PRICOL LIMITEDPlant III Perianaickenpalayam Coimbatore

INDUSRTIAL VISIT SEMINAR

Presented by,

ABHIN CHANDRAMOHAN , 8302

ARJUN CHANDRAN , 8309

DHEERAJ MURALI , 8316

PEEYUSH U, 8341

SHIJ IL P K , 8352

ABOUT PRICOL

PRICOL - Premier Instruments & Controls Limited

Started in 1975 as Automobile Ancillary Unit

Diversified toElectronic Control Instruments, Precision Machine Tools Panel and Sensor Instruments

Only Indian automotive instrumentation firm to obtain the coveted ISO 9001 Certificate

LOCATIONS

QUALITY & TPM TPM- Total Productive Manufacturing

TPM :- system with total involvement of all employees to achieve utilization of all resources.

Good quality achieved through i. Systematic training and motivation of

employeesii.Complying with customer requirements iii.Complying with statutory/regulatory

requirementsiv.Improving the efficiency and

effectiveness of the Quality Management Systems

CERTIFICATES

OHSAS 18001  International occupational health and safety management system specification

ISO 14000 Environmental management standards

ISO TS 16949Defect prevention and the reduction of

variation and waste in the supply chain

PRODUCTS

Idle Speed Control Valve

Oil pumpHydraulic Cab Tilting & Cylinder Assembly

Sintered components

CAB TILTING & CYLINDER ASSEMBLY

Pump Assembly Hand-operated reciprocating Piston type In-built Pressure Relief Valve

Cylinder Assembly Double Acting

CylinderBore Size- 25 mm, 35

mm & 50 mm

OIL PUMP

Geo rotor typeChain Driven /

Crankshaft DrivenInbuilt Pressure

Relief Valve

IDLE SPEED CONTROL VALVES

Part of the Fuel Management System

Controls the volume of air flowing through the throttle valve based on signals from ECU

Improves fuel efficiency by reducing and stabilizing the idle speed

SINTERED COMPONENTS

Oil-less BearingsGear Shifter partsPistonsSlack Adjuster Parts

GearsGerotorsHubsValve Plates

CUSTOMERS

DEPARTMENTSPDE Pumps

i. Endurance testingii.Protoshop

Pump production and assemblyCabin lift Production and

assemblyQuality controlHeat treatment Powder metallurgy

PDE PUMPS

RFQ

Flow Of Activities

Design & Drawings

Cost Estimation

EvaluationProtoshopManufacturing

RFQ

RFQ- request for quoteAn order from customerSpecifications of product like

dimensions, performance characteristic , duration of usage etc specified

Fed to PLM software PLM software used is WINDCHILLConnects sales, purchase, QE,

Materials section, production etc

DESIGN & DRAWINGDevelopers will sit together to decide on the

mode of operation

3 modes of development :-i. existing designii.modify a design iii.develop an entirely new design

Modifications to existing design preferred over entirely new design

Cost of development is considerably reduced

Dimensioned drawings are made in AUTOCAD

COST ESTIMATIONCosts of individual parts added

together to form the net costIncludes

i.Transportationii.Handling chargesiii.Tooling cost iv.Assembly line expensesv.Modification costvi.Development cost

EVALUATIONEvaluation of product is done

with respect to RFQ

Unsatisfactory Redisgn

Estimate of product passing the evaluation stage will be send to the customer.

If they are satisfied an order for sample product is placed.

PROTOTYPEDone in protoshop 2 type samples are created 1.Proto sample 2. Tooled up samplePrototypes tested for endurance

and performanceProducts send to the customerCustomer use those products and

send a report back contd

Feedback include corrections and alterations

Corrections made and product is send back

Procedure followed till a refined product is obtained

Frequent and orderly customer relations make up an essential part of PDE.

Proto type production is done by human beings without help of CNC machine.

