performed on four work stations, the header plate-tank welding is done on six workstations, and the side frame welding is done on five workstations. Rework is performed on two workstations. The weld shop employs fourteen workers.

Leak Test: This zone is responsible for hydro testing the welded radiator assembly. The zone has two bays, both having two testing tanks each. The test rig is bolted onto the inlet and outlet pipe of the radiator, subjected to the test pressure and checked for leaks. Faulty radiators are sent for rework. The leak test employs four people.

Maintenance: The maintenance departments responsibility is to ensure the operation of all the machines in the plant. The maintenance department performs preventive as well break down maintenance.

Store: The store stocks all spares, outsourced components and raw materials.

1.3Machines in Each zone

1.3.1Press Shop

Ruby Shearing machine

Cut to length machine

Ultrasonic Washing machine

Stress relieving Oven

Bemco Hydraulic Press

Russell Jewelform 100T Press

Godrej 25T Mechanical Press

Rigimax 25T Mechanical Press

10T Hydraulic Press

Isteco Jewel form 100T Press

Ambika 100T

Ambika 100T Mechanical Press

Number Punching Machine

1.3.2Core Assembly

Vibronics Ultrasonic Washing Machine

Fin and Tube Assembly Jig (3 No.s)

1.3.3Fin and Tube Shop

Pre Tinning Machine

Tube Re Cut Machine (New)

Tube Re Cut Machine (Old)

Straight Fin Machine

Electrical Hoist

Square Fin Machine (2 No.s)

Z Fin Machine

1.3.4 Core Baking & End Dipping Baking Oven

Gas Operated End Dipping Bath (2 No.s)

1.3.5Weld Shop & Painting

Gas Oerated Welding Torch (17 No.s)

Thermax Painting Machine

1.3.6Maintenance Generator 180 KVA ( Caterpillar )

Generator 250 KVA ( Caterpillar )

Compressor 360 360 CFM ( IR )

1.3.7Store

Macneil Fork Lift

Sayaji Electrical Hoist

1.4Machines Specifications

SR NO.Machine DescriptionSpecificationsProduction Capacity/ Shift

1Rigimax 25 T PressCapacity: 25 tons, Press Cushion Capacity: 3. 15 tons, Motor: 2.2 KW, 1500 rpm, 56 Strokes/min3750 pcs

2Jewelform 100 T PressMotor: 20 hp, Power: 2900 KW, Voltage:380/420 V AC, Current: 26 A, Working pressure:140 Kg/cm2.Setup time: 6.5 hrs,25 pcs/hr

3Suresh Seal 25T Press (H.P Trimming)Capacity: 25 tons, Press Cushion Capacity: 3. 15 tons, Motor: 2.2 KW, 1500 rpm, 56 Strokes/min5200 pcs

410 T Hydraulic Press (Fluid Dynamics Pvt Ltd.)Size: 2150mm*1250mm*530mm(h*l*w), Weight:1150 Kg, System Pressure: 199 Kg/cm2, Motor: 5 HP, 1500 rpm, Voltage:415 V AC .1920 pcs

5Godrej 25 T PressCapacity: 25 tons, Press Cushion Capacity: 3. 15 tons, Motor: 2.2 KW, 1500 rpm, 56 Strokes/min2500 pcs

6Pre- Tinning Machine (F.Gustav Siegmund)1 V Belt 1300*13, 2 Receiving rings,10 scrapers of filt,6 Scrappers of Rubber, 20 Coal fins, 8 Heating Elements.-

7Ruby Shearing MachineCapacity:3*610mm, Strokes/min:70

Motor: 2.2 KW, 1440 rpm. -

8Bemco Hydraulic PressMotor:25HP, 1470 rpm, Voltage: 415 V AC.350 pcs

9Vibronics Ultrasonic Washing MachineType VS 2 KW- 2 Stage, Voltage: 230V AC, 16V DC, Current: 3.7 A, Frequency: 22 KHz.-

10Imeco Washing MachinePower:6000W, No. of Chambers:4, Size: 900mm*700mm*400mm(l*b*h), Capacity/tank:252 l, Power Output:3500 W, Voltage:415 V AC.-

11Isteco Jewel form 100T PressMotor: 20 hp, Power: 2900 KW, Voltage:380/420 V AC, Current: 26 A, Working pressure:140 Kg/cm2.Setup time: 6.5 hrs,25 pcs/hr

12Tube Machine Old (F. Gustav Siegmund)Capacity:40 m/min, Cut Lengths: 200- 1000mm&1500mm, Max. Wall Thickness: 0.20 mm,Weight: 1250 Kg.-

