Tata AutoComp GY Batteries Pvt. Ltd.
Project report on Dross Generation in the Casting Section
Project by-Abhishek Roy
Project Head-Mr. Suvrajit Banerjee
Under the supervision of Mr. Mohit Bhakal
Tata AutoComp GY Batteries Pvt. Ltd.
Acknowledgement I have taken efforts in this project. However, it would not have been possible without the kind support and help of many individuals and organizations. I would like to extend my sincere thanks to all of them. I am highly indebted to Mr. Suvrajit Banerjee, Mr. Mohit Bhakal for their guidance and constant supervision as well as for providing necessary information regarding the project & also for their support in completing the project. I would like to express my gratitude towards operators of Casting section of TATA AutoComp GY Batteries Pvt. Ltd for their kind co-operation and encouragement which help me in completion of this project and for giving me such attention and time.
Tata AutoComp GY Batteries Pvt. Ltd.
Company Profile
Tata AutoComp Systems Limited, promoted by the Tata Group, provides products and services in the automotive industry to Indian and global customers, including Ashok Leyland, BMW India, Mercedes-Benz India, EicherMotors, Fiat, Force Motors, Ford India, General Motors India, Hero Honda, Hindustan Motors, Honda Scooters, Honda Siel Cars India Ltd, International Tractors John Deere India, Mahindra and Mahindra, Mahindra Renault, Man-Force Trucks, New Holland, Piaggio, Punjab Tractors, Royal Enfield, Skoda, Swaraj Mazda, Tata Motors, Toyota Kirloskar Motor Pvt. Ltd., Tractors and Farm Equipment Limited.
Tata AutoComp GY Batteries Pvt. Ltd.
Company Profile (TATA AutoComp GY Batteries)
TATA Green Batteries are a product of TATA AutoComp GY Batteries Pvt. Ltd. (TGY), a joint venture between TATA AutoComp Systems Ltd, India's leading auto component manufacturer and GS Yuasa International, Japan, one of the world's largest automotive battery manufacturers. These batteries are a combination of TATA AutoComp’s extensive experience in the Automotive Industry and GS Yuasa International’s superior technological know-how. With a low top-up requirement and being 90% recyclable, Tata Green Batteries allow a hassle free battery running experience
Tata AutoComp GY Batteries Pvt. Ltd.
Different Sections In the Plant
CASTING
Pasting
Assembly
Charging
Dispatch
*The project is undergone under this section
Tata AutoComp GY Batteries Pvt. Ltd.
Wal
king
Are
a Walking Area
Wal
king
Are
a
Way to the PASTING section
Raw Material Section Calcium –ve Alloy
Antimony Alloy Calcium +ve Alloy
Sb +
ve
Emergency Exit
Ca +veCa -ve
CASTING SECTION
Ca +ve
Cork Preparation Area
CAST
ING
Secti
on E
ntry
Offi
ce
Dross dumping
area
B1 B2 B3 B4 B5 B6 B7 B8
A1 A2 C6 C5 C4 C3 C2 C1C10 C9 C8 C7
Ca -ve
Ca -ve
Ca -ve
Ca -ve
Ca -ve
Ca -ve
Ca -ve
Ca -ve
Ca -veSb +
ve
Sb +
ve
Sb +
ve
Sb +
ve
Sb +
ve
Sb +
ve
Sb +
ve
Tata AutoComp GY Batteries Pvt. Ltd.
Gravity Casting Machine
Tata AutoComp GY Batteries Pvt. Ltd.
Working Of the machine
1
2
6
5
4
3
7
Tata AutoComp GY Batteries Pvt. Ltd.
Process
POT (Where The molten
lead is present)
FEEDLINE(which transfer the molten lead)
LADDLE
TRIM DIE SECTION
(to cut excess part of the panel)
COLLECTING AREA (The final product is kept
here )
MOULD(which give shape to the
molten lead)
ROLLER
1 2
6
5
4
3
7
The excess part is send back to the Pot
Tata AutoComp GY Batteries Pvt. Ltd.
