Internship Report
Submitted by
Amjad Mehmood, Faizan Ahmad, Mohsin Nazir
(University of Engineering and Technology, Lahore-54890, Pakistan)
Submitted to
Mr. Mudasir Chaudry
(Management Training Centre)
Incharge MTC
Mr. Ali Asghar
Dated: 15th July, 2015
Heavy Mechanical Complex (Pvt) Ltd Taxila: 47050 Pakistan
ii
Dedication
Dedicated to workers, staff members, supervisors and officers for their support and supervision
especially Mr. Ali Asghar (I/C MTC) and Mudasir Chaudhry for their guidance
A. Mehmood
F. Ahmad
M. Nazir
iii
PREFACE
Practical knowledge have become important in the industrial environment to produce products
for the service of mankind. The knowledge of manufacturing practices is highly essential for all
engineers for familiarizing themselves with modern concepts of manufacturing technologies. The
basic need is to provide practical knowledge of manufacturing processes to all the internee
students. Therefore, an attempt has been made through this internship to present the practical
knowledge. Considering the general needs of internee students and the fact that they hardly get
any exposure to hand tools, equipment’s, machines and manufacturing setups, this internship will
be very useful to them in their future.
At the end, we thank Ms. Ayesha Tayyab, Mr. Qaiser Naeem Butt, Mr. Shamshad Gill and Mr.
Abid Hussain for their special support and guidance.
A. Mehmood
F. Ahmad
M. Nazir
iv
Acknowledgement
We thankfully acknowledge the cooperation of Mr. Amjad Hussain (Instructor) as he helped
throughout our internship, with his kind cooperation; by which we had a complete exploration of
the practical experiences.
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Table of Contents
1. Introduction 1
Premises and Assets 1
Departments 1
Facilities 1
Products 2
Quality Certifications 2
Major Achievements 3
Technical Collaborations 3
Civic Amenities 4
2. Assembly Shop 6
Assembly 6
Fitting 7
Fits 7
3. Heat Treatment Shop 8
Heat Treatment 8
Heat Treatment Processes 8
4. Fabrication Shop 11
Fabrication 11
List of Machines 11
Raw Materials 11
Layout 12
Fabrication Techniques 13
Cutting 13
Forming Processes 13
Welding 15
Welding Defects 16
Surface Cleaning 18
Boiler 18
5. Production Planning and Control 20
Sales Order Numbering System 20
Core Planning 20
Project Planning 20
Material Management 20
Process Planning 21
Tool designing 21
vi
Dispatch Cell/Material Handling 21
Income tax Cost and Revenue 21
6. Steel Foundry 22
Casting Process 22
Advantages of Sand Casting 23
Limitations 23
Steel Melting Furnace 23
7. Non-Destructive Testing 24
Radiographic Testing 24
Ultrasonic Testing 24
Magnetic Particles Inspection 25
Liquid penetrant Testing 25
Eddy Current Testing 26
8. Basic Machine Shop 27
Production Planning Section 27
List of Machines 27
Machining 28
Classification of Machined Parts 28
Turning and Related Operations 28
Hobbing 28
Lathe Machine 29
Shaper Machine 30
Planar Machine 30
9. Technology Department 31
Feasibility Study 31
10. Material Testing Lab 32
Metallography 32
Mechanical Testing 32
Universal Testing Machine 32
Charpy Impact Testing Machine 33
Brinell Testing Machine 33
Rockwell Testing Machine 34
11. Inspection 35
APPENDIX: Schedule of Internship 37
[1]
Chapter No. 1
Introduction Heavy Mechanical Complex Pvt Ltd. Taxila is a State owned capital goods manufacturer which
brought Pakistan into the category of industrially advanced countries. Its performance is linked
with the policies and overall economy of the country
It was established in 1971 as a mechanical working company with the aim to shift emphasis from
manufacturing of consumer goods to capital goods, achieving optimum imports substitution in
plant, machinery and equipment, saving foreign exchange and achieving technological up
gradation. Its forgings and foundry section was established in 1977.
Premises and Assets
Total Factory Area: 226 Acres
Total Colony Area: 345 Acres
Total Area: 571 Acres
Covered Area in Factory: 46 Acres
Covered Area in Colony: 24 Acres
Total Covered Area: 70 Acres
Gross Assets: 2 billion PKR
Departments
• Sales and Marketing Department
• Design and Engineering Department
• Production Planning and Control Department
• Production Shops (HMC1 & HMC2)
• Quality Assurance Department
• Project Management Department
• Human Resources Department
• Finance and Budgeting Department
Facilities
• Fabrication
• Machining
• Heat Treatment
• Casting
• Forging
• Galvanizing
[2]
• Tool Making
• Assembly
• Design and Engineering with well-equipped Computer Aided Design (CAD) facility
• Well-equipped Quality Assurance Department with ISO 9001 Certification and
authorization to use ASME STAMPS, PP, S, U, U2
Products
• Sugar Plants
• Alcohol Plants
• Cement Plants
• Chemical and Petro Chemical Plants
• Oil and Gas Processing Plants
• Industrial Steam Boilers
• Thermal and Hydral Power Plants
• Road Construction Machinery
• Railway Equipment
• Over Head Traveling Cranes
• General Steel Structures
• Highly Sophisticated Castings and Forgings
• Items for Defence and Strategic Industry
Quality Certifications
ISO 9001
Scope
Design, engineering, manufacturing and commissioning of plants and machinery including
cement, sugar, thermal, hydro, chemical, oil and gas processing plants, agriculture machinery,
boilers, pressure vessels, heat exchangers, cranes, road construction machinery, steel structures,
plain and alloyed steel castings, free and automatic die forgings, steel billets and other similar
heavy engineering equipment.
ASME
ASME STAMPS
U: Pressure vessel according to ASME section VIII, Div. I
U2: Pressure vessel according to ASME section VIII, Div. II
S: Power Boilers
PP: Pressure Piping
[3]
LLOYDS
• First class manufacturer of fusion welded pressure vessels
• Registered as Qualified construction Company
Major Achievements
• Pioneer in getting ISO 9001 certification and helped other local industries to acquire
ISO 9001 certification
• Acquired Authorization from American Boiler Board to use ASME STAMPS for power
boilers, pressure vessels and pressure pipes
• Attained capability to design, engineer, manufacture machinery for turn-key supply of
higher module sugar and cement plants
• Pursue a dynamic marketing and engineering product diversification, policy as a
consequence diversified into energy sector (Thermal and Hydral Power Plants) and oil
& gas processing industry etc.
