REPORT ON

SUMMER VOCATIONAL TRAINING

At

Federal Mogul Goetze Ltd.

A TRANING REPORT SUBMITTED

IN PARTIAL FULFILLMENT OF THE REQUIREMENTS

FOR THE AWARD OF DEGREE OF

BACHELOR OF TECHNOLOGY

In

Mechanical Engineering

SUBMITTED BY

Name: Rajat Sharma Roll Number: 2314785

SUBMITTED TO

Department of Mechanical Engineering

Ambala College of Engineering and Applied Research,

Ambala

(Affiliated With)

Kurukshetra University, Kurukshetra

July 2015

Scrap Reduction in Moly Coated Indica KV1

Material

Piston Rings

At

Federal Mogul Goetze Ltd.

A TRAINING REPORT SUBMITTED

IN PARTIAL FULFILLMENT OF THE REQUIREMENTS

FOR THE AWARD OF DEGREE OF

BACHELOR OF TECHNOLOGY

In

Mechanical Engineering

SUBMITTED BY

Name: Rajat Sharma Roll Number: 2314785

SUBMITTED TO

Department of Mechanical Engineering

Ambala College of Engineering and Applied Research, Ambala

July 2015

CANDIDATE'S DECLARATION

I, Rajat Sharma, Roll Number: 2314785, hereby declare that the work which is

being presented in the Training Report entitled, “Scrap Reduction in Moly Coated

Indica KV1 Material Piston Rings”” in partial fulfillment of requirement for the award

of degree of B.Tech. (ME) and submitted in the Department of Mechanical

Engineering, Ambala College of Engineering and Applied Research, Ambala,

Kurukshetra University, Kurukshetra, is an authentic record of my own work carried

by me under the supervision of Dilmohan singh (M/c Shop, & Federal Mogul Goetze

Ltd. ).The matter presented in this Training Report has not been submitted in this or

any other University / Institute for the award of B.Tech Degree.

Rajat Sharma Dated:

Roll Number: 2314785

ACKNOWLEDGEMENTS

(It is just a format for hierarchy of the acknowledgement and can be extended/ reduced

accordingly)

The Training work is an important aspect in the field of engineering, where

contribution is made by many persons and organizations. The present shape of this

work has come forth after contribution from different spheres.

Give acknowledgement to all those persons who have helped during training

at industry.

Give acknowledgement to H.O.D

I would also like to thank my parents who helped me in my Training.

I express my sincere gratitude to Ambala College of Engineering and Applied

Research, Ambala and Kurukshetra University, Kurukshetra for giving me the

opportunity to work on the Training during my final year of B.Tech.

Signature of the Student

(Rajat Sharma) Roll Number:2314785

INTRODUCTION

To

The Company

1.1 History

1899 – 1940: Founded on Innovation

1941 – 1956: Diversifying for Success

1957 – 1974: Going Global

1975 – 2005: A Bright Future

Federal-Mogul Corporation is an innovative and diversified $6.3 billion global supplier of

quality products, trusted brands and creative solutions to the automotive, light commercial,

heavy-duty truck, off-highway, agricultural, marine, rail and industrial markets. The 45,000

people of Federal-Mogul located in 35 countries drive excellence in all they do.

Company’s globally networked engineering and technical centers in the U.S.,

Europe and Asia enable to bring customers breakthrough in advanced technology

and innovation.

Federal Mogul is a premier supplier of products, services and solutions to original equipment

manufacturers that use quality components in their vehicles and automotive systems, and to

aftermarket customers who sell company’s world-renowned brand-name replacement parts

through repair shops and retail outlets. As partner with a global network of suppliers whose

commitment to excellence and on-time delivery is crucial to company success.

For more than a century, Federal Mogul has developed the innovative products, which

customers need to produce the next generation of vehicles. Federal-Mogul has been creating

value through innovation and leading technology for more than 100 years. Today, the

company is a key player in the global marketplace, serving industries that range from

automotive and commercial vehicles to railroad and aerospace. Customers know they can rely

on Federal-Mogul’s quality excellence in products, trusted brands and creative solutions.

This company started with a bold idea, with a global workforce thousands strong. The

Federal-Mogul team has celebrated countless victories and worked hard to overcome the

inevitable challenges.

The company utilizes its engineering and materials expertise, proprietary technology,

manufacturing skill, distribution flexibility and marketing power to deliver quality products

and services, and leading brands. Federal-Mogul is focused on driving global profitable

growth and creating value to satisfy customer, employee and stakeholder expectations.

