INDUSTRIAL TRAINING

TRAINING REPORT

“GNA DURAPARTS”

SUBMITTED TO: SUBMITTED BY:

Name: C. R. Tripathy Satinder Pal Singh

HOD CAD/CAM Roll No. 1648

SATINDER PAL SINGH

INDEX

INTRODUCTION TO THE UNIT

Authorization of the unit

Contact information

Communication network

VARIOUS DEPARTMENTS IN GNA

DURAPARTS

Forging shop

(i) Forging I

(ii) Forging II

Heat treatment cell

Product planning control

(PPC)

Metallurgical lab

Engineering cell

SATINDER PAL SINGH

Computer network

control (CNC)

Die shop

MACHINES USED IN VARIOUS

DEPARTMENTS

PRODUCTS MADE IN GNA GROUP

General description

Brief notes on

production procedure of

some main products

SATINDER PAL SINGH

INTRODUCTION TO THE UNIT

The existence of GNA came into being in 1946, in a small village called

Bundala in District Jalandhar of Punjab. GNA has made its presence

prominent not only in India but also across the world.

Today, more than 6000 families are proud to be associated with this giant

colossal tree that bloomed from a seedling sown 59 years ago. Founded with

a modest beginning by Late Mr. Amar Singh Ji and nourished by his sons

Mr. Rachhpal Singh and Mr. Gursaran Singh, with the artistic creativity that

was gifted to the next generation by tradition, GNA is now boosted and taken

care by the third generation Mr. Jasvinder Singh, Mr. Maninder Singh, Mr.

Ranbir Singh and Mr. Gurdeep Singh. Today GNA group has created an

important place for itself in Indian as well as Global Automotive Industry.

GNA group is on a fast moving track towards growth and globalization.

The company has a large customer base covering different sectors of the

automotive industry with diversified product range. Along with this the

company shows steady growth profile even during the time when there is

demand fluctuations in the automotive sector.

GNA is an Original Equipment supplier to various Automobile Majors

besides having a strong presence in the replacement market.GNA has been

accredited with ISO 9002 and QS 9000 certifications for its quality systems,

holds a reliable name in the world of automotive components. Quality

Management at GNA is a timeless concept wherein, changes in customer

SATINDER PAL SINGH

expectations is a driving force to go beyond conformance to standards.

GNA’s quality assurance is equipped with the finest equipment ranging from

metallurgical microscope to mobile spectrometer, ultrasonic

flow detector, micro hardness testers, surface roughness testers, profile

projectors and involute profile testers.GNA sincerely believes in technology

up-gradation for keeping a competitive edge. Indeed, this explains the

continuous replacement of conventional manufacturing equipment with

modernized transfer lines resulting in increased productivity and efficiency

at low cost. GNA’s core competency lies in its strong knowledge base of

engineering and over 59 years of experience in manufacturing. GNA has

come a long way yet journey toward excellence is never ending Sri.

Amar Singh Ji made a modest beginning with an ‘atta-chakki’ {Flour mill.

Late Sardar Amar Singh established a small unit for the manufacture of

axles under the name of ‘Nirankar Auto Engg. works in and bounds and

established itself as a major source of vehicle paets in India as well as in

world. Exports market of GNA range of products have a wide spectra of

applications in heavy, medium and high commercial

vehicles i.e. passenger cars, jeeps, tractors, trucks etc.

GNA group is today spread over area of 3,50,000 sq.mts. employing a

total man power of about 2000 personnel with a turn over of 29.78 million

US $ coming from all units.

GNA group basically consists of following four companies:

M/S Guru Nanak Auto Enterprises Ltd., Bundala

M/S Guru Nanak Auto Udyog Ltd., Bundala

M/S Guru Nanak Auto Duraparts, Mehtiana

M/S Guru Nanak Auto Axles Ltd., Mehtiana

As per concern my training we will concentrate on M/S Guru Nanak Auto

Duraparts which was being established at Mehtiana {Dist. Hoshiarpur}

SATINDER PAL SINGH

which is situated 20 kms from Phagwada. This unit was set up in 1993, just

beside the previously set up unit M/S Guru Nanak Auto Axle Ltd. This unit is

covered in 1550 sq mts. Here in this unit all type of gears is manufactured by

high quality precision

imported hobbing and gear cutting machines. This unit also manufacure

rear axle shafts, UJ cross, propeller shafts, steering components, PTO shafts

etc.

Various departments in GNA Duraparts

SATINDER PAL SINGH

1). FORGING SHOP:

Forging involves heating of a metal stock to a desired temperature;

enable it to acquire sufficient plasticity followed by the operations like

hammering, bending & piecering etc. to give it the desired shape. The

forging process is very important and has indispensable position among the

various manufacturing processes generally adopted in the workshops due to

some reasons i.e. it refines the structures of metal, it renders the metal

stronger by setting the direction of the grains & it effects considerable

saving in time the labour and material as compaired to the production of

same by cutting from a solid stock and then shaping it.