Technical Collaboration
Table. 1.1 Technical Collaborations of HMC, Taxila
Product Company Country
Cement Plant and
Machinery
FULLER USA
KHD Germany
F. L. SMIDTH Denmark
FCB France
ONODA EN 66 Japan
Sugar Plant and Machinery POLIMEX-CEKOP Poland
WALKERS Australia
HEIN LEHMANN Germany
COMPLANT China
Alcohol Plants INTERIS France
Chemical/Petro Chemical CE-NETCO Singapore
TRITCHARD Corp. USA
[4]
TITAN PROTELTS Ltd. Canada
BABCOCK-KING UK
WILKINSON Malaysia
CHALLENGER USA
ESPACIALITY USA
Small Hydral Power Project SULZER ESCHER Switzerland
BIWATER UK
Boilers Industrial Utility COMPLANT China
THRONE INTL. UK
DEUTCHE BABCOCK Germany
TAKUMA Japan
Cranes R.STAHIL Germany
KONE Finland
Road Construction
Machinery COMPLANT China
BEUMAR Poland
SAKAI, TANAKA Japan
Auto Forging PARSON Turkey
Water Resistant Casting
and Grinding Media BRADLEY AND FOSTER UK
Civic Amenities
Residential Colony
• Family Accommodation: 1091
• Bachelor Accommodation: 342
• Flats: 30
• Mosques: 3
[5]
Schools
• Rehnuma Girls Higher Secondary School
• HMC Boys High School
• Junior Model School
Hospitals
• Male dispensary: 10 beds
• Female dispensary: 20 beds
Other facilities
• Shopping centre
• Officers Club
• Guest House
• Police Station
• Post Office
• Utility Stores
• Banks
• Play Grounds
• Subsidizing Electricity, gas and water supply, sewage, roads, horticulture etc. costing
Approx. 28 million per annum
Expenses on civic amenities are incurred by the company.
[6]
Chapter No. 2
Assembly Shop Assembly shop in HMC is responsible for all type of assemblies generally including assembly of
road rollers, overheard cranes, and mobile cranes, sugar and cement plant components etc.
Assembly
Assembly is a manufacturing process in which parts (usually interchangeable) are added to a
product in a sequential manner to create a finished product
Fitting
Fitting is the process of joining two mechanical parts to each other
Fits
The relation between two mating parts is called fit. Depending upon the actual limits of the hole
or shaft sizes, fits may be classified as clearance fit, transition fit and interference fit.
Clearance fit
Clearance fit is defined as a clearance between mating parts. In clearance fit, there is always a
positive clearance between the hole and shaft.
Interference fit
Interference fit is obtained if the difference between the hole and shaft sizes is negative before
assembly. Interference fit generally ranges from minimum to maximum interference.
Transition fit
Transition fit may result in either an interference or clearance, depending upon the actual values of
the tolerance of individual parts.
Fig. 2.1 Types of Fits
[7]
Fig. 2.1 (cont.) Types of Fits
System of Fits
In identifying limit dimensions for the three classes of fit, two systems are in use:
Hole Basis System
The size of the shaft is obtained by subtracting the allowance from the basic size of the hole.
Tolerances are then applied to each part separately. In this system, the lower deviation of the hole
is zero. The letter symbol indication for this is 'H'.
Shaft Basis System
The upper deviation of the shaft is zero, and the size of the hole is obtained by adding the allowance
to the basic size of the shaft. The letter symbol indication is 'h'.
[8]
Chapter No. 3
Heat Treatment Shop
Heat Treatment
Heat Treatment is process of heating a material to a specific temperature, then cooling at a specific
rate to achieve specific mechanical properties. Iron-Iron carbide Phase Diagram (Iron Carbon
Phase Diagram) is an important guide for heat treatment of different types of plain carbon steel.
Fig. 3.1 Iron Carbon Phase Diagram
Heat Treatment Processes
Annealing
Annealing is the process of slowly raising the temperature about 50ºC (90ºF) above the Austenitic
temperature line or line ACM in the case of Hypo eutectoid steels (steels with < 0.77%Carbon),
about 50ºC (90ºF) in case of eutectoid steel and 50ºC (90ºF) into the Austenite-Cementite region
in the case of Hypereutectoid steels (steels with > 0.77% Carbon).It is held at this temperature for
sufficient time for all the material to transform into Austenite or Austenite-Cementite as the case
may be. It is then slowly cooled at the rate of about 20ºC/hr. (36 ºF/hr.) in a furnace to about 50 ºC
(90 ºF) into the Ferrite-Cementite range. At this point, it can be cooled in room temperature air
with natural convection. The grain structure has coarse Pearlite with ferrite or Cementite
(depending on whether hypo or hyper eutectoid). The steel becomes soft and ductile.
[9]
Normalizing
Normalizing is the process of raising the temperature to over 60 º C (108 ºF), above line A3 or line
ACM Fully into the Austenite range. It is held at this temperature to fully convert the structure into
Austenite, and then removed from the furnace and cooled at room temperature under natural
convection. This results in a grain structure of fine Pearlite with excess of Ferrite or Cementite.
The resulting material is soft; the degree of softness depends on the actual ambient conditions of
cooling. This process is considerably cheaper than full annealing since there is not the added cost
of controlled furnace cooling. The main difference between full annealing and normalizing is that
fully annealed parts are uniform in softness (and machinability) throughout the entire part; since
the entire part is exposed to the controlled furnace cooling. In the case of the normalized part,
depending on the part geometry, the cooling is non-uniform resulting in non-uniform material
properties across the part. This may not be desirable if further machining is desired, since it makes
the machining job somewhat unpredictable. In such a case it is better to do full annealing.
Hardening
Flame Hardening
Flame hardening uses direct impingement of an oxy-gas flame onto a defined surface area. The
result of the hardening process is controlled by four factors: the design of the flame head; the
duration of heating; the target temperature to be reached; and the composition of the metal being
treated. The process is also effective at preheating bars, strip and various contours prior to forming
and forging. Flame Hardening Systems, Inc. manufactures a full range of equipment for efficiently
applying heat to a broad assortment of component parts. Basically there are four methods/types of
systems we build, depending on many factors.
Induction Hardening
A widely used process for the surface hardening of steel. The components are heated by means of
an alternating magnetic field to a temperature within or above the transformation range followed
by immediate quenching. The core of the component remains unaffected by the treatment and its
physical properties are those of the bar from which it was machined, whilst the hardness of the
case can be within the range 37/58 HRC.
Tempering
Tempering is a process of heat treating, which is used to increase the toughness of iron-based
alloys. It is also a technique used to increase the toughness of glass. For metals, tempering is usually
performed after hardening, to reduce some of the excess hardness, and is done by heating the metal
to a much lower temperature than was used for hardening. The exact temperature determines the
amount of hardness removed, and depends on both the specific composition of the alloy and on the
desired properties in the finished product. For instance, very hard tools are often tempered at low
temperatures, while springs are tempered too much higher temperatures. In glass, tempering is
performed by heating the glass and then quickly cooling the surface, increasing the toughness.
