REDUCTION OF PLATE SCRAP OF A BATTERY BY USING MECHANICAL METHODS

ByP.Satyanarayana 06191A0310D.Sudhakar Reddy 06191A0325D.Dinesh Kumar 06191A0314P.Sravani 06191A0304P.Anusha 06191A0321

Company Introduction

ARBL is one of the biggest plant in Asia (area of 165 acres), most

advanced microprocessor controlled and fully integrated state of the art

manufacturing facility located at Tirupati, Andhra Pradesh with capital outlay of

Rs.180 crores.

Amara Raja is a public limited company whose scip is a joint venture between

Amara Raja group and Johnson Control Inc., USA. As of now 26% equity is with

JCI & Amara Raja group each and the rest 48% is with the public.

Amara Raja is the tenth largest MF-VRLA battery manufacturer in the world.

Amara Raja is also the largest supplier of VRLA batteries for various applications to

Indian Railways such as Train Lighting, Air Conditioning, Signal and Telecom

Batteries & AC Loco Batteries

Oxide Plant

Grid Casting

Paste Mixing & Pasting

Plate

Curing

Plate Cleaning

StackingGroup

Burning

Insertion

Heat sealing

Post Burning

Leak Testing

Cell Packing

Acid Filling

Cell Forming

Cell Cleaning & Insertion

FinishingPacking & Dispatch

Process flow for LVRLA

Process flow for MVRLA

Heat sealing

Post Burning

Leak Testing

Cell Packing

Acid Filling

Cell Forming

Cell Cleaning & Insertion

FinishingPacking & Dispatch

Oxide Plant

Grid Casting

Paste Mixing & Pasting

Plate

Curing

Plate Cleaning

EnvolopStackin

g

Cast on Strap

Insertion

Inter cell welding

Manufacturing Section

PlatePreparation

Assembly

Formation

Finishing

Industrial Battery

Industrial Battery Division (IBD) - LVRLA

Oxide Plant

Grid Casting

Pasting

Manufacturing Sections of IBD - LVRLA

Sub-Section

Busbar Casting

Plate curingPlate cleaning

Dispatch

Plate Preparation

Oxide Plant Grid casting Pasting

Oxide Plant

Grid Casting

Pasting

Oxide Powder

Pbo2+H2So4 + Dm Water+Chemicals = PasteGrid + Paste=Plate

+

Pure Lead (99.97 %)

MFX & LCALead Alloys

Paste

Section/Process Input Output

Oxide Plant

Pasting

Grid Casting

POS & NEG Plate

POS & NEG Grid

Grid

Lead Oxide Manufacturing

Process Flow Diagram

Lead Ingot

Lead Ingot Melting

Reaction

Oxide Powder Filtering

Quality Check Points:1. % Free Lead2. Apparent Density3. Acid Absorption

Transfer to Silos

Oxide Storage in Silos

1. Molten Lead2. Water3. Air

Balox & Eagle Oxide plants

SilosHammer Milling

Additional activityFor MVRLA

Lead Oxide Plant – Input & Out put Diagram

Oxide Preparation

Exothermic reaction

Pure Lead(Pb) Ingots 99.97 %

Lead Oxide(PbO)

Pb + ½ O2 PboH2O

Pasting

Process Flow Diagram

Plate cleaning

Quality Check Points:1. Free Lead %2. Dry plate Moisture3. Vibration loss%

Curing & Drying

Dry Plates Storage

1. Wet plates 2. Boiler

Cleaned Plates

Curing Ovens

Lead oxide powder stored in silo for min of 18hr. Then it is used to produce paste mix.

Composition used: For Positive Paste:

Lead oxide 1000kgBinder 0.5KgSPTH 2KgDM water 126ltSulfuric acid 110kg(Sp. gravity 1.4)

For Negative Paste:

Lead oxide 1000kgBinder 0.5KgBarium Sulphate 20KgVanisperse 2KgCarbon Black 2KgDM water 116ltSulfuric acid 110kg(Sp. gravity 1.4)

PASTE PREPARATION:

Plate Curing – Input & Out put Diagram – LVRLA &

MVRLA

CuringWet pasted

platesDry

plates

PROBLEM: Plate scrap in pasting

OBJECTIVE:

To reduce the plate scrap in pasting.