Forging department is one of the most important as every production is

started from here it self. There are two types of forging sections. The

categorization can be done on the base of the mechanism of the various

machinery present i.e. in forging I we can say upsetting forging/closed die

forging and similarly in forging II we can say it as drop forging/open die

forging. These two sections consist of under mentioned machines:

Forging I : It consists of following machines:

SATINDER PAL SINGH

(i) Horizontal bandsaws having capacity of working upon

maximum diameter jobs of 245mm, power3HP or 2.2

KW, efficiency of 82% & RPM of 1430. The diameter

of job varies from 75 to 125mm.

(ii) Forging furnace can be gas or oil fired and are widely used for

heating the jobs for hammer forging. They prove quiet economical

and facilitate better temperature and atmosphere control. Here in

this shop oil fired is mostly used in which furnace oil is used as a

fuel. There are brick arrangements provided in these furnaces

Forging furnaces having working temperatures of 1123-1200

degree Celsius, mounted with 10hp powered motor & have

capacity of work to be done of 1.25 ton/hr.

(iii)Up set forging machine here are of two types and can be

differentiated with the help of its working load capacity i.e 500 ton

and 800 ton. The diameter of the job that can be worked upon

these machines are 115 and 150 mm respectively. The power used

for running of these machines is pneumatic type i.e. air

pressure.

(iv)Compressors for producing air pressure for working the

pneumatic machines. These are of reciprocating type. The oil used

in the is of type AWS 100. he capacity of oil tank is of 10 litres.

Working pressure is of 7kg/cm2g and hydraulic test pressure is

11.55 kg/cm2g.

In forging I two types of products are being made. One is

axle. The total production of the axle per day is 650 to 700. similarly

the product made is shaft & the total production per day is 200 to 300.

SATINDER PAL SINGH

Forging II : There are following machines in this shop:

(i)Forging furnaces are used to heat the raw material up to 1100

degree Celsius with the help of rough furnace oil, which is used as

fuel. The feed of rough material are given in batch type feed and in

continuous way. A pusher is provided to push the rectangular work

pieces, which are brought, from the band saws. This pusher is

operated by an electric motor. There is a pump to control the

amount of oil to the furnace.

(ii)Power hammers here are of two types are of two types i.e.

capacity wise one is of 6.5 ton and 2.5 ton. These hammers are

used to hit on to the die to form several shapes of products e.g.

crown etc. These machine are working on the principle of

pneumatic type i.e. power used is of air pressure. Pneumatic

hammer is operated by a rotary air compressor of single stage type

of two in quantity. Air is compressed to pressure of 7 bars and

temperature of 120 degree F. the maximum pressure can be

produced up to 20 bar. A foot operated lever controls the air

supply and required blows of the hammer is obtained. This hammer

is used for forging of ring gear, drive gear, tail pinion, star gear

and bevel gears etc.

(iii)Power presses are kept in adjacent side of these power

hammers so that they can be used for piercing and blanking

operations just after hammering. These presses are of mechanical

type and have capacity of 400 and 200 tones. These presses work

on the crank mechanism.

SATINDER PAL SINGH

(iv)Normalizing furnace is used to normalize the product, which is

to cover the cracks produced after hammering and other machines.

The normalizing temperature is kept at the constant value of 880 to

920 degree Celsius with the help of setting of thermocouple. The

type of structure obtained will depend upon thickness of the cross

section and rate of cooling. Thin section will give much finer grain

than that of thick section. Furnace oil is used as fuel in the

normalizing furnace. There are 3 heat zones while this process.

For example when material is 20MnCr5 zone I is of 880 degree C,

zone II is of 900 degree C & zone III is of 920 degree C. time taken

for all these is only 20 minutes. The purposes of normalizing are to

produce a uniform structure, grain refinement, reduce internal

stresses, improve mach inability & improve hardness, strength &

other mechanical properties.

(v)Short blasting machine is used for removing scaling produced

due to past processes. This is done by throwing small size balls on

the work material in batch way. This also produces somewhat good

surface finish. The common material of metal shorts is malleable

iron & cast steel.

(vi)Brinell hardness tester is used to know the hardness in

brinell scale before sending the product to next procedure.

In forging II there are also two main products i.e. crown and

bull gear. The total production per shift of these two products are 250

and 300 respectively. The total number of workers in both forging I

and forging II are 100.

Forging Furnaces:-

SATINDER PAL SINGH

The furnaces used in the unit are oil-fired furnaces. In these furnaces, first of

all from the main tank the supply of oil is provided to the furnace. A pumping

unit is provided to all the furnaces used and this pumping unit consists of a

heater which heats the oil to a temperature of 90-100 degrees and then the

oil is supplied to the furnace. A blower is present which moves the air into

the re-cubature. Its function is to heat the air to a temperature of about 250

degrees ant then move the air into the furnace. The furnace temperature

which is used for forging is 1250-1300 degrees. A regulating valve is present

and it is used to regulate the supply of oil and a butterfly valve is present to

regulate the supply of air.

Following are its two types:-

1. Pusher-type furnace: - In the pusher-type a pushing system is

provided which is used to push the work-pieces into the furnace. The

pusher mechanism which is used is hydraulic and it is controlled by

oil pressure. The temperature inside the furnace is 95-105 degrees

and the pressure is 12-15 pound per square inch (psi).

