PROJECT REPORT ON KASHMIR ISPAT

ACKNOWLEDGEMENT
Perseverance, inspiration and motivation have always played a great role in the success of any venture. At this level of understanding it is often difficult to understand the wide spectrum of knowledge without proper guidance and advice.

This report entitled "A STUDY OF PRODUCTION IN KASHMIR ISPAT" BARI BRAHMNA (J&K) . I extend my sincere gratitude to MR. Sanjay Mishra for granting me the opportunity to undergo my study in this organization and continuously guiding me throughout the span of my study .I am also thankful to all the team of this Unit who have given me their full cooperation and devoted their valuable time for rendering me their needy services and guidelines during the training period. With those sincere and precious efforts, I have been able to complete my practical training successfully.

WITH SINCERE THANKS PAYAL GUPTA

PREFACE
Practical training is an important part of the theoretical studies. It is of an immense importance in the field of management. It offers the student to explore the valuable treasure of experience and an exposure to real work culture followed by the industries and thereby helping the students to bridge gap between the theories explained in the books and their practical implementations. Training plays an important role in future building of an individual so that he/she can better understand the real world in which he has to work in future. The theory greatly enhance our knowledge and provide opportunities to blend theoretical with the practical knowledge where trainees get familiar with certain aspects of industries, like shop floor management, production process and industrial relations. I feel proud to get myself trained at Kashmir Ispat (Bari Brahmna). Kashmir Ispat is a leading TMT Bars manufacturer in J&K. I have taken up training in Production Department and have studied and explained the production arrangement. I availed this opportunity in a very satisfactory manner and have tried to cover each and every aspect that. I came across during my training period.

KASHMIR ISPAT
Kashmir Ispat is one of the largest manufacturers of TMT Bars in J&K State located at SIDCO Industrial complex, Bari Brahmna, Jammu (J&K). It was established by Dewan Bansal and now headed by Sahil Bansal (son of Dewan Bansal). The company is high profiled high tech rolling mill manufacturing TMT Bars of top quality and as per BIS standards. The company is an ISO 9001 company having its own source of raw material input from its sister concern i.e. M/s Narbada Steel Limited manufacturing M.S Ingots/ Billets as per BIS Standards. The company provides best quality products to end users, to their uttermost satisfaction. The company has developed fast under the guidance of high visionary Directors, having the experience in this field from last 40 years and dedicated staff. The company has highly contributed to upliftment of the state economy. The plant is highly equipped with full automated rolling and quenching process (EVCON TURBO) compatible with Tempcore (Germany). The company is fully equipped with quality control department, which ensures quality system from input on line and finished product with strict vigil for best performance and high standards. Adherence to to international standards, both in manufacturing process and quality of products .Company has ISO 9001:2008 QMS certification and also ISO 14001: 2004 Certification which ensure the environment protection.

SHAKTI TMT:
Kashmir Ispat high values the strong bond of relationship from petty consumer to bulk purchasers, builders, architect, dealers, distributors keeping all in high esteem with continuous interaction and fulfilling the needs with dedication. Its motto is to provide best quality to get more and more repeat orders.

Why Kashmir Ispat

Company understands the importance of steel to customers and offers a TMT construction bar that is like a 3 in 1: strong, with superior elongation and resistant to corrosion. Worldwide, TMT is the most widely used technology to impart these properties to construction grade bars.

TMT Process
TMT is a superior technology in steel making, bringing to you International product quality. Construction bars that sell in the market need to conform to ISI specifications; our bars offer you properties that are far higher than the ISI specs: in other words, greater strength and superior elongation. Our TMT technology ensures that corrosion is retarded. Traditional bars are twisted to increase strength, but this builds up stress and consequently rusting starts almost immediately. In case of TMT no twisting is required since a special Thermo Mechanical Treatment used on the bar, resulting in lesser corrosion and longer life.

