Company Project File

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Company Introduction

MENETA AUTOMOTIVES established in 1953. Sister company of MAT group.Meneta isDenmark based company. It manufacture & testing the shim plate, back plate, accessoriesetc.Incorporate in India in 2007.It is 100% EOU & OES supplier s . It is TS 16949/2009 certifiedcompany . There are 2 plants in India which play a leading role in back plate and shim plate of brakes.It is the one most top plant in fine blanking in India.

More than 500 employees in staff. It a multinational company, spread in USA, INDIA, DENMARK,CHINA, SINGAPORE.

There are two production lines i.e. HT line & MT line (heavy tonnage& medium tonnage). heavy presses in HT line (1- 800T, 4-400T, 1-345T, 1-315T, 2-300T, and 3-200T) ,power presses in MTline (65T to 200T) ,fine blanking machines (315 -400T) Leading top plant in case of fine blanking inIndia,laser cut,VMC,wire cut machines

Own tool room & also other machines like Vibro, short blasting, planisher, grinders, flatness roller,shearing machine, air compressor etc.

.


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Board of directors:-

Mr. Johnny Haakonsson

Mr.Shachindra Tiwari

Mr.P.K.Jain

Mr.S.S.Rewri

Company Hours

General shift-09:30am-06:30pm

First Shift- 07:00 a.m. to 03:00 p.m.

Second Shift- 3:00 p.m. to 11:00 a.m.

Third Shift- 11:00 p.m. to 07:00 am

Companys Address MENETA A/S

Kirkegyden 52

DK 5270 Odense N (Denmark)

Registered Office111 1 st floor,

Rishab Corporate Tower,

16 Community Centre,

Karkardooma Delhi - 110092

Works

Village Hassambad,

P.O. Bahalgarh,

District Sonepat (Haryana)


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CUSTOMERS:-


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MANUFACTURING PROCESS

MIS manufacturing unit comprise for the production of back plate, accessories & shim which are inIndia and other plants in world. Currently more than 150 types of back plate and shim are beingmanufactured here at MENETA, INDIA.

The infrastructure at the plants supports production of back plate and shim for the domestic as well asoverseas market. They have in house facility for machine, welding and finishing process such as

painting and packaging.

The Quality Assurance back assures that the manufactured plate and shim meets the requiredinternational standards for the satisfaction of customer and for excellence in every sphere. The

company ensures of effective and efficient utilization of not only of floor area but also of man powerand machinery. Though the manufacturing unit is established in industrial area but all themanufacturing machines (including CNCs and all press tools) all eco friendly, ensuring a good healthfor its employees and also give a reason to its customer to believe a sustainable development in allrespect.

We believe in taking care of not only the current needs of automobile industry but also the needs ofthe future


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Introduction to back plate & shim plate .

Back Plate

Backing plate is a part of brake shoe which holds the brake pad. It is made up of IS-2062 which is a

typical form of iron. The thickness of backing plate is between 5 to 7 mm. More than 150 types of backing plate are manufactured in Meneta India manufacturing plant. Some of the backing plates areas shown in fig.

Shim

Shim is a part of brake shoe which is mounted on backing plate. The function of shim is to reduce thenoise which is being produced when the ram strikes the brake shoe (i.e. when brakes are applied). Ashim is made up of steel and fiber (and with adhesive in case of stick on). A shim is generally of twotypes:

Clip on; Stick on.

Clip On Shim

A Clip on Shim is provided with legs which hold the back plate. This type of shim may or may notrequire adhesive material depending on the type of back plate.

Stick On shim

A Stick on shim is provided with glue or adhesive material. It doesnt have legs to hold the back plate.As the name suggest it gets stick on the backing plate and holds it firmly.


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REPORT

During my training period, I took training for six months in EDD dept, Production dept, Maintenancedept, which help me in understanding the working of a company. But specially took interest inmaintenance department.