2. Batch-type furnace: - In the batch-type furnace, a batch of the work

pieces is made & that batch of work pieces is heated at the required

temperature & afterwards the work pieces are moved one by one to

the forging machines.

Working procedure in forging shop: -

1. Material cutting: - This is the first step which is involved in

forging. After the material is received & inspected it is sent for the

material cutting. In material cutting operation the material is cut in

SATINDER PAL SINGH

accordance with the required dimensions. The material cutting is done

on band saw machines which are fully automatic in operation. After the

material cutting is done the material is sent into the forging shop.

2. Heating: - This is the second step which is involved. In this step the

material is heated to the forging temperature in the furnace. The

forging temperature is 1250-1300 degrees. The furnaces which are

used are oil-fired furnaces & they can be either pusher type or batch

type. After the material is heated it is sent to the forging machines.

The process of heating the stock can be divided into two stages: -

First stage (Preheating zone): - In this stage the temperature to which

the stock is heated is 500-700 degrees.

Second stage (Full heating zone): - In this stage the temperature is

1260-1300 degrees.

3. Forging: - In this step the material is forged on either a drop hammer

or a forging press or on the up-setter. The type of the machine which

is to be used depends upon the shape & size of the component to be

forged.

4. Trimming: - In this operation the excess & unwanted material is

removed from the forged component. After forging operation is done

then the forged component is passed to the trimming press for the

material removal.

5. Heat treatment: - After the trimming operation is done then the forged

component is ready for heat treatment. In this operation the forged

components are placed in trays made of mild steel & are placed in the

furnace for a suitable period of time. The heat treatment processes

which are done at GNAU are normalizing, hardening & tempering.

SATINDER PAL SINGH

The type of the heat treatment process which is to be done depends

upon the type of the steel. After heating, quenching of the heated

components is done in a quenching bath for a suitable period of time.

The heat treatment process is done to improve the mechanical

properties of steel & to relieve the internal stresses which are set up

due to forging.

6. Shot-blasting: - This process is done to remove the scales &

impurities which are caused during heat treatment. After the heat

treatment the components are put in the shot-blasting machine & thus

the scales are removed & the components are polished.

7. Grinding: - This is the final step involved. In this step the unwanted

material is removed from the components to provide them a smooth

surface finish. The grinding process is done on the grinding machines

which comprises of the grinding wheel.

After the grinding process is completed the hardness checking of

the components is done & afterwards these forged components are sent to

the machine shop for further machining.

Measuring instruments used in forging shop: -

The measuring instruments which are used in the forging shop are: -

1. Vernier caliper

2. Measuring scale

3. Measuring tape

4. External & internal calipers

Temperature measurement instruments used in forging shop: -

SATINDER PAL SINGH

1. Thermocouple

2. Optical pyrometer

The thermocouples are located at suitable heating zones inside the

furnace & they measure the temperature of the heating zone & this

temperature is represented on the digital temperature indicator to

the operator.

Furnace oil used in forging shop: -

The furnace oil which is used in the furnaces is the residual furnace oil

(RFO).

Fuel consumption in the furnaces is 100 liters.

4). HEAT TREATMENT:

Heat treatment is defined as an operation involving heating and cooling

of a metal or alloy in a solid state to obtain desirable conditions. There are

many causes of the heat treatment to be done to the product to be done. It is

done to cause relief of internal stresses developed during cold working

processes. It is done to harden and strengthen materials, improve machine

ability, change grain size, improve ductility and toughness, increase heat

wear and corrosion resistance of materials & to homogenize the structure.

SATINDER PAL SINGH

As the name refers it is the shop in which heat treatment is given to the

product to give it required hardness. This is done with the help of following

mentioned processes & various machines:

I. Carburizing: Carburizing is a method of introducing carbon into

solid iron-base alloys in order to produce a hard case. Carburizing

may be pack carburizing, gas carburizing and liquid carburizing.

But here only gas carburizing is being done. In this process

components are heated at 920 degree Celsius for four hours in an

atmosphere of gases of [CO+H2+N2]. The main motive of this

process is to diffuse into the outer surface of the components. It is

the process by which the increasing of percentage of carbon is

being done to gain good surface hardness. This can be only

possible with the help of following apparatus:

(i)EOT crane is used to carry the fixtures on which batches of

items are carried. This crane has capacity to load 2 ton.

SATINDER PAL SINGH

(ii)Washing bay is filled with casting soda in which is the products

which are covered with layer of oil & coolants are being washed.

This process is being done for 10 to 15 minutes.

(iii)Carburizing furnace is the apparatus used for carburizing

process. In this apparatus the temperature is maintained at 920

degree Celsius. In this after washing the crane lifts the fixture of

the products and put into this apparatus. This process is carried

for long period of 15 to 16 hours. The fluid used in this process is

carburizing fluid 440.

(iv)Super quenching apparatus is the area where the fixture from

the last process is put into. In this process the super quenching oil

is the quenching medium. There is heat exchanger arrangement

which does not allow the temperature of oil to raise more than 75

degree Celsius.

