Collega kom eens kijken Maandag 18/11/2013 - VCST Sint-Truiden 0
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Inleiding Paul Partoens bestuurslid – provinciaal bestuur PreBes Limburg
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Thema van vanavond ? Onze gastheren, Leon Vrancken en Dirk Govaerts Preventieadviseurs Milieucoördinator
Aankoopbeleid van equipment in een globale organisatie: van bestelling tot indienststelling. 2
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Agenda : volgende PreBes activiteiten…
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Agenda : Prenne’s
03.12.13 | Kursaal – Oostende 18.03.14 | Affligem - De Montil 19.06.14 | Gent - Flanders Expo 23.09.14 | Edegem - Ter Elst 04.12.14 | Genk
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Volgende activiteiten op de kalender :
Zie de PreBes website voor alle informatie ! www.prebes.be 5
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Ook terug te vinden op http://www.prebes.be/provincie/limburg
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Prebes als informatiekanaal vanuit uw comfortabele zetel…
Veiligheidsnieuws (inclusief links naar andere interessante nieuwtjes…) Update wetgeving Nieuwsbrief Forum WikiPrebia De Prebes-site
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Ook kandidaat voor één van de volgende edities van “Collega kom eens kijken?” Geef een seintje aan een bestuurslid of aan het Prebes-coördinatiecentrum! Ideeën voor de volgende Prenne? Mogelijke modules? Laat het ons weten ! 8
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Programma van vanavond
1. Presentatie door Leon Vrancken 2. Bedrijfsbezoek 3. Netwerken: nakaarten over het bezoek en uitwisselen van contactgegevens…
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Aanwezigheidslijst
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Attesten
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Bedankt voor uw talrijke opkomst !
Vanwege het Prebes bestuur Limburg
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Bezoek PREBES CKEK – 18/11/2013 08/11/2013 Dirk Govaerts - Leon Vrancken
C. THE EHS strategy and policy •
VCST EHS strategy Exceeding the society and employees expectation moving towards
Zero incidents, accidents with respect for: the shareholder, the employees, the environment and the society
•
VCST EHS policy improving the safety and health level throughout all activities and reduction of the
(BATNEEC- Best Available Techniques Not Entailing Excessive Costs)
environmental impact by using best available technologies
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VCST organigram
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VCST organigram
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VCST organigram
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VCST organigram
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Wat ? - Machines - Facility installaties - CE gerelateerde equipment issues : - nieuwe mallen - ombouw machine bv. Van natte bewerking naar droog, zacht draaien naar hard bewerken …….
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Machining Equipment – Process Turning (green material) Muratec, Hyundai Wia
Gear Grinding: Reishauer
CNC Machining (green material) Chiron, Makino, Cincinatti, Okuma
Shaving: Sicmat, Hurth
Hobbing Pfauter, Liebherr, Mutsubishi, Kashifuji, Felsomat
Polishing: 2 Polishing machines
Hard turning Pittler, Felsomat, Weisser, Hessap Laser Marking Trumpf Face Grinding Wolters ID Honing Gehring 20 20 20
Washing: Durr, Hurricane Equipment for Shafts: Hard Turning KIA, Robodrill, Gundrill Spline rolling Anderson Cook Grinding Toyoda, Junker CKEK_18122013
Process heat treatment Carburizing
4 AFC Holcroft batch furnaces with a capacity of 1500 Kg per load Dimensions: 1200 X 900 X 900 mm (L X W X H) Capacity utilization only for VCST MEX product portfolio State of the art equipped laboratory for metallurgical measurements and analysis
Induction Hardening
Single Frequency induction heating for shaft production (InductoHeat)
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Metrology Lab - Scope The Metrology Lab contains high technology equipment for dimensional control and acceptance. Range of features measured in the Metrology Lab: • • • • • • • • • • • • • 22 22 22
Lengths Diameters Heights Roundness True Positions Parallelism Squareness Lead and Involute Deviations Straightness Flatness Run Out Roughness Form Deviations CKEK_18122013
WELZIJNSBELEID ALGEMEEN Preventiehierarchie UITSCHAKELEN REDUCEREN
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Geen risico’s binnenhalen Gevaarlijke zaken vervangen door minder- of ongevaarlijke zaken
COLLECTIEVE MAATREGELEN
Afschermingen plaatsen
PERSOONLIJKE MAATREGELEN
PBM’s en Instructies
SIGNALISATIE
Pictogrammen en Audiovisuele middelen CKEK_18122013
WELZIJNSBELEID ALGEMEEN Wat is een risicoanalyse? Een risicoanalyse kan beschreven worden als een systematische en planmatige analyse van geïdentificeerde gevaren en risicofactoren in concrete arbeidsprocessen en arbeidssituaties.
