Samun nasara da ingantaccen samar da bututu ko bututu shine batun inganta sassa 10,000, gami da kiyaye kayan aiki.Tare da sassa masu motsi da yawa a cikin kowane nau'in niƙa da kowane yanki na kayan aiki, bin shawarwarin da masana'anta suka ba da shawarar kiyayewa ƙalubale ne.Hoto: T&H Lemont Inc.
Bayanan edita.Wannan shine kashi na farko na jerin kashi biyu akan inganta aikin tubing.Karanta kashi na biyu.
Kera samfuran tubular aiki ne mai wahala ko da a cikin mafi kyawun yanayi.Masana'antu suna da rikitarwa, suna buƙatar kulawa akai-akai kuma, dangane da abin da suke samarwa, gasa tana da zafi.Yawancin masana'antun bututun ƙarfe suna fuskantar matsanancin matsin lamba don haɓaka lokacin aiki don haɓaka kudaden shiga yayin da suke barin ɗan lokaci mai mahimmanci don kulawa.
Yanayin masana'antu a yau ba shine mafi kyau ba.Farashin kayan abu yana da tsada abin dariya, kuma sashe na sashe ba sabon abu bane.Yanzu fiye da kowane lokaci, masu kera bututu suna buƙatar haɓaka lokacin aiki da rage tarkace, kuma samun sashe na ɗan lokaci yana nufin gajeriyar lokutan samarwa.Gudun gajere yana nufin sauye-sauye akai-akai, wanda ba ingantaccen amfani da lokaci ko aiki ba.
"Lokaci yana da mahimmanci a kwanakin nan," in ji Mark Prasek, Arewacin Amirka Tubing da Tubing Sales Manager na EFD Induction.
Tattaunawa tare da ƙwararrun masana'antu game da shawarwari da dabaru don samun mafi kyawun kasuwancin ku suna bayyana wasu jigogi masu maimaitawa:
Gudanar da shuka a mafi girman inganci yana nufin haɓaka abubuwa da yawa, galibi waɗanda ke hulɗa da juna, don haka inganta aikin shuka ba koyaushe bane mai sauƙi.Shahararriyar zance daga tsohon marubucin jaridar The Tube & Pipe Journal Bud Graham ya ba da haske: “Mai sarrafa bututu kayan aiki ne.”Sanin abin da kowane kayan aiki yake yi, yadda yake aiki, da yadda kowane kayan aiki ke hulɗa da wasu shine kusan kashi uku na hanyar samun nasara.Tabbatar cewa komai yana goyan bayan kuma daidaita shi shine wani na uku.Na uku na ƙarshe an sadaukar da shi ga shirye-shiryen horar da ma'aikata, dabarun magance matsala da takamaiman hanyoyin aiki na musamman ga kowane mai kera bututu ko bututu.
La'akari da lamba ɗaya don ingantaccen aikin shuka ba shi da alaƙa da shuka.Wannan danyen abu, samun mafi yawa daga cikin injin naɗaɗɗen, yana nufin samun mafi kyawun kowane nau'in nada da ake ciyar da shi zuwa injin mirgine.Yana farawa da shawarar siyan.
tsayin nada."Ma'aikatan bututu suna bunƙasa lokacin da coils ya daɗe sosai," in ji Nelson Abbey, darektan Abbey Products a Fives Bronx Inc. Yin aiki tare da guntun nadi yana nufin sarrafa ƙarin nadi.Kowane ƙarshen mirgina yana buƙatar walƙiyar gindi, kuma kowane weld ɗin gindi yana haifar da juzu'i.
Matsalolin anan shine mafi tsayin igiyoyi na iya siyarwa don ƙarin, yayin da guntun coils na iya samuwa akan farashi mafi kyau.Wakilin siye zai iya so ya ajiye wasu kuɗi, amma wannan ba shine ra'ayin mutanen da ke samarwa ba.Kusan duk wanda ke gudanar da shuka zai yarda cewa dole ne bambancin farashin ya zama babba don rama asarar da aka yi da shi tare da ƙarin rufewar shuka.