[10]
Stress Releasing
Stress releasing is used to reduce residual stresses in large castings, welded parts and cold-formed
parts. Such parts tend to have stresses due to thermals cycling or work hardening. Parts are heated
to temperatures of up to 600-650 C (1112-1202 F), and held for an extended time (about 1 hour or
more) and then slowly cooled in still air.
Carburizing
Carburizing is a process used to harden low carbon steels that normally would not respond to
quenching and tempering. This is done for economic reasons (utilizing less expensive steel) or
design considerations to provide a tough part with good wear characteristics. Carburizing
introduces carbon into a solid ferrous alloy by heating the metal in contact with a carbonaceous
material to a temperature above the transformation range and holding at that temperature.
The depth of penetration of carbon is dependent on temperature, time at temperature, and the
composition of the carburizing agent. As a rough indication, a carburized depth of about 0.03 to
0.05 inches can be obtained in about 4 hours at 1700°F, depending upon the type of carburizing
agent, which may be a solid, liquid, or gas.
The primary object of carburizing is to secure a hard case and a relatively soft, tough core, only
low-carbon steels (up to a maximum of about 0.25% carbon), either with or without alloying
elements (nickel, chromium, manganese, molybdenum), are normally used. After carburizing, the
steel will have a high carbon case graduating into the low-carbon core. Once the carburization is
complete, the parts must be hardened and tempered to obtain the desired properties of both the core
and the case.
[11]
Chapter No. 4
Fabrication Shop
Fabrication
Fabrication is a process of building metallic Structures by cutting, bending and assembling process.
List of Machines
• Power Presses
• Roller Machines
• Radial Drill Machines
• Submerged Arc welding Machines
• Circular Saws
• Edge Planner
• Shearing Machine
• Parallel Flame Cutting Machine
• CNC Flame cutting machine
• De-coiling Machine
• Photocell Cutting Machine
• Brake Press
• Panel bending Machine
• Nibbling Machine
• Plasma Cutting Machines
• Tube welders
• Pipe Squeezing Machine
• Pipe Cutting and Bevelling Machine
• Tube Bending Machine
• TIG Welding Machine
• Welding Transformers
Raw Materials
Standard raw materials used by metal fabricators are:
• Flite metal Formed and expanded
• Tube stock
• Square stock
• Sectional metals (I beams, W beams, C-channel...)
• Castings
[12]
Layout
Marking out or layout is the process of transferring a design or pattern to a work piece, as the first
step in the manufacturing process. It is performed in many industries
Marking out consists of transferring the dimensions from the plan to the work piece in preparation
for the next step, machining or manufacture.
Typical Tools for Layout
Typical tools include:
Surface plate or marking out table
It provides a true surface from which to work.
Angle Plates
It assists in holding the work piece perpendicular to the table.
Scriber
It is the equivalent of a pen or pencil. It literally scratches the metal surface leaving behind a fine,
bright line.
Height Gauge or Scribing Block
It allows lines to be scribed at a preset distance, from the table’s surface.
Surface Gauge
An ungraduated comparison measuring tool that performs much the same function as the Vernier
height gage. It is often used in conjunction with a dial indicator and a precision height gauge.
Marking Blue
To provide a usable writing surface by covering any existing scratches and providing a contrasting
background.
Protractor
To assist in the transfer of angular measurements.
Tri-Square
To transfer 90° angles to the work piece.
[13]
Punches
It pricks or center punch to create permanent marks or dimples for drill bits to start in Ball peen
hammer used in conjunction with the punches to provide the striking blow needed.
Dividers or Measuring Compass
It is used for marking out circles of any desired radius.
Fabrication Techniques
To improve productivity of the process different types of production tools are used e.g. Fixtures,
Supports etc. these tools holds the work piece/Locate it or/and guide the tool, so reduce the time to
be used for locating or marking.
Cutting
The cutting part of fabrication is done via:
• Sawing
• Shearing (all with manual and powered variants)
• Oxy-Fuel Cutting (such as oxy-fuel torches or plasma torches)
• CNC cutters (using a laser, torch, or water)
• Semi-automatic cutting machines
• Electromagnetic cutting machines
• Plasma cutting machines
• Photocell cutting machines
• Parallel torch cutting machines
Forming Processes
The forming processes modify the work piece by deforming it i.e. without removing any material.
Forming is done with a system of mechanical forces and, especially for bulk metal forming, with
heat.
The Following is important forming processes:
• Bending
• Pre-Bending
• Roll Forming
• Drawing
• Deep Drawing
• Tube Expansion
• Tube Bending
• Coining
[14]
• Spinning
• Stamping
Bending
Bending is a manufacturing process that produces a V-shape, U-shape, or channel shape along a
straight axis in ductile materials, most commonly in sheet metal.
Pre-Bending
This process is performed before Roll Forming. A piece of sheet metal is bent slightly before it is
sent to a rolling machine for producing required curvature, this process is termed as pre- bending.
Roll Forming
Roll forming, also termed as rolling, is a continuous bending operation in which a long strip of
sheet metal (typically coiled steel) is passed through sets of rolls mounted on consecutive stands,
each set performing only an incremental part of the bend, until the desired cross-section profile is
obtained.
Drawing and Deep Drawing
Drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a
forming die by the mechanical action of a punch. It is thus a shape transformation process with
material retention. The process is considered "deep" drawing when the depth of the drawn part
exceeds its diameter.
Tube Expansion and Bending
In this process a tube is bended or expanded according to the desired Application.
Coining
Coining is a form of precision stamping in which a work piece is subjected to a sufficiently high
stress to induce plastic flow on the surface of the material.
Spinning
Metal spinning, also known as spin forming or spinning or metal turning, is a metalworking process
by which a disc or tube of metal is rotated at high speed and formed into an axially symmetric part.
Spinning can be performed by hand or by a CNC lathe.
Stamping
Stamping (also known as pressing) is the process of placing flat sheet metal in either blank or coil
form into a stamping press where a tool and die surface forms the metal into a net shape. Stamping
includes a variety of sheet-metal forming manufacturing processes, such as punching using a
machine press or stamping press, blanking, embossing, bending, flanging, and coining.
[15]
WELDING
Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics,
by causing coalescence. This is often done by melting the work pieces and adding a filler material
to form a pool of molten material (the weld pool) that cools to become strong joint, with pressure
sometimes used in conjunction with heat, or by itself, to produce the weld. This is in contrast with
soldering and brazing, which involve melting a lower-melting-point material between the work
pieces to form a bond between them, without melting the work pieces.