So theres 3 in 1 bar for homes that last forever ... at an affordable price. It's a lifetime investment and therefore the right choice is critical. The salient features which companys carve out an individual identity for itself are : Companys state-of-the-art infrastructure is well equipped with technologically advanced Machinery, and help in ensuring production of premium quality steel products. All the products are repeatedly quality checked in all manufacturing stages regarding their mechanical and tensile strength. Companys engineer and technicians possess the expertise required in the manufacturing process to deliver superior quality products to our clients. Companys products are well known in the market for their precision, quality and highly Competitive prices.

MASS PRODUCTION OF TMT RODS

MANUFACTURING PROCESS OF TMT BARS
It takes billets of size 100 mm2 from CCP and produces ribbed TMT bars of various diameters. The capacity is 0.28 million tone per annum thermo mechanically treated (TMT) ribbed bars of dia. 8 to 32 mm. Grade- Fe 415, Fe 500, Fe 550, Fe 415 D, Fe 500 D, Fe 550 D, Fe 600D TMT 415, TMT 500, TMT 550, TMT HCRM Input: billet of 100mm2 and 9m long

BASIC PROCESS
The processes of rolling of long products can be basically classified into following heads: A. Reheating: The reheating of inputs is done to make the material plastically deformable and pliable for rolling to give the desired shape and size. It is done such that the rolling gets completed above recrystallisation temperature. B. Roughing: Roughing also called cogging is done to give the input a rough shape. The maximum reduction in cross section is given in roughing mill. C. Intermediate Rolling: Intermediate rolling constitutes taking the roughing mill output as its input. Output of intermediate rolling is sent to finishing mill. D. Finished shape rolling: In finishing mill the finished profile shape is made. It takes metal from intermediate stands as its input. The reduction given in

these stands is lesser as compared to roughing and intermediate mill. Finished shape rolling is quality critical as the final output shape is made in these stands. In case of TMT bars thermo mechanical treatment of bars is done in this area. E. Cutting and stamping: The finished bar is cut to desired lengths as per customer requirement. Other activities performed here are cropping of ends, cutting of samples for profile dimensional checking and cutting of samples for destructive tests. In secondary mills stamping of cast number and other details are done on the rolled products in hot condition. These are required for identification and traceability of product and correlation with test results of destructive tests. F. Finishing: The finishing is done after the bar has been cooled to ambient temperature. Finishing activities at different mills may involve all or few of the following steps: Straightening either by roller straightening machines or by pulling the ends 88 End finishing either by milling or cold cutting Online non destructive testing of defects Heat treatment G. Inspection: Inspection is carried out by the producer and/or by customer deputed agency and/or by third party to inspect the products and ensure no defective products are sent to customer. Depending on the specifications, customer requirement the inspection may be in all or few of the following parameters: Dimensional tolerances (section) Length Straightness Squareness

Surface Quality Branding, colour coding and stamping H. Dispatch: The products are sent to required destinations primarily by road. The activities involve documentation (preparation of dispatch advice (DA), test certificate (TC). In some cases packaging is done prior to dispatch.

PROCESS
Reheating furnace has a two zone type arrangements for side charging and discharging. The output of furnace is 70 TPH. Temperature inside the furnace is 1250 1300o C. Separating skids are used to placed the billets on the furnace charging table. By using push-out bar, billets are discharged from the furnace to the first mill stand. For this, there is a pinch roll arrangement near the furnace. A pendulum shear is located between the pinch roll and first stand to cut the front end of the billets. The mill has 13 horizontal stands in which 7 are roughing, 4 intermediate and 2 are finishing stands. In between 7 & 8 stands, a crop cum cobble shear is provided to cut front end of all the rolled stocks passing out of the 7th stand. It is also used for cutting the rolled stock into pieces in case cobble is formed. Four 180 repeaters provided between 9 & 14 stands (13th stand is not there). These repeaters are provided to reduce the overall length of the mill. After the finishing mills Thermax carriages are situated for spraying water at high pressure on the rolled bars (to impart required structure). There is a rotary shear, which cuts the rod into the pre determined lengths, which are then accommodated in the cooling beds. After this the bars are cut to final sizes (as per customers demand) in the Bar Shears and sent to dispatch area after bundling and strapping.