Headquartered in Southfield, Michigan, the Company, which reported sales of $6.3 billion in

2005, employs 42,000 people worldwide. Federal-Mogul was founded in Detroit in 1899. The

Company’s principal customers include many of the world’s foremost original equipment

manufacturers of automotive, light commercial, heavy-duty truck, agricultural, marine, rail

and industrial vehicles and equipment as well as the worldwide aftermarket.

Federal-Mogul employees throughout the organization create value for their stakeholders and

continuously strive to exceed their customers’ expectations by following these core values:

We are a team first.

We respect, trust and help each other.

We act with integrity.

We are driven to be the best in all we do.

We create value through innovation.

We celebrate our success.

1.2 FEDERAL MOGUL GOETZE (INDIA) LTD.

BAHADURGARH, PATIALA

(History)

Goetze (I) Ltd., Bahadurgarh, Patiala was set up in 1954 with the collaboration of M/s.

Goetze Werke, Germany which started its production of Piston Rings for automobile industry

in 1957. The plant is situated at Bahadurgarh, about 10 kms. from Patiala on the Patiala-

Rajpura Road.

Considering the need of complete Piston assembly, Escorts Ltd. ventured into manufacturing

of Pistons in 1958 with the collaboration of M/s. Mahle GmbH, Germany, which delivered

the Indian automobile industry its Pistons in 1960.

Escorts entered in collaboration with M/s. SUKO GmbH, Germany for Piston Rings in 1967

and manufacturing started in 1968. To meet the increasing demand of market, in 1977, a

parallel unit for manufacturing Pistons and Piston Pins was set up in Bangalore.

From 1 October 1996, Escorts Ltd. entered into joint venture with M/s. Mahle GmbH,

Germany with the formation of the new company Escorts Mahle Ltd. in 1998, Goetze also

became a part of Federal Mogul, a well-known group of USA. In June 2000, both Escorts

Mahle Ltd. and Goetze have become QS-9000 certified companies.

The present capacity of the plant is 285.09 lacs nos. Piston Rings and 52.68 lac nos. Pistons

(on 302 working days). The total capital employed as on 31 March 2004 is 134.46 crores in

Ring Activity and Piston Activity. The workforce including managers and supervisors is 1131

nos. in Ring Activity and 1304 in Piston Activity as on 31 March 2004. The turnover of the

Patiala Plants is 159 crores excluding Excise (combined in Ring Activity and Piston Activity)

as on 31 March 2004.

BRANDS

2.1 Federal-Mogul Goetze (India) Limited

Manufacturer of world-class pistons, piston rings, sintered parts and cylinder liners

covering a wide range of applications including two/three-wheelers, cars, SUVs,

tractors, light commercial vehicles, heavy commercial vehicles, stationary engines

and high output locomotive diesel engines.

Widest range of piston rings and pistons varying from 30mm to 300mm diameter.

The most modern production facilities at Bangalore, Patiala and Bhiwadi are certified

TS 16949, ISO14001 and OHSAS 18001.

Market leaders both in OEM and aftermarket. Exports to many countries.

Goetze and Goetze Brico provide leading-edge technologies and competitive

solutions for original equipment manufacturers and the automotive aftermarket.

