Material Flow Layout at Siemens Pakistan

 

Material flow layout is very important in the production management . The materials are moved from one operation to another operation as the inputs are transformed into outputs by the manufacturing process. Mov4ment of materials is an essential feature of the factories.Raw materials and other input supplies reach the factory, where they are converted into finished goods; the latter are shipped either to the distributor or customer.

 

RAW MATERIALS

Raw materials are defined in Siemens as any input material whether it is finished, semi-finished or unfinished.

the alternators material flow chart  process is explained below

 

 

ELECTRICAL STEEL

The best quality of the electrical steel is selected and it is stored ion the store house . There are certain procedures and criteria, which the company follows to ensure the quality of the product. In fact this is the basic raw material which is used in the process of manufacturing of the alternators .  the electrical steel is used to make the rotors and stators .

 

NOTCHING AND PUNCHING

In this process the electrical steel is notched and punched and separated as stators and rotors as the main components of the alternators. This process is being done by low-skilled workers and they separate the rotors and stators  and put them in different bins. The internal supervisor takes the required quantity of the rotors and the stators. This is exclusively the internal production control of the plant and the planning department does not have any concern with it. As we have discussed in the class of Dr Z. HUDA the notching and punching is done  according to the size of the alternator and other specifications are also considered . At the time of notching and punching some of the  WORK EFFICIENCY PRINCIPLES OF Dr.Z, HUDA are exercised and that’s the reason the productivity and the efficiency  are increased considerably

 

 

CORE LAMINATION

After the notching and punching core lamination takes place . This process is very conveniently done by the workers because according to the official sources of Siemens the workers are properly trained and equipped to perform this operation. Core laminatin is very important because the performance of the alternator is dependent on the quality o0f the core lamination.

After core lamination the stators are bundled in a different packet and the rotors are packed in different packets so they can be easily transported to the next workstation

 

 

MACHINING OPERATIONS OF THE STATORS

At this stage the stators are to be worked upon separately from the rotors but at the same assembly line. The assembly line is process-oriented.

 

 

WINDING

The stators are transported to the winding workstation, at this work station the winding of the stators take place. First the winded stators are dipped in the special chemical and then they are heated in the oven at the optimum temperature. This completes the winding process of stator. Since the safety of the workers is the first priority of Siemens the workers are provided with the gloves so they cant ake out the stator from the oven without damaging the hands of the workers .

The raw materials at the stage of winding are added to the stators. They are insulating copper wire and insulating material

 

IMPREGNATION

At the time of impregnation resin is added as raw material again the quality of the resins is ensured by the established standards and the well judged criteria. These raw materials are added from the storehouse. At the time of the Impregnation the flow of the material is of more importance, that’s why the flow of the raw material is continuous.

 

STATOR PACKETS WITH WINDINGS

At this stage the stators are manufactured and now they proceed to the assembly line for the further work. At that time the quality of the stators is checked so the defected stators are not delivered for further processing. The defect is identified and they are reworked.

 

 

MACHINING IN THE ROTOR

The raw material used in shaft is stock, it is thehuge solid rods of steel they have a significant role in the manufacturing process of rotors.Since these shafts are very heavy they are not transported and the rotors are transported to the shafts. This saves significant amount of money because a huge crane would have been required had the shafts are to be transported. There is an special technique to lift the shafts so the safety of the workers is ensured.

 

 

ROTOR LAMINATION

Now the rotors are laminated, the process of lamination in rotors is very simple. This process is not a time consuming process that’s why the turnover rate is very high with respect to time.

 

 

ROTOR BUCKETING

In the process of rotor bucketing the aluminum and welding electrodes are used as the raw materials. The workers who are involved in thi process ae separate workers .In the bucketing the first the aluminum is used the  the welding elelctrodes are used

 

 

WINDING

The winding process is not very complicated but has the same function as in the stators.

 

 

ROTOR BUCKET WITH SHAFT

Now the rotor bucket is fused with the shaft . An optimum temperature is necessary for this process.