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ESMECH EQUIPMENT PVT. LTD.

Engineering Excellence...

INTERNSHIP REPORT

NAME OF STUDENT:

Kalpesh Gurunath Pawar

NAME OF COLLEGE:

Bharat College Of Engineering

B.E. (Mechanical Engineering)

NAME OF GUIDE:

Mr. Harish Sharma

DGM- Esmech Equipment Pvt. Ltd.

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ACKNOWLEDGMENT

I am highly indebted to Mr. Harish Sharma Sir, DGM-Assembly

department for their guidance and constant supervision as well as

for providing necessary information regarding the internship and

also for their support in completing the internship. I would like to

express my gratitude towards member of organization for their kind

co-operation and encouragement with help me in completion of

this internship.

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CERTIFICATE

This is to certify that Mr. KALPESH G. PAWAR have satisfactorily

completed this summer training in the FAB, MACHINE &

ASSEMBLY workshop at “ESMECH EQUIPMENT PRIVATE

LIMITED. WADA” during period from 20th

June to 7th July, 2015

Mr. Harish Sharma Mr. Mukesh Kapoor

DGM VP

Esmech Equipments Pvt.Ltd. Esmech Equipments Pvt.Ltd.

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Table of Contents

1 Company Overview 5

2 Introduction About Project 6

3 Planning Dept. 7-9

4 Fabrication Shop 10-11

5 Machine Shop 12-15

6 Assembly Shop 16

7 Reflection of Internship 17

8 Conclusion 18

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COMPANY OVERVIEW

Esmech Equipment is a Joint Venture between SMS Siemag AG

(Germany) and HB Esmech Pvt. Ltd (India), and is the leading manufacturer of World Class Cold Rolling Mills and Strip Metal Process Line equipment.

Esmech Equipment is a subsidiary of SMS Siemag AG, and is therefore a proud member of the SMS Group. Esmech Equipment’s mission is to combine SMS’s World Class Technology with Esmech’s low cost

manufacturing ability to give its customers an unbeatable advantage ! Esmech Equipment is headquartered in Thane, India (adjacent to

Mumbai). Esmech has its manufacturing facili ty in two locations Thane and Wada. Esmech Equipment has a very long reputation of quality supplies and has a

Reference List of over 275 Lines.

Esmech’s product Range Includes: ● Cold Rolling Mills (Single stand and Twin Stand-compact Mill) ● Skin Pass Mill ● Galvanizing Lines

● Color Coating Lines ● Pickling Lines

● Cut-To-Length Lines ● Recoil Lines ● Electrolyte Cleaning Lines

● Slitting Lines ● Tension Leveling Lines

● Blanking Lines ● Rewinding (Recoiling) and Trimming Lines

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INTRODUCTION OF PROJECT

In this project, we can understand the Manufacturing Process of various

parts of design structures/flat products in Fabrication shop. In Machining

department, various M/C processes done on fabricated parts. At last the

fabricated & machined parts of M/C assembled in assembly shop.

In Planning Dept. the planning of Project Manufacturing Process takes place.

In Fabrication Dept. with the help of M/C such as cutter, driller, CNC, Grinder,

Welding M/C components are to be fabricated. Various checking parameters

& inspection done with respect to Quality purpose & then structures/flat

products are passed to Machine shop.

In Machine Dept. of an Industry; carries out various kinds of processes to

finalize the assembly of a structure.

In Assembly Dept.; Assembly modeling, technology, and methods used by

computer aided design & product visualization software.

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PROJECT PLANNING DEPARTMENT

The Planning Dept. plays the role of Brain for the industry body.

Every Project in company starts from Project Manufacturing Process Planning

in Planning Dept.

Each Project has a Unique Identification NO.(UIN) given by the planning Dept.

A single project contains a no. of sub-assemblies (for Ex. For a single slitting

line has 49 Assemblies.)

In Design Dept. there is a folder contains particular assembly drawing,

drawing no., Assembly part list, part code, Such detail of assembly which den

transfer to Planning for further process.

In the Dept; Manufacturing Process Planning starts from raw material.

Requirement of Raw material is given by planning Dept.

RAW Material: Bill of Material (BOM)

Part List by Assembly Drawing

Drawing Reading.

Req. Raw material by Quantity

The list then transfer to Fabrication OR Machine shop according to the

operation.

