TATA ADVANCE MATERIAL LTD

LECTRA MACHINE PREPREG

MATERIAL CUTTING
NAME OF REPORTER: DEVARAJU V
PERIOD OF REPORT:JULY 19 TO 20
JANUARY 2017
AREA OF WORKING :LECTRA MACHINE
PREPREG CUTTING AREA PROCESS

1. CCA ROOM SAFETY

2. PARAMETER OF CCA ROOM
3. MATERIAL RECIVING
4. DOCUMENTATION
5. MATERIAL CUTTING
6. MATERIAL KITTING & PACKING
7. MATERIAL PUTTING IN COLD STORAGE
8. MATERIAL MOVEMENT
9. MISTAKE HAPPEN IN LECTRA MACHINE AREA
10.STUDY OF LECTRA MACHINE
1. PROJECT S AND IT’S PARTS NAME, IT’S MATERIAL
 Safety items to wear before
Entering into the LECTRA ROOM
 1)HEAD CAP
 2)LONG OVER COAT(Apron)
 3)SAFETY SHOE
 4)NOSE MASK
 5)GOGGLE
 6) GLOVES
 in this Six safety item First three are must and should we have
to wear to enter the LECTRA ROOM

 MAINTAIN 5S ACTIVITIES EVERYDAY IN CCA ROOM

 IMPORTANT PARAMETER IN CCA ROOM AND IMPORTANT
EQUIPMENT
IN CCA ROOM (CONTAMINATION CONTROLLED AREA)

 1)Room temperature it should be 22c'+/- 3

 2) Humidity it should be 40 to 60%RH

 3) DiffercentalPressure should be above 2Pa

 4)Prepreg roll stand for keeping the prepreg material it may be

UDor BD roll and to keep 6Mil,4mil.2Mil tarpulins , orange miles
and different kinds of mils
 5)Small crane is used to lift the material more than 200kg weight prepreg
roll material
 *Rack to store the material

 6)LECTRA MACHINE
 LECTRA IS THE NAME OF THE COMPANY THEY
 MANUFACTURE THE MATERIAL CUTTING
MACHINE EITHER COMPOSITE MATERIAL NOR
OTHER MATERIALS LIKE AUTO, FASHINON, TEXTILE
OTHER MATERIAL BASED ON CAD DESIGN (COMPUTER AIDED DESIGN
SOFTWARE
LECTRA CUTS THE MATERIAL IN X&Y AXIS
LECTRA BLADE IS MADE UP OF CARBIDE STEEL
LECTRA MACHINE, PREPREG MATERIAL CUTTING
MACHINE, PLYS CUTTER
LECTRA MACHINE ADVANTAG & DIS ADVANTAG
ADVANTAG S DISADVANTAGES

Reduction in production time – Less versatility

Increase in accuracy and More pollution

repeatability –
Less human error Large initial investment

Less employee costs Increase in unemployment

Increased safety – Unpredictable costs

Higher volume production

 7)Long table to collect cutted prepreg material

 8)Heat sealing machine to seal the kitting &Sorting prepreg

as per the ROUTE CARD orientation
 *Along with the ROUTE CARD seal the material cover
 *Write BATCH,ORDER NO,SERIAL NO,KITT NUMBER and
 kitted person name and Date on the material bag
 *Easy identification of kitt number

 9)Cold Storage to store kitting & Sorting prepreg material

in -18c and 0c room
 * when we want material then identify the kitt
 number and Date then take out from cold storage room

 10) Material movement move the material with checking
ROUTE CARD RT LIFE and SHELF LIFE DATE & QUALITY etc

 11) Flash tape,vaccume,ups,polythene cover, markers

&Cutter,CNC knife blade,thermal over coat(Wear before
going cold storage for safety )

 12)Without ROUTE CARD don't do any Kitting work

 Kitting means arrange the plies as per rout card orientation
(MATERIAL, ANGLE, Type of layer ex full or partial)
 INSERT KITT LIST WITH ALL DETAILS ALONG WITH ROUTE
CARD
• LECTRA MACHINE APPLICATION
FASHINON
AUTO
FURNITURE
COMPOSITE

