Description
Larsen & Toubro Limited, also known as L&T, is an Indian multinational conglomerate headquartered in Mumbai, India.
Larsen & Toubro Limited Hazira Works
Larsen & Toubro Limited Hazira Works
• ISO 9001-2000 • International Quality Rating System - Level 7
• Environment Health & Safety : ISO 14001
• Occupational Health Safety Assessment Series 18001 • International Quality Stamp : ASME ‘U’, U2’, ‘S’
Major Product Lines
1. Heavy Reactors & Pressure Vessels ( > 500MT)
– Hydrocracking / Hydrotreating Reactor – HDS Reactor – Urea Reactor – FCCU Reactor / Regenerator …..
2. High Pressure Heat Exchangers ( > 500MT)
– E.O. Reactor – Screw Plug Heat Exchangers…..
3. Equipment for Nuclear, Defence and Aerospace Application
– Steam Generator – End Shield – PSLV / GSLV Rocket Casings – Gas Bottle …...
Market
– Export
• Europe • USA • Canada • South America • Australia • Asia - China, Middle East • Russia • ……...
– Domestic
Hydrocracker Reactor for IOCL Baroda India’s first Hydrocracker Reactor
Dim Ø 3.35 m x 21 m LG x 232 mm Thk Weight: 430 T Year: 1991 Process: Chevron
DHDT Reactor for IOCL, Digboi
First ever DHDT Reactor built in India Weight 130 T Year 2000
I-MNTW Deck for ONGC
Size : 29Mx22Mx21M
Wt. : 3060 MT (4
Nos)
Year: 1993/94
Product Splitter for Saudi Polyolefins, Saudi Arabia
Longest
ever column made in India
Length:103 m
Weight: 750T
Year: 2002
500 MW End Shields for NPC India Limited for TAPP
Global benchmark in fastest
delivery
Strategies to Meet Global Challenges
• Optimal resource utilization • Reduction in Cycle Time / Delivery Time
•Mechanization of Manufacturing Technology
• Consistent Quality
Brainstorming Sessions
• Total Nos. of sessions : 02 • Session1
- No. of ideas
: 28.07.2003
: 17
• Session2
- No. of ideas
: 06.10.2003
: 09
Brainstorming on causes for long changeover time
• Hexagonal clamp of different sizes. • Non Standard Hexagonal clamps. -delay in assembly -vibration during welding • Weight of Head Assembly was high - Cyclomatic Lead Screw Damage • Frequent opening of head - insulation damage / lost
• Different configuration of the mounting plates. • Non availability of spares
Brainstorming on causes for long changeover time
• Breakdown of components
• Different sizes of Fasteners on various booms:
• Non availability because of variety • Different sizes and types of tools required.
• Improper Insulation
• Poor quality insulation • Non availability of insulation material
• Non Standard Hexagonal clamps.
• Delay in assembly • Vibration during welding
Brainstorming on causes for long changeover time
• • • • • • • • • • Heavy Head Assembly Cyclomatic Lead Screw Damage Frequent opening of head Insulation damage / lost Non Standard Hexagonal clamps Delay in assembly Vibration during welding Heavy Head Assembly Cyclomatic Lead Screw Damage Frequent opening of head
Cause-Effect Diagram
Non availability of material Different set up for different processes
Non availability of spares
Too much variety of fasteners and other spares Breakdown of components
Different arrangement for different welding positions
Long changeover time Lack of focus Non standard hexagonal clamps Different config. of mounting plates
Cross functional issues
Lack of procedural
More no. of components being used
Lack of planning
Long assembly time
Objective Setting
Arrangement / system should be :
• Easy to assemble - Flexible for adjustments
• Minimum & Interchangeable components • Inexpensive, Light weight & Cloneable
•Changeover within 10 Minutes
Flow-chart before implementation
Identify the Weld. Process Select appropriat e head assly.
Yes NO
Search for the head assembly
Locate new head assly.
NO
Dismantle the cable connections Remove the existing head assly. Fabricate mountings / Brackets for new head Search for missing Std. Components
Yes
Remove head assly. from nonpriority job
A
Contd ….
Flow-chart before implementation
Contd ….
A
Check availability in stores
Yes
NO
Initiate purchase / manufacture
Wait for components Receive & Inspect
Issue the items
Fix the items on head assly.
Fix the required head assly. Connect the cables Start welding
Problem solving
• Hexagonal clamp standardized
• Aluminum plate welded with Al Hexagonal Bar
• Drilled Hexagonal Bar Ends
• Weight reduced - Hollow Hexagonal Bar
• Reduced Hexagonal clamps
Problem solving
• Standardized Head mounting plate
• One Fastener Size - One Spanner required • Single piece - Insulation pipe & washer
Arrangement for Single Head Position-1
Arrangement for Single Head Position-2
Arrangement for Single Head Position-3
Arrangement for Single Head Position-4
Tandem welding
ESSC
TWIN HEAD SAW TWIN HEAD SAW.
Insulation made in One Piece.
Before
After
Standard clamps for Hexagonal Bar.
Standard Hexagonal Bar and Plate.