M/c Shop: Hacksaw Cutting-

pins, shafts/drum shafts, spacer.

Fabrication: Cutting List Drawing, FAB Drawing

STORE: Hardware, Baring, Hex-bolt, Hex-nut.

Cutting parts after Fabrication Process send for the process in M/C shop.

Inspection is done by the Quality Control Dept.

And components go for Assembling.

Planning Dept. maintain the schedule as per target date of the dispatch of

Project Assembly.

System ACR- All Component Readiness; to check whether component ready

within target date or not.

Dispatch of Project Assembly is then done according to Project Order.

IMP steps in Planning:

Drawing Reading:

Process Sequence (depends on requirement of product.):

Cutting

Finishing/Grinding

Fabrication

Turning

Milling

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ERP PROCEDURE

Enterprise Resource Planning (ERP)

Raw Material ISSUE :

Master data management—transaction--project assembly--UIN no---

copy.(drawing no--product no)

Procurement management—transactions--RM Issue--new-paste

Save-lines--new--product--key--paste--search--double click-

Storage bin--wip--enter--save & new-product--key--fab key

Paste--with store--select—ok--moment quantity--save --header

RM Issue completed --Document no

INTERNAL CHALLAN :

Internal challan--new--business pa--Wada –-save--lines--new

Product--paste--with stock--search-moment quantity--storage bin--enter--wip

select--new storage bin--IBP –enter--save

Challan line activity--new--sequence--ex--fabrications--save

Header-- challan send to approve--ok

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GOOD RECIEPT :

New --is internal challan --business partner--name--% esm %--All--search--

4no Wada select-save--creates line from--order--warehouse position--7 no

Wada -–save-ok—line--supplier challan –quantity--weight--save--header--

complete—ok

PRODUCTION MANAGEMENT :

Batch planning--planning--search record--product--key paste--search--select--

ok.--Po & Wo & Iwo--Good receipt--select sequence--fabrications--save--good

r. process--ok

REQUISITIONS :

Productions management--transactions-- req--non--project item--new--save--

lines--new—product--key--name—search—description--quantity--save--

header--completed--ok--print.

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FABRICATION SHOP

Raw Materials: Max length 6m.

Plates: As per thickness MS/C45/S355

I-Beam

C-Channels

L-Angle: As per angle 35/50/65/75/80/100 upto 250

Equal Angle (h=w)

Unequal Angle (h=/w)

Box(Square Tube): As per Length and Width

Equal Box(Square box)

Unequal Box(Rectangular box)

Bar(Round Bar): As per Diameter D25/50

Metal Cutting:

Hand Cutter: Directly cut over marking on structure.

Profile Cutting M/C: Gas Cutter(consist Nozzle) contains

LPG+O2

CNC Cutting M/C: Cuts only Plates. Capacity thickness max.

75mm.

PUG Cutting M/C: Moves on Rails

Straight Cut

Angular Cut

Metal Grinding/Finishing:

Handle Grinder/Angle Grinder: Uses Grinding Wheel

Shot Blasting: M/C in which small metal balls hits surface

of structure.

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Welding:

A union of material produce by heat & pressure.

A welding procedure is a systematic method. Heat is used to

repeatedly produce sound welds.

There is over 100 recognized welding or thermal joining processes.

ARC (MMA) welding: Uses Rectifier, sometimes transformer.

Dia of Rod 2.5/3.15/4/5/6

GMAW(MIG/MAG) Welding: Wire spool

Filler Wire 0.8/1/1.2/1.6

Fabrication:

With the help of fabrication Drawing structures are Fabricated after Metal

Cutting, Welding & Grinding.

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MACHINE SHOP/DEPT.

Machine Shop of an Industry; carries out various kinds of processes to finalize

the assembly of a structure.

Raw material/ Rough material from in-house workshop/outside vendor comes

at Machine Shop for Processing.

Mostly Fabricated/Forged/Casting/Hardened parts are in Raw Materials of

Machine Shop.

Various Operations/Processes at M/C Shop:

Milling: To cut a shape with Rotating tool/Grind in a mill.

Plano Milling M/C

Vertical Milling

Horizontal Milling

There are four types of Milling M/C are used.

Turning: In which cutting tool non-rotary tool bit describes a helical tool

path by moving more or less linearly while work piece rotates. Tool

axes of movement may be linearly a straight line, may be along some

set of curves or angles.

