Pickling The wire is pulled through the die, its volume remains the same, so as the diameter decreases, the length increases. % of areal reduction.

STEEL WIRE MANUFACTURING

Wire drawing is a metalworking process used to reduce the cross-section of a wire by pulling the wire through a single, or series of, drawing die(s)Applications: Tension-loaded structural components Stringed musical instruments

Types• Cold working• At elevated temperatures

PROCESS OF WIRE DRAWING

Pickling The wire is pulled

through the die, its volume remains the same, so as the diameter decreases, the length increases.

% of areal reduction

Single block wire drawing machines A bracket standing up to hold the die A vertical drum which rotates and by coiling

the wire around its surface pulls it through the die

The wire drum or "block" is provided with means for rapidly coupling or uncoupling

The block is also tapered Snatching

Continuous wire drawing machines

• A series of dies • A block between each die• The speeds of the blocks are

increased successively• Stringing-up• Intermediate anneals

Non-circular cross-section drawing

Lubrication

The following are different methods of lubrication:

Wet drawingDry drawingMetal coatingUltrasonic vibration

Copper sulphate solution

Mechanical Properties

The strength-enhancing effect Tensile strength can be as high as 3760 MPa

Drawing dies

Tungsten carbide Die angles usually range from 6–15 °

OPTIMIZATION OF OPERATIONS IN A STEEL WIRE MANUFACTURING COMPANY

Process flow chart :

The preliminary study at the plant

Wire breakages and maintenance resulted in approximately 60% of the total idle time

Downtime of any one of the KOCH machines will affect the productivity of Bekeart

No specific schedule was prepared for preventive maintenance

The time consumed and the frequency of each fault was not studied

No specific task was taken to change or to revise subassemblies or machine members design which are giving trouble periodically.

GOAL: NEED TO IMPROVE THE PRODUCTIVITY

Productivity can be increased in numerous ways :

By reducing the input for the same level of output

By increasing the output with the same level of input

By combining bothBy reducing down-time due to -Wire breakages, maintenance, reducing the material input,

by using better quality of goods, improved utilization of resources, reduction in working capital

IDLE-TIME ANALYSIS

Shift-to-shift detailed production chart of each machine

Reasoning for idle time occurrence per shift

Wire breakages were basically due to defective raw material, improper pickling and welding

Rare problems – very high time consumption

Regular problems – very less time consumption

Decision variables The number of arrivals of the entity

at the stores. The number of resources required Frequency and time of breakdown

maintenance of the KOCH machines Utilization of the KOCH machines

FINDINGS AND CONCLUSIONSOptimum Lot SizeThe objective was to reduce the blocking of

the coils in the processThe optimum arrival quantity – 42

ThroughputIncreasing the arrival quantityAdding an extra forklift

Variables Decision

Scenarios

1 2 3 4 5

% down,KOCH1

6.6 1.4 5.7 1.8 1.6

% down,KOCH2

8.6 2.6 8.2 2.5 2.5

% down,KOCH3

8.8 2.8 8.6 3.8 2.9

% down,KOCH4

9.1 3.1 9.1 3.4 3.0

% Utilizationof forklift1

99.9 100 79.8 79.9 80.0

% Utilizationof forklift2

44.5 43.5 99.4 99.5 99.5

Preventive Maintenance

FINDINGS AND CONCLUSIONS

PAVANKUMAR D. WADHONKART. Y. PROD

ROLL NO. 20807066 (PE – 03 46)

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