To reduce the plates scrap from 2.4% to 1.35% per month

“12-STEPS” FOR PROBLEM SOLVING

STEP-1 IDENTIFICATION OF PROBLEMS

STEP-2 SELECTION OF THE PROBLEM

STEP-3 DEFINITION OF THE PROBLEM

STEP-4 ANALYSIS OF THE PROBLEM

STEP-5 IDENTIFICATION OF CAUSES

STEP-6 FINDING OUT THE ROOT CAUSE

STEP-7 DATA ANALYSIS

STEP-8 DEVELOPING SOLUTION

STEP-9 FORESEEING PROBABLE RESISTANCE

STEP-10 TRIAL IMPLEMENTATION & CHECK PERFORMANCE

STEP-11 REGULAR IMPLEMENTATION

STEP-12 FOLLOW UP/REVIEW

Step-1 Identification of Problems

Using Brainstorming

S.NO IDENTIFICATION OF PROBLEMS CAT:A\B\C

1 Plate Weight variation. A

2 Improper Filling of paste on grids A

3 Lug side over paste A

4 Filling problem of paste on grids A

5 Tool setting problem A

6 Flash Drier chain Vibration A

7 Parter timing problem A

8 Temp problem in Flash Drier B

9 Grid cutting problem A

10 Parter center chain sprocket problem B

11 Belt Nylon bed problem B

12 Heaters set fixing problem C

13 Feeder chain timing problem A

14 Grid feeding Rubber roller problem A

15 Knurling roller Bush problem B

16 Knurling roller Shaft problem B

17 Drive roller problem A

18 Drive roller Pins problem A

19 Drive roller Black bush problem B

20 Hopper Shaft bush problem B

Step-1 Identification of ProblemsUsing Brainstorming

21 Hopper Guard bush problem B22 Hopper Bottom shoe guard problem B23 Transfer roller bush problem B24 Lug cleaning brush problem A25 Parter Speed control Sensor problem B26 Oxide leakage (Near Oxmaster lids ) B27 Mixer Scrapers worn-out A28 Slide gate Sensor problem B29 Thermo couple problem in mixer B30 Thermo couple Sensor problem in mixer B31 Thermo couple cylinder problem B32 Mixer Dumping Door Sensor problem B33 Slide gate Water leakage problem B34 Air leakage in mixer B35 Acid leakage in mixer B36 Acid Valve (Filling and Dumping) problem B37 Mixer motor guard problem B38 Oxmaster cone gear box problem B39 Oxmaster cone Cylinder problem B40 Oil leakage in mixer B41 Plates scrap in pasting A42 Hydraulic oil leakage in Hydraulic unit B43 Hydraulic pressure problem B44 Plates pallet Down in Assembly A45 Plate Sagging problem A

Using Brainstorming

Step-1 Identification of Problems

46 Scissor lift problem at plate collecting area B47 Bottom paste Tray problem B48 Parter width Adjustment problem B49 Fresh Air not working properly (Pressure low ) B50 Pallet truck problem in pasting B51 Plate Cross cutting problem in parter A52 Heaters Failure in Flash drier B53 Hydraulic pressure gauge Oil leakage B54 Feeder center guide not working properly A55 Lifting plates problem B56 "D" Type Ovens Plates Moisture problem B57 Transfer roller Speed problem B58 Parter chain Bearing problem B59 Forklift problem B60 Oxide transfer problem to Day tank B61 Day tank bin vent problem B62 Day tank load cells problem B63 Silos load cells problem B64 Lighting problem in Grid feeder B65 Weighing scale problem B66 Plate storage Stands problem A67 PP sheets problem A68 High pressure pump problem B

