Size of Factory
Capability to stock raw materials & to produce in colossal quantity.
Production can be backed by 100% stock of raw materials, due to bigger stocking facilities, leading to saving on the batch mode of procurement. For a 100 Tons job, if the batch of procurement is 50 Tons, the second cycle of 7 days of handling the second lot of 50 Tons is saved for the customer in terms of the time of delivery. The customer can decide the value of each day saved!
Material Handling
Capability to produce PEB Structures on time is directly proportional to Material Handling Infra.
As a thumb rule, suitable capacity of EOT / Gantry/ Transfer Trolleys / Transfer Conveyors / Cross Transfer mechanism / Flipper Mechanism / Hand pallets / Forklifts / Hydras/ Grabs / Magnetic or Vacuum Lifters
is required in each of the following processes:
Cutting → Splicing → Welding (HBeam) → Fit up → MIG Welding → Grinding → Drilling → Blasting → Painting → Heat Treatment → Stacking → Despatch
Cutting
Shearing:
This is a cold process that ensures that the material molecular structure of steel is not disturbed due to the heat process used by sub-standard and small PEB vendors.
Finishing of the edge of each PEB section is fine enough to be taken up on H Beam , thereby mitigating time otherwise spent on grinding of rough edges.
While making H Beam, the joining surfaces must align 100% to each other, failing which Pin Holes will happen during welding leading to a weak PEB structure.
50% of H Beam production time is saved for the customer due to elimination of the time invested in grinding of rough edges. For 10 units of one Ton material each, this saving will amount to one Manday.
Weak welding —> Faults —> Weak PEB Structure —> Non compliance of ASTM / IS standards, normally used for PEB in India. This is because these faults were never considered by the designer.
CNC High Definition Plasma Cutting:
Precision points of cutting are defined by CNC machines leading to accurate cuts.
Nesting software e.g. Omniwin ensures optimal usage of raw material while cutting.
2 mm steel goes as burning loss if the cutting is done without High Definition Plasma Cutters. You must ask the following questions to yourself.
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What is the value per day of PEB for you?
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Have you bothered to cross check the capability to produce PEB Primary structure with your PEB vendor?
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Is your PEB vendor equipped with suitable Material Handling infra?
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What is the cost of One Manday for the customer?
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How do you factor for all faults and stress points that the PEB structure can encounter today, tomorrow and day after tomorrow?
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who pays for this burning loss?
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Do you pay for the extra scrap generated due to non optimal usage of raw material not supported by any software available with your PEB vendor?
Splicing
Separate Automated Splicing machines for 2 Webs and one flange respectively feeds the H Beam line seamlessly.
100 % guaranteed joints which ensures that no fault or weak spot develops at the joining points of the structure.
No downtime between splicing and H-Beam feeding thereby ensuring a faster turnaround in production time. If automated splicers are not available, what is the point in having automation at the H-Beam stage if the plates are more than 12 meter in length?
Does your PEB vendor have automated Splicing machines? (Do they splice manually?)
Automated H-Beam Line with flipper and transfer mechanism
The H-Beam welding (Stitch or continuous) is far superior due to automation. The process is very fast as the Flipper and Transfer mechanism ensures that the H-Beam is flipped and put back for welding on the reverse side with automation.
Productivity increases. With no automation and no H Beam line, one H-Beam can take upto 3 hours. Whereas with Single H-Beam , upto 4 beams can be produced in 1 hr. With dual H-Beam mechanism with Flipper and Transfer system, in 1 hr upto 10 H-Beams can be produced with zero error.
How many H-Beam automated lines with Flipper and Transfer mechanism does your PEB vendor have?
The size of H-Beam decides the max. single piece size of work that can be taken up at a point of time.
The normal web size that can be taken up by simple H Beam lines is upto 1500 mm. Advanced H-beam lines can take upto 1850 mm single jobs.
The flange of job cannot exceed 20 mm in a normal H Beam line whereas advanced H Beam lines can take upto 32 mm flange thickness.
The max.width of flange in a normal H Beam machine is 400 mm whereas advanced H Beam machines can deliver single jobs of width upto 680 mm.
Taken all of above 3 together , normal H Beam lines can handle upto 4 Tons whereas advanced H Beam lines can handle upto 9 Tons easily for a single beam job.
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The flange of job cannot exceed 20 mm in a normal H Beam line whereas advanced H Beam lines can take upto 32 mm flange thickness.
The max.width of flange in a normal H Beam machine is 400 mm whereas advanced H Beam machines can deliver single jobs of width upto 680 mm.
Taken all of above 3 together , normal H Beam lines can handle upto 4 Tons whereas advanced H Beam lines can handle upto 9 Tons easily for a single beam job.
Advanced H Beam lines(Primo make) is a must if your PEB job has a single beam of dimension more than 1500mm width, 20mm flange thickness or 400mm flange width or 4 Tons weight of a single beam.
Surface Finish
Shot blasting as per SA 2.5 standards is a must for surface finish and make the same ready for painting.
Paint deposition on shot blasted surfaces ensures that Paint (Direct to Metal) has a better life on the metal.
Note: Sand blasting is hazardous from Pollution control point of view. (Not recommended)
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Does your PEB vendor have a shot blasting methodology in their infrastructure?
Paint Shop
Direct to Metal (DTM) Paint is applied to metal in a booth (not in the open) to ensure a min. of 80 Microns DFT (Dry Film thickness)
If paint is done in the open upto 40% of paint is wasted leading to increase in price of the same for the customer.
Are you paying more for your PEB just because your PEB vendor does not have a paint booth?
Post painting, the metal must go through an oven to ensure heat treatment leading to fastening of the paint to the metal at a much faster speed.
300% incremental productivity in the paint booth is observed when post painting heat treatment is done vis a vis no heat treatment.
Does your PEB vendor have a oven to give you the advantage of 300% incremental productivity?
A Conveyor roller system is inbuilt in the paint booth to ensure faster turnaround of goods between surface finish and final painting. This also leads to lesser material handling manually leading to better finish of the product.
A paint shop without Roller Conveyors will take 50% more time in processing 1 Ton of material, all other things being equal or similar.
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Does your PEB vendor give you advantage of time saving due to Roller Conveyors in its Paint shop?