II. Tempering: Tempering involves heating hardening components

below the lower critical temperature i.e. at 180 degree Celsius. In

this process this temperature is being hold for about 2 to 2 ½ hours

and the cooling is being done open air. At this temperature a

hexagonal lose packed carbide begin to form and with the rejection

of carbon the crystal structure of martensite changes from

tetragonal to body centered cubic characteristic of ferrite. This

process is being carried with the help of following apparatus:

(i)Tempering furnace is used for this process in which temperature

is being maintained between 200 & 250 degree Celsius. In this

furnace the walls inside are winded with the element which is being

SATINDER PAL SINGH

heated and there is a motor attached to fan to spread the hot air on

the fixture on which the products are being arranged.

III. Scaling removing: It is being done with the help of short blasting

machine. This process is used to clean the components after heat

treatment. The metal slides are thrown on the surface e of the

components. The material used as the short balls are malleable

iron, cast iron or cast steel.

IV. Hardness checking: It is being done with the help of Rockwell

hardness testing machine. The harness is kept between 58 & 61

Rockwell hardness.

Purpose of Heat treatment: -

1. To relieve the internal stresses set-up in the material after hot or

cold working in order to improve the machinability.

2. To improve the mechanical properties like tensile strength,

hardness, ductility, shock resistance etc.

3. To modify the structure of steel.

4. To increase the corrosion & wear resistance.

Furnace specifications: -

Type of furnace – Oil fired

Fuel used – Residual Furnace Oil (RFO)

Maximum loading capacity of trays - 150-200 kg at a time

Capacity of hardening furnace – 15 ton

Maximum loading capacity of furnace – 12 trays at a time

SATINDER PAL SINGH

Capacity of tempering furnace – 15 ton

Fuel consumption – Approximately 100 liters per day

Measuring instruments used in heat treatment: -

1. To check heat treatment furnace temperature, Temperature

controller / Indicator thermocouple are used.

2. To check hardness, BHN Testing Machine / Micro-measure are

used.

3. To quench oil temperature checking, temperature indicator is used.

Heat treatment of machined components: -

The first stage of the heat treatment was concerned with the heat

treatment of the components after forging. Now in the second stage comes

the heat treatment of the components after machining. These heat treatment

processes mainly comprises of the case hardening techniques of heat

treatment. The case hardening processes which are used in GNAU are: -

1. Induction hardening: - The Induction hardening is a surface

hardening process in which the surface layers of the metal are

hardened but a relatively soft core is maintained. The induction

hardening is achieved by passing a high frequency alternating

current through the work-piece which is placed in an inductor coil.

The alternating current generates a magnetic field of equal

intensity but of reverse polarity. Thus, the current penetrates & the

surface of the piece is hardened but a soft core remains.

2. Carburizing: - Carburizing is the process of saturating the surface

layer of steel with carbon. The main purpose of carburizing is to

obtain a hard & wear-resistant surface on machine parts by the

SATINDER PAL SINGH

enrichment of the surface layer with carbon. The various machined

parts are directly carburized after getting machined & after

carburization they are sent for final grinding. There are various

techniques of carburizing like – pack carburizing, gas carburizing

& liquid carburizing. At GNAU gas carburizing in the electrical

carburizing furnace is done.

Heat treatment equipments: -

1. Induction hardening machine (medium – frequency)

2. Carburizing furnace (electrical)

3. Tempering furnace (electrical)

4. Magnetic particle tester (MPT)

5. Hardness Testing machine

6. Grinding machine

7. Gas welding machine

Procedure for Induction hardening: -

1. Machining – After forging the components are sent to the machine

shop for the subsequent machining which is to be done & after

machining the components are ready for the case hardening.

2. Induction hardening – After the subsequent machining is done in

the machine shop the components are ready to be induction

hardened & the induction hardening is done on the induction

SATINDER PAL SINGH

hardening machines which are of medium & low frequency. The

main tooling of these machines is the induction coil.

3. Hardness testing – After the Induction hardening is completed the

hardness testing of the hardened pieces is done. The hardness

tester is used for testing the hardness.

4. Checking case hardness – After hardness testing is done the

checking of the case hardness of the components is done to find the

depth of the hardened layer. The micro-measure is used for

checking the case hardness.

5. Magnetic particle testing (MPT) – In this step the components are

checked for any cracks which might have been developed during

the induction hardening. First of all the components are sprayed

with kerosene oil & then they are viewed under the ultrasonic light

for finding any crack. If any crack might be present it would be

illuminated with green light.

6. Tempering – Tempering is done to remove the brittleness which

might have been developed during heat treatment & thus it restores

the ductility of the hardened component. The tempering is done in

the tempering furnace which is electrical in its operation.

7. Grinding – Grinding is the final step which is involved. In this step

any unwanted material which is present at the edges is removed &

a smooth finish is provided.

Procedure for carburizing: -

1. Carburizing – After the machining of the components is done then

they are sent for carburization. The carburizing is done in the

SATINDER PAL SINGH

carburizing furnace which is electrical in operation. The gas

carburizing is done in which the work-pieces are placed in a

medium of oxygen & a carbon containing gas & at high

temperature the oxygen decomposes the carbon present in the

other gas to evolve free carbon which then enters the surface

layers of the components. Thermocouples are used for the

temperature indication during the carburizing process.