13Gas Operated Solder Bath( End Dipping)Voltage:230 V AC, Operating Gas Pressure: 0.5 psi, V-800 naturally aspirated burner.-

14Flameless Stress Relieving FurnaceChamber Size:1300mm*1400mm*1900mm(w*h*l), Trolley size: 1100mm*1100*1800mm, Operating Pressure: 0.5 psi, Max. Temp: 400 C, Working Temperature:250 C, Operation time: 1hr, Voltage: 415 V AC.1400 pcs

15Trimming MachineMotor: 5 HP Induction Motor, 1430 rpm, Air Pressure: 4.5- 5 Kg/cm2400 pcs

1.5Types of Products

1.5.1Straight Fin Type

ESC-440

Eicher S-325

ESC-335

Farmtrac-50

FT-45

Escort Construction

Terex Vectra

ACE (Radiator Assembly)

Bulls Backhoe

TT-55HP

FT1104D-44T

Eicher 5510

New Holland 55

1.5.2Fin & Tube Type

1.5.2.1

Z Fin

TMTL Genset

FT-60

Izuzu Cross Flow

Eicher 9mm

1.5.2.2

Square Fin TT-70

TT-70- FSC

1.6Observations

1.6.1Safety

1.6.1.1

General Observations

Lacks a loud speaker system for emergency announcements.

No dress code. Different jobs should have different uniforms.

Low visibility through out the plant, windows to the right is blocked by the air duct.

Floor Plan is confusing.

Helmets are not in use.

Area under the Fin tube section is a low visibility zone. High visibility jackets should be provided.

Emergency plan hasnt been displayed.

Emergency doors exist, but are blocked.

Emergency equipment is sparsely located. Places of worship are present but no safety equipment.

Rubber mats are not present in the press shop. Card board has been used instead.

No safety briefing given to me, a new employee.

The air circulation system is not adequate.

Most machines have an emergency kill switch.

Both entry and exit of the plant are located at the far ends of the factory, no exits in near the center of the shop floor.

1.6.1.2

Machine Specific Observations

Slippery surface near the baking furnace.

Exposed motor belts above the furnace,located right under the fin tube shop.

Hoist alarm is not loud enough.

Proper gas masks for the workers in the painting booth are required.

Gas masks and safety glasses not in use, the worker working on the furnace, washing machine, welding need to wear safety equipment. All these work stations are potential hazard zones due the presence of hot gases, chemicals and toxic fumes.

Worker at the End Dipping station needs a mask; currently using a piece of cloth, the hot solder emits fumes.

Better fitting gloves should be provided to workers at the furnace.

Some of the machines are leaking hydraulic fluid. Slippery surface around these presses has been covered by card boards.

Godrej 25 T doesnt have an emergency stop button.

Old fin cutting machines have exposed moving parts.

The pre tinning machine emits fumes, the operator should use a mask.

1.6.2Ergonomics

A short study of man machine relations.

1.6.2.1


Most of the tasks performed on the shop floor require the operator to stand.

Task of the operator is to operate the designated machine, visually inspect the input and the output.

The working conditions with respect to productivity as well as ease of operation are different in different sections of the shop floor.

Most of the machines have been provided with the necessary auxiliary systems so as to enable the operator to work efficiently.

1.6.2.2


Operations such as tank welding , painting , core assembly ,baking, pre tinning, tube cutting, tube washing, end dipping, annealing, air leak testing require the person to operate the machine in an erect position.

The press shop work can be performed while sitting on a high rotating stool, given that the input material & output bins are located in the correct location.

Some of the press shop workers do have stools for easy and efficient operation of the machines.

The tools and dies are located on racks near the machine, all the tools, dies have been coded for easy identification, and proper lifting mechanism is also provided.

The CTL machine is easy to operate, but the operator could use a stool.

The straight fin core assembly section feeds the baking furnace, the assembly is done at one end of the furnace, the worker working on the other end has to carry the core from this location to the flux bath and then to the furnace. This setup makes it hard for the operators to work to their maximum efficiency.

The welding station basically performs three operations, welding of necks and tubes to the tank, welding the tanks to the core and welding the side frame to the radiator assembly. All these jobs are done in an erect posture. The workstation is located in a well lit area of the plant, fans are also provided. The fixtures provided for welding are swiveling for all direction access to the radiator assembly. The flux is located in tray next to the worker; the welding filler lead is conveniently located either in roll or cylindrical container.

