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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