final industrial training report me

7/22/2019 Final Industrial Training Report Me

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REPORT OF INDUSTRIAL TRAINING AT

JAY BHARAT MARUTI LIMITED

JBML-1

Submitted in partial fulfillment of the requirements for the

award of the

degree of

Bachelor of Technology

In

Mechanical Engineering

SUBMITTED TO SUBMITTED BY

DEPARTMENT OF ASHWANI KUMARMECHANICAL ENGINEERING ROLL NO.-1910

U.I.E.T,MDU (RTK.) BATCH:2009-13

UNIVERSITY INSTITUTE OF ENGINEERING & TECHNOLOGY

MAHARISHI DAYANAND UNIVERSITY ROHTAK, HARYANA(124001)


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CONTENTS

Topic Page Number

1. Chapter 1: About company1.1 Plant details iv

1.2 Company profile v

1.3Vision mission and core values vi1.4 Different departments of the company vii

1.5 Modular kitchens xiii

1.6 Stainless steel(Raw Material) xiii

1.7 Welding xviii

2. Chapter 2: Different types of machine used xxii

4. Chapter 4: Various types of theories used xxxv

4.1 TPM xxxv

4.2 Concepts of 5S xxxvii

5.Chapter 5: Project work xxxix

6.Chapter 6: Conclusion xlvi


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ACKNOWLEDGEMENT

For the training report, information has been obtained from various sources such as

catalogues, journals, internet, company sources etc. I would like to express my gratitude to our

Principal and faculty for encouraging and helping us to undergo industrial training. I would also

like to thank department heads and HR Department of JSL LIFE STYLE. The following firms

and individuals need special mention:

1. Mr SANDEEP MALIK Department head BRAND PRODUCTION JSL LIFE STYLEfor his guidance and supervision during my training at arttdinox.

2. Mr ASHUTOSH SINHA, Sr Manager HR JSL LIFE STYLE.

3. All the faculty members mechanical department UIET MDU Rohtak for their valuable

guidance and encouragement.

I acknowledge with deep sense of gratitude, the encouragement received from my teachers,

parents, friends and everyone who directly or indirectly held me during my industrial training.

YOGESH KUMAR


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Chapter 1

ABOUT COMPANY

1.1 PLANT DETAILS

Table1.1 Plant Details

pic 1.1 plant entrance

ROHAD PLANT

Plant location Rohad, Jhajjar (Haryana).

Total Site Area196,000 sq. feet

Head Office

Jindal Center 12, Bhikaji Cama Place,

New Delhi110 066, India

Phone: +91-11-26188340-50, Fax: +91-11-26189384

Email:[email protected]
mailto:[email protected]:[email protected]:[email protected]:[email protected]


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1.2 COMPANY PROFILE

(a) Arttdinox is the first brand from the house of JSL Lifestyle Ltd.; subsidiary of JSL Stainless

Ltd.; and was launched with the objective of bringing about excellent designs & forms in stainless

steel table ware & home dcor products in India. arttdinox, meaning the art of stainless steel, isan amalgamation of design with functionality. Modeled to enhance your lifestyle, it lends dignity

and sophistication unprecedented. Ms. Deepikaa Jindal, who took up the challenge to spread out

the arena of stainless steel from kitchen shelves to your entire house and office, started the brand

in 2003.

(b) The essence of the brand is that it Helps you create spaces that speak of you. As a brand

arttdinox takes cognizance of the changing sensibilities & aspirations of the consumers and

responds to them. Today arttdinox is one of the few Indian homegrown brands, which signify

luxury & lifestyle. In a span of couple of years, arttdinox has carved a niche for itself within the

lifestyle segment by becoming Indias premier Stainless steel home segment product

manufacturer and retailer.

(c) Through its state-of-the-art manufacturing unit in Haryana, India, arttdinox produces over six

categories of designer stainless steel products viz. home dcor, bar range, dining range, beverage

range & office accessories. Recently we have launched our premium cookware range with

features which are of international level. In an industry where steel is considered durable & not

designer, arttdinox was set up with the objective of creating exclusive and designer stainless

steel lifestyle products, which are synonymous with quality and functionality. The product range

redefines the dimensions of traditional steel in India, which have been creatively designed in

combination with ceramic, wood, acrylic and various other materials to not only enhance its

aesthetic appeal but make it functionally effective as well.


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(d) The in-house design studio bridges the gap between the real and surreal in the world of steel.

It has a team of professionally qualified designers who are dedicated to explore the challenging

frontiers of design and is committed to deliver aesthetic delight in functional forms to consumers

all over the world. In the lifestyle arena, especially austenitic steel segment, it is for the first time

that synergies between steel and various materials has been explored to create an edge over

traditional available designs, which are functional, affordable as well as designer.

(e) We our recent distribution channel we are present in more than 550 premium crockery outlets

and retail exclusively through our own stores in New Delhi and Gurgaon.

1.3 VISION MISSION AND CORE VALUES

1.3.1 VISION

WOW

1.3.2 EXTENDED VISION

WOW the World with Beauty, functionality and Innovations of our products WOW the World with

Indian excellence and Originality WOW our clients with the manufacturing expertise(OEM) WOW our

investors, stakeholders and colleagues with our service and profitability.