The test tank area has two tanks, and receives welded the radiators from one end. As the radiators are heavy the operation becomes a difficult task for the worker working at the second bay. Also the person working at the second bay is old. Otherwise, the workstation is effective, the gauges and the test equipment is easy to read and operate.

Painting booth has been equipped with auxiliary lighting, a small fan; the painting booth is not crammed and allows free movement of the radiator as well as the painter.

The finished radiators arrive on conveyor belt which makes it easy to add the caps and covers to the finished product, the belt moves at suitable speed i.e in sync with the time taken to perform the finishing operations. The product is the packed in card board box with thermacol packing and loaded onto push carts.

1.7Process Flow Chart

The various operations involved in the production were studied, the result is the following process flow chart.

SHAPE

Aluminium Plant

2.1Introduction

The aluminium plant is responsible for the production of a wide range of heat exchangers cores.

It is relatively a new establishment. The machinery in the plant is modern.

Various types of heat exchangers cores are manufactured in this plant. These are radiators, air coolers, combi coolers, oil coolers & inter coolers.

It also follows a batch type production system.

The workforce is employed on a contract basis.


Component Production Zone: This zone produces the components required for the products. The various components produced are short bar, long bar, separator sheet, heat transfer tubes, air fins, oil fins. All of the machines require one operator each. The operations performed in this work zone are cutting, shearing, fin forming, slitting, deburring and washing. The inventory level is maintained for a production period of one day. This zone employs eight workers.

Core Assembly: This zone assembles the cores of basically three type of heat exchangers, namely plastic tank radiators , charged air coolers and plate & bar type hear exchangers. The various operations performed in this work zone are core assembly, leveling, fluxing, tube flaring and brazing. This work zone employs fifteen workers.

2.3Machines in Each Zone

2.3.1Component Production Zone

Kawa Shearing Machine

10.2 mm Fin Forming Machine

Sahyog Bar Cutting Machine

Ramani Tube Re Cut Machine

Slitting Machine

Oil Fin Cutting Machine ( 8 pitch )

Square Fin Machine

Paint Flux Conveyor

Component Washing Master Handler

2.3.2Core Assembly

Plate & Bar Jig ( 3 No.s )

Sellecan Brazing Furnace

Drying Oven

Spray Fluxing Machine

PTR Header Setter ( 3 No.s )

9mm Ecko Fin Machine

7.55mm Ecko Fin Machine

Square Fin Machine

Oil Fin Cutting Machine

Tube Flaring Machine

CAC Header Jig ( 2 No.s )

2.4 Machine Specifications

SR NoMachine DescriptionSpecificationsProduction capacity/Shift

1Sahyog Bar Cutting MachineMotor:1.5 HP, 1440 rpm, Carbide saw, Speed:35mm/min, Max spindle speed:2100rpmShort Bar:

3000 pcs, Long Bar: 1500pcs.

210.2 mm Fin MachineMax fin Width:140mm,Cutting speed:25-30 m/min,Max coil diameter:1200mm, Min coil diameter: 300mm-

3Ecko 9mm fin Machine.Size: 1352mm*660.4mm*1651mm(l*w*h),Material width range:12.7mm to114.3mm, FPI:6- 25 fpi, Input speed: upto 500ft/min, Motor:2 HP, Voltage:240 V AC.-

4Kawa Shearing MachineSize: 2000mm*2000mm*1400mm(l*w*h) , Motor: 2 HP, 1400 rpm, Voltage 400/440 V AC.1800 pcs

5Ramani Tube Re Cut MachineLoading Height 1300mm, Operating Pressure: 6Kg/cm2, Power: 0.5 KW, Voltage: 415 V AC, 24 V DC.5000 pcs

6PTR Head Setter

(3 no.s)Pneumatic, Accepted Core Length: 400-500mm, Core width:400-500mm, Core thickness: 28-48mm, Fin width: 28,48,49.120 cores

7Paint Flux Machine (Ramani Automation)Sheet size: 40-220 mm, Sheet thickness: 0.8-1.6mm, Width of Spray zone: 600mm, Power: 10 KW, Operation Temperature:120-150 C, Voltage: 415 V AC.57mm sheet: 4000 pcs

8CAC Assembly Jig

( 2 no.s)Manual operation.140 cores

2.5Types of Products

2.5.1PTR (Plastic Tank Radiators)

E 440

(9mm Louvered Z Fin)

NH 55

(7.55mm 14 Square Wavy)

Piaggio

(7.55mm Louvered Z Fin)

Swaraj Mazda


2.5.2P&B (Plate and Bar)

Bulls

(10.2mm, Non Louvered Z Fin)

KPCL 57


Axxiom 30KW


IR 11KW


IR 22 KW


IR 37KW


Cumitas HOC

(10.2mm, Non Louvered Z Fin)

HP 140

(7.55mm 14 Square Wavy)

Elgie 45


2.5.3CAC ( Charge Air Cooler )

Eicher 483

(9mm, Louvered Z Fin)

Eicher 683


Avtec


2.6Observations

2.6.1Safety

2.6.1.1


Visibility is good.

