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Journal of Industrial Safety Engineering ISSN: 2395-6674(online)
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It is my privilege to present the print version of the [Volume 3 Issue 3] of our Journal of Industrial Safety Engineering, 2016. The intension of JoISE is to create an atmosphere that stimulates vision, research and growth in the area of Industrial Safety Engineering. Timely publication, honest communication, comprehensive editing and trust with authors and readers have been the hallmark of our journals. STM Journals provide a platform for scholarly research articles to be published in journals of international standards. STM journals strive to publish quality paper in record time, making it a leader in service and business offerings. The aim and scope of STM Journals is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high level learning, teaching and research in all the Science, Technology and Medical domains. Finally, I express my sincere gratitude to our Editorial/ Reviewer board, Authors and publication team for their continued support and invaluable contributions and suggestions in the form of authoring writeups/reviewing and providing constructive comments for the advancement of the journals. With regards to their due continuous support and co-operation, we have been able to publish quality Research/Reviews findings for our customers base. I hope you will enjoy reading this issue and we welcome your feedback on any aspect of the Journal.
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Journal of Industrial Safety Engineering
Contents
1. Discomfort Analysis in Pneumatic Grinding: Steam Generator Manufacturing Industry Mani Chidambaram, Sankaranarayanasamy Krishnasamy, Muthukumar Krishnamoorthy
1
2. Improvement of the Space Management of Any Organization Using Different Japanese Management Tool Yash D. Shah, G.D. Acharya 11 3. Metallic Pollution Level in Soils of Mymensingh Town, Bangladesh: An Impact of Urbanization and Industrialization H.M. Zakir, Md. Sohrab Hossain
17
4. Optimization of MRR and TWR on Electro Discharge Machining using Taguchi based GRA Shivani Yadav, Manoj Kumar Gaur, Sharad Agrawal
26
5. Optimization of Process Parameters in EDM Machine with AISI 304 Stainless Steel using TOPSIS Gurjeet Kaur, Manoj Kumar Gaur
33
6. Energy Saving Measures in Industrial Production: A Case Study Prashant Sharma, Waris Nawaz Khan
39
7. Recommendation on Personal Protective Equipment: Safety Review C.B. Mohod
43
Journal of Industrial Safety Engineering
ISSN: 2395-6674(online) Volume 3, Issue 3 www.stmjournals.com
Discomfort Analysis in Pneumatic Grinding: Steam Generator Manufacturing Industry Mani Chidambaram1, Sankaranarayanasamy Krishnasamy2, Muthukumar Krishnamoorthy3 1,2
Department of Mechanical Engineering, National Institute of Technology, Tiruchirappalli, Tamil Nadu, India 3 Department of Safety Management, Bharat Heavy Electricals Ltd., Tiruchirappalli, Tamil Nadu, India
Abstract
Steam generator manufacturing involves a lot of custom designed components requiring intensive fabrication activities of welding and grinding. Pneumatic grinding machines of different types are widely used in such industries as they offer flexibility and ease of use. However, the deployment of pneumatic tools are associated with hand transmitted vibration and related health issues. The present study aims to evaluate the extent of discomfort levels of operators and its relationship with the grinding intensity and at various times of the day. Pneumatic grinding operators involved in manufacturing steam generator components were chosen and data was collected based on Corlett and Bishop’s body part discomfort mapping, at various time intervals from starting to end of the shift, using a structured questionnaire. ANOVA was deployed to carry out the statistical analysis. The grinding operators working in ‘drums and headers’ product group reported the maximum discomfort compared to operators working in other product groups. The discomfort increases as the shift progresses and reaches the highest at the end of the shift. The study also brought out that most operators reported discomfort in ‘shoulder’ (93%), followed by wrist (85%), neck (70%), lower back (65%) and forearm (61%). Apart from providing leather and anti-vibration protective gloves to the grinding operators, the industry is working to reduce hand arm vibration problems by experimenting with modified handles and lower weight grinders. In addition to that, distributing the exposure of grinding operators amongst different product groups could bring a balance in discomfort faced by them, by periodical job rotation. Keywords: Discomfort mapping, hand arm vibration, pneumatic grinders, work-related musculoskeletal disorders
INTRODUCTION
Major industries like construction, mining, manufacturing, shipbuilding and aircraft industry deploy powered hand tools despite high level of automation. Because of ease of use and flexibility, powered hand tools play a vital role in aircraft industry. High exposure to vibration occurs during use of a riveting hammer. Tools like power screwdrivers, saws and grinding machines are other hand tools contributing to vibration exposure [1]. Deployment of powered hand tools gives the triple benefit of productivity, quality and time saving [2]. Intensive exposure to vibration from powered hand tools for a prolonged time may cause hand arm vibration syndrome (HAVS) [3–8]. Hand transmitted vibration has