1.3.3 MISSION

At Arttdinox, We Design and Manufacture exquisite and beautiful Homewares of the highest quality

that help our customers create happy places

1.3.4 CORE VALUES

-World Class Design-Functionality, Originality, Design Sensibility

-Excellence-

Benchmark for quality standards for the industry

-Best Service Practices-Customer First, Vendors, Our employees (appreciation) stakeholders

-Integrity-Intellectual honesty on time payment/deliveryAssociates/Employees

- Aligned with our values- Committed to giving their best- Curious & Passionate

-Teamwork-


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1.4 DIFFERENT DEPARTMENTS OF THE COMPANY

Personnel and administration (P&A) Production department Quality department Purchase department Tool room Polishing New product development department (NPD) Maintenance department

1.4.1 PERSONNEL AND ADMINISTRATION (P&A)

Personnel and administration department deals with the manpower management and administration in the

company. It is responsible for different day to day activities in company like housekeeping, security,

salary distribution, maintaining daily shift schedule for operators and helpers, canteen. P&A also is

responsible for companies CSR initiative .P&A provides transport facility to the employees for outdoor

duties.

1.4.2 PRODUCTION DEPARTMENT

Production department is the back bone of the company. It is responsible for the production. Production

department has following types of presses in the press shop.

Manual Press: These are either hand or foot operated through levers, screws or gears. A common press

of this type is the arbor press used for assembly operations.

Mechanical Press: Mechanical presses. These presses utilize flywheel energy which is transferred to the

work piece by gears, cranks, eccentrics, or levers.

Pneumatic Press: These presses utilize air cylinders to exert the required force. These are generally

smaller in size and capacity than hydraulic or mechanical presses, and therefore find use for light duty

operations only.


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Pic 1.2 Double Action press

Production department at ARTTDINOX is divided in two sections

OEM section Brand section

OEM stands for other engineering manufacturing. This section of production manufactures sub parts for

other companies. Presently OEM manufactures bowls of different volume ie. 5QT,6QT, 7QT etc.

Production department has several machines like nuematic presses, mechanical presses, welding

machines, beading machines, induction annealing machines etc.

Brand production manufactures different brand items under the names of crome and arttdinox. Brand

items are basically kitchen wares, table accessories, bar accessories etc.


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Pic 1.3 single action presses

Brand items ranges varies from dinner sets, tea-sets, pen stands etc. Brand items are of very high quality

and are for the high end customers.

In brand category, company manufactures all its products related to the brand ARTTDINOX and

KROME. The brand line has various type of machines listed below:

Single Action Press Double Action Press TIG Welding Machine LATHE Machine Forming Machine Sand Blasting Machine

The items coming in the category arttdinox are costlier as compared to the krome. krome targets the

common markets while arttdinox targets the very high level customers and it consists of very high end

quality lifestyle products.


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Pic 1.4 A CNC Bending Machine

1.4.3 QUALITY DEPARTMENT

Quality department is responsible for maintaining desired quality standards in the manufactured items bythe company. Quality department is sub divided into two teams

Inprocess quality Predispatch inspection quality Incoming quality

In process quality is responsible for maintaining quality standards during the process it self. It checks

different dimentions and product quality during the manufacturing process. Predispatch inspection quality

is responsible for checking quality of products before dispatch of finished items from the plant,

predispatch quality should be of highest level. Incoming quality is responsible for checking quality of

items and products which are out sourced. It is very important as out sourced sub parts and items should

also be of highest quality. Understanding customer requirements and supplying products as per their

requirements is ensured with the help of Quality Assurance and Quality Control groups. Across the entire

business chain of supplies, operations and marketing, appropriate quality assurance systems are in place

to ensure correctness at each step of the cycle. ISO 9001-2000 Certification of the plant is a testimony to

this. ISO 14001 and OHSAS 18001 Systems Certification of the plant assure our commitment towards the

environment and for providing a safe workplace for our employees. For ensuring quality at every step, the

production processes are constantly monitored and controlled to ensure that the finished products are as

per customers requirements. The plant has well equipped laboratories with a battery of modern

equipment such as Optical Emission Spectromtres, X-Ray Fluorescence analyser, Carbon Sulphur

analyser, Hydrogen analyser, Nitrogen and Oxygen analyser, Corrosion Testing facilities, Universal

Testing machine, Ultrasonic Testing unit, Impact Testing machine, all types of Hardness testers, Surface

Roughness tester and E-cupping testing machine. Well documented procedures ensure correctness in


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testing and certification of the products. quality assurance Micro Testing Spectrometer Metallurgical

Microscope Tensile Testing Machine 19.

1.4.4 PURCHASE DEPARTMENT

Purchase department is responsible for getting the raw material and different child parts for the company.

It keeps the raw material and other purchase items which are procured. Purchase department is also

responsible for getting different job works done for company .purchase department provides NRGPs &

RGPs for staff members for outdoor duties. Purchase department arranges the best and cheapest raw

material for the company.

1.4.5 TOOL ROOM

Tool room is the department which takes care of tools used by the production department. Tool room

keeps dies, jigs & fixtures in the best possible state. Tool room develops new dies and punches for the

press shop for launching of new products .Tool room regularly polishes dies to avoid defects in the

products. Tool room is concerned by production department when ever there is a problem in the dies or

fixtures.