2. Quenching – After the carburization is done the components are

quenched inside a quenching tank which can be either a water

quenching or an oil quenching tank.

3. Hardness & case-depth checking – After the quenching process is

complete the hardness & the case depth checking of the

components is done by using a hardness tester & a micro-measure.

4. Tempering – In this step the tempering of the case hardened

components is done to remove the brittleness. The tempering is

done the tempering furnace.

5. Grinding – This is the final step involved in which the unwanted

material is removed from the edges of the components on the

grinding machine.

SATINDER PAL SINGH

5). PRODUCT PLANNING CONTROL {PPC} :

PPC includes the investigation, co-ordination and it ensures timely

production of products through efficient and optimum use of facilities like

man, machine, material evaluation of manufacturing capabilities and

requirements and money. PPC’s function serves as the brain of the

organization. Its objective is to provide a physical system together with a set

of operational guidelines to efficiently convert materials, human skills and

other inputs into finished products. The highest efficiency in production is

obtained by manufacturing the required quality, at the required time by the

best and cheapest method. Management employs production planning and

control {PPC} to coordinate all manufacturing activities.

Products are manufactured by the transformation of raw materials.

Planning looks ahead, anticipates possible difficulties and decide that in

advance as how to production and how it can be carried out in best way. A

production planning control system has main function to perform some

before arrival of raw material and tools and other while the raw material

process undergoes processing. The main function of this section is to plan

about production of the product. This includes many things such as raw

material ordering, processing time management etc. This department

calculates the total production time of each product and thinks it advance

process working period. The main motive of this department is to reduce the

inventory of raw material. So there fore the planning is done such that the

total amount of steel kept in unit is under control. Following mentioned are

step by step calculations which are planned for raw material planning by

PPC department:

1) Number of components in

SATINDER PAL SINGH

(i). Cutting section

(ii). Forging

(iii). Forging vendor department

(iv). Vendor

(v). Machine shop

2) Total

3) Target of the month(say February)

4) Steel stock

5) Peaces that can be made from stock

6) Due steel

7) Pieces that can be made from the due steel

8) Total

9) Balance for next month(say march)

10) Weight of piece

11) Net steel required

From above all steps we can see that the main motive of PPC department

in raw material planning is that overhaul process will start 2 months before

the need so that forging takes place in 1st month and rest work in last month.

Thus by all this planning the department decides the need of net steel as raw

material.

SATINDER PAL SINGH

Objectives of PPC:

1. To maintain adequate but not excessive stocks of raw materials, work

in process and of finished goods to meet production requirements and

delivery schedules.

2. To coordinate the production activities of different departments.

3. To ensure effective utilization of production facilities.

4. To prepare production schedules advertisements to meet delivery

schedules.

5. To operate the plant at optimum level of efficiency.

6. To ensure production of right product in right quality at the right time.

Importance of PPC:

1. PPC acts as factory’s nervous system as it regulates all plant

operations just as nervous system regulates muscular movements.

2. PPC acts as an effective instrument for cost control.

3. PPC is helpful in accelerating industrial productivity.

SATINDER PAL SINGH

4. PPC rationalizes plant operations.

5. PPC benefits the society.

Functions of PPC: Following are the main functions of PPC:-

1. Planning: It is necessary to plan things properly for getting best

results. Similarly for production planning in advance, it is very

necessary that how planning should be done and controlled. It is the

department which decides about each element of the job, what should

be done, where, how & when?

Functions of Planning:

To investigate about the complete details and requirements of

the product to be manufactured.

Predetermination of future achievements.

Planning about quality and quantity of material.

Planning the design of the product to be manufactured.

Planning about the sequence of the operations.

Planning about interval transportation.

2. Routing: Routing may be defined as the selection of path, which each

part of the product will follow being transferred from raw material to

finished products. Path of the product will also give sequence of the

operations to be adopted.

SATINDER PAL SINGH

In other words routing means determination of most advantageous path

to be followed from department to department and machine to machine

till raw material gets its final shape.

Routing in industry depends upon the nature and the type of industry:

Continuous industry – As such these industries are also

automatic. Therefore the problem of routing in these industries

is very simple. Once the route is decided in the beginning,

generally no further control over the route is needed.

Assembly industry – Such industries require various

components to be assembled at a particular time therefore it is

necessary that no component should fail to reach at proper time

and proper place in the required quantity otherwise whole of

production line will be upheld resulting in wastage of time and

production delay.

(ii) Scheduling:- Scheduling determines the program for

the operations. In scheduling, order of sequence of

each operation and their starting time and finishing

time is decided so that the required materials,

machines may be kept ready as schedule. Thus, it may

be defined as a fixation of time and the date for each

operation as well as determines the sequence of

operations to be followed. This program is prepared

by the planning department and assigns things for

various operations.

Types of schedules:-

SATINDER PAL SINGH

Master schedule – It shows the dates on which important

production items are to be completed. It is a monthly or a

weekly break of the production requirements of each product.

Shop schedule – After preparing master schedule, shop

schedules are prepared. It assigns a definite period of time to a

particular shop for manufacturing products in the required

quantity.