also been identified as a contributing factor in the development of carpal tunnel syndrome (CTS) [9].Operators having exposure to hand transmitted vibration may either be affected with vascular and/or neurological disorder separately or together. In Europe, one in three workers are exposed to some type of vibration from the machines or tools and the duration of exposure is at least 2 hours a day [10]. About 1.7 to 3.6 % of the workers in USA and Europe run the risk of exposure to potentially harmful hand transmitted vibration. Workers with prolonged exposure also complain of muscular weakness, pain, lowering of handgrip strength and muscle force [11]. Other health issues include
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Journal of Industrial Safety Engineering
ISSN: 2395-6674(online) Volume 3, Issue 3 www.stmjournals.com
Improvement of the Space Management of Any Organization Using Different Japanese Management Tool Yash D. Shah1,*, G.D. Acharya2
1
Department of Mechanical Engineering, Atmiya Institute of Technology and Science, Rajkot, Gujarat, India 2 Principal, Atmiya Institute of Technology and Science, Rajkot, Gujarat, India
Abstract
This paper will fully deal on the Kaizen formula and 5S of Japanese strategies for the improvement in space management of several organizations. Global markets are continuously changing and demanding product of high quality and low cost. Cottage industries play an important role in Indian economy. There are large numbers of in industries and it is emerging an as providing larger employment opportunities next to agriculture. Lean manufacturing is one of the fundamental plans of action to achieve cost cutting using space management. Products can be produced using lean manufacturing; perhaps for basic quality management tool for cleaning for work place improvement, 5S and Kaizen are also used. Keywords: Space management, quality control, Kaizen, 5S, TQM
INTRODUCTION
This paper aim is to produce an absolute study between total quality management. Lean Manufacturing system was started by the Toyota production [1]. The lean manufacturing includes TQM, originally founded in the Japanese automotive industry; also process of lean manufacturing was generally carried out in the Western countries. The paper systematically categorizes the related literature of different survey, study the literature and ultimately prospect it methodologically [2]. The use of the term "Lean", in a business or manufacturing geographic area, tells about a philosophy that integrate a collection of tools and techniques for optimizing time into the business processes, and productivity, while improving the quality level of products and services to their customers [3]. The term "Lean" is used in a business or manufacturing environment, describes incorporates briefly in a collection of different tools and techniques into the enterprise processes and productivity, instead of raising the quality selection level of products and services to their customers [4]. There are two management approaches to optimization they are: Total Quality
Management (TQM) and Lean Manufacturing (LM). Total quality management (TQM) is “The management of quality at all stage of operations from planning and design through self-inspection, to continual process monitoring form provident opportunities� [5]. However, different definitions of TQM have been presented over the years. Dale claims that TQM is both a philosophy and a set of guiding principles for managing an organization [6]. LM is the production of using less number of goods. By Using LM with any company, the goals would be to use less waste, less human attempt, and less engineering to develop a new product [7]. Lean principles are fundamentally value driven for any customer, which makes many manufacturing in appropriate manner and distribution situations. Principles of LM are generally acknowledged as show Figure 1. Understanding customer value and what the customers realize as value of its importance. For understanding any Value for the customers, the next step is to analyze the business processes by adding values that any ones actually need. The best Japanese management practices is originated by the Kaizen management and is dedicated to the improvement of productivity, quality for
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Metallic Pollution Level in Soils of Mymensingh Town, Bangladesh: An Impact of Urbanization and Industrialization H.M. Zakir*, Md. Sohrab Hossain Department of Agricultural Chemistry, Faculty of Agriculture, Bangladesh Agricultural University, Mymensingh, Bangladesh Abstract