Wani abin la'akari, in ji Abby, shine ƙarfin kayan aikin decoiler da duk wani hani a wurin shigarwar niƙa.Yana iya zama larura a saka hannun jari a cikin kayan shigarwa masu ƙarfi don ɗaukar manyan juzu'i masu nauyi don cin gajiyar siyan nadi mai girma.
Yanke ma wani abu ne, ko a gida ake yin yankan ko kuma daga waje.Slitter rewinders suna da matsakaicin nauyi da diamita waɗanda za su iya ɗauka, don haka ingantacciyar wasa tsakanin jujjuyawar jujjuyawar juzu'i da slitter rewinder yana da mahimmanci don haɓaka yawan aiki.
Don haka, shine hulɗar abubuwa guda huɗu: girman da nauyin mirgine, girman da ake buƙata na slitter, yawan aiki na slitter da ƙarfin kayan shigarwa.
Mirgine nisa da yanayin.Yana tafiya ba tare da faɗi ba a cikin shagon cewa rolls ɗin dole ne ya zama daidai faɗi da girman daidai don samar da samfurin, amma kurakurai suna faruwa.Masu aikin birgima sau da yawa suna iya ramawa kaɗan a ƙarƙashin ko sama da faɗin tsiri, amma wannan batu ne kawai na digiri.Kusa da nisa na hadaddun tsaga yana da mahimmanci.
Yanayin gefen ɗigon ƙarfe kuma shine mafi mahimmancin batu.A cewar Michael Strand, shugaban T&H Lemont, daidaitaccen aiki na gefe ba tare da bursu ko wani rashin daidaituwa ba yana da mahimmanci don kiyaye daidaiton walda a tsayin tsiri.Juyawa na farko, kwancewa a tsaye da jujjuyawa shima yana aiki.Ƙwayoyin da ba a kula da su ba suna iya yin baka, wanda ke da matsala.Tsarin kafa, wanda injiniyoyin injiniyoyi suka ɓullo da shi, yana farawa da tsiri mai lebur, ba mai lankwasa ba.
kayan aiki la'akari."Kyakkyawan ƙirar ƙirar ƙira yana haɓaka yawan aiki," in ji Stan Green, babban manajan SST Forming Roll Inc., yana lura cewa babu wata dabarar samar da bututu guda ɗaya, don haka babu dabarun ƙirar ƙira ɗaya.Masu samar da kayan aikin Roller sun bambanta kuma hanyoyin sarrafa bututu sun bambanta, don haka samfuran su ma sun bambanta.Yawan amfanin gona kuma ya bambanta.
"Radius na abin nadi yana canzawa akai-akai, don haka saurin jujjuyawar kayan aiki yana canzawa a kan dukkan kayan aikin," in ji shi.Tabbas, bututun yana wucewa ta cikin injin niƙa da sauri ɗaya kawai.Saboda haka, zane zai iya rinjayar yawan amfanin ƙasa.Ya kara da cewa rashin kyawun zane yana lalata kayan aiki lokacin da kayan aikin ya zama sabo kuma yana kara muni yayin da kayan aikin ke sawa.
Ga waɗancan kamfanoni waɗanda ba su ba da horo da kulawa ba, haɓaka dabarun haɓaka aikin shuka yana farawa da tushe.
"Ko da kuwa nau'in shuka da abin da yake samarwa, duk tsire-tsire suna da abubuwa guda biyu - masu aiki da hanyoyin aiki," in ji Abbey.Yin aiki da kayan aiki tare da daidaito mafi girma ya dogara da daidaitaccen horo da kuma bin hanyoyin da aka rubuta, in ji shi.Rashin daidaituwa a cikin horo yana haifar da bambance-bambance a cikin saiti da matsala.