Sign indication tag

 Red color tag indicate Defect/Not ok
 Green color tag indicate No Defect/ok

 Without issue card in the box don't

load that Material into the lectra
OTHER ACCESSORIES IN LECTRA MACHINE
ROOM

 KNIFE
 FLASH BREAKER TAPE
 CELLO TAPE
 MASK ING TAPE
 YELLOW TAPE
 MARKER
PREPREG MATERIAL CUTTING FOR DIFFERENT
TYPES OF PROJECT AND PART NAME &
MATERIAL NAME AND IT’S SPECIFICATION
 MATERIAL NAME MATERIAL DESCRIPTION
CARBON BD 8552S /37 %/AGP280
PROJECT NAME
CARBON UD M21E /34 %/UD 268
GLASS M21 /56 %/1080
GLASS M21 /45 %/120
GLASS M21/37%/7581
ECF SM905M-43% 195GSM
SPIRIT
ECF SM905M-68% 73GSM
ADHESIVE FILM ADHESIVE FILM EA9695
MATERIAL THAWING CHECK
MATERIAL LOADING
MACHINE OPERATING PROCEDURE
1. F YOU WANT TO SWITCH ON THE MACHINE MAINTAIN 5S AROUND THE
MACHINE
2. NEXT ON POWER BUTTON IN SYSTEM PC THEN ON POWER BUTTON IN
MACHINE
3. THEN ON AIR
4. WAIT FEW MINUTES
5. AFTER FEW MINUTES THE SYSTEM SCREEN WILL OPEN
6. CLICK ON THE SCREEN REFRESH IT’S BEFORE OPEN SOFTWARE
7. AFTER CLICK CRUSER ON VECTOR PILOT ICON TO DOWNLOAD PROGRAM
8. THEN PANEL WILL OPEN ENTER PASSWARD
9. THEN CLICK ON MATERIAL STARTING ACTIVITIES
 GO TO FOLDER SELECT PROGRAM EX VSSC, CTRM, SPLICE
ANGLE ETC
 SELECT AND APPLY THE PROGRAM
 NEXT ADD JOB LIST
 SPOT CONTROL( MATERIAL SETT IN X&Y DIRECTION)
 THEN RUN THE PROGRAM
 THESE INSTRUCTION PERFORM WITH ANY
 SENIOR OPERATOR NOT ALONE
MATERIAL SPOT CONTROL
WHY?

1. MAY BE WE SELECT WRONG PROGRAM

2. WRONG SPOT CONTROL

3. BASIC SKILL REQUIRED TO OPERATE THE MACHINE IS

4. MATERIAL KNOWLEDGE
5. BASIC COMPUTER KNOWLEDGE
 PART NAME =H-SECTION
 MATERIAL =CARBON UD +GLASS 1080

 PART NAME =SPLICE-WEB-SPAR-FRONT-LH

 MATERIAL =UD TAPE M21E+GLASS M21/1080

 PART NAME :SPLICE ANGLE – FS UPR LH

 MATERIAL :M21/120GLASS+M21EUD TAPE +EA9695ADHESIVE FILM

 PART NAME :PNL 2OUT BD LWR CPD RH

 MATERIAL :COPPER FOILS AIMS 05-12-007+FABRIC 8552 S+GLASS 1080

 PART NAME :SPIRIT CLIPS

 MATERIAL :GLASS M21/37%/7581
H-SECTION (UD)
SPLICE WEB
SPIRIT CLIPS
LOWER PANELS
PART NAME : PFS PANEL UPR CPD ASSY RH
MATERIAL :CARBON BD +GLASS 1080 +GLASS 120+EXPANDED COPPER
FOIL +ADHESIVE FILM
PROJECT NAME MATERIAL NAME MATERIAL SPECIFICATION

CARBON BD 8552S/37%/AGP280

GLASS PREPREG 8552/42%/220G-965mm

GLASS PREPREG 8552/42%/120G-965mm

ADHESIVE FILM FILM ADHESIVE, FM300K – 36”

CTRM
SYNSKIN SURFACE FILM SYNSKIN HC 9837.1,180°C,115g
36”
CTRM MATERIAL
 PART NAME :PHASE1 , PHASE2 PANALS
MATERIAL :CARBON BD +SYNSKIN +220GLASS +ADHESIVE FILM +SYNCORE

IN CTRM THEY MAKE AILERON, TE ( IN WING OF AEROPLANE)

PROJECT NAME MATERIAL NAME MATERIAL SPECIFICATION

CARBON BD 914C-713-40+/-2.5%1500MM

CARBON BD 914C-703/713-40%+/-
2.5%1200MM
CARBON BD PREPREG C914/AS4C-3K 1500MM

CARBON BD PREPREG C914/AS4C-3K

FACC 1200MM
GLASS 914G-7781-37+/-3% 1524MM

GLASS 914 G-7781-37+/-3.0%

FACC MATERIAL
PROJECT NAME MATERIAL NAME MATERIAL SPECIFICATION

CARBON BD M18/32%/43090/460

CARBON UD M18/32%/116 M55J UD

CARBON UD M18/32 %/HTA UD-CUSTOMER

VSSC SUPPLIED
CARBON DRY FABRIC CARBON FABRIC
VSSC
GKN(GUEST KEEN NETTLEFOLDS)
 CARBON UD WITHOUT SURFACE FILM FOR
 FLANGE A, B AND UPPER MOULD, LOWER MOULD
 CUTTED FABRIC DIRECTION (0°,90°,+45°,-45°)
BOEING PREPREG MATERIAL FOR
APPLICATION, TAILCONE
AS PER WEEK PLAN
WE CUT THE MATERIAL WITH
RESPECT TO THAT PROJECT

NOTE :ALMOST MATERIAL CUTTING IS

REPEATED EVERY WEEK /MONTHS
MISTAKE HAPPEN IN LECTRA AREA
LAYER MISSING
REASON FOR LAYER MISSING
MISSING LAYER ARE PARTIAL OR FULL
LAYER
REASON FOR LAYER MISSING

1)Without knowledge ABOUT ROUTE

CARD
2)LACK OF KNOWLEDGE ABOUT MATERIAL
3)OVERCONFIDENCE ABOUT KITTING
4)FAST KITTING
5)SIDE ATTRACTION DURING KITTING TIME
(SPEAKING, SIDE SEEING)
6)NOT FOLLOWING PROCEDURE
THANK YOU ALL