(iii) Dispatching;- It is concerned with starting the

processes. It gives necessary authority to start a

particular work, which has already been planned

under routing and scheduling.

Functions of dispatching;-

The materials are removed from stores to machines.

To distribute machine loading and schedule charts, route sheets

and other necessary instructions and forms.

To issue inspection orders clearly stating the type of inspection

required at various stages.

To order tool sections for issuing proper tools, jigs and fixtures

and other essential articles.

(iv) Follow-up:- After dispatching production orders to

various shops, it is necessary to regulate the process

of job through various processes. For this purpose

follow-up section is formed.

SATINDER PAL SINGH

Functions of follow-up:-

It assures that material should reach the shop in required time

so that work should progress in a smooth way.

It observes that particular product is passing through all its

operations from raw material to its final shape as per schedule.

We can divide PPC department in following mentioned 3 phases:

I. Planning phase:

Forecasting : It includes type of estimation, quality and quality

of future work

Order writing : It provides authority to one or more persons to

undertake a particular job.

Product design : It is done for collection of information

regarding specifications bill of material and drawings.

Process planning : It is to find out the most economical process

of doing the work and deciding how and where the work will be

done.

Tool control : It determines the requirements and control of the

tool used in manufacturing processes.

Material control: It determines the requirements and control of

the material for the production of the product.

Loading : It is the assignment of the work to manpower,

machinery etc.

SATINDER PAL SINGH

Scheduling : It is time phase of loading and determines when

and in what sequences the work will be carried out.

II. Action phase:

Dispatching : It is the transition from planning to action phase.

In this workers are ordered to start work.

III. Control phase: The control of production is necessary to be sure

that the production schedules are being met and job will be

delivered as per the predefined plans, a production control group.

Receives work progress report

Compare them with scheduled plans

Removes causes of delays in production

Modifies the schedules or plant capacities

Expedites the work

Advantages of PPC:-

Better service to customer in promised delivery dates.

Fewer risk orders in plant and less overtime.

Lower inventory work in progress.

Less finished stock required to give the same service to

customer.

Better control of raw material.

More effective use of equipment.

SATINDER PAL SINGH

PPC department act as a bridge between the production section and

management. It gets manufacturing order from marketing department, raw

material and other equipments from purchase department, specifications

from engg. department and then makes plan accordingly. The PPC

department gets the manufacturing order 3 months before the product

issuing date because it has to make planning’s for production and get

material for 20 days before start of production. 10% extra material is

supplied to the production section because some pieces may be rejected

while inspection. If the work is more or the machines are not free due to

some other work then work has to be given to vendors. If there is any

problem comes whether in small or large way the PPC department have to

answer for it. So there fore the perfect planning is to be made so that there is

negligible amount of mistakes.

6). METALLURGICAL LAB:

This lab’s main purpose is of do inspection f raw material do acceptance

or rejection of the material. This also helps to now various contents of

material in the made specimen after forging processes. So there fore this

department is an essential part of the industry. This lab performs the

following functions:

(i) Macro Etch test in which HCl is being used to clean structure of

given metal.

(ii) Jominy hardenabily test is performed in which we do heating and

then end quenching and then check the hardness of the specimen.

(iii) Step down test is the test in which magnaflux on step down sample

is being done.

SATINDER PAL SINGH

(iv) Cracks detection is the test in which magnaflux powder and

kerosene mixture is used to clean the surface and the checking of

cracks is done in microscope.

(v) Grain size checking test is a test in which the grain size is being

checked with the help of microscope.

(vi) Microstructure checkup up is being done after normalizing,

tempering, hardening, carburizing etc.

The main frequently performed work in this lab is estimation of

percentage of carbon in the specimen in between the production

processes. In this the chips of the material is being produced using the

drilling machine. Then their chips are heated in the furnace with cupric

oxide (CuO) in presence of dry oxygen free from carbon dioxide. The

reaction took place is as below:

C + 2CuO = CO2 + 2Cu

Other gases and carbon dioxide are absorved in U tubes

containing anhydrous (CaCl2) and solution of K(OH) respectively. The

volumes of containers are noted before and after the combustion. These

volumes are compaired with the charts and thus percentage of carbon is

estimated.

Similarly there are some equipments and apparatus required for

performing various tests which are mentioned as in following:

I. Treatment or experimental zone:

(i) Combustion table furnace

SATINDER PAL SINGH

(ii) Control unit for carbon apparatus {used to know

about carbon content and working temperature kept

is 1200 degree Celsius}

(iii) Strohlein apparatus {used to know carbon content in

steel}

(iv) Weight balancing machine

(v) Barometer {used to know the atmospheric pressure}

(vi) Volumetric section {used to check % of Mn, Cr, Ni,

Cu, molebedinum,sulphur, phosphorus &vanadium}

(vii) Fume chamber

(viii) Distillation plant

(ix) Microscope

(x) Drilling machine

(xi) Phosphating tank

(xii) Surface grinder

(xiii) Muffle furnace{temperature ranges from 0 to 1200

degree Celsius}

(xiv) Jominy apparatus for quenching test

II Sample preparation zone:

(v) Polishing machine

(vi) Belt grinder

SATINDER PAL SINGH

(vii) Abrasive machine {used for sample cutting}

(viii) Muffle furnace {used for tempering, normalizing etc.}

(ix) Quenching tank

SATINDER PAL SINGH

7). ENGINEERING CELL:

In this department the main purpose is to make a file/report on the

product to be manufactured. First of all the customer send the intimation of

the product to the purchase department in which there are many things such

as bill of material to be used for manufacturing the product, drawing of the

product, tolerances, mechanical properties of the product etc. This file is

being brought to the engineering department.