Shielded Metal Arc Welding (SMAW)
Shielded metal arc welding (SMAW), also known as manual metal arc (MMA) welding or
informally as stick welding, is a manual arc process that uses a consumable electrode coated influx
to lay the weld. An electrician the form of either alternating or current from welding is used to form
an electric between the electrode and the metals to be joined. As the weld is laid, the flux coating
of the electrode disintegrates, giving off vapors that serve as shielding and providing a layer of
slag, both of which protect the weld area from atmospheric contamination.
Because of the versatility of the process and the simplicity of its equipment and operation, shielded
metal arc welding is one of the world's most popular welding processes. It dominates other welding
processes in the maintenance and repair industry, and though flux welding is growing in popularity,
SMAW continues to be used extensively in the construction of steel structures and in industrial
fabrication. The process is used primarily to weld iron and steels (including stainless but aluminum,
nickel and copper alloys can also be welded with this method.
Defects
As SMAW is manual welding process so it has no uniformity (for larger welds) and there is also
equality difference in welding (someplace thick and some other place thin). To remove this defect
SAW welding is used.
Submerged Arc Welding (SAW)
Submerged arc welding (SAW) is a common arc process. Originally developed by the Linde -
Union Carbide Company. It requires a continuously fed consumable solid or tubular flux cored)
electrode. The molten weld and the arc zone are protected from atmospheric Contamination by
being “submerged” under a blanket of granular fusible flux consisting of Lime, silica, manganese
oxide, calcium and other compounds. When molten, the flux becomes conductive, and provides a
current path between the electrode and the work.
This thick layer of flux completely covers the molten metal thus preventing spatter and sparks as
well as suppressing the intense ultraviolet radiation and fumes that are a part of the shielded metal
arc welding (SMAW) process. SAW is normally operated in the automatic or mechanized mode,
however, semi-automatic (hand-held) SAW guns with pressurized or gravity flux feed delivery are
available.
The process is normally limited to the flat or horizontal-fillet welding positions (although
horizontal groove position welds have been done with a special arrangement to support the
flux).Single or multiple (2 to 5) electrode wire variations of the process exist. SAW strip-cladding
utilizes a flat strip electrode (e.g. 60 mm wide x 0.5 mm thick). DC or AC power can be used, and
combinations of DC and AC are common on multiple electrode systems. Constant voltage welding
are most commonly used; however, constant current systems in combination with a voltage sensing
wire-feeder are available.
[16]
Gas Tungsten Arc Welding (GTAW)
Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc
welding process that uses a non-consumable tungsten electrode to produce the weld. The weld area
is protected from atmospheric contamination by shielding (usually an inert such as argon), and
fillers normally used, though some welds, known as autogenously welds, do not require it.
A constant-current supply produces energy which is conducted across the arc through a column of
highly ionized gas and metal vapors known as plasma GTAW is most commonly used to weld thin
sections of stainless steel and non-ferrous metals such as aluminum, magnesium, and copper alloys.
The process grants the operator greater control over the weld than competing procedures such as
shielded and gas welding, allowing for stronger, higher quality welds.
However, GTAW is comparatively more complex and difficult to master, and furthermore, it is
significantly slower than most other welding techniques. A related process, plasma uses a slightly
different welding torch to create a more focused welding arc and as a result is often automated
Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG)
welding or metal active gas (MAG) welding, is a welding process in which an electric arc forms
between a consumable wire electrode and the work piece metal(s), which heats the work piece
metal(s), causing them to melt, and join.
Along with the wire electrode, a shielding gas feeds through the welding gun, which shields the
process from contaminants in the air. The process can be semi-automatic or automatic. A constant
voltage, direct current power source is most commonly used with GMAW, but constant current
systems, as well as alternating current, can be used. There are four primary methods of metal
transfer in GMAW, called globular, short-circuiting, spray, and pulsed-spray, each of which has
distinct properties and corresponding advantages and limitations.
Originally developed for welding aluminum and other non-ferrous materials in the 1940s, GMAW
was soon applied to steels because it provided faster welding time compared to other welding
processes. The cost of inert gas limited its use in steels until several years later, when the use of
semi-inert gases such as carbon dioxide became common. Further developments during the 1950s
and 1960s gave the process more versatility and as a result, it became a highly used industrial
process.
Today, GMAW is the most common industrial welding process, preferred for its versatility, speed
and the relative ease of adapting the process to robotic automation. Unlike welding processes that
do not employ a shielding gas, such as shielded metal arc welding, it is rarely used outdoors or in
other areas of air volatility. A related process, flux cored arc welding, often does not use a shielding
gas, but instead employs an electrode wire that is hollow and filled with flux.
TYPES OF WELDING DEFECTS
Cracks
Cracks are produced due to properties difference of materials and wrong pre-heating.
Incomplete Penetration
This type of defect is found in any of three ways:
• When the weld bead does not penetrate the entire thickness of the base plate.
[17]
• When two opposing weld beads do not interpenetrate.
• When the weld bead does not penetrate the toe of a fillet weld but only bridges across
it.
Welding current has the greatest effect on penetration. Incomplete penetration is usually caused by
the use of too low a welding current and can be eliminated by simply increasing the amperage.
Other causes can be the use of too slow a travel speed and an incorrect torch angle. Both will allow
the molten weld metal to Roll in front of the arc, acting as a cushion to prevent penetration. The
arc must be kept on the leading edge of the weld puddle.
Distortion
Welding methods that involve the melting of metal at the site of the joint necessarily are pronto
shrinkage as the heated metal cools. Shrinkage then introduces residual stresses and distortion.
Distortion can pose a major problem, since the final product is not the desired shape. To alleviate
certain types of distortion the work pieces can be offset so that after welding the product is the
correct shape.
Gas Inclusion
Gas inclusions are a wide variety of defects that includes
• Porosity
• Blow holes
• Pipes
The underlying cause for gas inclusions is the entrapment of gas within the solidified weld. Gas
formation can be from any of the following causes: high sulfur content in the work piece or
electrode, excessive moisture from the electrode or work piece, too short of an arc, or wrong
welding current or polarity.
Undercut
Most structural failures originate from weld joint because it is the source of discontinuity or defects.
The most visible weld defect we can easily find in visual inspection is undercut. Undercut is usually
due to over current in electric arc welding. Over current causes wide melting zone in base metal
but not enough weld fusion metal to replace the gap. High lapping speed also leaves the gap poorly
filled with weld fusion metal and produces undercut. To avoid undercut, welder and welding
inspector must observe initial weld lap to see whether the current setting is appropriate. Post
welding inspection can be tricky since welder can cover undercut by running another lap using
lower grade welding electrode and low current. Undercut is dangerous because it amplifies the
stress flow due to reduction in section area and stress concentration of the notch form Undercut
and overlap.