1.4.6 POLISHING

ARTTDINOX has a full proof polishing section which is responsible for polishing of products being

manufactured by the company. Polishing section is divided into two section one for OEM and other for

brand items. Polishing done in the company is of three types matt finish, mirror finish, Saturn finish etc.

Polishing of arttdinox products is of very high standards.

1.4.7 NEW PRODUCT DEVELOPMENT

NPD is the department which is responsible for launching new products and designs the products

according to the needs of the designers. NPD department plans the production processes in such a way

that it costs least to the company and easy to manufacture by the production department. This department

also provides BOMs and PFCs for the company. NPD is also called NPD as this department

continuously strives for improvement in the productivity of the company.


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The company has its separate NPD section which develops new products through research and analysis

with the help of modeling in solid works. The NPD section is responsible for any change made in any

product.The NPD sections also develop the tools and dies with the help of tool and die department. The

NPD section has its separate presses, lathe, lancing machine, nibbling machine and milling machine. The

NPD division plays a pivotal role in retaining and consolidating companys leadership position in the

Stainless Steel industry. This is achieved through continuous up-gradation of quality, processes, services

and through product innovation to develop new products at competitive costs. Cross-fertilization of

knowledge between production, quality control and commercial units in order to maintain global

standards has been the guiding principle of the NPD function. Development of high value products to

serve niche markets. Quality up-gradation of existing products to enable enhanced global acceptance.

Cost reduction by process development, optimization and refinement to provide a consistent competitive

edge. Technology enhancement to increase quality production. Foster growth and develop new market

segments through knowledge sharing with customers and to assist them in their operations and

applications of our products In addition to the above, the NPD division closely interacts with reputed

national and international laboratories/ scientific institutions/ Universities to avail expert services and

knowledge for critical investigations.One section of the NPD department also controls all the outsourcing

work which includes the laser marking, any small parts, stone parts etc.

1.4.8 MAINTENANCE DEPARTMENT

Maintenance department takes care of all the maintenance works to be performed in the company so that

there is sound running of plant operations. There are two diesel generators in the company to fulfill the

power requirements of the company. Company has a very efficient maintenance department which takes

care of all the machines in the press shop. Maintenance department also takes care of different buildings

in the plant. Maintenance department has a highly qualified and dedicated team which is always eager to

give its best.


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1.5 MODULAR KITCHENS

(a) ARTTDINOX stainless steel kitchens from the house of JSL (largest Stainless Steel

manufacturers in India).

(b) ARTTDINOX kitchens are available in a variety of eye catching colors and patterns.

(c) We provide 360 degree solution from conceptualizing to design to the installation of the

kitchen.

(d) With timeless Stainless Steel as the building block ARTTDINOX modular kitchens offer

great functionality and innovative designs along with a wide range of options.

(e) It is totally hygienic, termite and pest proof.

(f) Stainless Steel also known as the new age green metal is 100% corrosion resistant, recyclable

and long lasting.

1.6 STAINLESS STEELS (RAW MATERIAL)

(a) When 11.5% or more chromium is added to iron, a fine film of chromium oxide forms spontaneouslyon the surfaces exposed to air. This film act as a barrier to retard further oxidation, rust or corrosion.

As this steel cannot be stained easily, it is called stainless steel.

(b)All stainless steel can be grouped into three metallurgical classes:- AUSTENITIC FERRITIC MARTENSITIC

1.6.1 AUSTENITIC STAINLESS STEEL

They possess austenitic structure at room temperature. They possess the highest corrosion resistance of all the stainless steels. They possess greatest strength and scale resistance at high temperatures. They retain ductility at temperature approaching absolute zero.


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They are non-magnetic so that they can be easily identified with a magnet. They have the following composition

C 0.03 to 0.25% Mn 2 to 10%

Si 1 to 2% Cr 16 to 26% Ni 3.5 to 22% P Normal S Normal Mo In some cases Ti In some cases

They are used in: Aircraft industry (engine parts) Chemical processing (heat exchangers) Food processing (kettles, tanks) Household items (cooking utensils) Dairy industry (milk cans) Transportation industry (Trailers and railways car), etc.

1.6.2 FERRITIC STAINLESS STEELS

They possess a microstructure which is primarily ferritic. Ferritic stainless steels have a low carbon-to-chromium ratio. This eliminates the effects

for thermal transformation and prevents hardening by heat treatment.

These steels are magnetic and have good ductility. Such steels do not wr4ok harden to any appreciable degree. Ferritic steels are more corrosion resistant than martensitic steel. Ferritic steels develop their maximum softness, ductility and corrosion resistance in the

annealed condition.

Ferritic stainless steels have the following chemical composition:


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C 0.08 to 0.20% Si 1% Mn 1 to 1.5% Cr 11 to 27%

Ferritic stainless steels have the following uses: Lining for petroleum industry Heating elements for furnaces Interior decorative work Screw and fittings Oil burner parts

1.6.3 MARTENSITIC STAINLESS STEELS

Martensitic stainless steels are identified by their martensitic microstructure in thehardened condition.

Because of the higher carbon-to-chromium ratio, martensitic stainless steels are the onlytypes hardenable by heat treatment.