Can be used for boring hole or drilling M/C.

Boring: When same essential cutting action as turning‖ when applied to

internal surface is called as boring.

The phrase ―turning and boring‖ categorized the large family of

(essentially similar) processes.

The cutting faces on work piece (i.e. surface perpendicular to rotating

axes) whether with turning and boring tool called ―Facing‖.

Boring can be done manually on lathe or CNC (Computer Numerical

Control).

Single point boring

Multipoint boring

Drilling: It is a cutting process that uses drill bit to cut or enlarge the

hole circular cross section in solid material.

The drill bit is rotary cutting tool.

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MACHINES SPECIFICATIONS

BORING MACHINE:

Sr.

No.

Machine Name

(Company)

Spindle Dia.

Table (LxW)

Spindle

Stroke

Remark

1 Boring-Conventional

(KARAM) INDIA

Ø100 1100x850 400 For Smaller Operations

2 Boring (STIM) ITALY Ø100 1250x1250 1000 Comparatively Large Structure.

3 Boring RUSSIAN Ø160 1800x1600 900 For Smaller Operations.

4 Boring-Conventional (BUCUREST) AFM 150

Ø150 2500x2000 1000 For Large Structures but slower in operations.

5 Boring (C & E) UK Ø130 1800x1600 1000 For Large Structures-comparatively Faster

in operations.

6 CNC Milling & Boring (UNION) GERMANY

Ø130 1600x1250 1600 Large Structures. Computer Numeric

Control-Ease in Operations.

7 CNC PRECITEC Ø150 - - Covers a Large working area.

8 CNC Boring (DOOSAN)

KOREA Ø130 2000x1800 700 For Heavy Machining.

9 STARRAG HECKERT - - 875 For Continuous Process of Operations.

Pallets to load jobs.

PLANO-MILLER & FTB MACHINE:

Sr. No.

Machine Name (Company)

Spindle Dia.

Table (LxW)

Spindle Stroke

Remark

1 Plano-Miller (LIBERTY) USA

HORZ-180 2800x5500 800 Ideal For Large Streuctures.

2 Plano-Miller (TITAN)

GERMANY

Ø180 1000x4210 1000 For small Structures

3 Plano-Miller (TITAN) GERMAN

Ø180 1000x4210 1000 For small Structures

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HORIZONTAL MILLING MACHINE:

Sr.

No.

Machine Name

(Company)

SpindleTaper.

Table (LxW)

Spindle

Stroke

Remark

1 Milling (FMT 700) ISO 50 2000x600 450 Horizontal Milling

Operations.

2 Milling (TOS) KARAM CZECK

ISO 50 2000x450 - Horizontal Milling

Operations.

VERTICAL MILLING MACHINE:

Sr. No.

Machine Name (Company)

SpindleTaper.

Table (LxW)

Spindle Stroke

Remark

1 Milling (WMW) GERMANY

ISO 50 1590x400 - Vertical Milling Operations

2 Milling (TIGER) ITALY ISO 50 1600x400 - Vertical Milling Operations

3 Milling (VF3) ISO 50 2130x350 - Vertical Milling Operations

4 CNC Milling (ZYER) ISO 50 5000x1000 - Vertical Milling Operations,

Dovetails, Max Capacity.

5 CNC Milling (MTE COMACT)

- 1700x750 2Tone Vertical Milling Operations,

Dovetails, Less Capacity

DRILLING MACHINE:

Sr. No.

Machine Name (Country)

Table (LxW)

Remark

1 HMT RM 61 (INDIA) 1200x640 Smaller Operations

2 HMT RM 63 (INDIA) 1600x750 Smaller Operations

3 HMT RM 65 (INDIA) 2200x850 Large Operations

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LATHE MACHINE:

Sr.

No.

Machine Name

(Country)

Chuck Dia.

Table

Length

Centre

Height

Remark

1 WMV (GERMANY) Ø1500 5300 800 For shafts/Rods of Large Size, Higher

Oprat.

2 Punjab Machinery (INDIA) 20 FEET

Ø760 6069 500 For shafts/Rods of Medium Size, 20‖,

Higher Oprat.

3 GRD (INDIA) Ø910 8950 610 For shafts/Rods of Medium Size Higher

Oprat.