The engineering department consists of designers, engineers and drafts

men who helps in performing their work in this department. The engineering

department first of draws the product lay out. Then the flowchart of the

manufacturing processes are being made. Then in the same serial order the

list of costs incurred for manufacturing of the product is being made. This

quotation may contain various kind of costs such as cost for raw material,

machining, labour, die arrangements etc. So there fore the main function of

the engineering department is of preparation of details of manufacturing

information of the product to be made.

This all work of engineering department is done for the requirements of

good production which are mentioned as following:

1). To ring customer satisfaction that the product will work properly and the

price is reasonable.

2). Adequate profit that it should be easy to manufacture with in the

available resources and should call for minimum number of operations.

According to this department the main part is the drawings of the part. A

designer communicates his ideas to the manufacturing section through the

medium of drawing. Drawing shows the exact size and shape of he product.

SATINDER PAL SINGH

An engineering drawing should contain following information for the

manufacturer:

1. Component part number and part description.

2. Dimensions from a common datum face to facilitate setting and

ganging.

3. Tolerances and limits allowable.

4. Material details or the specifications.

5. Finishing description.

8). COMPUTER NETWORK CONTROL (CNC) :

CNC shop is equipped with various costly machines, which may be

automatic, and computer controlled type. The labour used in this shop is

highly skilled type. The list of various machines used in this shop is as

following:

Gear hobber made by Churchill Company in England. This

machine is of mechanical type and have maximum full load current

15 amps.

Gear hobber made by Lorenz Company having maximum

hammering load capacity of 1.5 kg.

Gear hobber made by Lorenz Company having maximum

hammering load capacity of 1000 kg.

CNC – 03 made by Frontor 1856 weisser. It is assembled with a

monitor of simens. This machine is used for rough turning &

facing functions.

SATINDER PAL SINGH

CNC – 03 made by Frontor 1856 weisser. It is assembled with a

monitor of simens. But this machine is used for final turning,

boring, step facing etc.

Horizontal machining center made by Rolland, which is a

universal machine. The coolant used is biostable coolant. The

machining capacity is 500 L.

Grinder with a tapered wheel made by Fortuna Werke AG.

CNC Turning machine made by Frontor 1856 Weisser.

Vertical CNC machining center made by Hart Ford. The various

functions that can be performed are drilling, milling, boring,

reaming & tapping. This machine can be worked at higher RPM

i.e. 8000 RPM.

Surface broaching machine, which works vertically and is made

by Varinelli.

CNC machine used for turning operation and is made by Duplo

Standard. The control panel is of sinumerilic.

Then there are 5 CNC machines in line. These all are made by

Itala.

CNC drilling machine made by Leadwell.

CNC robodrill made by Hanuc.

Multiple spindle-drilling machine made by Eifco.

Radial machine.

SATINDER PAL SINGH

8 spindle drilling machine made by Wavis.

CNC turning machine made by Maho Grazino.

Shaft gear hobbing machine made by Churchill.

Lathe machine made by Lotus high cut.

Cylindrical grinder.

Rockwell hardness testing machine.

12). DIE SHOP:

Die is a cavity in which the hot piece is placed in forging & by the

application of force the hot metal is given the required shape. So the die is

the exact shape of the original component.

Dies are of two types: -

1. Rough blocker: - Blocker is the die which has the larger

dimensions so that more metal flow is incorporated in first blows.

2. Finisher: - Finisher is the die which has the exact dimensions

including tolerances used to give the product during forging whole

of metal not flows in the cavity. Some of it comes out to counter it a

hollow portion is incorporated around die & this portion is called

gutter.

Die is the most important tool for closed die forging. Making a die

as per design specifications is most essential work in automobile

industry. Die manufacturing is a completely sequential process,

due to this there is a separate die manufacturing section is

provided in the factory.

SATINDER PAL SINGH

Die making machines: -

The machines which are involved are as under: -

1. Lathe machine

2. Milling machine

3. Power hacksaw

4. Grinding machine

5. Drilling machine

6. Electric discharge machining (EDM) machine

7. CNC wire cut (for rimming dies)

8. Shaper

9. Electric arc welding set-up

Die material: -

Composition of the die materials used is as under:-

1. DIN 2713

Carbon – 0.55

Silicon – 0.30

Manganese – 0.66

Phosphorus & sulphur – 0.035

Chromium – 0.70

Molybdenum – 0.30

Nickel – 1.70

Vanadium – 0.10

2. DIN 2714

Carbon – 0.56

Silicon – 0.30

Phosphorus & sulphur – 0.035

Molybdenum – 0.50

Nickel – 1.72

SATINDER PAL SINGH

Vanadium – 0.10

Die making procedures:-

Block selection: - Here we have to select the size of the die block.