These steels are magnetic in all conditions and possess the best thermal conductivity ofthe stainless types

Hardness, ductility and ability to hold an edge are characteristics of martensitic steels. Martensitic stainless steels can be cold worked without difficulty, especially with low

carbon content, can be machined satisfactorily, have good toughness, show good

corrosion resistance to weather and to some chemicals and are easily hot worked.

Martensitic stainless steels have the following composition:

C 0.15 to 1.2% Si 1% Mn 1% Cr 11.5 to 18%

A few typical use of martensitic stainless steels are as follows:


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Pumps and valve parts Rules and tapes Turbine buckets Surgical instruments, etc

1.6.4 COMPOSITION OF STAINLESS STEELS

1.6.4.1 AUSTENITIC STEEL

TABLE 1.2

TYPE Cr Ni C OTHERS

301 16/18 6/8 0.15 -

302 17/19 8/10 0.15 -

303 17/19 8/10 0.15 SO.18/O.35

304 18/20 8/12 0.08 -

308 19/21 10/12 0.08 -

309 22/24 12/15 0.20 -

310 24/26 19/22 0.25 MO,2/3

321 17/19 9/12 0.08 Ti, 5XC min

347 17/19 9/13 0.08 Cb,10XC min

201 16/18 3.5/5.5 0.15 Mn,5.5/7.5

N, 0.25 max.

202 17/19 4/6 0.15 Mn,7.5/10 N,

0.25 max.


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1.6.4.2 FERRITIC STEELS

TABLE 1.3

1.6.4.3 MARTENSITIC STEELS

TYPE Cr C(MAX) OTHERS

405 11.5/14.5 0.08 Al,0.10/0.30

430 14/18 0.12 -

442 18/23 0.25 -

446 23/27 0.20 N,0.25max.

TYPE Cr C(max) OTHERS

403 11.5/13 0.15 -

410 11.5/13.5 0.15 -

414 11.5/13.5 0.15 Ni,1.25/2.5

416 12/14 0.15 S,0.18/0.35

Mo,0.60 max

418 12/14 0.20 Ni 1.8/2.2

W 2.5/3.5

420 12/14 0.25/0.35 -

422 11.5/13 0.20/0.25 Mo 0.75/1.25

V 0.17/0.27

W 0.25/1.25

431 15/17 0.2 Ni 1.25/2.5


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1.7 WELDING

(a) Welding is the process of joining similar metals by application of heat with or without

application of pressure and addition of filler material. The application of welding are so varied

and extensive that it would be no exaggeration to say that there is no metal industry and no

branch of engineering that does not make use of welding in one form or another.

TYPES OF WELDINGS:-

1.7.1 TIG WELDINGTIG welding is a commonly used high quality welding process. TIG welding has become a

popular choice of welding processes when high quality, precision welding is required and it is

mainly used for Stainless Steel because it gives good finish as compare to MIG welding.

1.7.1.2 TIG WELDING BENEFITS

Superior quality welds Welds can be made with or without filler metal Precise control of welding variables (heat) Free of spatter Low distortion

1.7.1.3 SHIELDING GASES

Argon Argon + Hydrogen Argon/Helium


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Fig 1.1 TIG Welding

1.7.2 MIG WELDING

MIG welding is a commonly used high deposition rate welding process. Wire is continuously

fed from a spool. MIG welding is therefore referred to as a semiautomatic welding process. It

is mainly used to Mild Steel But when sheet thickness is above 3mm it is also used for Stainless

Steel.

1.7.2.1 MIG WELDING BENIFITS

All position capability Higher deposition rates than SMAW Less operator skill required Long welds can be made without starts and stops Minimal post weld cleaning is required

Fig 1.2 MIG Welding


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1.7.3 ARC WELDING

It is mainly used for Mild Steel But when sheet thickness is above 6mm it is also used for

Stainless Steel and 409 Grade is used for Mild Steel and Stainless Steel. Due to the use of arc

welding primer is used on that area.

1.7.4 SPOT WELDINGSpot welding is a type of resistance welding used to weld various sheet metal products.

It is used between 1mm to 3mm thick sheet.

Fig 1.3 spot welding

1.7.5 STUD WELDING

Stud welding is a form of spot welding where a bolt or specially formed nut is

welded onto another metal part. The bolts may be automatically fed into the spot

welder. It is used for studding portion and they did not give back impression.

Pic 1.6 various examples of studs
http://en.wikipedia.org/wiki/Spot_weldinghttp://en.wikipedia.org/wiki/Screw#bolthttp://en.wikipedia.org/wiki/Nut_%28hardware%29http://en.wikipedia.org/wiki/Image:Nut-hardware.jpghttp://www.google.co.in/imgres?imgurl=http://diagrams.org/images/gif/medium/f00010.gif&imgrefurl=http://diagrams.org/fig-pages/f00010.html&h=629&w=520&sz=14&tbnid=wljPI5-3acgJ::&tbnh=137&tbnw=113&prev=/images?q=spot+welding&hl=en&sa=X&oi=image_result&resnum=2&ct=image&cd=1http://en.wikipedia.org/wiki/Image:Nut-hardware.jpghttp://www.google.co.in/imgres?imgurl=http://diagrams.org/images/gif/medium/f00010.gif&imgrefurl=http://diagrams.org/fig-pages/f00010.html&h=629&w=520&sz=14&tbnid=wljPI5-3acgJ::&tbnh=137&tbnw=113&prev=/images?q=spot+welding&hl=en&sa=X&oi=image_result&resnum=2&ct=image&cd=1http://en.wikipedia.org/wiki/Nut_%28hardware%29http://en.wikipedia.org/wiki/Screw#bolthttp://en.wikipedia.org/wiki/Spot_welding


