Nation Builders. Indian Multinational. India s Largest E&C Co. It s All About Imangineering

Transcription

1 Nation Builders Indian Multinational India s Largest E&C Co. It s All About Imangineering 1 of 45

2 Founded L&T Net worth 1938 Employees 12% FIIs 18% 15.6 Net worth Others 14% 15 Share holders 14.5 USD 16 Bn Market Cap , Number of Emp. Gov. & Pvt. Financial Institutions 31% General Public, 25% Thrust on Sustainable Growth 2 of 45

3 4th in the Global List of Green Companies in the Industrial Sector by international reputed magazine Newsweek World s 9th most Innovative Company by Forbes International Company of the year by Business Standard & Economic Times First in Quality in Wall Street Journal Asia Pacific Survey 7th time in row In Forbes Asia s fabulous 50 for three consecutive years Industrial Excellence Awards from Indian Nuclear Society (INS) received two times Among Top 5 in Environment, Social & Governance Rating 3 of 45

4 Infrastructure Hydrocarbon Heavy Engineering Power Metal & Material Handling Machinery & Industrial Products Electrical & Automation Buildings & Factories Heavy Civil Infra Power T&D Others Transportation Water & Ren. Energy Major Subsidiaries IES Shipbuilding Shipbuilding Infra. Dev. Pvt. Ltd. L&T Finance Sp. Steels & Heavy Hyd. Metro Forgings Realty L&T Infotech 4 of 45

5 BUSINESS GROUPS Process Plant & Nuclear Equipment Refinery, Oil & Gas Equipment Defense & Aerospace Special Steel & Heavy Forgings Weapon systems Land Systems Fertilizer, Petrochemical & Power Plant Equipment Flight Systems Nuclear Power Strategic Electronics 5 of 45

6 Sohar, Oman Vadodara Hazira Powai Talegaon Bangalore Coimbatore Micro ENTIRE SPECTRUM COVERED Mega 6 of 45

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8 Vadodara Heavy Engineering Works Total Plot Area : 32,000 m2 Certifications: Quality Systems Process Industry Safety Environment Care Information Security Shop Area: 11,000 m2 (20m x 138m x 4Bays) : ISO , AS-9100 Rev. C : ASME U, U2-Stamp, N, NPT, NS, NA : OHSAS : ISO : ISO of 45

9 Product Portfolio Reactors, Heat Ex & Vessels Process Internals Reactor Internals FCCU Cyclones Ammonia Converter Basket Proprietary Internals CB&I - CLG Shell SS / LAS clad Reactors SS / DSS & Clad Hxs Screw Plug Hxs Titanium Products Vessels of Hastelloy Advanced Composites Advanced Composites Nuclear Products Thermal Insulation Panels Spent Fuel Basket Steam Generator Internals Aerostructures structures Aero Missilesystems systems Missile Special SpecialStructures Structures Aero AeroEngine EngineAssemblies Assemblies 9 of 45

10 Customers Across The Globe 10 of 45

11 Reactor Reactor Shell Perforated Tray Grid Beams Top Bed Bed # 1 Grid Tray with Screen Quench Pipe Bed # 2 Skirt Shell Tray Support Beams Nozzle Tray 11 of 45

12 TEAM PARAMARSH Members Gulab Vanzara (Team Leader) Kamlesh Vaghela Dinesh Vaghela Facilitator Vishrut Shah 12 of 45

13 TEAM PARAMARSH Objective Improvement in Tray Support Beam fabrication to achieve 40% saving in Manufacturing Cost 13 of 45

14 Flow of Presentation Project Details Issues faced in past QC tools implementation & Innovations Benefits Achievements and Results 14 of 45

15 Project Detail Customer :- Sinopec Engineering Group (SEG) -China Number of Assembly = 14 Number of Beam /Assembly = 6 Total Number of Beam = 84 Diameter of Assembly = 5470 mm Type of Beams = 3 type Final level of assembly should be 6 mm Tray Support Beam 15 of 45

16 Tray Support Beam Part 1 Welding by GTAW + SAW WEB of Beam Flange of Beam Part 2 16 of 45

17 SAW Welding Schematic SAW Welding Machine Turn to other side 17 of 45

18 Project Requirement Vertical bow of beam 3 mm Horizontal bow of beam 3 mm Average Distortion observed in past Horizontal bow : mm Vertical Bow : mm 18 of 45

19 Major Challenges Handling and mounting of each beam for SAW welding Need of Temporary attachments for locking Crane availability Distortion control of the beam during welding Time Constraint 19 of 45