For this we have to check the number of cavities. Approximately

20 mm of gutter is provided around a cavity of size 100 – 125 mm.

next thing is to check the thickness of the block for general pieces

70 mm thickness & half the clearances.

Block preparation: -

- Automatic hand raw cutters are used to cut the blocks.

- Both sides are given reference

- Dove tail marking & machining is done.

- No tool mark should be there.

- Impression marking & marking of other location is done by

choosing one machined surface as datum surface.

Primary machining: -

- Facing is done on lathe machine

- Impression turning is done on milling machine

- A hole is machined on both sides which are known as tong hole.

Tong bars are put into these holes & die can be easily lifted.

- Then marking is done. Marking means drawing up the marks

where machining is done. It is done with the help of height gauge

& surface plate.

- The cavity can be made by either machining on a milling machine

or by the help of an electrode on the EDM machine.

Pressing & polishing: - By using a hand grinder the grinding is

done. Also the tool marks are removed. Carbide cutter is used.

Polishing is done with iron stone to have better surface finish &

also easy withdrawal.

SATINDER PAL SINGH

Final inspection: -

- Dove-tail parallelity check

- Dove-tail alignment check

- Top surface level check

- Dove-tail reference check

SATINDER PAL SINGH

2). Shafts

Power Take

off Shafts

Hollow

Shafts

Hydraulic Lift

Shafts

Live Power

Take Off

Shafts

Drive

Shafts

Tie Rod

Assembly

(i)Power Take off Shafts for Transmitting power from tractor to implements.

(ii)Hollow Shafts for transmitting power in the tractor and off highway vehicles.

Utility  Applicable

Automobile -

Off Highway

Agri

Machinery

SATINDER PAL SINGH

Utility  Applicable

Automobile -

Off Highway

Agri

Machinery

(iii)Hydraulic Lift Shafts for transmitting power to lift arms.

Utility  Applicable

Automobile -

Off Highway -

Agri

Machinery

(iv )Live Power Take Off Shafts

(v)Drive Shafts

3). Spur and Helical Gears

SATINDER PAL SINGH

Utility  Applicable

Automobile -

Off Highway -

Agri

Machinery

Utility  Applicable

Automobile -

Off Highway

Agri

Machinery

Bull Gears Bull Pinion Shafts Gears for Gear Boxes

(i) Bull Gears for torque transmission in off highway and tractors.

Utility  Applicable

Automobile -

Off Highway

Agri

Machinery

Bull Pinion Shafts

(ii) Bull Pinion Shafts for transmitting torque in off highway vehicles.

Utility  Applicable

Automobile -

Off Highway

Agri

Machinery

(iii) Gears for Gear Boxes

Utility  Applicable

Automobile -

SATINDER PAL SINGH

Off Highway -

Agri

Machinery

4). Epicyclic Reduction Gears

Ring Gears Spur Satellite Gears Flanges

(x) Ring Gears for Epicyclic Reduction in off highway vehicles

and tractors.

Utility  Applicable

Automobile -

Off Highway

Agri

Machinery

Spur Satellite Gears

(ii) Spur Satellite Gears for Epicyclic Reduction.

SATINDER PAL SINGH

Utility  Applicable

Automobile -

Off Highway

Agri Machinery

Flanges

(iii) Flanges for off highway transmission.

Utility  Applicable

Automobile -

Off Highway

Agri

Machinery

-

4). Epicyclic Reduction Gears

SATINDER PAL SINGH

5). Hypoid and Bevel Gears

Crown Wheel &

Pinion for Trucks

Crown Wheel & Pinion

for Off Highway

Crown Wheel & Pinion

for Cars and SUV

(i) Crown Wheel & Pinion for Trucks

Utility  Applicable

Automobile

Off Highway -

Agri

Machinery

-

(ii) Crown Wheel & Pinion for Off Highway

Utility  Applicable

Automobile -

Off Highway

Agri

Machinery

(iii) Crown Wheel & Pinion for Cars and SUV

SATINDER PAL SINGH

6).Right Angle Drive Gear Boxes

Right Angle Drives with 1 & 2 outputs in different gear ratio for various agriculture and

other implements.

Utility  Applicable

Automobile -

Off Highway -

Agri

Machinery

 

SATINDER PAL SINGH

Utility  Applicable

Automobile

Off Highway -

Agri

Machinery

-

7). Propeller Shaft Assy & Components

Propeller Shaft Assy. Various components

(xi) Propeller Shaft Assy. Of various sizes suitable for

Cars, SUV’s, LCV and heavy trucks upto 20 tonnes.

Utility  Applicable

Automobile

Off

Highway

-

Agri

Machinery

Various components

(xii) Various components like U.J. Cross, Splined yokes

etc.

Utility  Applicable

Automobile

Off

Highway

-

Agri

SATINDER PAL SINGH

Machinery

8). Steering Column Assy.

Steering Column Assemblies for LCV’s, HCV’s. Also available for various tractors.

Utility  Applicable

Automobile

Off Highway -

Agri

Machinery

SATINDER PAL SINGH