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1.7.6 WELDING SYMBOLS

Table 1.5 welding symbols


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Chapter 2

DIFFERENT TYPES OF MACHINES USED

2.1Water Jet Cutting MachineCan cut depth up to 200 mm of thickness of the job which indicates its high machining

capability.

2.1.1 Technical specification for water jet Cutting machine

Model : Nanojet 3015

Structure : Gantry Bridge Structure.

Axis movement : Ac Servo Motors Ball Screw with Linear Guide Ways

Axis Detail : Stroke (mm) Speed(mm/min.)

X-Longitudinal : 3000 20 m/min

Y-Transversal : 1500 20m/min

Z-Vertical : 250 20m/min

Lubrication : Automatic

Make : KMT (Germany)

The main advantage of this machine is to cut a job upto 200mm thickness which shows its highmachining capability. In cutting operation sand (Silicate) mesh quality are used:-

80 Mesh 120 Mesh(Better cutting quality)


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2.1.2 ADVANTAGESQuick to setup and easy to program (make money on short runs)High accuracy control of cutting, upto 0.001mm.Special pressure ramping technique to prevent delaminating (cracking) brittle

materials while piercing (drilling).

Steady cutting stream, no abrasive output interruption.Low cutting consumable cost.

2.2BENDING MACHINE

Capacity : 125Tonne

Capability of Bending : 3mm

Length of Bend : 3000mm

As the length of the sheet decreases 3 meter the thickness of the sheet may be increases

spontaneously.

2.2.1 TYPES OF BENDING PROFILE

Fig 2.1 bending profile


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2.3 LASER CUTTING MACHINE

Possess good speed and precise cut when cutting thin material. Laser yields no burr, a little HAZ. Laser is

suitable to cut non-reflective mild steel.

2.3.1 Principle

An extremely concentrated force of water is used in such kind of machines to cut jobs of very high

thickness. In this machine water at very high pressure that is ranging from 30000-60000 psi(N/m^2)when

mixed with very fine abrasive garnets (Silicate or sand ) is used to cut very hard materials like stainless

steel, titanium, Glass, ceramic tile, marble and granite. Also due to the fact that water at room temperature

itself is used as a cutting tool therefore the Heat Affected Zone (HAZ) is very less. Hence a very high

grade finishing is obtained compared to other machining processes. Moreover, since it is a cold cutting

process hence it is safe to cut inflammable materials as well.

Sheet Holding Size : 2500mm X 1250mm

MILD STEEL=16mmSS=12mm

AL=6mm

CAPACITY

CUTTING

CAPABILITY


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2.3.2 COMPARISION BETWEEN GAS CUTTINGS

Areas Air Nitrogen Oxygen

Cost Low High Medium

Finishing quality Low High Medium

Toleranges Low High Medium

Table 2.1 comparison between gas cuttings

Pic 2.1 laser cutting machine

GASES USED FOR

CUTTING

AIR CUTTING

UPTO 3mm

NITROGEN CUTTING

UPTO 3MMOXYGEN CUTTING

UPTO 12mm


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2.4 TURRENT PUNCHING MACHINE

This machine is mainly used for Embossing as well as cutting operations.

The sheet thickness maintain in embossing operation is 1mm to 1.6mm.

2.4.1 TYPES OF PATTERNS /EMBOSSING

Dot pattern Oval Pattern Forming pattern Round pattern Diamond pattern Square Pattern Laser Pattern

Sheet Holding Size : 2500mm X 1250mm

CUTTING

CAPABILITY

CAPACITY

SS=2.5MILD STEEL=3mm AL=3mm


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2.5PIPE BENDING MACHINE

Model Number : RG125

Angle Bending Capacity : 0 to 180 degree

Pipe Sections Can Be Bended : 19,25,32,38,50,62,60

Pipe upto 6m length and 3mm thickness can be bended.

As the length of the pipe decreases the pipes with thickness >3 mm can be bended. Hollow Pipe sections

of standard lengths 6m and sizes19,25,32,38,50,62,60 can be bended upto an angle ranging from 0


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The tailstock can be used to support the end of the work piece with a center, or to hold tools for

drilling, reaming, threading, or cutting tapers. It can be adjusted in position along the ways to

accommodate different length workpices. The ram can be fed along the axis of rotation with the tailstock

hand wheel.

2.7MILLING MACHINEMilling machines are very versatile. They are usually used to machine flat surfaces, but can also

produce irregular surfaces. They can also be used to drill, bore, cut gears, and produce slots at 90 degree

angle.

2.7.1 TYPES OF MILLING CUTTERS

In vertical mills, milling cutters with solid shafts are usually used.