Untreated urban and industrial wastes disposal in Mymensingh town are the major problem and responsible for soil and water pollution. Total 24 soil samples were collected from different locations of Mymensingh town to assess metallic pollution level as well as to study some other physicochemical properties of soils. The mean total concentrations of Cu, Zn, Pb, Cd and Fe in soil samples were 68.69, 193.06, 62.47, trace and 18481.82 µg g -1, respectively. The present study revealed that the average Cu, Zn and Pb contents in soils were higher compared with several other industrial areas in home and abroad as well as geochemical background values of continental crust. Iron content in soils showed highly significant positive relationship with Zn and Pb, which indicate that these metals were interrelated with each other and may be originated from the same source to the study area. The calculated I geo for Pb, Zn and Cu exhibited positive values and Igeo class: 1–3, indicating moderately to strongly polluted soil quality. Similarly, considering EFc, 100, 55 and 14% locations had EFc values > 5.0 for Pb, Zn and Cu, respectively, which indicates anthropogenic enrichment of these metals to the area. Keywords: Metallic pollution, soil, industrialization, Bangladesh
INTRODUCTION
Soil and water, both the resources have been subjected to severely degraded or polluted due to urbanization and industrialization. The pollution includes point sources such as emission, effluents and solid discharge from industries, vehicle exhaustion and metal from smelting and mining, and nonpoint sources such as soluble salts, use of agrochemicals, disposal of industrial and municipal wastes and others [1, 2]. Each source of contamination has its own damaging effects to plants, animals and ultimately to human health, but those that add metals to the environment are of serious concern due to their persistence and carcinogenicity. They cannot be destroyed biologically but are only transformed from one oxidation state or organic complex to another [3]. In Bangladesh, last few decades industrialization is encouraged to engage a huge volume of young forces to the economy as well as to meet up the basic demand of the population. As a result, there is a progressive increase in industrial wastes, which causing severe contamination to the air, water and
soils, thus polluting the environment. During the last few years, a number of research works has been reported severe metallic contamination to soil, water and sediments [4–9] in different parts of the country. The same scenario is also applicable for Mymensingh town, which is highly susceptible to environmental pollution due to over population, rapid industrialization and urbanization in last few years. A study reported that total volume of waste generation from different mills and industries of BSCIC area of Mymensingh town is 9758 kg/day of which 1223, 3115 and 5420 kg/day of wastes are produced by the small, medium and large category industries, respectively [10]. Considering the above facts, the present study was planned to determine the concentration of some toxic metals in soils of Mymensingh town as well as to assess their contamination level.
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Optimization of MRR and TWR on Electro Discharge Machining using Taguchi based GRA Shivani Yadav*, Manoj Kumar Gaur, Sharad Agrawal Department of Mechanical Engineering, Madhav Institute of Technology and Science, Gwalior, Madhya Pradesh, India Abstract
Electro Discharge Machining (EDM) is one of the most effective nonconventional machining processes in order to obtain better finishing quality result. It is vastly used to machine the most complex as well as intricate shapes so as the productivity increases in a very short time interval. The input parameters are; discharge current, voltage and pulse on time. Taguchi L9 orthogonal array is used to find out the Signal to Noise ratio by optimizing the performance parameters based upon the input parameters. The performance parameters so optimize as material removal rate, tool wear rate. Using the GREY RELATIONAL ANALYSIS, the correlation has to be draw out that makes the optimized value very accurate. Keywords: MRR, TWR, Grey Relational Analysis, Current, Pulse on time
INTRODUCTION
In order to improve the productivity, continuous production is required without any noise factor so as the better performance has to be created. Electro Discharge Machining (EDM) is a very beneficial machine in order to machine the most intricate as well as complicate shapes. It contains cathode as well as the anode electrode. The tool electrode is taken as negative terminal as well as the workpiece is taken as the positive terminal. When the positive electrons moved from the workpiece towards the tool electrode, a plasma channel is created between both the electrodes, due to which the avalanche motion is created by the electrons that thereafter created the thermal conductivity so that spark is generated. That is why it is called as Spark Erosion Machine. For this, the tool electrode should be having high thermal conductivity and electrical conductivity. The working principle of EDM is based on thermoelectric energy. Hence, this is a type of electrothermal process. Due to the less time interval of the pulse on time, the heat generated is very low. The heat affected zone can be carried out to 2–4 µm of the spark crater. Dielectric fluid is used to ionize the electrons, it should be oxygen free. Transformer oil is used as the dielectric fluid. The tool material copper is used. Besides having its high cost, it satisfies all the required properties having high density, high thermal as
well as electrical conductivity. In this research paper, the workpiece performance examined by MRR and TWR by using the input parameters.
