six weeks training report or presentation for b.tech

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SIX WEEKS TRAINING REPORT AT NEW SWAN AUTOCOMP PVT. LTD. From 11 th june To 23 rd July. NAME : Deepinder Singh ROLL NO. : 80101115008 COLLEGE : GURU NANAK DEV ENGG. CLG. BRANCH : PRODUCTION

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six week training report or presentation for b.tech mechanical engineering students. can be used as any semester training report or presentation(1 to 8).

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Page 1: Six Weeks Training Report or presentation for b.tech

SIX WEEKS TRAINING REPORTAT NEW SWAN AUTOCOMP PVT. LTD.

From 11th june To 23rd July.

NAME : Deepinder Singh ROLL NO. : 80101115008COLLEGE : GURU NANAK DEV ENGG. CLG.BRANCH : PRODUCTION

Page 2: Six Weeks Training Report or presentation for b.tech

CONTENTS• Introduction• Statistics• Achievements• Manufacturing Processes• Machinery Used• Departments • Future Plans• Improvements Suggested

Page 3: Six Weeks Training Report or presentation for b.tech

IntroductionNew Swan Group started manufacturing precision fine blanking parts in its early stage, and later developed metal body part and sub-assemblies manufacturing. This Group provides convenience, comfort and safety to their customers. We certainly accomplish their commitment through ever improvement of production with latest technology.& this therefore puts us in the frontline of quality auto spare part manufacturers in India & global Market. This Group provides latest machinery present in the global world at present.

Page 4: Six Weeks Training Report or presentation for b.tech

New Swan AutocompPrivate Limited

Location Ludhiana, India (Pb)Yr. of Establishment 2002Employees 260Total Space 1,17,000 Sq. Ft.Production Area 60,000 Sq. Ft.Sales (2007-08) 5.25 US$ MillionQS Standard TS –16949 : 2002Power / Self Generation 900 KVASpare Capacity 35%Product Range Fine Blanked Components &

Assemblies

Page 5: Six Weeks Training Report or presentation for b.tech

Core Competence• Second largest co in India for fine blanking part for automobiles as

well other applications. • Leading group for catering Stamping, Tubular Parts, Welded ,Coated

parts, Cold Forged Parts, Door Latches ,Seat Latches, Hood Hinges, Parking Brake Parts, Gear Shifting Mechanism & Assembly , Seat Recliner to most of Indian Automobile as well global tier 1 cos.

• 100% tooling support from in-house R&D & advance design tool manufacturing centre for world class manufacturing.

• Capacity of timely development of products with highest quality & accuracy.

• Capacity of Stamping, Welding, Assembly ,Heat Treatment & Surface Treatment under one roof.

• In house facility of Testing Lab, Inspection as well all related endurance test for most of item manufactured.

• 25 % Export of total group sales.

Page 6: Six Weeks Training Report or presentation for b.tech

Mission Statement

MISSIONNew Swan Group is focusing on providing superior products in automotive market. Our mission is to be locally and globally competitive in quality and value. VALUESWhole standard product to our customers through quality, reliability and technology. PEOPLEWe encourage the involvement and reward the contribution of each employee. QUALITYQuality is important in everything we do. Quality is everyone's responsibility, and is achieved through continuous improvement. LOCALIZATIONWe always look for the local supply of materials in order to reduce disadvantage of import through our own development or the coordination of our reliable suppliers. DESIGN & DEVELOPMENTWe design and develop our product to serve the requirement of our customers with the latest technology

Page 7: Six Weeks Training Report or presentation for b.tech

Group Companies

New Swan Components , Gurgaon New Swan Enterprises – II , Ludhiana

New Swan Enterprises , Ludhiana New Swan Autocomp , Ludhiana

Page 8: Six Weeks Training Report or presentation for b.tech

Quality

Quality Policy:

New Swan is TS 16949:2002 Company. New Swan is committed to continuous improvement in quality of its

products and services to exceed the customer expectations.

Page 9: Six Weeks Training Report or presentation for b.tech

Achievements

Page 10: Six Weeks Training Report or presentation for b.tech

Manufacturing Abilities

FINE BLANKING:

TheplantisequippedwithStateofArtTechnologyofFineBlankingPressesrangingfrom80Tto630T.