Een risicoanalyse is een systematisch onderzoek naar:
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Welke gevaren letsels of schade kunnen veroorzaken Of die gevaren kunnen worden uitgeschakeld Hoe die gevaren kunnen worden uitgeschakeld Welke maatregelen kunnen of moeten genomen worden om te voorkomen dat het gevaar schade berokkent of letsel veroorzaakt.
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INVULLING PREVENTIEBELEID ALGEMEEN
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INVULLING PREVENTIEBELEID IN DE PRAKTIJK Procedure aanschaffen en indienststelling arbeidsmiddel, machine…... START
1e bijeenkomst met de aanvrager
2e bijeenkomst met de aanvrager
-Welke normen zijn van toepassing?
-punten van de normen checken met aanvraag
-Welke specifieke vereisten?
-concrete voortstellen en adviezen i.v.m. aankoop
- Toelichting project (planning, machines, ...)
CE-peilingsvragen/ te respecteren VCST Normen- Lastenboek
Rapport Veiligheidseisen bij de bestelling
Bouwen na goedkeuring elektrische schema’s-> risico-analyse (door machineconstructeur)
Afname en controle bij de leverancier vóór levering. Indien alles OK > Levering
CE-certificaat? (label + conformiteitsverklaring + Technisch dossier + Risicoanalyse)
Keuring elektrisch (vlg AREI door externe technisch dienst)
Afname en in dienststelling (vrijgave) door PA, BGD , Projectengineer; toelichting in CPBW
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INVULLING PREVENTIEBELEID IN DE PRAKTIJK Aanvraagformulier vóór bestelling.
Advies vóór bestelling
Advies blusinstallatie
Overzicht VCST Normen- Lastenboek
Risicoanalyse leverancier
Checklist Elektrisch
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INVULLING PREVENTIEBELEID IN DE PRAKTIJK Risicoanalyse VCST
Afnameverslag VCST
CE Conformiteitsverklaring
Elektrische keuring externe technische dienst
Machine vrijgaveformulier Safety Integrated 28
Original changes CKEK_18122013
Documentbeheer
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Documentbeheer
SAFETY
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Documentbeheer
SAFETY : Machines
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Documentbeheer SAFETY : Machines : Technical Equipment Documentation
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Mister Safety Oktober 2013
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KPI’s Safety 13/11/2013 : Record – 239 dagen zonder verletongeval
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KPI’s Safety 13/11/2013 : Record – 239 dagen zonder verletongeval
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DANK U VOOR UW AANDACHT! VRAGEN??
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Main manufacturing processes July 2012
Plant VCST IP - Area definition 1.
Machining
2.
Administration – Canteen – Locker room
(Smoke detection)
6 12 3
11 3
3.
Logistics
4.
Engineering- Locker room
(Smoke detection)
5.
Warehouse chemicals
6.
Warehouse packaging and some oils
7.
Warehouse gas
8.
Transformer station
9.
LT station (level 0&1)
4 1
8
9 10
(VESDA detection)
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10.
HT station
(Inergen as fire protection)
2 13
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11.
Battery station 1
12.
Battery station 2
13.
Guard
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Gear manufacturing process Main process steps in gear manufacturing Hard operation
Gear grinding
Hard turning
Hard operation
Nitriding
Case hardening
Heat treatment
Gear finish hobbing
Gear shaving
Gear hobbing
Green operation
Broaching
Drilling, milling, tapping
Turning
Green operation
Auxiliary process steps like chamfering & deburring, assembly operations, lasermarking, washing, quality checks, are dependent on the specific gear and its application. 39 39 39
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Green operations Turning (CNC Turning Late) This operation is one of the most basic machining processes. The part is rotated while a single point cutting tool is moved parallel to the axis of rotation. Turning can be done on the external surface of the part as well as internally (boring). The starting material is bar stock or forged material.
BEFORE (Bar stock)
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AFTER (Blank)
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Green operations Gear hobbing is a machining process for making gears and sprockets on a hobbing machine, which is a special type of milling machine. The teeth or splines are progressively cut into the work piece by a series of cuts made by a cutting tool called a hob. Compared to other gear forming processes it is relatively inexpensive but still quite accurate, thus it is used for a broad range of parts and quantities
BEFORE
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AFTER
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Green operations Gear chamfering & deburring is a machining process that cuts a chamfer between the face of the gear and the lead and removes the burrs from the hobbing process in order to: - prevent damage to gears and bearings. If burrs are not removed, they are prone to chip off during operation and can cause damage to gears and bearings inside the gear train. - prevent poor toollife of the hard finishing tools. Hardened burrs lead to premature wear of hard finishing tools used in the subsequent finishing operations. - prevent injury. Handling of a gear with sharp edges and burrs can cause injury to the operator.