LITERATURE REVIEW
Today the research on EDM is going to be very important not only the area of technical specifications but also on the aspect of productivity. The main objective of this paper is to investigate the performance of workpiece based upon the input parameters. The workpiece taken as AISI 202 SS. The EDM machine used was TOOLCRAFT A50 EDM SPARK EROSION MACHINE. The dielectric medium is so taken to make oxygen free machining process. It is taken as transformer oil. The tool electrode is taken as negative terminal and workpiece is taken as positive terminal due to which the movement of free electrons takes place from workpiece towards tool. A spark is generated due to the formation of plasma channel. The experimental data carried upon by the Taguchi L9 orthogonal array to identify the graphs relating to S/N ratio. It is accompanied by the grey relational analysis to make correlation between both the factors. For MRR, “Large the better” is taken
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ISSN: 2395-6674(online) Volume 3, Issue 3 www.stmjournals.com
Optimization of Process Parameters in EDM Machine with AISI 304 Stainless Steel using TOPSIS Gurjeet Kaur*, Manoj Kumar Gaur Department of Mechanical Engineering, Madhav Institute of Technology and Science, Gwalior, Madhya Pradesh, India Abstract
The effective solution based on TOPSIS approach to determine the optimal process parameters in die sinking electrical discharge machining. Taguchi L9 orthogonal array is used to gather information regarding the process with less number of experimental runs. Experiments have been conducted using three process parameters such as peak current, gap voltage, pulse on time, with three levels are selected to optimize the multiple objectives. AISI 304 stainless steel as a work-piece material and copper as electrode material used for the experiments are arranged on the electrical discharge machine for the research work in order to develop the optimal condition of the response parameters MRR and TWR. Keywords: Response parameter (MMR, TWR), EDM, AISI 304, TOPSIS, ANOVA
INTRODUCTION
Die sinking Electrical Discharge Machining is one of the earliest nontraditional machining processes. EDM process is based on thermoelectric energy in which electrical energy is used to generate electrical spark and material removal occurs due to thermal energy produced by the spark. A pulse discharge occurs in a small gap between the work-piece and the electrode. Then fresh dielectric fluid rushes in the gap, flushing away the debris and quenching the surface of work-piece. The EDM SPARK EROSION MACHINE TOOLCRAFT A50 spark generator used for the experiments which is having a maximum current capacity of 50A and maximum allowance is 0.1 mm. Today variety of industries require materials that are highly temperature resistant and provide higher strength, toughness, highly resistant to corrosion and other properties therefore, it has become essential to have such process that are safe and conveniently machined the hardened materials with accuracy hence nonconventional machines are preferred. For machining of hardened steel, the preferred metal cutting process is electrical discharge machining. This process is characterized by good material removal rate, better dimensional accuracy and good surface finish [1]. This study presents a methodology for evaluation and ranking by TOPSIS approach along with
Taguchi orthogonal array [2]. The experimental analysis using the proposed approach gave the optimized and profitable result. The overall analysis of the process parameters is done by statistical ANOVA approach in MINITAB 17.0 to have accurate results [3].
LITERATURE REVIEW
To establish a relation between input parameters and output parameters various approaches like empirical relation, nonlinear regression, response surface methodology, fuzzy-logic, VIKOR, TOPSIS, etc. Now we have considered here TOPSIS, simple additive weighting [4]. Supported case study shows the effective use of methodology in a (EDM) nontraditional manufacturing processes. The proposed models used peak current, gap voltage, pulse on time, and pulse off time as input parameters. The predictions based on the above developed models were verified with another set of experiments and were found to be in good agreement with the experimental results. All theoretical statements are illustrated by numerous examples and calculations. Rao et al. aimed at optimizing the hardness of surface produced in die sinking electric discharge machining (EDM) by considering the simultaneous effect of various input parameters [5, 6]. It was observed that type of material effectively influences the
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Energy Saving Measures in Industrial Production: A Case Study Prashant Sharma*, Waris Nawaz Khan
Department of Mechanical Engineering, Noida International University, Noida, Uttar Pradesh, India
Abstract
The energy efficiency project for the industries will improve energy efficiency in public and social facilities and enabling environment for sustainable energy financing. The primary and secondary aim of this paper is to save energy that will results in economical environment friendly production practices. This paper proposes ideas that how energy saving can be executed in industries by the application energy saving products. Case studies have been carried out to bring out the quantitative data for the comparison, analysis and decision making regarding implementation. The paper tries to convert the energy saving into the monetary value to showcase the actual impact of suggestive measures on the production economy. The end results show 54% savings to investment ratio with a payback period of 137 days. Keywords: Energy, efficiency, savings, production economy