Incomplete Fusion
Other welding defect is incomplete fusion which is due to undercurrent. Arc welding uses
concentrated high-temperature electric arc to melt both base metal and welding electrode. These
melted base metal and electrode mix and fuse together into weld pool which subsequently bonds
adjoining base metals. If the welding current is set too low, ideal melting Temperature cannot be
achieved and base metal doesn’t melt completely. Furthermore, weld Pool material is not adequate
[18]
and gap between adjoining base metals is not properly filled. This will leave empty holes inside or
outside weld joints.
Surface Cleaning
It is done to preserve the surface from corrosion etc.
Following are the types of Surface Cleaning Process:
• Shot Blasting
• Sand Blasting
• Chemical Cleaning (pickling)
Boiler
Boiler is one of the major products of Heavy Mechanical Complex, Taxila. It has the vast
experience of manufacturing small as well as large Power and Industrial Boilers.
There are two types of boilers:
• Fire tube boiler (Smoke Tube Boiler)
• Water tube Boiler (spelled water-tube)
Fire tube boiler (Smoke Tube Boiler)
A fire-tube boiler is a type of boiler in which hot gases from a fire pass through one or (many)
more tubes running through a sealed container of water. The heat of the gases is transferred through
the walls of the tubes by thermal conduction, heating the water and ultimately creating steam.
Fig. 4.1 Fire Tube Boiler
Water tube Boiler
A water tube boiler (also spelled water-tube and water tube) is a type of boiler in which water
circulates in tubes heated externally by the fire. Fuel is burned inside the furnace, creating hot gas
which heats water in the steam-generating tubes. In smaller boilers, additional generating tubes are
separate in the furnace, while larger utility boilers rely on the water-filled tubes that make up the
walls of the furnace to generate steam.
[19]
Fig. 4.2 Water Tube Boiler
Third Party Inspection
In all type of pressure vessels an inspection company (termed as third party) accredited by boiler
boards or international standardizing organizations e.g. ASME also inspects the vessel time to time
during manufacturing this inspection is known as third party inspection.
[20]
Chapter No. 5
Production Planning and Control (PPC)
Sales Order Numbering System
The sales order numbering system allocates a unique identification system to each order acquired
by the sales and marketing department. This sales order consists of six digits.
The first two of these numbers designate the product group number of the products to be
manufactured or services to be provided by the organization.
The next two digits specify the fiscal year in which the order is received.
The last two digits denotes the serial number of order of a particular type.
For example, a job order given as111504 is read as follows
11: product group for sugar spares
15: represents 2014-15 as the fiscal year
04: specifies the fourth order for the current year that is fourth order of sugar spares in 2015.
Core Planning
Core planning section has following works.
Master schedule planning.
Order Activity plans.
Monitoring of all the schedules.
Project Planning
To ensure receipt of all drawings and documentation from design.
To issue the material purchase requirement.
To prepare the requirements of materials to be issued.
To prepare and issue job orders and prepare the follow up.
Material Management (MMG)
Material requirement planning.
Intending and follow up of indent.
To keep updated purchase status of all project documents.
Establish stock levels for general consumable items and raw materials.
Coding of store items.
Insurance of material to appropriate job.
To keep and maintain updated stock status of all store items.
[21]
Process Planning
Preparation of following documents:
Detail parts list
Route card (machining and fabrication) if required
Cutting plans
Time sheets
Tool designing
Designing of all types of press tools, dies, templates, jigs and fixtures.
To produce drawings for machinery components for maintenance.
Cutting plans, cutting/marketing templates for shop.
Dispatch Cell/Material Handling
To receive finish goods from shops/material handling sections.
To draw the standard items/equipment from stores for dispatch to costumer/sites.
To organize preservation/packing. Mostly painted with red oxides to prevent from
corrosion.
Maintain detailed dispatch records of finished goods, equipment, standard items against
each contract.
Organize transportation.
Ensure complete and accurate documentation along with each dispatch.
To prepare the dispatch plans and ensure compliance.
Income tax Cost and Revenue (ICR)
To defend in litigation/adjudication and contravention
To organize industrial survey.
To obtain the consumption certificates and release of guarantee.
[22]
Chapter No. 6
Steel Foundry A foundry is a workshop that produces metal castings. Metals are cast into shapes by melting them
into a liquid, pouring the metal in a mold, and removing the mold material or casting after the metal
has solidified as it cools. The most common metals processed are aluminum and cast iron.
Casting Process
Casting process contain the following steps:
Pattern Making
Pattern making is the first stage for developing a new casting. The pattern, or replica of the finished
piece, is typically constructed from wood but may also be made of metal, plastic, plaster or other
suitable materials. These patterns are permanent so can be used to form a number of moulds.
Pattern making is a highly skilled and precise process that is critical to the quality of the final
product. Many modern pattern shops make use of computer-aided design (CAD) to design patterns.
Mould Making
The mould is formed in a mould box (flask), which is typically constructed in two halves to assist
in removing the pattern. Sand moulds are temporary so a new mould must be formed for each
individual casting. A cross-section of a typical two-part sand mould. The bottom half of the mould
(the drag) is formed on a moulding board. Cores require greater strength to hold their form during
pouring. Dimensional precision also needs to be greater because interior surfaces are more difficult
to machine, making errors costly to fix.
Melting and Pouring
Many foundries, particularly ferrous foundries, use a high proportion of scrap metal to make up a
charge. As such, foundries play an important role in the metal recycling industry. Internally
generated scrap from runners and risers, as well as reject product, is also recycled. The charge is
weighed and introduced to the furnace. Alloys and other materials are added to the charge to
produce the desired melt. In some operations the charge may be preheated, often using waste heat.
In traditional processes metal is superheated in the furnace. Molten metal is transferred from the
furnace to a ladle and held until it reaches the desired pouring temperature.
Fettling, Cleaning and Finishing
After the casting has cooled, the gating system is removed, often using band saws, abrasive cut-off
wheels or electrical cut-off devices. A ‘parting line flash’ is typically formed on the casting and
must be removed by grinding or with chipping hammers. Castings may also need to be repaired by
welding, brazing or soldering to eliminate defects.
[23]
Advantages of Sand Casting
Use is widespread; technology well developed.
Materials are inexpensive, capable of holding detail and resist deformation when heated.
Process is suitable for both ferrous and non-ferrous metal castings.
Handles a more diverse range of products than any other casting method.
Produces both small precision castings and large castings of up to 1 ton.
Can achieve very close tolerances if uniform compaction is achieved.
Mould preparation time is relatively short in comparison to many other processes.
The relative simplicity of the process makes it ideally suited to mechanization.
High levels of sand reuse are achievable
Limitations
Typically limited to one or a small number of moulds per box.
Sand: metal ratio is relatively high.
High level of waste is typically generated, particularly sand, bag house dust and spent shot.
Steel Melting Furnace
Molten metal is prepared in a variety of furnaces, the choice of which is determined by the quality,
quantity and throughput required.
