Scrap Managemnt in Sheet metal industry

SCRAP MANAGEMENT IN PUNCHING STATION OF SHEET METAL INDUSTRY

Guided by : Dr. Gukan Rajaram

MISAA 2015

Department of mechanical EngineeringP S G T E CH

KANNAN P

E-mail : [email protected]

mailto:[email protected]

PLANT DETAIL

• Plant name - Madras Radiators & Pressings ltd.

• Manufacturing type - Job shop production

• Product - Sheet metal product

• Major customer - L & T, Gilbarco India, Bull India and Tafe.

• Production capacity - 60 tons per month


MISAA 2015

PROBLEM STATEMENT

• In the current method there is no system to track the scrapped sheet coming out

of the punching station which leads to increased scrap inventory in the shop floor

and reduced utilization of scrap sheets for further production.


MISAA 2015

LITERATURE REVIEW• Taner Arsan, Emrah Bas_kan, Emrah Ar and Zeki Bozkus [1] have developed the

“Inventory Management System” to replace the traditional paper work based

inventory records. In their project they have designed the front end application

which have an interface with the SQL database for storage and retrieval of data.

The developed application has the ability to track, to keep history, to give detailed

reporting for each inventory with reduced human intervention.

• Winston Rey S. Aguirre and Jayson P. Bartolome [2] have developed the

“Laboratory inventory system” for the engineering college. They have develop the

Bar code for each component in the laboratory and information of those

components is stored in the database. Then they have installed the bar code

scanner to identify the information of the particular component.


MISAA 2015

LITERATURE REVIEW

• Arulogun O. T., Olatunbosun, A., Fakolujo O. A., and Olaniyi, O. M. [3] have developed

the “RF id based student attendance management system” to eliminate the time waste

in the manual collection of attendance. RF id technology facilitate the automatic

wireless identification using electronic passive and active tags with suitable readers.

RF id tag information along with student detail is stored in the database. The receiver

captures the signal from the tag and marked the arrival and departure time of the

particular student.

• Chitresh.S. and Amit.K [4] have developed the “Automatic Attendance System” using

“Fingerprint Reconstruction technique”. Here they designed a system such that

attendance report is generated using the thumb impression of student or staff. Hence

by implementing this system they try to reduce the false data in the attendance record.


MISAA 2015

OBJECTIVE• To Increase the utilization of resource by availing the suitable scrap sheets for

Punching operation.

• To develop the Scrap tracking and management system to track the scrap

sheets formed in the punching station of sheet metal industry.

• To Store and retrieve the particular sheet in the inventory without any confusion.

• To Track the scrapped material from the punching process without extra effort.

• To Reduce the requirement of measuring the scrapped inventory each time for

reusing the scraps.


MISAA 2015

METHODOLOGY


MISAA 2015

PRODUCT SELECTION

• Product name - CE Carrier Assembly

• Customer - Gilbargo

• Average demand - 500 products

• Lead time to delivery - 15 days

• Application - Fuel dispensing pump


MISAA 2015

CATIA DIAGRAM OF PRODUCT


CE Carrier Assembly

MISAA 2015

PROCESS MAP


Punching Part removal Filing

DeburringPressing operationWelding/

fabrication

Pre-treatment Powder coating Drilling process

Packing Inspection process Paint touch up

MISAA 2015

CATIA MODEL OF PUNCHED SHEET


MISAA 2015

EXISTING METHOD


MISAA 2015

PROPOSED METHOD


MISAA 2015

SCRAP MANAGEMENT APPLICATION

DATABASEPLANNING COMMITTE

NEED OF SCRAP MANAGEMENT SYSTEM• To reduce the time required to track the information of particular material in the

inventory.

• To locate the required material in the storage without any confusion.

• To eliminate the measurement activity to identify the dimensional information of

the material.


MISAA 2015

FUNCTIONAL REQUIREMENT• The application should allow only authorized user to use the application.

• It should have the database in the back end to store the information about

scrapped sheets.