PROBLEM CLASSIFICATION

ABC-ANALYSIS

CATEGERORY

NO

.OF

PR

OB

LEM

S

A-21

B-46

C-01

Problems solved by qc members

Where help is required from other departments

Where management help is required

Using Brainstorming

VICTORY

Step-2 Selection of the Problem

Ranking method

Ranking 01 - Low 05 - Moderate 10 - High

Sl No Problems V.R.R K.V D.S G.G Y.M Total

1 Plate Weight variation. 6 7 5 8 6 32

2 Improper Filling of paste on grids 5 6 4 5 4 24

3 Lug side over paste 9 9 10 9 10 47

4 Filling problem of paste on grids 5 6 2 4 5 22

5 Tool setting problem 5 6 4 3 6 24

6 Flash Drier chain Vibration 5 5 5 5 5 25

7 Parter timing problem 6 6 6 6 6 30

8 Temp problem in Flash Drier 6 4 4 4 4 22

9 Grid cutting problem 5 6 6 6 7 30

10 Parter center chain sprocket problem 4 5 5 5 5 24

11 Belt Nylon bed problem 5 7 5 4 5 26

12 Heaters set fixing problem 6 5 6 5 4 26

13 Feeder chain timing problem 5 5 7 7 6 30

14 Grid feeding Rubber roller problem 6 8 6 7 3 30

15 Knurling roller Bush problem 5 4 7 2 5 23

16 Knurling roller Shaft problem 6 6 4 5 4 25

17 Drive roller problem 5 5 5 4 5 24

18 Drive roller Pins problem 7 4 5 6 3 25

19 Drive roller Black bush problem 5 6 6 4 6 27

20 Hopper Shaft bush problem 6 7 7 3 8 31

21 Hopper Guard bush problem 8 4 6 4 4 26

22 Hopper Bottom shoe guard problem 5 6 7 5 6 29

23 Transfer roller bush problem 8 5 4 6 5 28

24 Lug cleaning brush problem 6 7 6 4 7 30

25 Parter Speed control Sensor problem 7 6 5 5 2 25

26 Oxide leakage (Near Oxmaster lids ) 6 8 4 7 4 29

27 Mixer Scrapers worn-out 6 5 8 8 6 33

28 Slide gate Sensor problem 6 6 6 4 5 27

29 Thermo couple problem in mixer 5 8 7 5 4 29

30 Thermo couple Sensor problem in mixer 4 7 6 4 7 28

31 Thermo couple cylinder problem 5 6 8 5 5 29

32 Mixer Dumping Door Sensor problem 6 5 2 6 6 25

33 Slide gate Water leakage problem 5 8 4 5 4 26

34 Air leakage in mixer 4 6 6 6 3 25

35 Acid leakage in mixer 5 5 4 7 4 25

36 Acid Valve (Filling and Dumping) problem 6 7 6 6 4 29

37 Mixer motor guard problem 5 4 5 5 5 24

38 Oxmaster cone gear box problem 4 5 5 4 5 23

39 Oxmaster cone Cylinder problem 6 4 7 6 6 29

40 Oil leakage in mixer 7 5 6 5 4 27

Ranking method

Step-2 Selection of the Problem

Ranking 01 - Low 05 - Moderate 10 - High

41 Plates scrap in pasting 10 9 9 10 9 4742 Hydraulic oil leakage in Hydraulic unit 5 5 6 6 4 2643 Hydraulic pressure problem 5 7 5 5 7 2944 Plates pallet Down in Assembly 10 9 9 10 9 4745 Plate Sagging problem 5 6 4 6 4 2546 Scissor lift problem at plate collecting area 2 6 6 8 6 2847 Bottom paste Tray problem 5 5 5 5 5 2548 Parter width Adjustment problem 4 4 4 6 4 2249 Fresh Air not working properly (Pressure low ) 6 4 5 5 5 2550 Pallet truck problem in pasting 3 5 7 6 4 2551 Plate Cross cutting problem in parter 5 5 6 7 6 2952 Heaters Failure in Flash drier 4 5 4 5 4 2253 Hydraulic pressure gauge Oil leakage 3 5 6 6 7 2754 Feeder center guide not working properly 