Fit-up and WeldingT 72013325 Ladle beam

72006986 Spreader Beam 1 = FG1 - Dhanu

Section 73019827 Hand sanitizing stn - opt 1 2 = FG2 - Prabodh
Area/Bay 72012198 Car frame 3 = FG3 - Binod
73017780 HS Support 4 = FG4 - Mansa

Studied by RAVI TEJA + SUNDARA RAJA ABHISHEK + HARISH

WELDER GANG
AREA GANG
PO-72013325 PO-72013325 PO-73017780 PO
Welder Welder Welder Welder Welder Welder Welder Welder Supervisor Gas Cutter Grinder Grinder Gas Cutter Crane Rigger Rigger
Helper Helper Helper Helper Operator
Time
Kedar P.N.Das Gandhi / - Mahadev - - - Dilip Arjun Sanatan Bhim Anand MahAshish Bahadur Subhas Name
Lalu

8:30 AM F37 F31 F63 F6 2+F6 1+ 1

8:40 AM F7 F31 F63,F5 2+F6
8:50 AM F39 2+F54 2+F65 3+ 3
9:00 AM F39 F39 2+F54 2+F6 2+F65 3+ 3 3
9:10 AM F39 F41 2+F54 1+RW 3+F63 3+F63 3+F63
9:20 AM F39 3 2+F6 1+RW 3+F63 3+F63 3+F63
9:30 AM F43 F37 3 2+F6 1+RW
9:40 AM F39 F39 4+F67
9:50 AM F35 F35 F39 3+F22 2+F54 4+F67
10:00 AM F39 F41 F39 3+F22 3+F6 4+F67 4+F63 4+F63 4+F63
10:10 AM F39 F31,F36 F39,F41 3+F6 4+F63 4+F63 4+F63
10:20 AM F35 F39,F41 3+F15 4+F63 4+F63 4+F63
10:30 AM F33,F39 F39,F41 3+F22 3+F15 2+F15 4+F67
10:40 AM F39 F41 F39,F41 2+F15 6 6
10:50 AM F39,F41 F39,F41 3+F22 2+F15
11:00 AM F39,F41 3+F22 2+F15 2+F15 3 3 3
11:10 AM F39,F41 F41 F39,F41 3+F22 2+F15
11:20 AM 3+F22 2+F15 2+SUPPORT3+FITT 3+ 3
11:30 AM F39,F41 F39,F41 3+F22 2+DP 2+SUPPORT3+FITT 3+ 3
11:40 AM F39 F41 F39 3+F22 2+DP 2+SUPPORT3+DP 2+DP 2
11:50 AM F39 F39 2+F15 2+SUPPORT2+ 2+ 2
12:00 PM F36,F41 3+F22 2+F44
12:10 PM F39 F31,F36 F39
12:20 PM F39 F36 F39
12:30 PM F39 F39 F22 F54 F6 F5
1:00 PM LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH
1:10 PM LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH
1:20 PM LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH
1:30 PM LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH LUNCH F5+2 F54+2 F6+4 F5 F16+4 F16+4 F16+4
1:40 PM F39 F41 F39,F41 F39,F41 F39,F41 F5+2 F54+2 F6+4 F5 F16+4 F16+4 F16+4
1:50 PM F39 F41 F39 F39 F39,F41 F5+2 F24+2 F24+4 F5 F4+3 F4+3 F4+3
2:00 PM F39 F41 F39 F39 F39,F41 F5+2 F6+2 F4+3 F4+3 F4+3
2:10 PM F39 F39 F39 F39,F41 F5+2 F6+4 F16+4 F16+4 F16+4
2:20 PM F39 F39 F39 F39,F41 F5+2 F6+4 F4+1 F4+1 F4+1
2:30 PM F39 F41 F39 F39 F5 F4 F4 F4
2:40 PM F41 F39,F41
2:50 PM F39 F39 F39,F41
3:00 PM F36 F39 F39 F39,F41 F6+4 F4+4 F4+4 F4+4
3:10 PM F39 F39 F39 F39,F41 F6+4 F4+4 F4+4 F4+4
3:20 PM F39+F41 F39,F41 F39,F41 F39,F41 F6+4 F4+4 F4+4 F4+4
3:30 PM F39,F41 F39,F41 F6+4 F4+4 F4+4 F4+4
3:40 PM F39 F41 F39 F39,F41 F39,F41 F6+4 F4+4 F4+4 F4+4
3:50 PM F39 F41 F6+4 F4+4 F4+4 F4+4
4:00 PM F39 F6+4 F4+2 F4+2 F4+2
4:10 PM BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK
4:20 PM BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK
4:30 PM BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK BREAK F5+4 F6+4 F4+2 F4+2 F4+2
4:40 PM F39 F39 F39 F39 F5+4 F6+4 F4+2 F4+2 F4+2
4:50 PM F39 F39 F39 F39 F4+3 F4+3 F4+3
5:00 PM F39 F39 F39 F39