Electric Induction Furnaces
Electric induction furnaces are the most common type used for batch melting of ferrous, copper
and super alloys. This method involves the use of an electrical current surrounding a crucible that
holds the metal charge. Furnace sizes range from < 100 kg up to 15 tons. For production of super
alloys and titanium, melting may be undertaken in a vacuum chamber to prevent oxidation.
[24]
Chapter No. 7
Non-Destructive Testing (NDT) Lab Non-destructive testing (NDT) is a wide group of analysis techniques used in science and industry
to evaluate the properties of a material, component or system without causing damage. The terms
Non-destructive examination (NDE), Non-destructive inspection (NDI), and Non-destructive
evaluation (NDE) are also commonly used to describe this technology. Because NDT does not
permanently alter the article being inspected, it is a highly-valuable technique that can save both
money and time in product evaluation, troubleshooting, and research on Destructive testing (NDT)
Methods:
Radiographic Testing (RT)
Ultrasonic Testing (UT)
Magnetic Particle Testing
Liquid Penetration Testing
Eddy Current Testing
Radiographic Testing
Radiographic Testing (RT), or industrial radiography, is a non-destructive testing (NDT) method
of inspecting materials for hidden flaws by using the ability of short wavelength electromagnetic
radiation (high energy photons) to penetrate various materials. The followings steps are involved:
Job is divided into sections
Separate room is used for testing
After developing process, illuminators of different ranges are used to see the defects that
are capture through the film.
Developing of Film
This process is consisting of following steps
Developer: alkaline changes the exposed salt to black metallic silver 5-6 minutes
Stop bath: It neutralizes the developer and stop the developing process.
Fixer: At this step, the effects of faults are fixed.
Water tank: It cleans the film from chemicals.
PF. Solution: It prevents water to make spot.
Ultrasonic Testing
Ultrasonic testing (UT) is a family of non-destructive testing techniques based on the propagation
of ultrasonic waves in the object or material tested.
A typical UT inspection system consists of several functional units, such as the pulser/receiver,
transducer, and display devices. A pulser/receiver is an electronic device that can produce high
voltage electrical pulses. Driven by the pulser, the transducer generates high frequency ultrasonic
energy. The sound energy is introduced and propagates through the materials in the form of waves.
When there is a discontinuity (such as a crack) in the wave path, part of the energy will be reflected
back from the flaw surface. The reflected wave signal is transformed into an electrical signal by
[25]
the transducer and is displayed on a screen. In the applet below, the reflected signal strength is
displayed versus the time from signal generation to when an echo was received. Signal travel time
can be directly related to the distance that the signal traveled. From the signal, information about
the reflector location, size, orientation and other features can sometimes be gained.
Probe types
Normal beam probes: radiate their sound wave perpendicular to specimen surface.
TR probes: separate crystal for receiving and transmitting waves
Angle beam probes: probes that radiate their sound wave at an angle.
Advantages
It is sensitive to both surface and subsurface discontinuities.
The depth of penetration for flaw detection or measurement is superior to other NDT
methods.
Only single-sided access is needed when the pulse-echo technique is used.
It is highly accurate in determining reflector position and estimating size and shape.
Limitations
Surface must be accessible to transmit ultrasound.
Skill and training is more extensive than with some other methods.
It normally requires a coupling medium to promote the transfer of sound energy into the
test specimen.
Materials that are rough, irregular in shape, very small, exceptionally thin or not
homogeneous are difficult to inspect.
Cast iron and other coarse grained materials are difficult to inspect due to low sound
transmission and high signal noise.
Magnetic Particles Inspection
Magnetic particle Inspection (MPI) is an NDT process for detecting surface and slightly subsurface
discontinuities in ferromagnetic materials such as iron, nickel, cobalt, and some of their alloys. The
process puts a magnetic field into the part. The piece can be magnetized by direct or indirect
magnetization.
Magnet ink is used as magnetic powder which is attracted to local pole sat defects. Mostly the
white powdering is done on the job to increase the contrast before magnetizing.
Liquid penetrant Testing
Penetrant testing (PT), is a widely applied and low-cost inspection method used to locate surface-
breaking defects in all non-porous materials (metals, plastics, or ceramics).
Principle
[26]
DPI is based upon capillary action, where fluid having low surface tension penetrates into clean
and dry surface-breaking discontinuities. Penetrant may be applied to the test component by
dipping, spraying, or brushing. After adequate penetration time has been allowed, the excess
penetrant is removed and a developer is applied. The developer helps to draw penetrant out of the
flaw so that an invisible indication becomes visible to the inspector. Inspection is performed under
ultraviolet or white light, depending on the type of dye used - fluorescent or no fluorescent (visible).
Inspection steps
Pre-cleaning
Application of Penetrant
Excess Penetrant Removal
Application of Developer
Inspection
Mostly cleaner for the penetrant which used are solvent and water emulsifier.
Eddy Current Testing
Continuous wave eddy current testing is one of several non-destructive testing methods that use
the electromagnetism principle. Conventional eddy current testing utilizes electromagnetic
induction to detect discontinuities in conductive materials.
A specially designed coil energized with alternating current is placed in proximity to the test
surface generating changing magnetic-field which interacts with the test-part producing eddy
current in the vicinity.
[27]
Chapter No. 8
Basic Machine Shop In the development of every nation industries are very important and for industries machinery’s
key factor. To check the development of any industry check it’s machinery. The machine shop of
HMC contains various types of machines.
Production Planning Section (PPS)
This section is known as the main branch of machine shop. Working is Given Below:
Job order receiving from PPS
Drawing set receiving from PPS
Cutting plan received (if required)
Material receiving
Drawing/Job order Planning
Loading
Machining
Inspection
Movement
o Assembly Shop
o Dispatch Cell
o Fabrication Shop
List of Machines
Lathe machine (Three jaws and four jaws chucks, turret)
Planer machine
Shaper Machine
Milling machine
Cylindrical Grinding Machine
Drilling machine
HDL (Heavy duty lathe)
BVT (Boring vertical turret lathe machine)
Gear hobbling machine
Gear shaper machine
Straight bevel machine
Horizontal lathe machine
Radial drilling machine
[28]
Slotting machine
Double housing planner
Face plate machine
Column drilling machine
Machining
A material removal process in which a sharp cutting tool is used to mechanically cutaway material
so that the desired part geometry remains.
Most common application includes to shape metal parts. Machining is the most versatile and
accurate of all manufacturing processes in its capability to produce a diversity of part geometries
and geometric features (e.g. Screw threads, gear teeth, flat surfaces).
Classification of Machined Parts
Rotational - cylindrical or disk-like shape
Achieved by rotation motion of the work part e.g. turning and boring.