4 7 5 5 5 2655 Lifting plates problem 6 6 4 6 8 3056 "D" Type Ovens Plates Moisture problem 2 4 6 7 4 2357 Transfer roller Speed problem 6 5 5 4 5 2558 Parter chain Bearing problem 5 4 5 6 6 2659 Forklift problem 5 3 4 5 4 2160 Oxide transfer problem to Day tank 4 5 3 4 4 2061 Day tank bin vent problem 5 4 4 2 2 1762 Day tank load cells problem 4 5 4 4 3 2063 Silos load cells problem 5 4 2 3 4 1864 Lighting problem in Grid feeder 4 3 3 5 2 1765 Weighing scale problem 4 4 2 2 5 1766 Plate storage Stands problem 5 5 4 4 2 2067 PP sheets problem 4 3 5 3 4 1968 High pressure pump problem 5 2 2 2 5 16

Step-2 Selection of the ProblemRanking method

Ranking 01 - Low 05 - Moderate 10 - High

Step-2 Selection of the Problem

PRIORITY METHOD

S.NO Problem NOT URGENT(0) URGENT(2) VERY URGENT(5) TOTAL

1 Lug side over paste 1 2 2 14

2 Plates scrap in pasting …. 2 3 19

3 Plates pallet Down in Assembly 2 2 1 9

PLATES SCRAP IN PASTING HAS SCORED MAXIMUM MARKS AND IS SELECED FOR OUR PROJECT

Step-3 Definition of the Problem

Pasting Process Flow Chart

PASTING

GRID FEEDER

HOPPER PASTE MIXER

FLASH DRIER

PARTER

PASTE

STACKING

Step-4 Analysis of the Problem

Problem analysis was carried out through 4W 1H Technique

WHAT - Plates scrap in pasting

WHEN - During pasting

WHERE - In pasting section WHO - Pasting operators

HOW - By analysing the causes and developing solution

Step-4 Analysis of the Problem

Manufacturing cost ProductivityOperator stress

WEEKS PRODUCED SCRAP PLATE REJECTION

COST(Rs)

WEEK1 287130 1747 37300

WEEK2 357637 14363 30665

WEEK3 467330 8375 17881

WEEK4 406708 12813 27355

AVERAGE: 9324 No 28308 RS

Step-5 Identification of Causes

Men Machine

MethodMaterial

Lack of awareness

Lifting problem feeder

Feeder chain timing change

Driver roller bush and block worn out

Driver roller worn out

Oxide usage with out aging

Grids usage with out aging

Paste problem

Improper tool setting

Cause and effect diagram

Plates scrap

Conveyor chain vibration

Porter dog chain timing change

V belt worn out

Brush worn out

Pressure plate improper setting

First sample checking

Cross cutting

Improper pate filling

198400

55007

41956

3095820832 18024 15496

10109 7221 6376 5081 4116 3483 3445 2372 1384 672 600 500 118 28

46.6%

59.5%

69.3%

76.6%81.5%

85.7%89.3%

91.7% 93.4% 94.9% 96.1% 97.0% 97.9% 98.7% 99.2% 99.5% 99.7% 99.8% 100.0%100.0%100.0%

0

50000

100000

150000

200000

0.0%

10.0%

20.0%

30.0%

40.0%

50.0%

60.0%

70.0%

80.0%

90.0%

100.0%

Pareto analysis

No

of

pla

tes

76% OF REJECTIONS OCCURING DUE TO VIBRATION LOSS,CROSS CUTTINGPARTER JAMMING,IMPROPER PASTE FILLING

Causes

Step-4 Analysis of the Problem

Step-6 Root Cause Analysis

Data collection

FROM DATA COLLECTION 76% OF REJECTIONS OCCRING DUE TO

1. VIBRATION LOSS2. CROSS CUTTING3. PARTER JAMMING,4. IMPROPER PASTE FILLING

Vibration losses Cross cutting Parter jamming Improper paste filling

Action (3W 1H)