Hobbed without chamfering and deburring
Hobbed, chamfered and deburred
Finished gear (ground) without chamfering and deburring Finished gear (ground), chamfered and deburred after hobbing 42 42 42
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Green operations Gear shaving is a manufacturing method for finishing gears prior to hardening by removing small amounts of metal from the flanks of the gear teeth. Shaving improves the finish on tooth surfaces and can eliminate tooth-end load concentration, reduce gear noise, and can increase load-carrying capacity. The shaving operation is done with cutter and gear at crossed axes. The action between gear and cutter is a combination of rolling and sliding. Vertical serrations in the cutter teeth take fine cuts from the profiles of the gear teeth.
Shaving cutter
workpiece
Shaving cutter
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Green operations Gear finish hobbing is a machining process for finishing gears prior to hardening. A first hobbing operation (pré hobbing) is followed by an integrated chamfering & deburring operation and finished by a second (finish) hobbing operation. A workpiece is machined in one spindle whilst other workpieces are being exchanged in the other spindle. This reduces the nonproductive time where the cutting tools are not machining, to only the indexing time between spindles, which is a minimum. Additionally the concept offers the opportunity to chamfer/deburr between a rough hob cut and a finish hob cut. This ensures the removal of a secondary burr in the tooth flank, and offers the optimal condition for the finish hobbing process.
roughing finishing section of the hob 44 44 44
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Green operations Broaching (broaching machine) Broaching is a machining process that uses a multi-toothed tool, called a broach, to remove material. In large-series production involving precision metal cutting on workpieces with complex profiles (spline, keyway,…), broaching is one of the most rational production processes. The advantages lie in the technical principle: The profile is cut in one work step by a multi-toothed tool, the cutting edges of which lie one behind the other and are graduated by one cutting thickness each time. The process begins by clamping the workpiece into a special holding fixture, called a workholder, which mounts in the broaching machine. The broaching machine elevator, which is the part of the machine that moves the broach above the workholder, then lowers the broach through the workpiece. Once through, the broaching machine's puller, essentially a hook, grabs the pilot of the broach. The elevator then releases the top of the pilot and the puller pulls the broach through the workpiece completely. The workpiece is then removed from the machine and the broach is raised back up to reengage with the elevator.
Keyway
Spline
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Green operations Machining (drilling, milling, tapping, reaming,..) Machining can be defined as the process of removing material from a workpiece in the form of chips. A sharp cutting tool is used to physically remove material to achieve a desired geometry. Drilling is a cutting process that uses a drill to cut or enlarge a hole in solid materials. The drill is a multipoint, end cutting tool. It cuts by applying pressure and rotation to the workpiece, which forms chips at the cutting edge. Milling is the process of cutting away material by feeding a rotating multiple tooth cutter past a workpiece. The cutting action of the many teeth around the milling cutter provides a fast method of machining. The machined surface may be flat, angular or curved. The surface may also be milled to any combination of shapes. Reaming is a process which slightly enlarges a pre-existing hole to a tightly toleranced diameter. A reamer is similar to a milling tool in that it has several cutting edges arranged around a central shaft. Tapping is a process of cutting screw threads using a tap. Drilling tool Milling tool
Tap
Example of machined part Before machining 46 46 46
Reamer
After machining CKEK_18122013
Hard operations Hard turning is a turning operation done on materials with a Rockwell C hardness greater than 45. It is performed after the work piece is heat treated. Hard turning, when applied for purely stock removal purposes, competes favorably with rough grinding.. Hard turning is appropriate for parts requiring roundness accuracy of 0.512 micrometers, and/or surface roughness of Rz 0.8–7.0 micrometers.
BEFORE
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AFTER
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Hard operations Gear grinding is an abrasive finishing process that removes a considerable amount of metal after the heat treatment operation to obtain a predetermined quality gear. It is the last step in the gear creation process. Gear grinding is done to meet the exact requirements of form, dimension and surface texture. It gives a very high degree of dimensional accuracy. Gear grinding uses a grinding wheel as the cutting tool. The grinding wheel has a rack or straight sided shape with the side angle corresponding to the pressure angle of the gear. This rack is in continuous contact with the gear during the grinding operation while the involute generation is occurring.
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Auxiliary operations Washing is an operation that is used to clean the gears from cutting fluid, debris and to preserve the gears against rust. The intermediate washing operation is done in 3 steps: Washing, rinsing and drying. Final washing is done in 4 steps: Washing, rinsing, preserving and drying. Normal operation conditions are between 45 to 60 Celsius degrees.
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Auxiliary operations Laser marking is the practice of using lasers to engrave or mark an object. The technique does not involve tool bits which contact the engraving surface and wear out. This is considered an advantage over alternative engraving technologies where bit heads have to be replaced regularly.
