Professional Documents
Culture Documents
Products
Ø Chettinad Royal Grade – 53
Ø Chettinad Grade – 43
Ø Chettinad Super Grade – 53
Ø Sulphate Resistant Portland cement
Ø Chettinad Super Steel cement
Ø
Outline of the manufacturing process
Outline of the manufacturing process
Packing and dispatch unit
Roto packer
Method study
•
Objectives of method study
The process selected for the method study analysis was the
cement packing and dispatch in packer unit 1 of Chettinad
Cements Corporation Ltd.
The reasons for selecting the job are:
Ø The packing unit was not part of the plants central control
unit, so any changes done had no effect on the operation
of the plant.
Ø The packing unit was the major contributor to the high
inventory carrying cost of the plant.
Ø The layout of the unit lacked smooth work flow.
Ø There was frequent complaints from the worker regarding
the tiring work.
Recording the flow of work
The selected job is recorded using flow process chart using
the following symbols:
OPERATION
INSPECTION
TRANSPORTATION
DELAY
STORAGE
Flow process chart (Material type)
Time chart for material flow
8 15min
2 12min
26min
2
1 2min
Flow process chart (Man type)
Time chart for worker
8 25 min
7 12 min
Critical Examination
Suggestions:
Instead of having a manually operated diverting head,
automate the system by developing a pneumatic mechanism
for opening and closing of the diverting head and coupling it
with the main operation of the packing unit.
Development of a new method
The process flow was altered by redesigning the diverting
head assembly.
The elements of change in the new design are:
Ø The material of the diverting head was selected as
structural steel ASTM- A36.
Ø The opening and closing of the diverting head was done
using a pneumatic cylinder.
Ø A new electromagnetic locking design was made
Development of a new method
Existing Design
Development of a new method
New design
The new process sequence
Ø The electromagnet near the closing side gets de-
energized, the diverting head gets unlocked.
Ø As soon as the lock is released the pneumatic cylinder
gets actuated and plunges the diverting head.
Ø The diverting head is opened .
Ø The electromagnet on the other side (i.e opening side)
gets energized thereby it attracts the armature
present in the diverting head and hence locking it.
Ø Once the electromagnet in the opening side gets de-
energized, the lock is released.
Ø The pneumatic cylinder gets actuated and plunges the
diverting head.
Ø The diverting head is closed.
Ø The closing side electromagnet gets energized and
hence locks the diverting head.
•
Magnetic lock
Ø A magnetic lock is a simple locking device that
consists of an electromagnet attached to the side
frame and an armature to the diverting head.
Ø The current passing through the electromagnet
attracts the armature plate holding the diverting
head shut.
•The reasons for choosing an electromagnetic lock is:
1. Easy to install
2. Quick operation
3. Ability to withstand high loads.
Selection of material
•
Design of pneumatic system
• Calculation of system parameters
Theoretical force applied by the pneumatic piston (Ft)
•
Design of pneumatic system
Ft = π * D2/4 * P (for forward stroke)
Ft = π * (D2 – d2)/4 * P (for return stroke)
Fr = weight of the diverting head (w)
Load ratio = (Fr / Ft) * 100 %
•In practical load ratio must be 85% or lower.
•Diameter of piston
Ft = π * D2/4 * P
933 = π * D2/4*5*10^5 ; D = 50 mm
Acceleration Force (Fa) = (Ft) – (Fr)
Fa = 933 – 746 = 187 N.
• The pneumatic system is designed by using a pneumatic
cylinder with piston diameter of 50 mm.
Time chart for material flow after
re-design:
8 15min 0 min
2 12min 0 min
5min 21 min
2
1 2min 0 min
Time chart for worker after re-
design:
Time reduced
Symbol Frequency Time
8 20 min 5 min
7 3 min 9 min
From both charts Delay time reduced by 80%
Operation time of worker reduced by 20%,
Transportation time of worker reduced by 75%.
Conclusion
The project has successfully presented a method study
for the process flow of cement packing and
dispatch. For doing the method study packing unit 1
was chosen and all facts related to it were recorded
using a flow process chart both material type and
man type. The recorded data were critically
examined and suggestions were made to re-design
the diverting head assembly.
After the re-design it was found that the delay time in
material flow reduced from 26 minutes to 5 minutes.
In the worker chart the time of operation of the
worker reduced from 25 minutes to 20 minutes and
time of movement of the worker reduced from 12
minutes to 3 minutes.
ACKNOWLEDGMENT