8 kgs 5 kgs
 RAVI TEJA + SUNDARA RAJA
51 32 21 36
WELDER GANG
PO-72013325 PO-72013325 PO-73017780 PO
Welder Welder Helper Welder Welder HelWelder Welder HelWelder
Kedar P.N.Das Gandhi / Lalu - Mahadev - -
1 F37 F31
2 F7 F31
3 F39
4 F39 F39
5 F39 F41
6 F39
7 F43 F37
8 F39 F39
9 F35 F35 F39
10 F39 F41 F39
11 F39 F31,F36 F39,F41
12 F35 F39,F41
13 F33,F39 F39,F41
14 F39 F41 F39,F41
15 F39,F41 F39,F41
16 F39,F41
17 F39,F41 F41 F39,F41
18
19 F39,F41 F39,F41
20 F39 F41 F39
21 F39 F39
22 F36,F41
23 F39 F31,F36 F39
24 F39 F36 F39
25 F39 F39
26
27
28
29
30 F39 F41 F39,F41 F39,F41 F39,F41
31 F39 F41 F39 F39 F39,F41
32 F39 F41 F39 F39 F39,F41
33 F39 F39 F39 F39,F41
34 F39 F39 F39 F39,F41
35 F39 F41 F39 F39
36 F41 F39,F41
37 F39 F39 F39,F41
38 F36 F39 F39 F39,F41
39 F39 F39 F39 F39,F41
40 F39+F41 F39,F41 F39,F41 F39,F41
41 F39,F41 F39,F41
42 F39 F41 F39 F39,F41 F39,F41
43 F39 F41
44 F39
45
46
47
48 F39 F39 F39 F39
49 F39 F39 F39 F39
50 F39 F39 F39 F39
51
 TOTAL TIME 510
LALU 360
KEDAR 320
Welder Helper P.N.DAS 210
-

TOTAL WELDING TIME

Shop wise gang size of proposed Contract Manpower

Fabrication shop

Fitter Gas
SN Gang type Fitter Grinder Welder
Helper Cutter

1 Fit-up 1 1 0.5 0.5

2 Welding 1
3 Area Support 2
4 Support to own Fit-up 1 0.5 0.5

Machine shop Operator Crane

SN Gang type / Marker Operator Rigger Dresser Set up
5 Machine operator 1
6 Area support 1 2 1 1

Assembly shop Fitter Gas Crane

SN Gang type Fitter Helper Welder Cutter Operator
7 Fit-up 1 1 0.3 0.3
8 Area support 1 0.3 0.3 1

Crane Manufacturing
Crane Fabrication Fitter Gas
SN Gang type Fitter Helper Cutter Grinder Welder
9 Fit-up 1 1 0.5 0.5
10 Welding 0.25 1
11 Area gang 2

