FORTNIGHTLY PROJECT REPORT - 4

By

Name of the students:

Thomas Abraham
ID Number: 15B00080
Mechanical - 2

Prepared in the partial fulfillment of the

Practice School III Course

AT

Rockman Industries Limited

Village Asoj, Taluka Waghodia, Vadodara
Gujarat

A Practice School III Station of

BML MUNJAL UNIVERSITY

27th March 2019

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 Acknowledgements

I am highly indebted to our Vice Chancellor, Dean SOET for providing us such a great PS 3
opportunity to enhance our self and showcase our talent. I am whole heartedly thanking our
plant head Mr. Pramod Kumar Upadhyay, Rockman industries and Mr. Alok Puranik,
Rockman industries helping us through out. Extending my gratitude to our PS 3 program
coordinators. Finally I wanted to whole heartedly thank our industry mentor Mr. Bhaskar
Pandey, Rockman Industries and faculty mentor Mr. Neeraj Sharma, BMU for constantly
monitoring and guiding us through out.

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 Abstract

HPDC is a widely used casting process using which most of the automotive parts like
Cover panel, Crank case etc. many other components are being produced. Most of the
production rate at Rockman Industries Ltd is generated through the HPDC process.
Important customers for which Rockman Industries supplies are Hero MotoCorp,
Ford, Graziano etc. through High Pressure Die Casting. In this report, HPDC is
explained in Safety Point of View.

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Table of Content:

S.no Description Page

1. Die Casting Safety 5
2. Personal Protection 5
3. Die Casting Machine Safety 6
4. Takt Time Calculation 8
7. Conclusion 9

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Die Casting Safety

Any industrial environment has hazards in it. The die casting plant has specific
hazards that you must be aware of to work safely. The die casting plant uses molten
metal at very high pressures. This requires that you should be thinking about safety,
whatever you are doing.

The pursuit of safety requires that top management must be fully committed to safety.
The company must provide well-maintained and properly guarded equipment in a
clean working environment. Supervisors and production personnel must work
together to teach and motivate safe work attitudes and habits. If an accident occurs, an
objective analysis must be made to determine its cause and avoid its repetition.

The types of hazards that occur in the die casting plant can be characterized as pinch,
snag, strike, burn, electric shock, pierce, slip-fall, trip-fall and fire.
These hazards are not unique to the die casting plant, however. As with any activity
that has special safety requirements, such as driving a car, you must become familiar
with the potential safety hazards in order to avoid injury to yourself or an associate.

Personal Protection

For your personal protection it is important to wear the proper protective clothing and
accessories.
Because of the hazards associated with liquid metals, high pressures, and high
temperatures, it is important to “cover up”. Cotton or woolen clothing is appropriate
as opposed to polyester or synthetic materials that will melt under conditions of high
temperature.
A die casting machine operator should always wear protective clothing.
- Shirts with long sleeves, buttoned at the wrist
- Long pants
- Safety shoes
- Gloves
- Safety glasses
- Safety glasses with side shields are required in the presence of potentially
splashing liquid metal.
- Helmets
Other jobs in the die cast plant require special protective clothing.
- The furnace cleaner has to wear special clothing to protect from radiant heat
given off by
the furnace. Radiant heat burns faster than the sun burns an unprotected
sunbather.
- The metal handler has to wear special protective clothing to protect against
metal splashing.

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Die Casting Machine Safety

The die casting machine has moving parts, pinch and shear points, lubricants,
hydraulic fluid, and electrical controls. Particular areas of the machine may be hot; the
hydraulic fluid could be hot.
Auxiliary equipment such as furnaces, conveyors, reciprocators, robots and the like
have specific safety considerations. These are discussed in detail machine manual.

 Trip-fall hazards

The work area also requires special safety considerations. Keeping your work area
neat and clean is the first step to a safe environment and maintaining your personal
safety.
- Tripping obstacles can cause injury.
- Machines will have components that project from them. These are trip-fall
hazards.
These items should be painted with standard OSHA color coding in order to
make them more visible.

 Noise
Excessive noise can be a hazard that can result in hearing loss. OSHA has published
regulations regarding noise levels in the industrial environment. Modern machines
and equipment are built to meet these regulations. However, the combination of
noises in the industrial workplace make it prudent to use hearing protection. At
minimum, earplugs are recommended and are usually readily available. Hearing
protection is required in some plants.