Floor plan is clearly marked out.

All the machines and equipment are in their respective locations.

Lack of loud speaker system, fire alarm etc.

No marked out evacuation plan.

Emergency exits are not present.

Fire fighting equipment is not adequate.

The space between the degreasing machine and the wall may be an issue in an emergency.

Exhaust fans are effective in dispelling gases produced by the drying oven.

The Nitrogen tank has been properly secured outside with proper fencing.

The portion of the building housing the RO plant is crammed, might be problem area in case of an emergency.

2.6.1.2


10mm Fin forming machine: external cover is present, but moving gears are exposed.

Control panels for most machines are suitably located suitably located for both operation & emergency.

Some work areas need to have a mat for better grip.(10mm fin machine, Bar cutting machine)

The equipment is well designed

Flux machines produce particulate matter, operators should wear masks.

The shearing machine needs better lighting.

The PTR jigs retract back their original position in the case of power loss, operators hand might get injured.

The Nitrogen tank has been secured properly.

2.6.2Ergonomics

2.6.2.1


Almost all operations are performed in an erect position.

Fin forming: There a total of six fin forming machine, all of them are linear in operation; the operator has to visually inspect the fin for defects. All the machines are easy to operate. The control panel is located at suitable height so that operator of any size can operate the machine without discomfort. The 9mm Ecko fin machine and the CAC assembly line behaves as a small cellular manufacturing system. Such a sequence in operation results in higher productivity in this line.

Tube re cut machine: The input material, control unit are suitably placed, the output is delivered to the box automatically, and no inspection is required.

Core Assembly jigs: The operator is required to stand to perform the job, the input materials are located in bins on both sides of the machine, and adequate light is present. The assembly of the cores is efficiently achieved with minimum loss of energy.

Par and Bar type leveling station: Lighting is essential for this job, workers require more lighting to perform their jobs efficiently, also the work space requires have better tooling solutions

Paint Flux Station: This machine is operated by two workers, location of the machine leads to rise in particulate matter when door next to machine is opened,

Brazing furnace: This machine requires the operator to load the machine and start the brazing operation, the process take a long time during which the person can perform other jobs.

PTR tube flaring station requires better tooling solutions

2.7Process Flow Chart

The various operations involved in the production were studied, the result is the following process flow charts.

Charge Air Cooler

Plastic Tank Radiator

Plate & Bar Type

SHAPE

SHAPE

SHAPE

Wigman Center & Laboratory

3.1Introduction

The Wigman center is responsible for the finishing operations on the heat exchanger cores produced by the aluminium plant.

It is relatively new establishment.

Tanks for all aluminium cores are welded in this establishment.

All new products and prototypes of prospective products are tested in the lab.

The establishment has modern TIG welding machines.

All heat exchangers produced are sent for powder coating to another company.


Fin & Tube Shop/CAC Shop: The fin & tube shop is responsible for welding of tanks to the CAC cores. The tanks are outsourced; they undergo stress relieving and hydro testing before they are welded to the core. The various operations performed in this zone are cleaning, welding, inspection and packing. Welding is performed on four workstations. This work zone employs nine workers.

Plate & Bar Shop: The plate & bar shop is responsible for welding of C channel tanks to cores. The tanks are cut from C section channels, inlet-outlet holes are drilled at the development center. The operations performed here are welding, grinding, brushing, inspection and packing. This work zone employs nine workers.

Plastic Tank Radiator Shop: The PTR Shop is responsible for the fitting of plastic tanks to the fin and tube type radiators. The plastic tanks are outsourced. The operations performed in this work zone are pipe fitting, clinching, crimping, side frame fitting, accessory fitting, dry testing and packing. The PTR shop employs ten workers.

Laboratory: All new products and prototypes undergo various tests at the laboratory. The tests are heat dissipation test, vibration test, thermal cycle test, corrosion test, internal cleanliness test and hydraulic pressure test.