The company workouts in various departments:-

1. ENGINEERING DESIGN AND DEVELOPMENT;

2. NEW PRODUCT DEVELOPMENT;

3. PRODUCTION

4. QUALITY CONTROL;

5. SALES AND PURCHASE;

6. MAINTENENCE;

7. HUMAN RESOURCE DEPARTMENT.


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ENGINEERING DESIGN AND DEVELOPMENT


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ENGINEERING DESIGN AND DEVELOPMENT

The main aim of EDD is to analyze the request send by the customer. The EDD department processesthe request according to companys requirement. Here at MENETA ADVANCE AUTOCAD,SOLID EDGE, AND UG software are used for designing. All the paper work is done by the EDDdepartment which includes:

i. Makes designingii. Development of new product

iii. Development of vender.iv. The customer problems & complaints v. Documentation of APQP & PPAP.

vi. Approval of 1 st lot productionvii. ECN/ECR change according to customer requirement.

viii. Editing in deigningix. Using toolx. Controlling process etc.

Calculation of no. of stages;

1. Wt. of product;2. Cost of production;3. Process layout for production;4. Bill of material.

As every organization aims to obtain maximum profit and reduction of scrap (waste material). So herealso, great stress on reduction of scrap and to get maximum productivity out of raw material available.All these above mentioned process are carried out to attain maximum profit.

PROCESS LAYOUT

The term process layout refers to the execution of operations involved in production of a newcomponent. A set pattern is being prepared in order to produce the product and to avoid any kind ofdiscrepancy in work. In process layout of any component every step (piercing, punching, piloting,

pips, blanking etc) required for its production is mentioned. Process layout helps in understanding theseries of operations through which the sheet has to pass.


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STRIP LAYOUT

Strip layout refers to the calculation of all the activities that are involves to take out as manycomponents out of a metal strip. Strip layout deals with the calculations of:

strip weight; net weight; gross weight; margin to be left; scrap wt; tonnage; no. of components; % utilization of strip.

Strip layout could be of:

1. Single cavity;2. Double cavity;3. Multiple cavities.

In multiple cavity strip layout more than 2 components can be taken out at one time.

The advantage of using the method of strip layout is maximum utilization of material. Hence the productivity of company increases automatically.

Strip weight: The total weight of strip (after sizing and before performing any manufacturingoperation on it) is its strip weight.

Strip weight = Length * Width * Thickness * Density

Net weight : The weight of component of ejected from the strip is the net weight.

Net weight = Area of component * Thickness * Density

Scrap weight : Area of scrap * Thickness * Density


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Gross weight = Net weight + Scrap weight

Gross weight = Strip weight/ No. of components

Pitch : The distance between two consecutive components is known as pitch.

Tonnage : it is defined as the load (in terms of tones) to be put on strip in order to perform desiredoperation. The value of tonnage for every operation is different.

Tonnage = Perimeter of blank * Thickness * Shear strength

No. of components = Length of strip/ Pitch

% utilization of strip : it tells about up to how much % the strip is utilized. It helps us in calculatingthe scrap involved in production.

% utilization of strip = Net weight * no. of components * 100

Strip weight

In case of single cavity 25 tones is added to tonnage and 35 tonnes in case of double cavity as a factorof safety


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Tool Book

It is also known as process sheet . The aim behind making Tool Book is to have complete informationabout the component (backing plate/shim). In other words it is used for controlling the operation.

A Tool Book consists of information regarding:

Tool type no., Parts, operation, no of operations, type of tool, Customer name, Material type, Dimensions (both general and critical).

About Operations

Thickness of sheet, No. of strokes to make a single piece of component, Manufacturer of machine, Tool type, Pressure produced, Feeding and rejection of strip (manual/ automatic), Lubrication, Lubricating oil, Safety of component from, Comments on component.