The following are the ranging :

TONNAGE NO MAKE80T 1 No FEINTOOL160T 4 No FEINTOOL400T 1 No HEINRICH SCHMID630T 1 No FEINTOOL

Page 11: Six Weeks Training Report or presentation for b.tech

Fine Blanking Facility

630 ton press ( Fein tool make )

Page 12: Six Weeks Training Report or presentation for b.tech

Stamping Facility

Press shop and Production

The Plant is Equippped with latest presses ranging from 20t to 250 t most of them with the automation. Total nearly 250 no. of presses . Presses are maintained in manner for continuous work flow.

Page 13: Six Weeks Training Report or presentation for b.tech

Welding Facility

MIG Welding

TIG Welding

Going for up gradation of the facilities with Robotic welding

Page 14: Six Weeks Training Report or presentation for b.tech

Testing Lab

Computerized UTMSST ChamberCold Chamber & Hot ChamberSplash Chamber Cupping TestMegna flux Machine (Crack Detection)Endurance Testing Facility

Page 15: Six Weeks Training Report or presentation for b.tech

Heat Treatment Lab

SQF – Heat Treatment Plant

Carburising

Carbon – Nitriding

Hardening

Microscope for checking microstructure

Page 16: Six Weeks Training Report or presentation for b.tech

Tool Room FacilitiesTool room is equipped with latest machines like : VMC - CNC – Wire Cut Machines - EDM - CNC Pipe Bending, CNC Strip Forming & Other Latest equipment related to most modernized tool room ie : Hi-tech Drills, Lathes, Grinders Etc

Page 17: Six Weeks Training Report or presentation for b.tech

Surface Treatment FacilityPlating plant :

- Tri -Valent plating

Bright

- Alkaline

Bright

Yellow

Green

Golden

- Zinc Nickel Plating

Page 18: Six Weeks Training Report or presentation for b.tech

Standard Room

Standard room is a place in a company where standard and precious measuring instruments are used for accurate measurements ,for checking dimensions of all components or products very accurately . It has a motto to defect the problem and give actual status. It also requires some environmental conditions : 1. Temperature – 22 + 2 degree celcius 2. Humidity – 50% + 10% (more than 50% ) 3. Pressure should be positive

Page 19: Six Weeks Training Report or presentation for b.tech

Imp. Instruments Used• Digital Vernier Calliper (D.V.C)• Digital Micrometer (D.M.M)• Digital Height Gauge• Linear Height Master (L.H.M)• Bevel Protector• Profile Projector (lens of 10x and 20x)• Slip Gauge Box• Torque Wrench• Tripod• Radius Gauges• Roughness Tester

Page 20: Six Weeks Training Report or presentation for b.tech

Digital Vernier Calliper

Linear Height Gauge

Digital Micrometer

Page 21: Six Weeks Training Report or presentation for b.tech

Linear Height Master

Profile Projector

Page 22: Six Weeks Training Report or presentation for b.tech

Roughness Tester

Radius Gauge

Page 23: Six Weeks Training Report or presentation for b.tech

Imp. Processes in Std. Room• Caliberation• Sample Inspection• Layout Inspection• S.P.C• M.S.A• Dock Inspection

Caliberation : Caliberation is a process of caliberating and keeping a record

of any changes to a gauge used for checking the components or products by using its tolerances provided . Any changes to a gauge leads to a reissue of a gauge .

Page 24: Six Weeks Training Report or presentation for b.tech

It can also be stated as a process in which every single gauge has a particular frequency of time after which the gauge dimensions has to be checked with instruments after particular interval.S.P.C :SPC is a tool, which applies basic statistics to control the process. C.P – Process Capability C.P.K – Process Capability index C.P >= 1.33 and C.P.K >= 1.67 C.P is always greater than CPK.

M.S.A : Measurement system analysis R and RR – Repeatability (Instruments Variation and within Appraiser )R – Reproducibility (Appraiser Variation and Between Appraiser )(a)Up to 10% errors – Measurement system acceptable.

Page 25: Six Weeks Training Report or presentation for b.tech

(b) (10-30)% errors – May be acceptable based on importance of acceptance.(c) Over 30% errors – Measurement system needs improvement, make every effort to identify the problem and have them removed. BIASBias = Observed Avg. – Reference Value. ATTRIBUTE STUDYIt is only for rec. gauges study (whether it’s accept the OK pcs. And reject the NG pcs. Or vice versa.) STABILITY STUDYIt verifies the Appraiser, Equipments and Environment. LINEARITY STUDYDock Inspection – It verifies the packing standard of the component and pre-dispatch inspection also for the component only.