20 QC Tools How to Achieve desired output? QC tools 20 of 45

21 Beam Fabrication Process Flow Chart Start Receipt of material after cutting Leveling of Web for setup Setup of flange # Web Inspection Root Run + Hot Pass in T-beams by GTAW W/L of balance joint by using SAW Completion of W/L 21 of 45

22 Deployment of Man-hours Due to Distortion Handling Time Rework time Due to NVA s Alignment time 34 SAW arrangement & welding time 18 DOT welding Time 13 Set up time Previous Method 22 of 45

23 Cause and Effect diagram for Distortion Man Man Machine Welding Parameters Welding Position Distortion Type of Welding Method Method Fixturing Type of Material Material Material 23 of 45

24 Cause and Effect diagram for NVA s Man Man Machine Machine Crane Availability Rework Welding Position Amount of Handling NVA s Fixturing Type of Welding Method Method 24 of 45

25 Data Collection Major obstacles during Fabrication ( Per Beam) Alignment time at SAW station Shifting time by crane Beam rotation time : 2 Hours : 45 min : 30 min Maintenance problem : 6 min Total NVA time ( Alignment + Shifting + Rotation ) : 3 hours 21 min Total Number of beams = 84 Total Idle time in beam fabrication = 84*201 min = min = Hrs 282 Hrs 25 of 45

26 Pie Chart 3% 19% How to Shifting time by crane Solve this Beam rotation time Maintenance problem Problem? Alignment time at SAW station 57% 21% 26 of 45

27 Brainstorming Idea 1 :- Mounting T-beam on I- Beam Less Amount of Distortion! Low Productivity Distortion: Bow in vertical direction = mm Bow in horizontal direction = mm 27 of 45

28 Deployment of Man hours Rework time Dismantling Time Handling Time Alignment time SAW arrangement & welding time DOT welding Time Previous Method Mounting beam on I-beam Set up time 28 of 45

29 Brainstorming Idea 2:Back to Back Beam Arrangement Low amount of Distortion Medium Productivity Distortion Control Bow in Vertical Direction = mm Bow in Horizontal Direction = mm 29 of 45

30 Time Analysis Rework time Dismantling Time 82 Handling Time Previous Method Mounting beam on I-beam Alignment time SAW arrangement & welding time DOT welding Time Set up time Back to Back 2 beams 30 of 45

31 PDCA Cycle 4.Act:- Implementation of Modifications 1.Plan:- Planning of activities to achieve desired output 3.Check:- Monitor the output at every stage and try to amplify the same 2.Do:- Do as per the planning 31 of 45

32 Idea 3 Back to Back 4 Beam Arrangement Low amount of Distortion High Productivity Distortion Control : Bow in Vertical Direction = 2-3 mm Bow in Horizontal Direction = 3-4 mm 32 of 45

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34 Rotating Arrangements Positioner Support Beam SAW Boom Channels Dummy Shell Tank Rotator 34 of 45

35 Set Up Fixture Components:- Cleats, Bolts and Nuts, Wedges Low cost components are used for making of the set up fixture Catalyst Support Beam I Beam Bolts Support Cleats 33 of 45

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37 Tangible Benefits Cost Savings Reduced Cycle Time High Productivity Control over Distortion No Rework 37 of 45

38 Intangible Benefits Welder s Comfort Team Building Crane Availability Safety Better Space Utilization No need of Skilled Manpower Improved Customer Satisfaction 38 of 45

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40 Distortion Results Before After Horizontal bow : mm Vertical Bow : mm Horizontal bow :- 2-3mm Vertical Bow :- 3-4 mm Percentage control over distortion Horizontal bow = % (Approx.) Vertical Bow = 93-94% ( Approx.) 40 of 45

41 Time Analysis Rework time Dismantling Time 82 Handling Time Alignment time Previous Method Mounting Beam on I-beam Back to back 2 Beams Back to back 4 Beams SAW arrangement & welding time DOT welding Time Set up time 41 of 45

42 Time Analysis Before Implementation After Implementation Percentage Man hour consumption= 100 % Percentage Man hour consumption = 44 % Targeted Man Hour Saving = 40% Percentage Hour Savings = ( ) % = 56% 42 of 45

43 Cost Savings (Rs Lacs) Previous Method I-Beam 2 BeamB2B 4Beam B2B 43 of 45

44 Sustainability and Standardization Revised procedure is developed for Support Beam Fabrication Institutionalisation of process in future projects across 44 of 45

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