Instructions for controlling

Customer name, Drawing no., Time required for all the operations, Description of dimensions, Checking interval, Measuring tool and method,


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Design and Development Outputs (Product design)

- Design FMEA, reliability results,

- Product special characteristics, specifications,

- Product error proofing, as appropriate,

- Product definition including drawings or mathematically based data,

- Product design reviews results, and

- Diagnostic guidelines where applicable.

Manufacturing process design output (Process Design)

- Specifications and drawings,

- Manufacturing process flow chart/ layout,

- Manufacturing process FMEAs

- Control plan

- Work instructions

- Process approval acceptance criteria

- Data for quality, reliability, maintainability and measurability

- Results of error proofing activities, as appropriate, and

- Methods of rapid detection and feedback of product/manufacturing process

Nonconformities


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ACTIVITIES IN EDD DEPTT ; (Engineering drawing and development)

1) Enquiry received along with projection and drawing.

2) Update the enquiry register.

3) Conduct feasibility and it approved by CFT

4) Checks parts available with existing range; including leister tool or new.

5) Prepare costing data released to marketing/ PPC.

6) MENETA no: (SAP no: arrangement).

7) Preparation of part drawing in MENETA format.

8) Tool type, process sequence finds and gets application, by CFT or MDK (in case of

other than simple standard design).

9) SAP activity

10) Prepare tool pay back calculation, (apex and asset code arrangement).

11) Find tool design, order the tool and mark CC to Development cell while ordering.

12) Check availability of rings (top, bottom rings, master frame cavity) no punching and f

fixtures etc.

13) Follow up with supplier for timely delivery.

14) Follow up with tool room for tool inspection.

15) Drawings, process layout and tool book provided to development cell.

16) Raw materials availability for tool trial.

17) Arrangements of drawings, part layout, tool book etc before trial.

18) Conduct tool trial plan.


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19) Review trial observation, prepared the tool trials sheet and give feed back to concern

deptt; get corrected the tool etc.

20) Do PPAP.

21) Provide tool observation to concern person for modification of all engineering

documents like process layout, tool book etc.Disposes the rejected materials.

22) Review the SAP activity as per actual trial and update.

23) PPAP submission to customer.

24) Drawing uploads on the server.

25) Customer approved PSW (part submission warrant) status.

26) Handover the engineering documents (dwg; tool book, process layout etc) BOM etc.


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1. Fine blank machine2. Power press machine3. PDI (pre dispatch inspection)


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Press tool

A tool that works on pressing is known is press tool. Most of the back plates and shim are prepared on

press tools. A press tool is generally of two types namely-

1. Compound & blanking press tool;2. Progressive press tool.

Simple press tool A simple press tool is that press tool in which a single operation can be performed at one time i.e. either blanking, piercing, bending, pips, chamfering etc.

Progressive press tool In progressive press tool we can perform more than one operation at onetime i.e. blanking with piercing and pips. Such tools are not only tie preventing but also economicalfor the vender.

The press tools are not only known for their efficiency but also the product manufactured from themdoes not let the customer to loose his pocket. There is a wide a variety of press tool machines avilablein market. A hard classification of press tools machine is given below:

In a hydraulic press tool machine the driving force is produced by the liquid. The liquid used in themhas some advanced properties (as non - compression ability, high boiling temperature).

In case of a numetic press tool machine the machine works by the air pressure.

And in electronic press tool machine as the name suggest it works on electricity.

The most important thing about the press tool machine is the pressure produced by the machine whichis measured in terms of tones.

Here at Meneta separate press tools are prepared for Backing plate and Shim.


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In general a press tool consists of the following things:

Top plate Punch hold plate Punch Die plate Bottom plate

And a typical press tool consists of:

Top plate Punch back plate Punch plate Punch Die Die back plate Bottom plate Pillars and bush Nuts


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FINEBLANK MACHINE SHOP

N: OF FINEBLANK MACHINE: - 15

Leading top plant in India in fine blank


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History

The fineblanking process was patented for the first time in 1923 in Germany. The original idea was toapply a counter pressure force while blanking to prevent the edges from breaking and causing them toshear over the total thickness of the material. This technology was initially employed mainly in theoffice machine industry and the watch and clock industry.