Skilled labour is an essential part of protoshop.

contd

Pricol houses machines like lathe, surface grinder, filing machine, drilling machine, ultra finishing machines

Prototypes produced are tested for accuracy and dimensional correctness

Quality analysis of prototypes produced are done

Instruments like profile projector, hardness testing machines, gauges, circularity checker etc. are present

ENDURANCE & PERFORMANCE TESTING

Testing a product is generally done in three stages. 1.Before Endurance2. Endurance Test3. After Endurance.

Before Endurance testing Specifications are entered into test

report. Visually inspected for severe damage. Run in test rig to detect any loosely

fitted part

Endurance testing:- Major part of testing procedure. Product subjected to extreme conditionPumps are run at rated speed for 500 hours.

Every day the machine runs as three shifts.

Continuous supervision of testing is carried out.

After the prescribed testing duration report send to supervisor.

After Endurance test:- Data is verified by supervisor Checks whether value is in permissible range

If values within limits then the product is certified fit for working

TEST RIGS AT PRICOLVarious test rigs present at Pricol are

1. Endurance Test Rig -Oil Pump Assy – 4S2. Endurance Test Rig -Table Top Type3. Endurance Test Rig -AFC & Fuel Pump Assy4. Endurance Test Rig -Oil Pump Assy - 2S5. Endurance Test Rig- Actuator - 2S6. Endurance Test Rig-Cabin cylinder & Pump7. Climatic Chamber -Hot, Cold & Humidity Chamber

8. Vibrometer

PRICOL has the most modern PM plant in South India

Process of -Blending fine powdered materials,-Pressing them into a desired shape -Heating the compressed material

4 basic steps: (1) Powder manufacture(2) Powder mixing and blending(3) Compacting(4) Sintering

POWDER METALLURGY

Powdered metal - obtained from suppliers - stored in silos based on their grade number.

Blending: Proper mixing of powders and additives to achieve metal composition of desired quality.

Fe, Cu and C: major constituents

To the mixture lubricant named kenolube is added.

Blending is done by rotating the powdered mixture for about 40 minutes.

MH system like crane and EOT used to transport powder 

3rd stage is compacting

Process of pressing the powder in die

Stage where the powders attain shape of product

Density of product is determined by tonnage used

Presses of tonnages 400T, 200T & 145T used

Die for compacting is made from tooling section

Spark cutting, wire cutting etc are used to cut tool from HSS.

Sintering: After compacting the product is heated

Heating stars at 350°C and ends at 1250°C.

Heating is gradual

After heating the product is passed to vibro de-burring system

Extra fins are removed by vibrating material along with marble like granules.

After de-burring the product is sized

These products are sent for heat treatment.

HEAT TREATMENT

Heat treatment of sintered product is carried out.

Rotary furnace is used to carry out heat treatment of sintered product

Parts are arranged in trays

Placed inside underground chamber from where it is heated

FURNACES

PRODUCTION & ASSEMBLY

Aluminum casting brought from other factories

Casting are finished and made dimensionally correct using CNC machines

Gears for pumps are procured from PM plant

Assembling is carried out in assembly line

Parts are brought into assembly line are entered in register

Man and machine together assemble the components

Compressed air operated screwdrivers are used

Each and every part cleaned by jet of compressed air

Entire room air conditioned to prevent dust

Assembled products are checked for flaws

Certified products are packed

Packed products send to store

Dispatching section is attached to store

QUALITY ENGINEERING

Quality of product is checked frequently

Randomly selected samples send to QE

Products are tested based on standards

Inspection grade slip gauges are kept here

Calibration of shop floor measuring insturment carried out

Instruments used at QE

Digital Superficial Rockwell Hardness Testing Machine

Vickers Hardness Testing Machine

Brinnel Hardness Testing Machine

Case Hardening Process Tester

Micro Vickers Hardness Testing Machine

Coordinate Measuring Machine

Profilometer

THANKS TO

M r s . D I V YA R S E N I O R O F F I C E R , T R A I N I N G , P R I C O L

Mr. RAJASEKHARAN H E A D P D E P U M P S , P R I C O L

M R . G E R A L D D E S I G N E N G I N E E R , P R I C O L

M r. S E N T H I L

S U P E R V I S O R , P R I C O L

THANK YOU