• There should be an option in front end to add and update the database by

entering the required information in the front end.

• There should be an option in the front end window to check whether the particular

record is available in the database or not.

• There should be an option in front end to check current stock status of scrapped

inventory.


MISAA 2015

REAL TIME DATA TRACKING SYSTEM-SOFTWARE ARCHITECTURE


Data base

Scrap management

applicationEnd user

MISAA 2015

REAL TIME DATA TRACKING SYSTEM-FUCTIONAL ARCHITECTURE


MISAA 2015

REAL TIME DATA TRACKING SYSTEM-FRONT END


MISAA 2015

REAL TIME DATA TRACKING SYSTEM-ADD DIALOG BOX


Login

Valid User Invalid User

No

YesDisplay

Menu bar

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REAL TIME DATA TRACKING SYSTEM-MDI WINDOW


MISAA 2015



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ADD

Data missing

Required data are missing

Yes

Duplicate data

NoSheet id already

exist

Yes

No

Database updated

MISAA 2015

REAL TIME DATA TRACKING SYSTEM-UPDATE DIALOG BOX


MISAA 2015



Update

Data missing

Required data are missing

Yes

Duplicate data

NoSheet id doesn’t

exist

Yes

No

Database updated

MISAA 2015

REAL TIME DATA TRACKING SYSTEM-SEARCH DIALOG BOX


MISAA 2015



Search

Valid sheet id

Invalid sheet id

No

YesDisplay

the data

MISAA 2015

REAL TIME DATA TRACKING SYSTEM-STOCK STATUS DIALOG BOX


MISAA 2015

REAL TIME DATA TRACKING SYSTEM-BACK END


MISAA 2015

CREATION OF SCRAP TAG• Sheet id must be unique to prevent the duplicate data

• Length of sheet id must be in 6 digit

• 1st and 2nd digit = Length of sheet

• 3rd and 4th digit = Width of sheet

• 5th and 6th digit = Thickness of sheet

• [E-x] Sheet id = 803015 represent the sheet having length of 8ft width of 3ft and

thickness of 1.5mm


MISAA 2015

SYSTEM REQUIREMENTFollowing software should be installed before installing the scrap tracking and

management system

1. Microsoft access database

2. Microsoft .NET Framework 4 client profile(x86 and x64)

3. SQL server compact 3.5 SP2

4. Windows installer 3.1


MISAA 2015

BENEFITS• Scrap management and tracking system is development and implemented for trial

run.

• Traditional manual tracking and retrieving of information is replaced with the Real

time data tracking system.

• Requirement of measuring the sheet each time to identify the dimensional

information is eliminated by introducing the scrap tag.

• Manual searching by labor to check the availability of particular sheet is

eliminated.

• The database file containing the information of scrapped material is saved in the

local disk(D) as shown in figure.


MISAA 2015

REFERENCE1. Taner Arsan, Emrah Baskan, Emrah Ar and Zeki Bozkus, A Software Archiecture

for Inventory Managemnt System Innovation and Advances in Computer, Information, System Sciences and Engineering, vol. 4, Issue 12, 2013.

2. Winston Rey S. Aguirre, Jayson P.Bartolome, John Erick T.De Torres, and Mark Joseph P. Fajilan, Automated Laboratory Item-Inventory System With Bar Code IJETAE, vol. 3, Issue 12, December 2013.

3. Arulogun O.T., Olatunbosun, A., Fakolujo O.A., and Olaniyi O.M, RF ID Based Student Management System International Journal of Scientific And Engineering Research, vol. 4, Issue 2, Feburary 2013.

4. Chitresh. S and Amit K (2010), An efficient Automatic Attendance Using Fingerprint Verification Technique International Journal on Computer Science and Engineering, Vol. 2. Pp 264-269

5. Jams Foxall, Teach yourself Visual C# 2008, John Wiley & Sons, Nov 2012.


MISAA 2015

THANK YOU


MISAA 2015

Scrap Managemnt in Sheet metal industry

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