Non-rotational (also called prismatic) - block-like or plate-like
Achieved by linear motion of the work part e.g. milling, shaping, planning and sawing
Turning and Related Operations
Turning
A single point cutting tool removes material from a rotating work piece to generate cylindrical
shape. The tool is fed linearly in a direction parallel to the axis of rotation Performed on a machine
tool called a lathe.
Facing
Tool is fed radially inward to create a flat surface.
Chamfering
Cutting edge cuts an angle on the corner of the cylinder, forming a "chamfer".
Threading
Pointed form tool is fed linearly across surface of rotating work part parallel to axis of rotational a
large feed rate, thus creating threads.
Hobbing
Hibbing is a machining process for making gears, splines, and sprockets on a hobbling machine,
which is a special type of machine. The teeth or splines are progressively cut into the work piece
by a series of cuts made by cutting called a hob. Compared to other gear forming processes it is
relatively inexpensive but still quite accurate, thus it is used for a broad range of parts and quantities
It is the most widely used gear cutting process for creating spur and helical gears and more gears
are cut by hobbling than any other process since it is relatively quick and inexpensive.
[29]
Types of Gears
Spur Gears
Helical Gears
Worm Wheel
Sprocket
Bevel Gear
Spiral Bevel
Rack and Pinion
Cutters Used for Gear Cutting
Mechanical Cutter
Hob Cutter
Disc type Cutter
Taper shank Cutter
Sprocket Cutter
Blades
Lathe Machine
Most lathe machines are horizontal but vertical lathe machines are also used for jobs with large
diameter relative to the length and for heavy work. The size of the lathe is designated by swing and
maximum distance between centres. Swing is the maximum work part diameter that can be rotated
in the spindle.
Fig. 8.1 Lathe Machine
[30]
Shaper Machine
A shaper is a type of machine tool that uses linear relative motion between the work piece and a
single-point cutting tool to machine a linear toolpath. Its cut is analogous to that of a lathe, except
that it is (archetypally) linear instead of helical. (Adding axes of motion can yield helical toolpaths,
has also done in helical planning.) A shaper is analogous to a planer, but smaller, and with the cutter
riding a ram that moves above a stationary work piece, rather than the entire work piece moving
beneath the cutter. The ram is moved back and forth typically by a crank inside the column;
hydraulically actuated shapers also exist.
Planar Machine
A planer is a type of metalworking machine tool that uses linear relative motion between the work
piece and a single-point cutting tool to machine a linear toolpath. Its cut is analogous to that of a
lathe, except that it is (archetypally) linear instead of helical. A planer is analogous to a shaper, but
larger, and with the entire work piece moving on a table beneath the cutter, instead of the cutter
riding a ram that moves above a stationary work piece. The table is moved back and forth on the
bed beneath the cutting head either by mechanical means, such as a rack and pinion drive or a
leadscrew, or by a hydraulic cylinder.
[31]
Chapter No. 9
Technology Department
Technology department has two major functions:
Provide feasibility study or quantitative details of a project before taking the order
Technology Preparation for workshops
HMC I & II has different Technology departments e.g. Technology I and Technology II.
Technology I is responsible for fabrication, machining and assembly.
Technology II is responsible for casting and forging.
Technology department designs the entire process for completion of a project including all major
as well as minor details.
Feasibility Study
Sales and marketing department receives a quotation about any project.
It sends a letter to technology department and asks for its feasibility study.
Then Technology department prepares a feasibility report to sales and marketing
department.
Further, the report is sent to accounts department for cost analysis.
Then, it is sent back to Sales and marketing Department, which replies the quotation or
receives the order.
[32]
Chapter No. 10
Material Testing Lab
Material testing laboratory is divide into three sections:
Metallographic
Mechanical testing
Chemical analysis (ferrous, non-ferrous, refractory materials)
Metallography
Metallography is the study of the physical structure and components of metals, typically using
microscopy In HMC metallographic section the microscope with the following magnification is
available.
100x 450x 1000x 2000x
Mechanical Testing
In this section the tests being performed are:
Tensile Tests
o Tensile strength
o Yield strength
o Elongation
o Reduction in area
Bend Tests
Impact Tests
Crushing Test
Hardness
Shear Test
Universal Testing Machine (UTM)
A universal testing machine (UTM), also known as a universal tester, materials testing machine or
materials test frame, is used to test the tensile strength and compressive strength of materials. It is
named after the fact that it can perform many standard tensile and compression tests on materials,
components, and structures.
The set-up and usage are detailed in a test method, often published by a standards organization.
This specifies the sample preparation, fixturing, gauge length (the length which is under study or
observation), analysis, etc.
The specimen is placed in the machine between the grips and an extensometer if required can
automatically record the change in gauge length during the test. If an extensometer is not fitted,
[33]
the machine itself can record the displacement between its cross heads on which the specimen is
held. However, this method not only records the change in length of the specimen but also all other
extending / elastic components of the testing machine and its drive systems including any slipping
of the specimen in the grips.
Once the machine is started it begins to apply an increasing load on specimen. Throughout the tests
the control system and its associated software record the load and extension or compression of the
specimen.
Charpy Impact Testing Machine
Charpy impact testing involves striking a standard notched specimen with a controlled weight
pendulum swung from a set height. The standard Charpy-V notch specimen is 55mm long, 10mm
square and has a 2mm deep notch with a tip radius of 0.25mm machined on one face. The specimen
is supported at its two ends on an anvil and struck on the opposite face to the notch by the
pendulum. The amount of energy absorbed in fracturing the test-piece is measured and this gives
an indication of the notch toughness of the test material.
The pendulum swings through during the test, the height of the swing being a measure of the
amount of energy absorbed in fracturing the specimen. Conventionally, three specimens are tested
at any one temperature and the results averaged.
Charpy tests show whether a metal can be classified as being either brittle or ductile. This is
particularly useful for ferritic steels that show a ductile to brittle transition with decreasing
temperature. A brittle metal will absorb a small amount of energy when impact tested, a tough
ductile metal absorbs a large amount of energy. The appearance of a fracture surface also gives
information about the type of fracture that has occurred; a brittle fracture is bright and crystalline,
a ductile fracture is dull and fibrous.
The percentage crystallinity is determined by making a judgement of the amount of crystalline or
brittle fracture on the surface of the broken specimen, and is a measure of the amount of brittle
fracture.
Lateral expansion is a measure of the ductility of the specimen. When a ductile metal is broken,
the test-piece deforms before breaking, and material is squeezed out on the sides of the compression
face. The amount by which the specimen deforms in this way is measured and expressed as
millimeters of lateral expansion.
When reporting the results of a Charpy test, the absorbed energy (in J) is always reported, while
the percentage crystallinity and lateral expansion are optional on the test report. It should be
emphasized that Charpy tests are qualitative, the results can only be compared with each other or
with a requirement in a specification - they cannot be used to calculate the fracture toughness of a
weld or parent metal.