1. End mills are designed for cutting slots, keyways and pockets.2. Two fluted end mills can be used to plunge into work like a drill.3. End mills with more than two flutes should not be plunged into the work.4. Ball end mills can produce a fillet.5. Formed milling cutters can be used to produce a variety of features including round edge.

2.8SHOT BLASTING Shot blasting is Machine in which surface of annealed stainless steel is been blasted forcibly with

the help of steel shots of dia 0.5 mm for cleaning of hard scales before pickling section.

Every HR coil is to be shot blasted. The shots first inserted in the Hooper, from there the shots divided into 4 sections and then to

Magna valves and through valves to wheels for striking to the strip goes to the wheels.

From wheels after blasting shots get collected at lower abrasive conveyor & thro. Elevator itsgoes at the top thro. Upper abrasive conveyor it is collected at shot storage Hooper.


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Elevator consists of a belt on which large no. of buckets are attached. With the help of thesebuckets, shots are carried at the top from their the shots goes to Hooper 1 & 2.

Shots are made of iron carbide.

2.8.1 SHOT BLASTING TECHNOLOGYThe principle of blast cleaning technology is based on the use of the high kinetic energy of shot and grit

resulting from its mass and impact velocity see Figure 1 (on the left). A bundled stream of grain-sized

hard particles is accurately flung at high speed against a surface or work pieces. Depending on the reason

for blast cleaning a wide variety of surface conditions on the work piece treated can be produced.

Depending on the application, different materials are used for shot blasting

Fig. 2.2 animated shot blasting


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Fig 2.3 animated shot blasting flow process

2.8.2 ROUTINE ACTIVITIES

Ensure uniform blasting in full width on strip. Check the Wheel current 5to6 times in every shift. Turbine load to be around 40 to 60 amps. If it

is less the blasting will be insufficient. Note down the load in log book

Maintain minimum 75% of shots level in the storage bunker in the running operation. Switch off all the wheel in case of breakdown Clean the shots in the bottom of bucket elevator before switch on the elevator Switch OFF control supply when the machine is not in use. Check the leakage from any part of machine. If there is some noise in the machine, inform to maintenance dept.


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2.8.3 OPERATING PROCEDURE

Dust CollectorON Rotary air lockON Upper Abrasive ConveyorON Bucket ElevatorON Lower Abrasive ConveyorON Blow off fanON Wheel # 2 (bottom)ON

Wheel # 3 (bottom)ON

Wheel # 1 (top)ON Wheel # 4 (top) - ON

2.9 AUTOMATIC ABRASIVE REPLENISHER Each machine inline will be equipped with one ton automatic abrasive replenisher in event low

abrasive level.

In abrasive storage hopper an element signal will automatically actuate the abrasive replenisher toadd the abrasive to the system

Abrasive feed : Abrasive gate controlled gravity conveyed Capacity: 4000 Lbs.

2.10DUST COLLECTOR SYSTEM


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Fan / Blower of dust collector: consist of one top mounted direct drive blower withcarbon steel housing, radial wheel , 415 V , 3 ph, 50 Hz, 40 Hp TEFC motors & manual

discharge damper.

This blower suck the dust from shot blasting machine & gets accumulated at particularplace. With the help of pneumatic high air pressure this dust blow off from that place &

collected at Dust Collector Trolley.

Pic 2.2 dust collector

Fig 2.4 dust collector system


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2.10.1 SAFETY & ENVIRONMENT MEASURES

Wear all protective equipments (like goggles, hand gloves, protective shield) before going to shotblasting machine.

Always use the nose mask before going to the exhaust system of shot blasting machine.

No person other than the S/B operator & Shift incharge will operate the m/c. Keep rotary valve open. Rectify leakages whenever line goes down. Always ensure that the screw conveyor & dust collecting system are working. If it is not working

then immediately stop the machine.

Ensure cleaning of floor in & around shot blasting machine. Check the leakage (Lubricating oil, Hydraulic oil, air etc.) if any abnormality found immediately

inform to concern department.

Put the waste (used hand gloves etc.) in the proper dust bin. If in any case any fire then immediately use the fire extinguisher available in that area & inform

to safety department.

Keep constant watch on running of blowers if any abnormality observed immediatelyinformed to maintenance people & use ear plug in that area.

2.11 SCALE BREAKER FUNCTION

2.11.1FUNCTIONo The function of the scale breaker is to break the scale layer on the strip surface.o This will be done by bending the production material around the working rolls &

then flattening it to correct the shape of the input material.


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o The strip can be lengthened by the combination of the bending (work roll) &tension (bridle roll), which leads to better strip shape.

o Top cartridges will be lifted rapidly (auto/manual) during the pass of the weldingportion.

oConsist of one bending & 2 anti crossbow sets welded in monoblock frame.

2.11.2FEATURES

Monobloc frame Fully enclosed against dust/Scale exit. Doors for inspection pass line rolls dry brush roll 1 at entry & 2 at exit side. upper adjustable cartridges & 3 lower fixed cartridges bending cartridges 2 Flattening cartridges Cartridges with one full width work roll and short support rolls Support rolls with purging air to avoid scale/dust in the bearings 2 Clamping Cylinder per cartridge

Blower pipes with special nozzles for Scale removal Compressor with drier & Exhaust system with filter The cartridges changing car will be used for changing the cartridges of Scale

Breaker

2.12EXHAUST SYSTEM The exhaust system sucks the scale dust out of the scale breaker & conducts it via pipes

towards the filter system. It has volume of 35000 m3/hr.