INTRODUCTION
Energy is the primary source that is only responsible for doing any work in the day-today life or in the plants. Energy is being produced by many ways then it is utilized in many ways. The industrial sector alone accounts for about 50% of the commercial energy. It uses both, the thermal and electrical energy in various equipment like boilers, compressors, furnaces, diesel generating engines, motors, pumps, refrigeration, etc. Here are tips for energy saving through these equipment. The main objectives of saving energy are as follows to protect the global environment, energy-saving laws, ISO14000 compliant (corporate social responsibility), reduce production costs (more profits for companies). Types of Energies Used in the Industries Electrical Energy: General The industrial sector consumes about 33% of the total electrical energy consumed in the country. Compressed Air It is the air more than the atmospheric pressure i.e. 1 bar. Compressed air is a major source of energy used in the industries and is responsible
for major applications such as pneumatic tools, cleaning purpose, vacuum applications, suction etc. It is preferred in industries because of its convenience and safety and easy availability. Cooling Towers It is a type of specialized heat exchanger in which air and water are placed into direct contact together for the transfer of heat. It is a tall, cylindrical concrete tower, open-topped used for cooling water or condensing steam from an industrial process. It is used for providing cooled water for air-conditioning, manufacturing and electric power generation. Electric Motors The electric motors are used to provide motive power to equipment such as compressors, pumps, blowers, etc. It is important that the industrial users define their need accurately to enable proper selection of a motor for a particular application. Of the total electricity consumed in the industrial sector, electric motors account for approximately 70%. Lighting A lumen is the measurement of light output from a lamp, often called a tube or a bulb. All
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Journal of Industrial Safety Engineering ISSN: 2395-6674(online) Volume 3, Issue 3 www.stmjournals.com
Recommendation on Personal Protective Equipment: Safety Review C.B. Mohod* Department of Chemical Engineering, Government Polytechnic, Arvi, Wardha, Maharashtra, India Abstract
Personal protective equipment are used to avoid contaminated exposure. The risks of hazards depend upon concentration of hazardous chemicals at work place. So, protective equipment are always used to guard human body parts. This review paper has recommended safety guidelines in present discussion. These guidelines are surveyed to adopt safety precautions at work environment for all users, while this paper has also included procedure to use respiratory and non-respiratory protection for health safety against dangerous environment. Keywords: Respiratory, personal clothing, safety
INTRODUCTION
Personal protective equipment (PPE) includes all clothing and work accessories projected to protect user from workplace hazards in many working industries like explosive, petrochemical, chemical industry and sensitive industries like food, dairy industry, and pharmaceutical industry. In industry, it is mandatory to wear personal protective equipment as required, while entering a campus of an industry or research laboratory etc. Personal protective equipment’s are used to prevent exposure and contamination. Dangerous chemicals are often used and handled at workplaces. The risk of injury or ill health depends upon exposure to the hazards of the chemicals at work place. Therefore, personal protective equipment (PPE) is one of the safety measures in point of accidents or injury. PPE is referred as equipment that is proposed to be worn or used by a person at work place and that protects the person against one or more risks arising from chemical or physical operation to the person’s safety or health. Training helps user in acquiring the necessary attitude, knowledge and skills in order to be experienced in using PPE for handling and use of chemicals. PPE is widely accepted and used by employers for the beneficiary of a user.
Users often demand safety equipment for their safety at workplace.
LITERATURE REVIEW
Spectacles containing reflective metallic coatings and materials that filter out infrared are the ideal means, while aluminium and inconel (and alloy of iron, nickel and chromium) provide excellent infrared reflectance [1]. The main difficulty with using reflective metallic coatings is that they are susceptible to scratching, abrasions and other faults that cause the breakdown of the coating. American Optical (‘Pfund’s glass’), in which a gold layer reflects 96% of infrared while transmitting 75% of visible light. The metal is sandwiched between clear optical crown glass and crookes a glass, which absorbs 100% of ultraviolet [1]. Corrective eyeglasses worn by users lift up a problem when fitting respirators, while special mountings are available to hold corrective lenses inside full face pieces provide good vision, comfort, and proper sealing. Latex can cause allergic skin responses, while wearing latex gloves. Radio frequency (RF), the most apparent biological effects of RF energy to living cells are due to heating [2]. Respiratory and facial protection is required for those organisms that are usually transmitted via the droplet/airborne route, or
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