Don samun fa'ida daga shuka, kowane ma'aikaci dole ne yayi amfani da daidaitattun saiti da hanyoyin magance matsala, mai aiki zuwa mai aiki da matsawa zuwa matsawa.Duk wani bambance-bambancen tsari yawanci ya ƙunshi rashin fahimta, munanan halaye, sauƙaƙawa, da hanyoyin warwarewa.Wannan ko da yaushe yana haifar da wahalhalu a cikin ingantaccen gudanar da kasuwancin.Waɗannan matsalolin na iya zama cikin gida ko kuma suna faruwa lokacin da aka ɗauki ma'aikaci mai horarwa daga mai gasa amma tushen ba shi da mahimmanci.Daidaituwa shine maɓalli, gami da masu aiki waɗanda ke kawo gogewa.
"Yana ɗaukar shekaru don haɓaka ma'aikacin injin bututu, kuma da gaske ba za ku iya dogaro da tsarin gabaɗaya, mai girman-daidai-duk ba," in ji Strand."Kowane kamfani yana buƙatar shirin horarwa wanda ya dace da shuka da ayyukansa."
"Maɓallai guda uku don ingantaccen aiki shine kula da na'ura, kula da kayan masarufi da daidaitawa," in ji Dan Ventura, shugaban Ventura & Associates."Wannan na'ura tana da sassa masu motsi da yawa - ko injin niƙa da kansa ko na gefe a mashigar ciki ko mashigar, tebur na rawa ko duk abin da - kulawa na yau da kullun yana da mahimmanci don kiyaye shi cikin babban yanayi."
Strand ya amince."Duk yana farawa ne da tsarin kulawa na rigakafi," in ji shi."Wannan yana ba da dama mafi kyau don gudanar da aiki mai riba na shuka.Idan mai kera bututun ya amsa gaggawar gaggawa kawai, ba ta da iko.Ya danganta da rikicin na gaba”.
"Kowane kayan aikin da ke cikin shuka dole ne a daidaita shi," in ji Ventura."In ba haka ba masana'antun za su kashe juna."
Ventura ya ce "A yawancin lokuta, lokacin da nadi ya wuce rayuwarsu mai amfani, suna taurare kuma a ƙarshe suna karye," in ji Ventura.
"Idan ba a kiyaye iska a cikin yanayi mai kyau tare da kulawa akai-akai, ranar za ta zo da za su buƙaci kulawar gaggawa," in ji Ventura.Idan aka yi watsi da kayan aikin, in ji shi, za a cire kayan fiye da sau biyu zuwa uku don gyara su fiye da yadda aka saba.Hakanan yana ɗaukar tsayi da ƙari.
Strand ya lura cewa saka hannun jari a kayan aikin ajiya na iya taimakawa hana aukuwar gaggawa.Idan ana yawan amfani da kayan aiki don dogon gudu, za a buƙaci ƙarin kayan gyara fiye da kayan aikin da ba kasafai ake amfani da su ba don gajerun gudu.Har ila yau, iyawar kayan aiki yana shafar matakin tsammanin.Haƙarƙari na iya karyewa daga kayan aikin ribbed kuma na'urorin walda suna ba da damar zafin ɗakin walda, matsalolin da ba su dame su da ƙirƙira da calibrating rollers.
"Ayyukan kulawa na yau da kullum yana da kyau ga kayan aiki, kuma daidaitaccen daidaitawa yana da kyau ga samfurin da yake yi," in ji shi.Idan aka yi watsi da su, ma'aikatan masana'anta za su ƙara ɗaukar lokaci suna ƙoƙarin cimmawa.Lokacin da za a iya kashewa don ƙirƙirar samfur mai inganci wanda ake buƙata a kasuwa.Wadannan abubuwa guda biyu suna da mahimmanci, amma sau da yawa ana yin watsi da su ko kuma a manta da su, Ventura ya yi imanin cewa suna ba da mafi kyawun dama don samun mafi kyawun shuka, haɓaka yawan aiki, da rage sharar gida.
Ventura yana daidaita kula da injina da kayan masarufi tare da kula da motoci.Babu wanda zai tuka mota dubun-dubatar mil tsakanin canjin mai da busa taya.Wannan zai haifar da gyare-gyare masu tsada ko haɗari, har ma ga tsire-tsire marasa kulawa.