Crane Assembly
Fitter Gas Crane
SN Gang type Fitter Helper Welder Cutter Operator
12 Fit-up gang 1 1 0.3 0.3
Welder Crane Superviso
Rigger
Helper Operator r

0.25
1 2 1

Cleaning

Superviso
Rigger r Driller
0.33
2 0.33

Welder Crane Superviso

Helper Operator Rigger r

0.25
1 2 1

Superviso
Rigger r Driller Grinder
0.33 0.33
Activity sheet

Activity Value Added

Section Process Activity type chart (V)/ Non Value
number Added (NV)
Fabrication Fit-up Refer Drawing & Process sheet F1
Fabrication Fit-up Bed Preparation & levelling before layout F2
Fabrication Fit-up Layout preparation and marking F3
Fabrication Fit-up Identify and handle items with crane F4
Fabrication Fit-up Gas cutting F5
Fabrication Fit-up Dressing F6
Fabrication Fit-up Chiseling F7
Fabrication Fit-up Scraping F8
Fabrication Fit-up Manual lapping F9
Fabrication Fit-up Cutting by grinding F10
Fabrication Fit-up Marking for drilling / tapping below 12 mm F11
Fabrication Fit-up Drilling below 12 mm F12
Fabrication Fit-up Tapping below 12 mm F13
Fabrication Fit-up Fitting, Tack welding & provide supports F14
Fabrication Fit-up Grinding F15
Fabrication Fit-up Material handling for shifting for stage welding F16
Fabrication Fit-up setting up of piano wire for inspection F17
Fabrication Fit-up Assist inspector dueing inspection F18
Fabrication Fit-up Stage Inspection after fitting F19
Fabrication Fit-up Shifting of job for final welding F20
Fabrication Fit-up Final check after welding & recording actual
values in Inspection format F21
Fabrication Fit-up Heating & Straightening after final welding
inspection, if distortion found F22
Fabrication Fit-up Shifting of job for SR F23
Fabrication Fit-up Support cutting, grinding for dressing of jobs F24
Fabrication Fit-up Levelling of job for final inspection F25
Fabrication Fit-up Final inspection after SR F26
Fabrication Fit-up Final check after Shot Blasting & Paint F27
Fabrication Fit-up Job identification by painting / punching F28
Fabrication Welding Receiving the sub-assembly/assembly to be
welded from Fit and Tack assembly section F29
Fabrication Welding Refer instructions given in ITP, drawing, process
technology sheet, WPS F30
Fabrication Welding Setting up the Welding Machine for Welding
i.e.depending on the process MMAW, FCAW, TIG,
SAW machine is selected
F31
Fabrication Welding
Assign the sub-assembly to a welder with all the
necessary information for welding the joint. F32
Fabrication Welding Set up the weld parameters F33
Fabrication Welding Check welding torch and accessories F34
Fabrication Welding Change welding torch and accessories(whenever
required) F35

Page 9 of 14
Activity sheet

Activity Value Added

Section Process Activity type chart (V)/ Non Value
number Added (NV)
Fabrication Welding Fix pre-heating burner, electrode holding oven,
set gas flow meter F36
Fabrication Welding Pre-heating the job F37
Fabrication Welding Welding of the Supports, Clamps and fixing the
job rigidly with the bed F38
Fabrication Welding Welding and maintaing the interpass as per WPS
F39
Fabrication Welding Interpass cleaning of slag with Pneumatic Chipper
in MMAW F40
Fabrication Welding Interpass cleaning of slag with chipping hammer
in FCAW F41
Fabrication Welding Interpass cleaning of slag with Wire cup brush in
Hard facing F42
Fabrication Welding Interpass cleaning by grinding F43
Fabrication Welding Back gouging F44
Fabrication Welding Check size and visual F45
Fabrication Welding Weld dressing for visual F46
Fabrication Welding Weld visual Self-inspection to identify the weld
size , weld defects F47
Fabrication Welding Grinding of the zones adjacent to weld to prepare
for NDT F48
Fabrication Welding Weld inspection by NDT F49
Fabrication Welding Load plates in straightening machine F50
Fabrication Welding Assign the joint to qualified welder for
traceability & record. (Weld joint Vs welder
mapping)
F51
Fabrication Area Shifting of job to Shot Blasting area & Paint
Support F52
Fabrication Area Back grinding
Support F53
Fabrication Area Back gouging / grinding DP Test
Support F54
Fabrication Area DP Test for back grinding
Support F55
Fabrication Area Surface cleaning for MPT
Support F56
Fabrication Area Development of band width for UT probe
Support F57
Fabrication Area Grinding for fixing films during radiography
Support F58
Fabrication Area Grinding of areas where support had been used
Support for fitting and clamping purposes F59
Fabrication Area
Support Coordinate for stress relieving F60