BEFORE
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AFTER
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Surface Treatment Company - STC N2
Voorraad opgekoolde producten
T7-K
T7-K P6 T7-O
BANDSTRALEN
LLF10-K
Diepkoelen Inkomend werk wassen
Gaslokaal
POMPENHUIS
VACUUMOVEN
Straalwerk
Carroussel Pers
Gestellen
N2
NH3
LLF8-K
KANTOREN STC
LLF10-K
LLF8-K LLF10-K
LLF8-K
WASSEN Rübig
INOXSTRALEN
LLF10-K LLF8-K LLF10-W
Nitreergereedschap
P6
IN
UIT
T7-O LLF8-W
Transf.
H2 / O2
KANTOOR
EINDCONTROLE
Methanol
AF
HDH 4
Opbouwgereedschap
OP STRALEN
Gestelbouw
AF Gestelbouw
6371
OP
HDH 3
Opbouwgereedschap
Leeggoed nitreren
Opbouwgereedschap
Briro-E
Beladen Ontladen
Condursallen
Leeggoed LLF8 / LLF10
WASSEN
BUFFER VOOR EINDCONTROLE RICHTEN + MAGNATEST
ANODISEREN
HONEN
FDF
BU
LEGE EMBALLAGE
FDF
Rondtakt
CFEI
PIT Opslag chem.
Inkomend werk inductieh.
Inkomend werk inductieh.
IN
IN
AUTOM. RICHTEN MAE
NEITZ
Heraus
AUTOM. RICHTEN MAE
WC
UIT
UIT
WASSEN
BELADEN WASMACHINE
VERPAKKING
AFVALWATERVERWERKING Ketelhuis
TEM Bosch P-350
ONDERHOUDSHOEK Afvalwaterbehandeling
Inkomend werk LLF8 / LLF10
Inkomend werk Toyoda + Wema
Afgewerkt Transfo
Afgewerkt
IN
TEMMEN ER TE VO M OR
FF
BUFFER VOOR WASSEN IN
AFGEWERKT
CONTROLE
EINDCONTROLE
FOSFATEREN Blasberg
WASSEN Wache
Condursallen
Dim. contr.
KANTOREN
DAWSON
Opbouw P6
BU FF AN ER OD VO ISER OR EN
Fluxen + Fosfateren
Leeggoed LLF8 / LLF10
Blokkeerrek
Schrot
Inkomend werk P6 / T7 Afgewerkt
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ONDERHOUD
FLUXEN
HONEN
Transf.
Transfo's + LS-lokaal (1ste verdiep)
Transf.
Beladen Ontladen
PC
Pompenlokaal + afvalwaterbehandeling + noodstroomgroep (1ste verdiep)
Inoliën
HDH 2
PLASMA
Leeggoed T7
STRALEN Berger
LLF10-O
LLF8-O
BUFFER VOOR WASSEN
Leeggoed P6
Opbouw T7
Fluxen
Nitreergereedschap
WASSEN Rübig
WASSEN T7
Inkomend werk nitreren
T7-K
LLF10-O LLF8-O HDH 1
Inkomend werk nitreren
P6
LLF10-O LLF8-O
Leeggoed nitreren
T7-K
Opbouw P6
Op/Afbouw
Inkomend werk wassen
T7-W
Opslag Gereedschap
Afgewerkt
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Carburizing: goal and equipment Carburizing is a heat treatment process in which iron or steel absorbs carbon liberated when the metal is heated in the presence of a carbon bearing material, such as carbon monoxide, with the intent of making the metal harder. Depending on the amount of time and temperature, the affected area can vary in carbon content. Longer carburizing times and higher temperatures lead to greater carbon diffusion into the part as well as increased depth of carbon diffusion. When the iron or steel is cooled rapidly by quenching, the higher carbon content on the outer surface becomes hard via the transformation from austenite to martensite, while the core remains soft and tough as a ferritic and/or pearlite microstructure The proces takes place in a sealed furnace with integrated oil bath. Additional equipment like a washing machine, tempering furnaces and shot blasting machine completes the line.
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Process flow
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Picture: Jigging
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Picture: Carburizing line
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Picture: Loading a Furnace
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Picture: Quality control Surface hardness Core Hardness Case depth Microstructure
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Picture: shot blasting
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Nitriding: goal and equipment In gas nitriding the donor is a nitrogen rich gas, usually ammonia (NH3). When ammonia comes into contact with the heated work piece it disassociates into nitrogen and hydrogen. The nitrogen then diffuses from the surface into the core of the material. The thickness of the resulting white layer and the diffusion depth is function of the nitriding time and temperature of the process. Typical proces temperatures are between 510-570 °C.
Typical treatment times are 10–25 hours. The proces takes place in a retort or pit furnace
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Process flow
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Washing machine (T1 ecobelt)
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Picture jigging
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Picture: Nitriding furnace
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Picture: Quality control Surface hardness Core Hardness Case depth Microstructure
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