Production Capacity: Piston rings 55 Million

Pistons 13 Million

Turnover: April 05 -March 06 INR 5124 Million

Net Profit (after tax): April 05 -March 06 INR (505) Million

MILESTONES

1954 Incorporated as a JV with Goetze Werke

1957 Ring & liner production

Patiala

1958 Piston production as escorts (Automotive Division) (Collaboration:Mahle)

Patiala

1960 Cast iron / Forged piston production started

Patiala

1968 Pins / ring carrier production started

Patiala

1977 Piston / ring production started

Bangalore

1982 Steel rings / Large bore locomotive piston

Bangalore

1985 Light alloy products

Patiala

1989 Auto thermic pistons production

Bangalore

1990 Moly coated / IKA / chrome oil rings

Patiala

1992 Large bore rings / pistons for battle tanks

Bangalore

1994 Composite pistons / new ring foundry

Bangalore

1996 Escorts (Automotive Division) hived off into joint venture with M/S Mahle, Germany

1997 Goetze TP (India) Ltd. - Manufacturer of steel rings

2001 Merger of Federal-Mogul sintered products Ltd. with Goetze (India) Ltd.

2003 Merger of Escorts pistons activities with Goetze (India) Ltd.

2004 Introduction of chrome-ceramic rings

2004 Technical collaboration for pistons with Federal-Mogul Corporation

2006 Majority stakeholding acquisition by Federal-Mogul Corporation

2006 Name changed "Goetze (India) Limited" to "Federal-Mogul Goetze (India) Limited"

Management

Board of directors Name

Chairman Mr. Charles B.Grant

Vice Chairman, Managing Director

& C.E.O. Mr. Arun Anand

Directors Mr. Rainer Juestock

Mr. Charles H. Polzin

Mr. Mukul Gupta

Mr. Vishavjeet Kanwarapal

Corporate Leaders

Executive Directors–Sales & Marketing Mr. Mohan Narayan

a) Original Equipment Sales Mr. Yogesh

b) After Market Sales Mr. Sanjeev Singh

c) Exports Mr. G.S. Arshi

Executive Directors – Manufacturing Operation Mr. Andreaf Kolf

a) Bangalore Plant Mr. K. Saravana

b) Patiala Plant Mr. Sunit Kapur

c) Bhiwadi Plant Mr. A. R. Ahuja

Financial Controller & Company Secretary Mr. Rajan Luthra

General Manager Corporate Planning Mr. Ashish Mathur

Quality Policy

FEDERAL MOGUL GOETZE (INDIA) LIMITED commits itself to leadership in national

market for all its products and ensuring total customers’ satisfaction highest in industry. It

commits to develop and build an image in the international market to achieve a sustained

annual growth in exports.

Policy

We shall continue to manufacture all our products in conformity with accepted international

norms/ standards.

We shall also continue to retain our leadership in development of products through technical

know-how from our Collaborators and in-house developments. Consistent development of

human resources through training at all levels will be our major thrust area.

MR.CHARLES B.GRANT

(Chairman & Managing Director)

Mission of the Company

“Steadily moving towards leadership with piston with vision strategy seeing it as the best

way to leaders in business”

Vision of the Company

“To be one of the worlds leading automotive solutions provider”

Share Holding Pattern:

Federal-Mogul Corporation 51.0 %

Goetze India Ltd. 24.5 %

Teikoku Piston Rings Co. Ltd., Japan 24.5 %

EXPORT DESTINATION

Dubai

Bangladesh

Singapore

Egypt

Mauritius

U.S.A

Germany

Nepal

Sri Lanka

Uganda

COLLABORATIONS

A. GERMANY

o Faun

o Class

B. JAPAN

o Yamaha

o Kayaka

o Mikni

C. UK

o JCB (Goetze)

o Ford

D. USA

o HUGHES

E. FRANCE

o Bosch

o Dynapal

PROJECT CHARTER

Business Case

From Jan-Dec 2014, 21.95% average total machining and fdy.

Scrap in MOLY COATED INDICA KV1 Rings

Target = 17.8% at the end of July 2015

Problem Objective

To reduce the scrap of moly coated indica rings in KV1 material

from 22.95% to 17.8% by July 2015

Boundaries

From grinding process till final inspection

PROCESS FLOW OF INDICA KV1 RINGS

LISTING OF KNOWN PROBLEM IN JULY 2015

Edge Breakage observed in indica Moly KV1 rings.

Corner breakage observed in KV1 rings.

DATA COLLECTION SHEET FOR EDGE BREAKAGE

AND CORNER BREAKAGE IN INDICA KV1 RINGS IN

PROCESS AT BRUSHING

DATE LOT

SIZE

QTY % REMARKS DETAIL

06/07/15 2200 230 10.45% Edge/Corner breakage At pg-100, At honing-50, At

gap-80

07/07/15 1500 223 14.8% Edge/Corner breakage At pg-123, At honing-60, At

gap-40

08/07/15 2300 200 8.6% Edge/Corner breakage At pg-125, At honing-55, At

gap-20

09/07/15 2400 256 10.45% Edge/Corner breakage At pg-156, At honing-68, At

gap-32

10/07/15 2300 245 10.65% Edge/Corner breakage At pg-98, At honing-100, At

gap-47

14/07/15 2500 288 11.52% Edge/Corner breakage At pg-168, At honing-90, At

gap-30

16/07/15 3000 350 11.66% Edge/Corner breakage At pg-150 At honing-90, At

gap-110

18/07/15 3000 332 9% Edge/Corner breakage At pg-132, At honing-60, At

gap-40

DATA COLLECTION SHEET FOR EDGE BREAKAGE

AND CORNER BREAKAGE IN INDICA KV1 RINGS IN

PROCESS AT INSP.

DATE LOT

SIZE

AXIAL WIDTH

LESS

EDGE

BREAKAGE

FDY

SCRAP

05/12/14 2200 40 120 45

06/12/14 1500 20 50 55

08/12/14 2300 50 145 65

09/12/14 2448 42 185 125

10/12/14 2300 30 125 75

PROFILE GRINDING - Breakage

PROFILE GRIND. DEFECTS-CAUSE VALIDATION OF

HIGH RANKING DEFECTS (indica)

ACTION TAKEN AGAINST THE DEFECTS

ACTION TAKEN AGAINST THE DEFECTS