During the early years, fineblanking dealt mainly with materials from 1 to 3mm. Today more than 60% of fine blanked parts are used in the automotiveindustry with thicknesses of up to 19 mm.

Considerable technological breakthroughs have been made intooling, presses and materials for fineblanking in recent years. Companiesare considering fineblanking at the design stage, taking full advantage of itscapabilities.

Today, the fineblanking method of manufacturing has become a necessity in several major industrialsectors. Although first initiated in Europe, fineblanking has taken an important place particularly inthe Japanese and North American automotive industry, replacing many of the more expensivemanufacturing options.
http://www.fineblanking.org/process/presses.htmhttp://www.fineblanking.org/process/materials.htmhttp://www.fineblanking.org/process/materials.htmhttp://www.fineblanking.org/process/presses.htm


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perpendicular and has no fracture is obtained by using a plate holder that has a knife edge-shaped V

ring, a counter holder, and punches and dies that have extremely small clearances.


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Features & structure of body

1. The frame is welded integral structure, careful annealing has been applied.2. Cylinder, Bolster and Ram are using special steel.

3. Ram slide has long and widely eight guides. Can withstand the load eccentricity incomposite tool.

4. Top stop device, high-precision fine thread called Mechanical stopper has been used.Mechanical stopper. During production, mechanical stopper is fixed at four hydrauliccylinders. And, the accuracy will remain in a repeat stop within 0.01mm. Therefore, youcan maintain a stable high-quality composite moulding; also prevent damage to themold.

5. Lamb, it takes pressure from below by hydraulic and is controlled so as not to vibrate atthe lower stop.

6. Main cylinder, V-ring cylinder, Counter cylinder, Auxiliary cylinder of their pressureand timing can be adjusted individually.

Main cylinder Main piston Mechanical stopper

Bottom Bolster Counter Piston Slide Centre support Eight surface guide Bottom guide V-ring piston

Top bolster Fast approach cylind Tool safety cylinder


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Standard equipment.

Tool safety equipment

After a stroke, if remain in the tool such as products and slag, when detect them, pressstop suddenly, to prevent mold damage.

Shut height adjustment equipment When you re-polishing punch, you can resume production by simply shut height

adjustment.

Material feed unit When you use coil material and sheet material, you need inlet and outlet material feed

unit.

According to the material, the width direction and path line position can be adjusted.

When using the sheet material, you can input the condition in the CPU, to do so you cancontinuous production by automatic control.

You want to save installation space of the device, you can use NC leveller feeder withoutinlet feeder.

Parts remove and slag exhaust To increase the working efficiency, the air blow is effective.

However, if you use a parts remover, products and slag are separated automatically, andnot mixture of two sides of the product. Therefore, to prevent denting of the production,to prevent contamination by cutting oil at equipment around, eliminate the noise caused

by air blow.

Lubricating unit In Fine blanking, select the cutting oil, depending on the product.

Felt roller type is standard. That can save the cutting oil and not mist occurs.Cutting oil on the bolster is collected through the groove.When cutting oil reduces the amount of cutting oil tank, the press will stop automaticallydetects the amount of oil degradation.

Hydraulic unit Hydraulic oil tank, in a separate unit was separated from the press, does not have any

impact on the heat or vibration.Because it uses hydraulic equipment and pumps made in Japan, is also advantageous tothe preservation and running costs.

Management of the oil temperature is the standard equipment of water-cooled heatexchanger.(For cold climates, delivery can also be air-cooled heat exchanger and the heater.)Hydraulic oil tank is equipped with electrostatic oil cleaning filter unit, the removal offine contaminants in hydraulic oil, to prevent deterioration of the hydraulic oil andhydraulic equipment malfunction.