3.3 Machines on the Shop Floor

Kemppi TIG Welding Machine (8 No.s)

Dry leak Test Machine (2 No.s)

Top Crimping Machine

Hot Water Generator

Thermic Fluid Heater

Combined Vibration & Pulsation Test Rig

Thermal Cycle Test Rig

Hydraulic Test Machine

Electro Dynamic Vibration Shaker

Corrosion Test Chamber

Internal Corrosion Test

Tensometer

Hydro Test tanks (3 No.s) and Hoist.

3.4Machine Specifications

SR No.Machine DescriptionSpecification

1Kemppi 3500W TIG Welding Machine.Voltage: 400 V AC, Rated Power: 60% ED: 350A/11.7KVA, 100% ED 280A, Open Circuit Voltage: 70 V DC, Power: 18 W, Efficiency: 80% (350A/34V), Size: 690mm*260mm*870mm(l*w*h), Weight: 74 Kg, Max Pressure of Cooling Unit: 350 Kpa.

2Electro Dynamics Vibration ShakerVibration: Sine, sweep & random, Rated force: 1500 Kgf , Acceleration: 10g, Rated displacement: 35mm, Velocity: Upto1.5 m/sec, Frequency range: 5Hz to 3 KHz, Payload capacity: 300 Kg, 3D vibrations.

3 Hydraulic Pressure TestHydraulic Pressure: Upto 100 Kg/cm2, Fluid flow: Upto 10 lpm.

4External Corrosion Resistance TestSolution temperature: Ambient to 45-55 C, Air pressure: Upto 4 Kg/cm2, Fog rate: 10-20 Ml/hr per 80 cm2,Solution Type: Salt solution spray test( 5 % NaCl soln prepared in D.M water), Agricultural fertilizer test( 5% fertilizer soln in D.M water), SWAAT( 42g of synthetic sea salt + 10 ml of glacial acetic acid/l).

5Vibration TestAcceleration: 3g fixed, Amplitude: 3mm fixed, Frequency: Upto 16 Hz, Direction: Vertical, Max. payload: 20 Kg.

6Combined Vibration & Pressure Pulsation TestVibration Test (Acceleration: 3g max, Amplitude: 5mm max, Frequency: Upto to 25 Hz, Direction: Vertical, Max payload: 15 Kg.), Pressure Pulsation Test( Fluid Pressure: Upto to 2.0 bar, Fluid Temperature: Upto to 130 C, Frequency: Upto 25 CPM.

7Thermal Cycle TestCold fluid temperature: min 5 C, Hot fluid tempearature: max 130 C, Chamber temperature: 17-23 C, Cycle time: Computer control on spray time.

8Heat Dissipation TestAir Velocity: 1- 30 m/s, Coolant flow: 1.5-223 l/m, Coolant heating capacity 130C, Oil flow: 2-225 l/m, Oil Heating Capacity: 55 C, Test Range (size): 100*100mm to 1350*1350mm

3.5Observations3.5.1Safety

Work area is well marked out.

Lighting is good.



Curtains have been provided for all welding stations. All workers use shields.

Fire fighting equipment is sparsely located.

No emergency exits or plans.

No uniforms.

Only one entry and one exit, both located at ends of the shop floor. Also, the exit doesnt lead to an open area.

3.5.2Ergonomics

All the operations performed here need the worker to be in an erect position.

TIG welding station: The operator has been provided with all the necessary equipment to enable him to work efficiently.

PTR assembly: Plastic tanks are provided next to the machine, the brazed core a conveniently located on a pallet, bolt guns, bolts, o rings etc are located in trays. Everything is organized and labeled.

The inspection and packing area is also well chalked out, the gauges are easy to read, and all the packing requirements have been provided. Packed good are placed onto a pallet next to the workstation.

Development Center

4.1

Introduction

The Development Center is responsible for the development of new machines, machining of tools & dies and other machining for maintenance purposes.

It is old part of the factory.

It has both new and old machinery.

Most of the workers are permanent employees of the company.

4.2Machines on the Shop Floor

HMT Surface Grinder

Surface Grinder

Lathe Machine

HMT Milling Machine

Shaping Machine

Power Hacksaw Machine

C Channel Cutting Machine

Radial Drilling Machine

Accumax Drilling Machine

4.3Machine Specification

SR NO.Machine DescriptionSpecification

1Surface Grinding Machine(small)Size:46*9(l*w), Working surface: 18*9, Motor: 1 HP, Spindle speed: 2800 rpm, Working pressure: 120psi, Longitudinal traverse: 19, Cross traverse: 7, Head Traverse: 11.