Page 26: Six Weeks Training Report or presentation for b.tech

Types of Gauges used in Caliberation

• Receiving Gauges • Plug Gauges• Snap Gauges

Each and every gauge has a upper and lower limit in records which can also be called as its GO and NOGO . For plug gauges its upper limit is NOGO and lower limit is GO whereas it is vice versa for snap gauges.

Page 27: Six Weeks Training Report or presentation for b.tech

Each and every gauge has its own speciality and its own purpose :

Plug gauges are the one used for only and only checking holes of different sizes

Receiving gauges are the gauges used mainly for checking its length, breadth and height of a product or component

Snap gauges are the one which are used for checking some dimensions for a component .

There are also some other types like fixtures which are used for fitting in a machine .

Page 28: Six Weeks Training Report or presentation for b.tech

Sample Inspection

Sample inspection is a kind of procedure in which with the help of a drawing we check all the dimensions of a sample or newly designed component with very limited quantity . After checking the sample the report is made named as sample inspection report in which all the dimensions are measured after checking with the instruments also whether the sample is pass or not is mentioned . Some of the mentioned dimensions in this report are c.d , radius , flatness etc.

Page 29: Six Weeks Training Report or presentation for b.tech

Layout Inspection

Layout Inspection is the complete measurement of all part dimensions shown on the design record. A layout inspection is required for some customers for all products annually unless another frequency is established in a customer approved control plan. In this inspection all the minor and major readings of the product are checked completely as shown in the drawing of the component issued by the company whose product is to be made.

Page 30: Six Weeks Training Report or presentation for b.tech

Other Specialities

Other Facilities Like Expert Design Department Equiped with Workstations and Softwares like Autocad, Solidworks Etc. Various Type of Coating and Surface Treatments, Powder Coating, Cold Forging, are also done in the works

Page 31: Six Weeks Training Report or presentation for b.tech

Details of Press ShopPOWER PRESS

CAPACITY NOS

250T 1

150T 2

100T 6

75T 4

50T 2

30T 23

20T 1

10T 3

5T 2

HYDRULIC PRESS

CAPACITY NOS

80T 1

160T 4

400T 1

630T 1

Page 32: Six Weeks Training Report or presentation for b.tech

Detail of hydraulic press

Total capacity 80t

Max shut ht 215

Min shut ht 200

Max cutting force 40t

Total capacity 150t

Max shut ht 265

Min shut ht 230

Max cutting force 100t

Total capacity 400t

Max shut ht 400

Min shut ht 360

Max cutting force 220t

Total capacity 630t

Max shut ht 400

Min shut ht 320

Page 33: Six Weeks Training Report or presentation for b.tech

Details of Machine ShopTYPE NOS

Lathe 6

CNC lathe (8 tools) 1

Bench grinder 2

Grinder 6

Edm 1

Wirecut 1

Drill machines 20

Special purpose lathe 3

Broaching 1

Sletion 1

Centre less grinding 1

Special purpose lathe 1

Buffing 1

Boring 1

Page 34: Six Weeks Training Report or presentation for b.tech

Details of Welding shop

MIG WELDING 18 SETS

PROJECTION WELDING 3 SETS

Page 35: Six Weeks Training Report or presentation for b.tech

Raw Materials Used

Carbon Steel -- CRCA, C45,C55, C60, C80, SK5,CS4,

Alloy Steel -- 16MnCr5, SCM 415, SCM 435

Stainless Steel -- 304, 409, 304L,439

Special Steel -- 11SMn30

Page 36: Six Weeks Training Report or presentation for b.tech

Components or Products

• Sheet metal assemblies ,door latches,parking brakes

Page 37: Six Weeks Training Report or presentation for b.tech

Fine blanked and other components

Page 38: Six Weeks Training Report or presentation for b.tech

Future Plans

•To Strengthen the Product line for 4 – Wheeler Automobile Segment

•To Upgrade the manufacturing Facility with Latest Technologies

•Setting up new manufacturing plants in various places closer to customers.