Hexagonal Bar
Standard Mounting Plate
doc_899454424.pptx
Larsen & Toubro Limited, also known as L&T, is an Indian multinational conglomerate headquartered in Mumbai, India.
Larsen & Toubro Limited Hazira Works
Larsen & Toubro Limited Hazira Works
• ISO 9001-2000 • International Quality Rating System - Level 7
• Environment Health & Safety : ISO 14001
• Occupational Health Safety Assessment Series 18001 • International Quality Stamp : ASME ‘U’, U2’, ‘S’
Major Product Lines
1. Heavy Reactors & Pressure Vessels ( > 500MT)
– Hydrocracking / Hydrotreating Reactor – HDS Reactor – Urea Reactor – FCCU Reactor / Regenerator …..
2. High Pressure Heat Exchangers ( > 500MT)
– E.O. Reactor – Screw Plug Heat Exchangers…..
3. Equipment for Nuclear, Defence and Aerospace Application
– Steam Generator – End Shield – PSLV / GSLV Rocket Casings – Gas Bottle …...
Market
– Export
• Europe • USA • Canada • South America • Australia • Asia - China, Middle East • Russia • ……...
– Domestic
Hydrocracker Reactor for IOCL Baroda India’s first Hydrocracker Reactor
Dim Ø 3.35 m x 21 m LG x 232 mm Thk Weight: 430 T Year: 1991 Process: Chevron
DHDT Reactor for IOCL, Digboi
First ever DHDT Reactor built in India Weight 130 T Year 2000
I-MNTW Deck for ONGC
Size : 29Mx22Mx21M
Wt. : 3060 MT (4
Nos)
Year: 1993/94
Product Splitter for Saudi Polyolefins, Saudi Arabia
Longest
ever column made in India
Length:103 m
Weight: 750T
Year: 2002
500 MW End Shields for NPC India Limited for TAPP
Global benchmark in fastest
delivery
Strategies to Meet Global Challenges
• Optimal resource utilization • Reduction in Cycle Time / Delivery Time
•Mechanization of Manufacturing Technology
• Consistent Quality
Brainstorming Sessions
• Total Nos. of sessions : 02 • Session1
- No. of ideas
: 28.07.2003
: 17
• Session2
- No. of ideas
: 06.10.2003
: 09
Brainstorming on causes for long changeover time
• Hexagonal clamp of different sizes. • Non Standard Hexagonal clamps. -delay in assembly -vibration during welding • Weight of Head Assembly was high - Cyclomatic Lead Screw Damage • Frequent opening of head - insulation damage / lost
• Different configuration of the mounting plates. • Non availability of spares
Brainstorming on causes for long changeover time
• Breakdown of components
• Different sizes of Fasteners on various booms:
• Non availability because of variety • Different sizes and types of tools required.
• Improper Insulation
• Poor quality insulation • Non availability of insulation material
• Non Standard Hexagonal clamps.
• Delay in assembly • Vibration during welding
Brainstorming on causes for long changeover time
• • • • • • • • • • Heavy Head Assembly Cyclomatic Lead Screw Damage Frequent opening of head Insulation damage / lost Non Standard Hexagonal clamps Delay in assembly Vibration during welding Heavy Head Assembly Cyclomatic Lead Screw Damage Frequent opening of head
Cause-Effect Diagram
Non availability of material Different set up for different processes
Non availability of spares
Too much variety of fasteners and other spares Breakdown of components
Different arrangement for different welding positions
Long changeover time Lack of focus Non standard hexagonal clamps Different config. of mounting plates
Cross functional issues
Lack of procedural
More no. of components being used
Lack of planning
Long assembly time
Objective Setting
Arrangement / system should be :
• Easy to assemble - Flexible for adjustments
• Minimum & Interchangeable components • Inexpensive, Light weight & Cloneable
•Changeover within 10 Minutes
Flow-chart before implementation
Identify the Weld. Process Select appropriat e head assly.
Yes NO
Search for the head assembly
Locate new head assly.
NO
Dismantle the cable connections Remove the existing head assly. Fabricate mountings / Brackets for new head Search for missing Std. Components
Yes
Remove head assly. from nonpriority job
A
Contd ….
Flow-chart before implementation
Contd ….
A
Check availability in stores
Yes
NO
Initiate purchase / manufacture
Wait for components Receive & Inspect
Issue the items
Fix the items on head assly.
Fix the required head assly. Connect the cables Start welding
Problem solving
• Hexagonal clamp standardized
• Aluminum plate welded with Al Hexagonal Bar
• Drilled Hexagonal Bar Ends
• Weight reduced - Hollow Hexagonal Bar
• Reduced Hexagonal clamps
Problem solving
• Standardized Head mounting plate
• One Fastener Size - One Spanner required • Single piece - Insulation pipe & washer
Arrangement for Single Head Position-1
Arrangement for Single Head Position-2
Arrangement for Single Head Position-3
Arrangement for Single Head Position-4
Tandem welding
ESSC
TWIN HEAD SAW TWIN HEAD SAW.
Insulation made in One Piece.
Before
After
Standard clamps for Hexagonal Bar.
Standard Hexagonal Bar and Plate.
Hexagonal Bar
Standard Mounting Plate
doc_899454424.pptx