2Milling Machine(HMT)Main motor: 7.4 HP/5.5 KW, Rapid traverse motor: 2.0 HP/1.5 KW, Coolant pump motor: 0.13 HP/0.1KW, Spindle speeds: 68-1270, Max. payload: 315 Kg, Weight: 2900 Kg., Size: 2300mm*2000mm*1850mm(l*w*h)

3Accumax Drilling MachineDrill motor: 5 KW, Elevating motor: 0.55 KW, Coolant motor: 0.12 KW, Size: 1285mm*1880mm*1925mm(w*d*h)

4Kirloskar Hacksaw MachineMotor: 1 HP, 7200 RPM, Voltage: 400/440 V AC.

5Surface Grinding Machine(HMT)Grinding motor: 5.7 HP, 720 RPM, Speed: 2880 RPM, Max traverse of grinding wheel: 320mm, Longitudinal traverse: 1150mm, Grinding length: 1000mm.

4.4Observations

4.4.1Safety

Visibility is good.

Floor plan is clearly marked out.



No marked out evacuation plan.

Fire fighting equipment is not adequate.

4.4.2Ergonomics

Machining is the primary operation of this work space, hence upright position is necessary to perform the job.

Platforms have been constructed for better visibility and access, stools are also available.

All the machines and tools are labeled for easy identification.

Equipment to lift and place the raw material has been provided.

Raw Material Storage



Storage

Fin Forming

Fin Forming

Blank Cutting

Blank Cutting

Outsourced Straight Fin Core

Drawing

Trimming

Hole punch

Pipe Seat Dimple Forming

1st Forming

Logo Embossing

2nd Forming

Trimming

Slot Punching

Stress Relieving

Fin Leveling & Combing

Stiffener Insertion

Core Fluxing & Baking

End Dipping

Tank, Side Frame Welding

Core Assembly

Air Fin

Z & Square

Air Fin

Straight Fin

Tank

Header Plate

Protection Cap & Packing

Copper Brass Plant

Inspection

Stress Relieving

Inspection

Temporary Storage

Header Plate Fitting


Pre Tinning

Tube Forming

Tube

Washing

Temporary Storage

Gauging

Pipe Welding

Leak Test

Not OK

Rework

Leak Test

Not OK

Radiator Drying, PRC Application & Painting.

OK

Accessory Fitting

OK

Visual Inspection

Packing

Rejection


Radiator Drying, PRC Application & Painting.



Storage


Storage

Storage

Fin Forming

Washing

Tank Periphery Cleaning

Blank Cutting

Drying

Washing

Corner Cutting

Drying

Forming

Punching

Washing

Drying

Fluxing

Degreasing & Drying

Brazing

Tank Fitting

HP to Tank Welding

Core Assembly

Leak Test

Leak Test

Rework

Rejection

Accessory Fitting

Visual Inspection

Packing

Air Fin

Tube

End Plate

Header Plate

Tanks


Charge Air Cooler

OK

Not OK

OK

Not OK


Washing

Inspection







Fin Forming

Fin Degreasing

Bar Cutting &

Deburring

Bar Washing

Fin Forming

Fin Degreasing

Bar Cutting & Deburring

Bar Washing

Sheet Cutting & Deburring

Sheet Washing

Drying

Sheet Cutting & Deburring

Sheet Washing

Drying

Core Assembly

Material Storage

Clamping

Leveling

Brazing

Visual Inspection

TIG Welding

Rework

Packing

Air Fins

Oil Fins

Long Bar

Short Bar

Separator Sheet

End Plate

Tank

Leak Test

Leak Test

OK

Not OK

OK

Not OK

Plate and Bar Type

Fluxing



Storage


Storage

Storage

Fin Forming

Washing

Blank Cutting

Drying

Washing

Corner Cutting

Drying

Forming

Punching

Washing

Drying

Fluxing

Degreasing & Drying

Brazing

Gasket Fitting

Tank Crimping

Core Assembly

Leak Test

Leak Test

Rework

Rejection

Accessory Fitting

Visual Inspection

Packing

Air Fin

Tube

End Plate

Header Plate

Plastic Tank, Rubber Gasket


Plastic Tank Radiator

OK

Not OK

OK

Not OK


Inspection

Final

Documents

straight fin machine

fin tube shop employs

straight fin core assembly

shop floor press shop

z fin machine

fin tube type

press shop employs

painting machine