i

ABSTRACT

The Raw Materials division of TVS Sundram Fasteners, Madurai Unit was

experiencing a problem with a wire drawing machine named Invert Vertical

Drawing Machine IVD 800. The workers were not able to run the machine at high

speed and also the diameter of the wire fed into the machine was limited to 14.6

mm as against the maximum diameter of 18 mm, that the machine was capable. In

order to increase the capacity of the machine, we need to introduce a roller, in

addition to the existing two rollers. The rollers support the wires and are

responsible for holding the wires strongly. If the wire is held strongly, we can

increase the speed of the machine and also increase the diameter of the wire that is

fed in the machine. The third roller is introduced after discussing various solutions

and also finding the need by using Forced Field Analysis. We construct geometry

for finding out the changes we need to make in order to introduce the third roller.

Finally, a design is created for implementation of third roller which will improve

the efficiency of the machine, which will ultimately improve the amount of the raw

material processed in the unit.

 ii

TABLE OF CONTENTS

CH.NO TITLE PAGE. NO

ABSTRACT i
LIST OF FIGURES iv
LIST OF UNITS & NOMENCLATURE v

1. INTRODUCTION 1
1.1 ABOUT THE COMPANY 1
1.2 GLOBAL PRESENCE 2
1.3 ENVIRONMENTAL POLICY 3
1.4 PRODUCTS 3
1.5 AWARDS 4

2. PROCESS CARRIED OUT IN THE INDUSTRY

2.1 RAW MATERIAL RECEPTION 8
2.2 WIRE ANNEALING 8
2.3 WIRE PHOSPHATING 9
2.4 WIRE DRAWING 11
2.5 FORGING PROCESS 12

3. PROBLEM DESCRIPTION 14
3.1 ABOUT INVERT VERTICAL DRAWING
MACHINE IVD 800 14
3.2 WORKING OF THE MACHINE 14
3.3 PROBLEM FACED IN THE MACHINE 15
 iii

4. PROBLEM SOLVING METHODOLOGY 16

4.1 FISHBONE DIAGRAM 16
4.2 HOW TO USE THE TOOL 17
4.3 FISHBONE DIAGRAM FOR POOR
PERFORMANCE OF IVD 800 19
4.4 FORCE FIELD ANALYSIS 21
4.5 FORCE FIELD DIAGRAM
FOR IVD 800 22

5. SOLUTION
5.1 SUGGESTED SOLUTION 24
5.2 DETERMINATION OF DIMENSIONS
FOR THE THIRD ROLLER 25
 iv

LIST OF FIGURES

Fig No Description Page No

1.1 Sundram Fasteners Global Presence 2
1.2 Manufacturing locations in India 4
2.1 Process Carried Out in the Industry 7
2.2 Process carried out in Wire Phosphating 9
2.3 Concept of Wire Drawing 12
2.4 Concept of Forging 13
3.1 Model of IVD 800 13
4.1 Fishbone diagram for IVD 800 19
4.2 Force Field Diagram for IVD 800 22
5.1 Diagram for introducing third roller 24
5.2 Top View of Original Roller Support 25
Used for Rollers 1, 3
5.3 Top View of Modified Roller Support for Roller 2 26
 v

UNITS & NOMENCLATURE

1. IVD Invert Vertical Drawing Machine

2. mm millimeter

3. m/min meter per minute (amount of wire drawn)

4. cm centimeter

5. C degree Celsius (unit of temperature)

6. UTS- Universal Testing Machine

7. rpm Revolutions