Front safety shutter Continuous operation is possible only when the safety shutter is closed. Can be also

equipped with an optical safety device.

Scrap cutter

Hydraulic cutter, you can set the cutting cycle, Cutter has a shearing angle

to be able tocut at lower pressure.


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Features of touch panel.

By shape, material and thickness of the product, you can input on touch panel optimal processing conditions of the tool.

Input data, you can have up to 100tools data stored in the CPU. (It is also possible toincrease capacity.)

If you replaced the tool, you can select the number of tool at touch panel, easy toreproduce the processing conditions.

Operation of the touch panel is simple and can be reproduced immediately prior to processing data. Tool change time has been reduced, improving the work efficiency inhigh-mix low-volume production.

On the screen you can check the operation of hydraulic equipment and sensors. Then,when an error occurs, the error message will be displayed on the screen to help yousolve the problem.

During production, the processing conditions can be changed without stopping the press.You can check and modify the processing conditions of a tool for the next production.

On the touch panel, so you can aggregate uptime of the press. You can also aggregate thetime of the stop press when mold change and other factors. Those data can help your

production management.

To display the screen, a place that requires a maintenance inspection on a regular basis.


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ensures that after the die plate is ground during regular die maintenance, the size of the die cavitydoes not grow (as it would if the die cavity was tapered). This ensures that the parts produced inevery production run will maintain the same nominal dimensions as when the part was first made.

Radiuses cutting edges:

Fine blanking is as much an extrusion process as a stamping process. The cutting edges of the diecavity are not sharp - they are radiuses. This allows the metal to flow into the die cavity.

Tool Construction:

Fine blanking tools are compound dies, meaning that the part is ejected out of the die cavity. Mostfine blanking dies are single station dies, with all features created at one time with a single stroke ofthe press. Parts made in a single station tool have extremely consistent relationships between features.The use of progressive fine blanking dies is increasing rapidly, in an effort to provide more and morecomplex features on parts right out of the tool - eliminating secondary operations and enhancingdesign possibilities.

Because of the extremely close punch and die clearances and the pressures inherent in the process,

fine blanking tools must be produced with very tight fit among all tool components.

There are two types of fine blanking tools: sliding punch and fixed punch. Generally, sliding punchtools are used for smaller and less complex parts, while fixed punch tools are used for larger andmore complex parts. Sliding punch tools are less expensive to build, set-up, and maintain, but are notas rigid as fixed punch tools - and cannot be used in every application.


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Materials

The raw material for fine blanked components is primarily rolled metal coils, although extruded androlled strips are also used. In some cases non-metallic materials are fine blanked.

Because fine blanking is as much an extrusion process as a stamping process, the consistent flowingof material into the die cavity is critical. For this reason soft materials and materials with fine grainstructure are preferred. When an application requires a hardened component, heat treatable alloys areused.

Here is a partial listing of materials that are commonly fine blanked:

Steels: carbon steels, alloy steels, and stainless steels. Aluminium alloys Copper alloys and brasses


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Fine blank Characteristics

Fine blank is a hybrid metal forming process combining the technologies of stamping and coldextrusion. Triple-action presses combined with specially designedtooling produce parts impossible to make with any otherstamping process. Fineblank yields parts with the followingcharacteristics:

Cleanly sheared straight edges, with little or no die break Small holes relative to material thickness Thin web sections Excellent flatness

Components made from rolled stock from 0.005" to morethan 0.750" (0.13mm - 19mm) thickness

Eliminate Machining

Fineblank unique characteristics mean parts that would otherwise require extensive machining afterstamping to complete the design can often be produced to net shape. Costly shaving, milling, reamingor grinding to eliminate die break are no longer needed. Fine blank can produce clean edges evenwhere part function requires full bearing or sealing contact on sidewalls, or where edges must besmooth for cosmetic reasons.