4 flanges for the exhaust pipes at the back of the scale breaker. 2 more pipes will be connected to each dry brush machine. The pipes will be connected to one big exhaust pipe.


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xxxvi

Chapter 3

VARIOUS TYPES OF THEORIES USED

3.1 TPM-(TOTAL PRODUCTIVE MAINTENANCE)

It is a maintenance process developed for improving productivity by making processes more reliable and

less wasteful.TPM aims to---

Continuously improve all the operating conditions, within a production system; by stimulating daily

awareness of all the employees.

TPM primarily focuses on manufacturing but was later expanded to cover suppliers and customers as

well. Basically it is a company-wide team-based effort to build quality into equipment and to improve

overall equipment effectiveness.

Goals of TPM

Zero Breakdown Zero Losses Zero Pollution Zero Health Hazards

3.1.1 Eight Major Pillars of TPM

Jishu Hozen(Autonomous maintenance)Uninterrupted operation of equipments.

Flexible operators to operate and maintain machines and equipments.

Eliminating the defects at source through active employee participation.

Stepwise implementation of Jishu Hozen activities.

Planned Maintenance


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Achieve & sustain availability of machines for production Optimum maintenance & spare parts costs Implementation of TBM/CBM & planned maintenance structure Improved reliability & maintainability of machines Support & train operators for JH activities

Kobetsu Kaizen Achieving zero losses in every sphere of activity Relentless pursuit to achieve cost reduction targets in all resources Relentless pursuit to improve all plant equipment effectiveness Extensive use of Performance Management analysis as a tool for

eliminating losses.

Education & Training Improvement of knowledge, skills and techniques for autonomous

maintenance

Creating a training environment for self learning based on felt needs Training curriculum/tools/assessment etc; conducive to employee

revitalization

Enhancement of morals and motivation levels of individuals. Quality Maintenance

Accidents No health damage No fires No No pollution

Office TPM Involvement of all people on support functions for focusing on better

plant performance.

Clean and pleasant work environment. Better utilized work area. Reduced administrative Costs.

Research and Management Flexible design of products, machines and equipments. Poka Yoke (Fool Proofing) Implementation. Timely up gradation of products as per customer needs and environment.


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Making available low cost, trouble free, accident free, customer focusedand attractive products.

3.1.2 TPM Role in Industry

Increased equipment productivity Reduced equipment downtime Increased plant capacity Lower maintenance and production costs Approaching zero equipment-caused defects Enhanced job satisfaction Increased Return On Investment

3.1.3 Benefits of TPM

Direct benefits of TPM Increase productivity and OPE (Overall Plant Efficiency) by 1.5 or

2 times.

Reduce accidents. Follow pollution control measures.

Indirect benefits of TPM Higher confidence level among the employees. Favorable change in the attitude of the operators. Achieve goals by working as team. Horizontal deployment of a new concept in all areas of the

organization. Share knowledge and experience.

The workers get a feeling of owning the machine


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3.2 Concept of 5 S

SEIRI-------Sorting SEITON-----Systematic SEISO------Cleaning SEIKETU----Standardisation SHIT SUKE----Training & Discipline

3.2.1 The Origins of 5S

5S developed, as with so many of todays best practice tools, in Japan. We first heard of it

as one of the techniques that enabled what we then termed Just in Time Manufacturing. The

Massachusetts Institute of Technologys 5-year study into the future of the automobile in the

late 1980s[2]identified that the term was inappropriate since the Japanese success was built

upon far more than components arriving only at the time of requirement. John Krafcik, a

researcher on the project, ascribed Lean to the collective techniques being used in Japanese

automobile manufacturing; it reflected the focus on waste in all its forms that was central to

the Japanese approach. Minimised inventory was only one aspect of performance levels in

companies such as Toyota[3]

and in itself only arose from progress in fields such as quality

assurance and Andon boards to highlight problems for immediate action.

5S was developed by Hiroyuki Hirano within his overall approach to production

systems.Many Western managers coming removed stored elsewhere or eliminated

completely. By differentiating between Seiri and Seiton, Hirano made the distinction explicit.

He taught his audience that any effort to consider layout and flow before the removal of the

unnecessary items was likely to lead to a sub-optimal solution.
http://en.wikipedia.org/wiki/5S_(methodology)#cite_note-1http://en.wikipedia.org/wiki/5S_(methodology)#cite_note-1http://en.wikipedia.org/wiki/5S_(methodology)#cite_note-1http://en.wikipedia.org/wiki/5S_(methodology)#cite_note-2http://en.wikipedia.org/wiki/5S_(methodology)#cite_note-2http://en.wikipedia.org/wiki/5S_(methodology)#cite_note-2http://en.wikipedia.org/wiki/5S_(methodology)#cite_note-2http://en.wikipedia.org/wiki/5S_(methodology)#cite_note-1


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Chapter 5

PROJECT WORK

5.1 MY RESPONSIBILITIES AND TARGETSAfter joining as GET (Graduate Engineer Trainee) in the company we have

gone through a very good induction period of one month in which we learnt

each and every function of the company , its working culture , our colleagues ,

and after the completion of the induction programme. They gave me my

responsibilities and duties in production department under the guidance of Mr.