Page 10 of 14
Activity sheet

Activity Value Added

Section Process Activity type chart (V)/ Non Value
number Added (NV)
Fabrication Area
Support Coordinate for dressing F61
Fabrication Area
Support Coordinate for inspection F62
Fabrication Area Provide material during fitting (material handling)
Support F63
Fabrication Area Provide material during welding (material
Support handling) F64
Assembly Refer Drawing, Process sheet, BOM A1
Assembly Bed Preparation, set up of jigs / fixtures, wooden
logs, felt pad etc…. A2
Assembly Identify and material handle for fitting A3
Assembly Handle Level equipment A4
Assembly Material handle for Assembly fitting A5
Assembly Alignment and check A6
Assembly Heating for interference and transition fitting A7
Assembly Interference, transition fitting A8
Assembly Fastening by Bolt, tightening with torque wrench
A9
Assembly Pre-heating for Assembly welding A10
Assembly Assembly welding A11
Assembly Gas cutting A12
Assembly Clean all components to remove rust/dust/chips
A13
Assembly Grinding for achieving contact pattern / fitting A14
Assembly Gear box testing A15
Assembly Pressure testing, Leak testing A16
Assembly Movement testing A17
Assembly Greasing / lubricationg A18
Assembly Pickling & passivation A19
Assembly Dynamic - static balancing A20
Assembly Record dimensions, parameters in Inspection
report A21
Assembly Assembly Inspection A22

Page 11 of 14
ACTIVITY 12-May 13-May 14-May 15-May 16-May
WELDING TIME(mins) 680
HELPER ENGAGED TIME(mins) 210
RATIO 3

12-May 13-May 14-May 15-May 16-May

TOTAL TIME(mins) 510
LALU WELDING TIME(mins) 360
LALU % EFFECTIVE 71%
KEDAR WELDING TIME(mins) 320
KEDAR % EFFECTIVE 63%
 Joint Welding
Name JOB Material Shift time(mins)
Configuration time(min)
1.LADLE BEAM Double-V
LALU PARMANIK Carbon Steel 480 360
2.CAR FRAME Fillet
KEDAR MANDAL 1.LADLE BEAM Carbon Steel Double-V 480 320

Lalu Paramanik losses:- Kedar Mandal losses:-

1.Preheating losses-40mins. 1.Preheating losses-50mins.
2.Root cleaning by grinding-10mins. 2.Root cleaning by grinding-20mins.
3.Start loss-10mins. 3.Start loss-10mins.
4.Machine shifting for other job-20mins. 4.Wire changing for other job-5mins
5.Stitch welding/support welding of Car frame-10mins. 5.Cleaning during passes -30mins.
6.Cleaning during root , fill passes-20mins
 Quality of
Position V I Weld(kg)
weld
1G 1.RT JOINT
22-28 140-240 8.2
3F 2.NO TESTING
1G 1.RT JOINT 26-29 180-240 9.1

dar Mandal losses:-

reheating losses-50mins.
oot cleaning by grinding-20mins.
art loss-10mins.
Wire changing for other job-5mins.
eaning during passes -30mins.