 Slip-fall hazards
The die casting process consumes a large amount of lubricants, release and cooling agents. These
often get on the floor and cause a slip-fall hazard. Good housekeeping practices must be
maintained to keep floors clean. When liquid spills occur, surface-drying compounds should be
used immediately. Rigid equipment maintenance and preventative programs should be used to
minimize the leakage of fluids from machines and dies.

 Floor clutter
Floor clutter creates slip-fall hazards. This includes electric cords, cables, and hoses
running across the floor. If hoses, pipes and cables must be at approximately floor
level, they should be in a trench that is properly covered. Floor clutter could also
include process debris such as scrap, biscuits, runners, overflows, and sprues.

 Operator platforms
Operator platforms are used to establish the proper working height and prevent
fatigue. The platforms should be of uniform height for similar machines. The
platforms need to provide a non-skid surface to minimize any slip-fall hazard. Proper
working heights are necessary to minimize pains that result when a person works in
an awkward position.

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  Machine controls
Machine controls must also be at the proper height to avoid fatigue. A maximum
height of 70 inches to the top of the operator control panel has been determined
satisfactory.
Handling materials can also be injurious. Correct handling of objects in the die casting
plant is important. The following pointers to the correct procedure for handing various
materials should be observed. This is not a comprehensive list, but a starting point.
- Inspect materials for slivers, jagged or slippery edges, and burrs.
- Keep fingers away from pinch points, especially when setting materials down.
- When handling long objects such as pipes and panels, keep hands away from
the ends
to prevent pinching hands.
- Wipe off greasy, wet, slippery or dirty objects before trying to handle them.
- Keep hands free of oil and grease.

Working with liquid metals can be hazardous. The burn hazard from the liquid metal
or hot casting is obvious. In the die casting plant, one always has to pay attention to
what is touched. Many surfaces may be hot, and not necessarily marked or otherwise
indicated.

 Explosion
With liquid metal, there is even a greater hazard than burns, EXPLOSION! If any
liquid containing water gets under the surface of the liquid metal, the water will turn
to steam, causing the metal to explode and spray out of the furnace. This could cause
the door or a wall of a furnace to blow out causing serious injury to any nearby
personnel.

When water turns to steam, it rapidly expands to 1500 times its volume. One drop of
water will create 1500 drops of steam. This is what causes the metal to erupt from the
furnace. If enough water is available, the eruption will be so violent and so fast that
the liquid metal will be turned into a fine particle spray (dust).
Nothing wet should ever be charged under the surface of molten metal. All tools to be
used in the furnace must be coated and preheated prior to use. All ingots or scrap
should be stored in a dry place and preheated prior to charging into the furnace.

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Takt Time and cycle time of the part ABC :

Takt Time is the rate at which products or services should be produced to meet the rate of
customer demand. It is derived from the German word, Taktzeit, which is often referred to as
the heartbeat or drumbeat of production in Lean Manufacturing.

The value, in conjunction with the current loading (production) rates, is used to analyze
process loads, bottlenecks, and excess capacity. The study will indicate which operations are
ahead of the demand rate and which are not, both indicating opportunities for improvement.
This is strictly a formula and calculation. Use it to compare the measured "loading" to
quantify whether an operation meets, exceeds, and by how much.

The unit of time in the numerator & denominator must be the same.

The numerator, Available Work Time, is often expressed as Minutes/Shift, Seconds/Day,

Minutes/Day and so on.

The denominator, Customer Demand Rate, is often expressed as Parts/Min, Units/Shift,

Pieces/Day, and so on.

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Part ABC :

Process A (Part XYZ)

Customer schedule / daily 5000 Planned time - Hrs. 22.5
Efficiency 85% Working days 25
Rejection 10%
Machine Name & spec. A1 A2 A3
No of part - loading (Kg) 450 130 1200
No of Machine allocated 2 2 2
Total CT (per part) 8.73 9.22 20.67
Takt Time 12.39 12.39 12.39

Takt Time : 12.39 Sec

Machine requirement is also planned according to these charts only. For example if
takt time is 12.3 sec, cycle time is 9 sec then we only need 1 machine for production.
But if the cycle time is 35 sec then one machine can’t fulfil the requirement. So we
need to use 2 machines in place of 1.

Conclusion:
In this report Takt time Vs Cycle time graphs are made for one of thhe part and
machine requirement is planned according to the customer requirement of parts. Also
Die casting related safety issues also talked in this report.

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