Sandeep Malik (Associate manager) where I am working as a GET in brand

section (arttdinox and krome) .where I am expected to fulfill my targets and

my targets are as under:

To improve productivity To reduce rejections and rework in weld shop and polishing dept. To improve OEE i.e Overall Equipment Efficiency Ensure on time delivery from lathe shop and weld shop

According to companys terminology, they called these responsibilities

as KEY RESPONSIBLE AREAS (KRA) a type of score card in which

every employee has its monthly , quaterly and annual targets, and on

the basis of the individual performance one has to rate himself byGRADES (A,B,C,D) and then it has to be verified by the boss.

Based on the KRA grade we have got a PLI scheme i.e Performance

Linked Incentive .


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As a new joinee every employer has its default grade as C so its mine

but in the 4th

month i.e the month of april my rating was found to B.

5.2 IMPROVEMNENT PROJECT- To improve the quality aswell as life of the draw tool

The panel of experts in the company decided to give me an improvement

project as I joined the organization with a lot of expectations. They offer me

to be a part of team which is going to work on the improvement of the life and

quality of the draw tools. I accepted this opportunity and started working on it

with the team. The details of the project are as under:

5.2.1 DETAILS


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5.2.2 TEAM MEMBERS AND THEIR DEPARTMENTS

5.2.3 PROJECT DETAILS

Existing conditions:

The life of tool is 1800 Pcs. After that we need to grind tool again

for reuse that tool. Burr on circle causes draw lines and wrinkles

on bowls and also affect tool life.


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Pic 5.1 double action machine under study

Pic 5.2 before improvement


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Pic. 5.3 wrinkle defect before improvement

5.2.4 Corrective action taken by usAfter doing a lot of study and we observe that due to some

irregularities and burrs on the outer periphery of the circle the pressure

plate and tool are gradually degrading. And for this we decided to add

an operation in the sequence of the operations. What we did is just

have the periphery of the circle polished before the initial operation

(draw) in the sequence. So that the burrs can be removed from the

periphery of the circle.


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5.2.5Improvement seen by the actionIt is observed that now the cycle time of grinding the tool of double

action press is increased by a healthy margin. The whole team got

satisfied by their efforts.

pic 5.4 image showing that earlier tool breaks after every 1800 strokes

but now the scenario has changed. The tool life has increased and

hence the productivity also increased.


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Pic 5.5 tool breakdown slip showing that the no. of pieces before tool

grinding requirement is increased to 5020.

5.2.6 RESULTS Life of tool is increased by 3200 strokes Earlier we use to grind the die after 1800 strokes but

now grinding required after 5000 strokes.

Productivity is increased as well


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Chapter 6

CONCLUSION

6.1 It has been a great learning experience for me here at Arttdinox. In these three months I

have learned the practical implications of the theory I have learned in my engineering college and the best

part is that the learning never stops. Employees, their talent and contributions are valued the most in the

company. The company believes in offering the best motivation to their employees in terms of work,

culture and compensation. Arttdinox has given me an opportunity to work with the best people in the

industry and develop the passion to excel, required skills and aspirations to deliver my hundred percent.

6.2 ARTTDINOX has an extended vision and the company stands by whatever it commits. The

vision of Arttdinox is WOW:

Wow the World with the Beauty, Functionality and Innovation of their Products Wow the World with Indian Excellence & Originality

Wow their Clients with the Manufacturing Expertise (OEM) Wow their Investors, Stakeholders, and Colleagues with their Service & Profitability.

6.3 The vision itself is so inspiring and challenging that all employees are committed to deliver

more than their hundred percent. Arttdinox designs and manufactures exquisite and beautiful

Home wares of the highest quality that helps their customers create happy places. This has helped

me to understand the role customer satisfaction plays in any business.

6.4 This has been my first corporate experience and I feel so glad to be part of this company

where I have learned about World Class Design (in terms of Functionality, Originality, Design

Sensibility), Excellence (Benchmark for quality standards for the industry), Best Service

Practices (Customer First, Vendors, Employees, Stakeholders), Integrity (Intellectual honesty on

time payment/delivery) and Teamwork. All the employees here are aligned with the values of the

company, committed to giving their best, curious & passionate.


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REFERENCES

Topics Page no. Reference

1. Company Profile V www.arttdinox.com/aboutus2. Vision mission and core value VI www.arttdinox.com/careerwithus3. Modular Kitchen XIII www.arttdinox.com4. Composition of stainless steel XVI official diary of JSL5. Welding fig 1.1,fig 1.2,table 1.1 XIX,XXI www.wikipedia.com
http://www.arttdinox.com/aboutushttp://www.arttdinox.com/aboutushttp://www.arttdinox.com/careerwithushttp://www.arttdinox.com/careerwithushttp://www.arttdinox.com/http://www.arttdinox.com/http://www.wikipedia.com/http://www.wikipedia.com/http://www.wikipedia.com/http://www.arttdinox.com/http://www.arttdinox.com/careerwithushttp://www.arttdinox.com/aboutus

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