Type Pot Temp. Ladle Temp. Moving mould Temp. Fixed Mould Temp. Feed Line Temp.
Sb +ve 420±30 600±30 200±30 200±30 490±30
Ca -ve 420±30 600±30 200±30 200±30 490±30
Ca +ve 420±30 600±30 200±30 200±30 490±30
Grid information
Tata AutoComp GY Batteries Pvt. Ltd.
Grid Nomenclature
Y M 83A
Plate thickness (100-83)/10=1.7±0.1mm
Grid thickness ((100-83)/10)-0.2=1.7±0.1mm
Small
Calcium
OTHER NOTATIONS:-C Antimony
G Big
In case ofPlate thickness=(100- )/10=2.1±0.1mm Grid thickness=((100- )/10)-0.2=1.8±0.1mm
C G 80A 79
79
80
Tata AutoComp GY Batteries Pvt. Ltd.
DrossDross is a mass of solid impurities floating on a molten metal or dispersed in the metal, such as in wrought iron. It forms on the surface of low-melting-point metals such as tin lead zinc or aluminium or alloys by oxidation of metals as tin, lead, zinc or aluminium or alloys by oxidation of the metal(s). Dross, as a solid, is distinguished from slag, which is a liquid. Dross product is not entirely waste material; for example, aluminium dross can be recycled and is used in secondary steelmaking for slag deoxidation.
Dross
Tata AutoComp GY Batteries Pvt. Ltd.
16 Major Losses In a Company
8 Availability LossesMachine LossSetup & adjustingTool changeStart-up lossesMinor stoppageSpeed lossDefect and reworkShutdown
5 Productivity lossesManagement lossesOperating MotionLine organisationLogisticsAdjustments
3 Production losses•Loss of energy•Die-tool losses•Yield loss
Tata AutoComp GY Batteries Pvt. Ltd.
Time Study of the Machine (B3-B4)
Total sample time for the production- 180 minutesNo of panels to be produced– 3690 panels
Actual Time taken for production- 144 minutesNo of grids produced- 3168 panelsMajor losses occurred during the process-• Shut Down Loss/Defect and rework- 20 min• Setup Loss-5 min• Die/Tool Loss- 5 min• Line organisational loss-6 min
Tata AutoComp GY Batteries Pvt. Ltd.
Date April'16 May'161st 237 02nd 432 4093rd 385 3414th 427 2855th 426 3216th 471 3237th 373 4078th 0 3949th 457 41210th 379 34211th 431 42512th 292 55713th 341 44414th 397 49715th 324 29916th 431 49317th 418 26618th 300 46419th 206 42820th 289 51121st 436 51522nd 300 44223rd 430 45924th 304 45125th 366 36326th 417 027th 455 028th 398 029th 367 8930th 323 45231st n/a 470
possible reasons-- temperature variations-manpower variation-Impurities in the ingot
highest amount of dross generated
Tata AutoComp GY Batteries Pvt. Ltd.
Dross Generation Data
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th 16th 17th 18th 19th 20th 21st 22nd 23rd 24th 25th 26th 27th 28th 29th 30th 31st0
100
200
300
400
500
600
Dros
s (in
kg)
highest amount of dross gen-erated
Tata AutoComp GY Batteries Pvt. Ltd.
Action PlanThere are ways by which we can reduce the generation of
dross-• By induction heating- induction heating helps in reducing
dross generation and also helps in energy saving. The idea is being proposed and is in a prototype position.
• By minimising the surface area of the opening of the pot- The opening present in the pot is the reason for the generation of dross as more amount of air can enter through it to oxidise with the lead. If the conveyor length is increased so that it ends at the inside the opening and the opening is made small enough so as to make the dross removal easier for the operator and putting a cover on it, the dross generation can be reduced by 5%.