Step-8 Development of Solutions

WHAT WHO WHEN HOW

P.Satyanarayana 24feb-20marFlash drier chain modification

do Increasing quantity of binder addition

D.Dinesh Kumar do Sprocket modification

do Giving awareness to the operator

do Changing freuency of cutter fixing

D.Sudhakar Reddy do Brush level modification

p.Anusha do Prater on/off switch near to operator

do Pressure plate adjustment

IMPROPER FILLING p.sravani do cone switch near to operator

VIBRATION LOSSES

CROSS CUTTING PLATES

PORTER JAMMMING

Step-8 Development of Solutions

Using Brainstorming

Vibration looses

Flash drier chain modification

Increasing quantity of binder addition

Cross cutting

Sprocket modification

Giving awareness to the operator

Fixing the changing frequency of cutter

Step-8 Development of Solutions

Using Brainstorming

Parter jamming Brush level modification

Parter on/off switch near to operator

Improper paste filling Pressure plate adjustment

Cone switch near to operator

BEFORE

Problem ImprovementDue to more length of chain, plates are getting vibrated

The length of the chain has decreased by removing six links

AFTER

Flash drier chain modification

Step-10 Trail Implementation & Check Performance

BEFORE

Problem ImprovementDue to frequent loosing of sprocket causing

Dog chains unlevel leading to cross cutting

Sprocket was fixed with supporting rod provide to prevent frequent loosing

AFTER

Sprocket Modification

Step-10 Trail Implementation & Check Performance

Step-10 Trail Implementation & Check Performance

BEFORE

Problem ImprovementDue to brush unlevel causing plates disturbance leading to cross cutting of plates

Brush level is fixed with supporting rod to avoid cross cutting

AFTER

Brush level modification

Step-10 Trail Implementation & Check Performance

BEFORE

Problem ImprovementDue to unlevel of pressure plate causing over paste on lugs leading to disturbance at the brushes

The springs in the pressure plate has modified.

AFTER

Pressure plate modification

Step-10 Trail Implementation & Check Performance

BEFORE

Problem Improvementswitch is near to cone due to this operator feeling difficult for frequent access

Cone switch provided near to operator so that he can frequently fill the paste in hopper

AFTER

Cone switch

Step-10 Trail Implementation & Check Performance

BEFORE

Problem Improvement Cross cutting occurring due to Parter on/off switch far from operator

Parter on/off switch provided near to operator

AFTER

Parter switch

STANDARDISATION

Step-11 Regular Implementation

To avoid vibration losses binder addition increased from 1kg to 1.25kgs for positive and 1kg to 2.5kg for negative.

Check list for Parter cutter changing for every 800000 plates STANDARDISATION

Step-11 Regular Implementation

Step-12 Follow Up & Review

12813

5342

1137 1297

0

20000

40000

60000

80000

100000

120000

140000

PLATE REJECTIONS

NO

.OF

PL

AT

ES

RE

JEC

TE

D

GOAL: To reduce the plates scrap from 2.4% to 1.35%

TANGIBLE BENIFITS

INTANGIBLE BENIFITS

1. Developed leader ship Qualities2. Pride in achievement3. Opportunity of learning4. Self motivation

Plates saved per week =4177 NoCost saved per week =89178 Rs/-

Before modify scrap%=(avg.scrap/produced plates)(9324/379701)=2.4%After modify scrap%=5147/379701=1.35

1. Brain Storming

2. Bar Graphs

3. Ranking Technique

4. Flow Diagrams

5. 4W&1H Method

6. Ishikawa Diagram

Application Segments / Costumers

Industrial Batteries Railways Power Generation Oil & Gas Process Industry Defence Motive Power DG Set- Auxiliary power Telecommunications

Plates scrap in pasting has played prominent role in reduction and wastage of huge amount , large amount of workers working hours so we have reduced by implementing some of the mechanical techniques.

As we had the goal to reduce the plates scrap from 2.4% to 1.35%, But we achieved 1% by implementing the all techniques and tools used.