Binciken kayan aikin na lokaci-lokaci bayan kowace ƙaddamarwa shima ya zama dole, in ji shi.Kayan aikin dubawa na iya bayyana matsaloli kamar microcracks.Gano irin wannan lalacewa nan da nan bayan an cire kayan aiki daga na'ura, maimakon kafin a shigar da shi don wucewa na gaba, yana ba da damar ƙarin lokaci don kera kayan aikin maye gurbin.
"Wasu kamfanoni suna aiki akai-akai yayin rufewar," in ji Greene.Ya san zai yi wahala a hadu da lokacin da aka tsara a irin waɗannan lokutan, amma ya lura cewa yana da haɗari sosai.Kamfanonin jigilar kayayyaki da manyan motoci ko dai sun yi yawa ko kuma ba su da ma'aikata, ko kuma duka biyun, don haka ba a yin jigilar kaya akan lokaci a kwanakin nan.
"Idan wani abu ya lalace a masana'anta kuma dole ne ku ba da odar maye gurbin, me za ku yi don a kawo shi?"– Ya tambaya.Tabbas, isar da iska koyaushe yana yiwuwa, amma wannan na iya ƙara farashin bayarwa.
Kula da niƙa da rolls ba kawai game da bin tsarin kulawa ba, har ma game da daidaita tsarin kulawa tare da tsarin samarwa.
Girma da zurfin gwaninta yana da mahimmanci a cikin dukkanin sassa uku - ayyuka, gyara matsala da kiyayewa.Warren Whitman, mataimakin shugaban sashen kasuwanci na T&H Lemont's Die and Die, ya ce kamfanonin da ke da masana'antar bututu guda ɗaya ko biyu don amfanin kansu yawanci suna da mutane kaɗan da za su kula da niƙa kuma su mutu.Ko da ma'aikatan kulawa suna da masaniya, ƙananan sassan suna da ƙarancin kwarewa idan aka kwatanta da manyan sassan kulawa, suna sanya ƙananan ma'aikata a cikin matsala.Idan kamfani ba shi da sashen injiniyanci, dole ne sashen sabis ya gyara matsala da kansa.
A cewar Strand, horar da ma'aikatan ayyuka da kula da su yanzu ya fi kowane lokaci muhimmanci.Gudun ritayar da ke da alaƙa da tsofaffin jarirai masu haɓaka yana nufin cewa yawancin ilimin kabilanci wanda da zarar ya taimaka wa kamfanoni don kewayawa da faɗuwar su yana raguwa.Duk da yake yawancin masana'antun bututu na iya dogaro da shawarwari da jagoranci na masu samar da kayan aiki, har ma wannan ƙwarewar ba ta da girma kamar yadda ta kasance kuma tana raguwa.
Tsarin walda yana da mahimmanci kamar kowane tsari da ke gudana wajen kera bututu ko bututu, kuma ba za a iya raina aikin na'urar walda ba.
Induction walda."A yau, kusan kashi biyu bisa uku na umarnin mu na sake fasalin," in ji Prasek.“Suna maye gurbin tsofaffi, masu walda masu matsala.A yanzu, kayan aiki shine babban direba."
A cewarsa, mutane da yawa sun fadi a bayan kwallaye takwas saboda danyen ya fito a makare."Yawanci, lokacin da kayan ƙarshe ya zo, mai walda ya tafi," in ji shi.Wani abin mamaki na masu kera bututu da bututu har ma suna amfani da injina bisa fasahar bututun bututu, wanda ke nufin suna amfani da injinan da suka kai shekaru 30 aƙalla.Ilimi a cikin kula da irin waɗannan inji ba shi da kyau, kuma yana da wuya a sami tubes masu maye gurbin kansu.
Matsalar tubing da tubing masana'antun da har yanzu amfani da su ne yadda suka tsufa.Ba sa kasawa da bala'i, amma suna raguwa sannu a hankali.Ɗaya daga cikin mafita ita ce a yi amfani da ƙarancin zafin walda da rage saurin injin niƙa don ramawa, wanda zai iya guje wa babban kuɗin saka hannun jari a sabbin kayan aiki cikin sauƙi.Wannan yana haifar da tunanin cewa komai yana cikin tsari.