4 16 Foot Ø910 3600 600 Larger Chuck 16‖, Various Operations

5 GUJRAT Ø350 2300 250 Small Lathe

6 BULGARIA Ø250 1500 200 Small Lathe

7 KIRLOSKAR (INDIA) Ø350 2750 190 Larger Chuck, Various Operations,

Max Capacity

VTL MACHINE: Verical Turret Lathe

Sr. No.

Machine Name (Country)

Chuck Dia. Vertical Travel

Cross Remark

1 VTL WMV (GERMANY) 2200 1100 2200 Turning,Boring,

Grinding

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ASSEMBLY DEPT.

Assembly is an act of combining components of Manufacturing.

Assembly modeling, technology, and methods used by computer aided design

& product visualization software.

Assembly Line, a manufacturing process in which parts are added to a

product in a sequential manner.

In Assembly Dept. no, of Sub-Assemblies of a single project are combined

together.

Fabricated/Machined parts/readymade parts from outside vendor; store

material are combined with the help of Assembly Drawing.

For a single line there are no. of subassemblies; in such condition lines are

assembled at the working/installation site of line.

Sometimes Errors arises during assembly of a project.

As much as concern, Dimensional errors are the most occurring errors at the

site of Assembly section.

These errors are classified by characteristics and solved/Manipulate by

Quality control Dept.

Fully assembled project then dispatched by Assembly Dept. as per

requirement of client.

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REFLECTION OF INTERNSHIP

In this chapter, regarding my learning goals I shortly discuss my

experiences; if I have achieved my goal, whether I experienced

difficulties and what I think I have to improve.

Learning Goals:

● The functioning and working conditions of a non-governmental

organization.

At the beginning I didn’t have any experience of working within a NGO.

Although I have seen one, I understand better the functioning like the

organization structure and setting up projects.

● The use of skills and knowledge gain in university.

It is difficult to say what skills and knowledge gained in my study I could put

in my internship.

● Organizing Projects

Within the internship I did lot a field work, because of this I have seen of what

aspects you have to think while organizing a project. Furthermore I have

learned how an education program can be set up and what things have to be

taken into account. Before the education I didn’t have any experience in

environmental education I had no idea if that would work.

● Skills and knowledge that might be improved to work in professional

environment

Although you learn and develop the necessary skills and knowledge while

working in organization, there are several things that I could improve already.

I did not have totally clear what activities I could have done to reach my

learning goals. Therefore during my stay I had some difficulties to determine

tasks what I could carry out. In advance of my internship I talked with the

organization about the project I could participate, however clear agreements

on my activities were not made. A more assertive attitude from my side could

have helped. To prevent uncertainties in future projects I will pay more

attention to my clear agreements and back-up plans.

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CONCLUSION

On the whole, this internship was a useful experience. I have gained new

knowledge, ski ll and met many new people. I achieved several of my learning

goals. I got inside into professional practice. I learned different facts of

working within a NGO. I experienced that assembling is an important factor

that progress of project related to my study. I learned more about the

Fabrication, Machining and Assembling. There is still a lot to discover and to

improve.

The internship is also good to find out what my strength and weakness

are. This helped me to what skill and knowledge I have to improve in coming

time. It would be better at the knowledge level of the language is sufficient to

contribute fully to project. However I could perform certain tasks better if I

practice more. It would be better at knowledge level of language is sufficient

to contribute fully to project. However I could perform certain tasks better if I

practice more. It would also better if I can present and express myself more

confidently.

At last internship has given me a new rights and motivation to

pursue a carrier in industrial background.

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SPECIALLY THANKS TO…

Planning Dept.: Mr. Rajan Raut Sir (HOD)

Mr. Nikhil Pashte

Fabrication Dept.: Mr. Deshpande Sir (HOD)

Mr. Vijay Abdar (Jr. Engg)

Mr. Manjeet Pawar (Welding Inspector)

Mr. Deepak Bagul (GET)

Mr. Arvind Shingare (CNC & Tracing)

Mr. Mahendra Pal (Jr. Engg)

Machine Dept.: Mr. Bhatt Sir (HOD)

Mr. Akshay Kumbhar (Jr. Engg)

Assembly Dept.: Mr. Harish Sharma (HOD)

Mr. Navin Rao (Jr. Engg)

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