Ingot (raw material) Furnace (1300 degree C) Roughing stand Intermediate stand Finishing stand Quenching Box (Thermo Mechanical Treatment)

Colling Bed
Testing (tencile machine)

MAJOR EQUIPMENTS
Reheating furnaces: capacity of 30 tonnes per hour Pinch rolls :for feeding of billets Pendulum shear to cut the end of billets 13 horizontal roll stands;7 roughing stands, 4 intermediate stands and 2 to 3 are finishing stands Two 180 degree Repeaters to reduce the overall length of the mill Crop cum cobble shear for cutting the front end of rolled stock after it comes out from 7th mill stand. It is also used for cutting the rolled stock when cobble is formed 3 thermax carriages for spraying water at high pressure on the rolled bars results in the formation of martensitic structures. Rotary shear Bar shear for cutting rods into specified lengths required by customers

Quality Assurance
It ensures quality at every step, from the input of raw material to the final product delivered on site. With a high automated plant and continuous checks at every level and is able to produce the best quality re-bars in the state. The quality team is equipped with modern testing facilities which ensure that the products meet stringent norms and quality standards. TMT Rebar in Sizes (in mm) :8,10,12,16,20,25,28, 32 Tencile 484 N/mm2

Yield Stress 415N/mm2 Elongation 18%

INSPECTION STAGES IN PRODUCTION OF TMT RODS INSPECTION STAGES

Inspection of TMT bars is carried in stages. The inspected billets are properly marked and cut down to the required length for reheating. The inspected billets must conform to certain IS standards

Policy: The identification and traceability of all materials and products at all
stages are established and maintained.

Scope: The process covers

identification and traceability of product from receipt stage, inprocess inspection and final inspection till despatch. the

Procedure: The billets thus

produced are then surface checked, visually inspected and tested for chemical composition. Any non-conforming material is identified and marked by red paint and sent to rejection yard. The tested material is then colour coded by blue paint and a Batch Number is given. It is then sent to the Rolling Mill raw material yard.

Then visual inspection and chemical analysis of the material is carried out. Thereafter, such tested material is given a Batch Number and stored in Rolling Mill Raw material. Each such batch weighs 25 M.T. The Billets are then sent for production in the Rolling Mill. During the production process, inspection at various stages is carried out and any non-conforming product is identified and segregated properly. The finished product is then subjected to final inspection and a Lot Number is allotted to it before being stored in the finished product yard. The finished product is properly tagged which carries the following information: I. Name of the Company II. Lot No. III. Size of the product IV. Grades

STAGE WISE INSPECTION DETAILS

A typical inspection stages of TMT rods

Figure 8(a): Incoming Material Inspection

Figure 8(b): In Process inspection data collected for TMT rods

Figure 8(c): Final Inspection stages of TMT rod

TYPES OF DISTRIBUTION CHANNEL:Basically there are two types of distribution channel:1) Consumer distribution channel 2) Industrial distribution channel The Company follow these two types of production and distribution system.

C O M P A N Y

DIRECT

C O

RETAILER (ZERO LEVEL CHANNEL) RETAILER WHOLESALER

N S U M E R

(TWO LEVEL CHANNEL)

SWOT ANALYSIS S: STRENGTH

Cheap Scope for entry of private firms Much demand in local Low price Easily available Cheap labour Cheap land Flexibility for expansion

W: WEAKNES
Poor R & D wing is good, Poor work force Poor Lab facility Advertisement & publicity is poor Poor range & size Poor in customer trust & faith Poor sales technique and ability to customize Preparation is from its scrap only Poor in share market Poor mechanical and physical strength

O: OPPERTUNITIES
Good internal market More demand to common men

 Expansion facility Flexibility in future Distribution network

T: THREATS
Local competition Availability of raw materials Availability of power Poor response Unawareness to local people Poor lab facility

PROBLEMS
Bearing breakage Roll break Rolling Defects

Slivers Twist Shear distortion Burnt edges Rolled in scales Laps Roll marks Underfills Buckle and kink Camber

RECOMMENDATIONS/ SUGGESTIONS
They must use oil furnace instead of coal furnace. Workers are working without any safety measures, so the organization should ensure that the workers should work using the safety equipments.