A cewar Prasek, saka hannun jari a cikin sabuwar hanyar samar da wutar lantarki don waldawar shigar da wutar lantarki na iya rage yawan amfani da wutar lantarki.Wasu jihohi, musamman waɗanda ke da yawan jama'a da cunkoso, suna ba da rangwame mai karimci bayan siyan kayan aiki masu inganci.Ya kara da cewa dalili na biyu na saka hannun jari a sabbin kayayyaki shine yuwuwar sabbin damar masana'antu.
"Sau da yawa, sabon walda yana da inganci fiye da tsohon kuma yana iya adana dubban daloli ta hanyar isar da ƙarin ƙarfin walda ba tare da haɓaka wutar lantarki ba," in ji Prasek.
Daidaita inductor da resistor shima yana da mahimmanci.John Holderman, babban manajan EHE Consumables, ya ce girman da ya dace da kuma shigar da telecoil yana da matsayi mafi kyau dangane da dabaran walda kuma yana buƙatar daidaitaccen sharewa a kusa da bututu.Idan an saita shi ba daidai ba, nada zai gaza da wuri.
Ayyukan blocker yana da sauƙi - yana toshe kwararar wutar lantarki, yana jagorantar shi zuwa ƙarshen tsiri - kuma kamar kowane abu a cikin injin birgima, matsayi yana da mahimmanci, in ji shi.Madaidaicin wurin shine saman walda, amma wannan ba shine kawai abin la'akari ba.Shigarwa yana da mahimmanci.Idan an haɗe shi zuwa madaidaicin da ba shi da ƙarfi, matsayi na bollard na iya canzawa kuma zai jawo ID ɗin tare da kasan bututu.
Yin amfani da abubuwan da ake amfani da su a cikin abubuwan da ake amfani da su na walda, ra'ayoyin rabe-rabe na iya yin tasiri mai mahimmanci akan lokacin shuka.
"Manyan injinan diamita sun daɗe suna amfani da ƙirar macijin tsaga na tsawon lokaci," in ji Holderman."Maye gurbin ginanniyar induction naúrar yana buƙatar yanke bututu, maye gurbin na'urar, da sake yanke shi akan injin niƙa," in ji shi.Zane-zanen tsaga na coil guda biyu yana adana duk lokacin da ƙoƙarin.
"An yi amfani da su a cikin manyan injinan birgima ba tare da larura ba, amma don amfani da wannan ka'ida ga ƙananan coils na buƙatar wasu injiniyoyi masu kyau," in ji shi.Masu masana'anta kawai ba su da abin da za su yi aiki da su."Ƙananan, reel guda biyu yana da kayan aiki na musamman da kuma dutse mai wayo," in ji shi.
Game da tsarin sanyaya impedance, masana'antun bututu da bututu suna da manyan zaɓuɓɓuka guda biyu: tsarin sanyaya na tsakiya don shuka, ko keɓaɓɓen tsarin samar da ruwa, wanda zai iya zama tsada.
"Ya fi kyau a sanyaya resistor tare da sanyaya mai tsabta," in ji Holderman.Don wannan, ƙaramin saka hannun jari a cikin tsarin tacewa na musamman na injin injin sanyaya na iya haɓaka rayuwar impedance sosai.
Ana amfani da Coolant akan masu hana ruwa gudu, amma mai sanyaya na iya ɗaukar ƙarfe mai kyau.Duk da yunƙurin kama ƙananan ƙwayoyin cuta a cikin tace ta tsakiya ko kuma amfani da tsarin maganadisu na tsakiya don kama su, wasu daga cikinsu sun wuce kuma sun shiga cikin blocker.Wannan ba wurin foda karfe bane.
"Suna zafi a cikin filin shigarwa kuma suna konewa ta jikin resistor da ferrite, suna haifar da gazawar da ba ta da lokaci ba tare da rufewa don maye gurbin resistor," in ji Haldeman."Suna kuma haɓaka kan wayar tarho kuma a ƙarshe suna haifar da lalacewar baka."
Lokacin aikawa: Janairu-15-2023