Brinell Testing Machine
The Brinell hardness test method as used to determine Brinell hardness, is defined in ASTM E10.
Most commonly it is used to test materials that have a structure that is too coarse or that have a
surface that is too rough to be tested using another test method, e.g., castings and forgings. Brinell
testing often use a very high test load (3000 kgf) and a 10mm wide indenter so that the resulting
indentation averages out most surface and sub-surface inconsistencies.
The Brinell method applies a predetermined test load (F) to a carbide ball of fixed diameter (D)
which is held for a predetermined time period and then removed. The resulting impression is
measured across at least two diameters – usually at right angles to each other and these result
[34]
averaged (d). A chart is then used to convert the averaged diameter measurement to a Brinell
hardness number. Test forces range from 500 to 3000 kgf.
A Brinell hardness result measures the permanent width of indentation produced by a carbide
indenter applied to a test specimen at a given load, for a given length of time. Typically, an
indentation is made with a Brinell hardness testing machine and then measured for indentation
diameter in a second step with a specially designed Brinell microscope or optical system.
The resulting measurement is converted to a Brinell value using the Brinell formula or a conversion
chart based on the formula. Most typically, a Brinell test will use 3000 kgf load with a 10mm ball.
If the sample material is aluminum, the test is most frequently performed with a 500 kgf load and
10mm ball. Brinell test loads can range from 3000 kgf down to 1 kgf. Ball indenter diameters can
range from 10mm to 1mm.
Generally, the lower loads and ball diameters are used for convenience in “combination” testers,
like Rockwell units, that have a small load capacity. The test standard specifies a time of 10 to 15
seconds, although shorter times can be used if it is known that the shorter time does not affect the
result.
Rockwell Testing Machine
The Rockwell hardness test method, as defined in ASTM E-18, is the most commonly used
hardness test method. The Rockwell test is generally easier to perform, and more accurate than
other types of hardness testing methods. The Rockwell test method is used on all metals, except in
condition where the test metal structure or surface conditions would introduce too much variations;
where the indentations would be too large for the application; or where the sample size or sample
shape prohibits its use.
The Rockwell method measures the permanent depth of indentation produced by a force/load on
an indenter. First, a preliminary test force (commonly referred to as preload or minor load) is
applied to a sample using a diamond indenter. This load represents the zero or reference position
that breaks through the surface to reduce the effects of surface finish.
After the preload, an additional load, call the major load, is applied to reach the total required test
load. This force is held for a predetermined amount of time (dwell time) to allow for elastic
recovery. This major load is then released and the final position is measured against the position
derived from the preload, the indentation depth variance between the preload value and major load
value. This distance is converted to a hardness number.
Preliminary test loads (preloads) range from 3 kgf (used in the “Superficial” Rockwell scale) to 10
kgf (used in the “Regular” Rockwell scale) to 200 kgs. Total test forces range from 15kgf to 150
kgf (superficial and regular) to 500 to 3000 kgf (macro hardness).
A variety of indenters may be used: conical diamond with a round tip for harder metals to ball
indenter’s ranges with a diameter ranging from 1/16” to ½” for softer materials.
[35]
Chapter No. 11
Inspection Inspection is a process in which the material is just visually Checked by using many apparatus like
Vernier Caliper, Micro meter screw gauges, Tapes, Compasses etc. When this is done, then a report
is prepared containing all the references with respect to that the material was passed out from the
inspection stage and this is a necessary step to assure the quality of the product. And is done where
the status of the manufacturing industry is to be maintained and the Quality of the manufactured
product is too kept up to the standards.
The working process starts with agreement between purchaser and manufacture, the manufacture
provides Preformat Invoice (PI) to the purchaser which explains the equipment specification and
related price. Then the purchaser issues the Purchase Order (PO) which confirming the preformat
invoice. Before start of manufacturing, the purchaser must provide equipment inspection and test
plan (ITP) to the manufacture. The ITP identifies all inspection points for purchaser inspector.
Then the manufacture needs to prepare the project quality control plan based of this inspection and
test plan. The manufacture notifies purchaser inspector in advance to attend to her factory for
witnessing the inspections and tests. The communication and coordination channel between
manufacture, purchaser inspector and purchaser are agreed in the Pre-inspection meeting
(PIM).Based the international practice manufacture sends her notification to the purchaser, and
purchaser reviews the notification and after her approval sends to the inspector.
Then the inspector will be attended in the in manufacture shop to witness the test or inspection.
The purchaser inspector will send his/her inspection visit report to the purchaser. Purchaser can
assign his/her own inspector which is her own direct employee or hire a third party inspection
agency to carry out inspection.
Inspection and test plan has tabular format and its content extracted from construction code. In
each row of the table there is quality control and inspection requirement and determine which party
is responsible for control and inspection. There are three parties in ITP:
Manufacturer
Third Party Inspector (TPI)
Client or purchaser.
Final Inspection before manufacturing section consists of Pre-Inspection Meeting (PIM) and
review of quality control documents which need to be approved before start of manufacturing.
There are 3 or 4 important terminologies in the ITP which determines the responsibility of each
party. These are:
Hold point (H)
Hold on the production till TPI Inspector perform inspection and supervise the required test, as
general; attendance to the PIM meeting, raw material inspection and identification, Post Weld Heat
Treatment Review, Hydrostatic Test, Performance Test, Run-Out Test and Final Inspection are
Hold points. Normally manufactures shall notify TPI Inspector 7 working days in advance.
Witness Point (W)
Manufacture shall notify client and TPI Inspector but there is no hold on the production, client can
waive this inspection based on his discretion and inform TPI Inspector.
[36]
Spot Witness (SW)
For items with spot witness manufacture shall notify TPI inspector as fulfilling the monitoring for
example one random visit for whole UT Tests or one or two visit for whole surface preparation
work for painting.
Review (R)
Review means Review document, which includes the review of quality control records, test reports
and etc. When TPI Inspector make visit for hold or witness point, the inspector can review the
related documents.
[37]
APPENDIX
Schedule of Internship Start: June 17th, 2015
End: July 15th, 2015
S. No. Date Training Workshop/Program
1 June 17th, 2015 Introduction to HMC
2 June 18th, 2015 Assembly Shop
3 June 19th, 2015 Heat Treatment and TTC
4 June 20th-25th, 2015 Fabrication Shop
5 June 26th-27th, 2015 PPC/Dispatch Cell
6 June 29th- July 3rd, 2015 Steel Foundry
7 July 4th, 2015 NDT Lab
8 July 6th-10th, 2015 Basic Machine Shop
9 July 11th, 2015 Technology Department
10 July 13th, 2015 Material Testing Lab
11 July 14th-15th, 2015 Inspection