Reduce Costly Secondary Operations

Fineblank ability to pierce small holes and create thin web sectionsoften eliminates the need for costly secondary drilling and

machining operations. Because these features are created in the samestroke as the finished part, these features maintain a consistent position from part to part within a production lot and from thefirst production lot to the last.


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Sample Gallery

Backing plate for disc brake pad

Why Fine blanked? Fine blank provides excellent flatness characteristics and fully shearededges where required in the "ears".

What is it made of? Low carbon steel, 0.230" (5.85mm) thick.

Knife blade blank Why Fine blanked? Fine blank provides excellent flatness characteristics and fully shearededges. The excellent surface finish on the cut edges significantlyreduces polishing cycle time.

What is it made of?420 Stainless steel, 0.120" (3.05mm) thick.

Large transmission ring.

Why Fine blanked? Fine blank was able to create this with all holes 13" (330mm) partcomplete off-press, with all holes pierced in a single station die. Fine

blank provided a significant cost saving compared with machining.

What is it made of?Low carbon steel, 0.350" (8.89mm) thick.

Commercial lock component, hub.

Why Fine blanked?Fine blank provides all features right off-press. Square hole has cleanlysheared edges, required for tight fit of handle.

What is it made of? 1035 carbon steel, 0.230" (5.85mm) thi


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Cradle

Why Fine blanked?Fine blank provides fully sheared edges, in functional areas. Form iscreated in-press. Holes of 0.197" (5mm) are pierced in 0.250"

(6.36mm) thick material.

What is it made of? Low carbon steel.

Crimping tool handle blanks .

Why Fine blanked? Fine blank provides excellent flatness, tight control of location of

features, small radii on teeth in crimping area. Form is created in-press.

What is it made of? 1075 carbon steel, 0.187" (4.75mm) thick.

Flange for automotive system.

Why Fine blanked? Fine blank provides excellent flatness and cleanly sheared pierced holes

very close to part edge.

What is it made of? Low carbon steel and stainless steel, 0.315" (8.0mm) thick.

Ratchet blank.

Why Fine blanked?Fine blank provides fully sheared gear teeth, without need for

secondary broaching. Centre hole, 0.375" (9.53mm) 0, is pierced in0.350" (8.89mm) thick material.

What is it made of?8620 alloy steel, 0.350" (8.89mm) thick.


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Types of Parts

Fine blank unique features and cost effectiveness for manufacturing provides value to many industries. Here is a partial listing of the majorindustries that employ the fine blanking process:

Automotive: seating, safety, power train, brakes, fuel, HVAC,exhaust, general hardware.

Electronics: disc drives, printers, plotters, heat sinks.

Cutlery: Multi-tool components, knife blades.

Tools/Hardware: lawn and garden equipment, power tools, locks


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TOOL DETAILS SHEET (Fine Blank)

S.NO : Drawing Name Part No:Matching

No; Coil WidthSheet

thickness PitchScrap

Weight


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TOOL D ATA SH EET

M/C NO:- MAKE:-

PARTS NO:- DATE : -

Total stroke (MM) Cutting SpeedSensing Stroke (MM) Total Force (Pressure)Tool Safety (MM) Ring Groove (Pressure)

Ejection Start (MM) Control PressureTool Height V Ring Holding Force

Counter Force(Pressure)

Press Ring Top Low Pressure Press Ring Bottom Feeder Pressure

Pilot (Feeder GripperOpen) MM

Air Blast Air blast Start (M.S) Air blast Time (M.S)

Ram dwell Time Straitener roll 1 (MM)

Ejection Synchrony Straitener roll 2 (MM)Straitener roll 3 (MM)

Prepared By :- Approved By :-


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Tool setting points (FINEBLANK)

1. Selection of top and bottom ring acc;to the tool top & bottom pressure pin

2. Check height of machine all bottom pressure pin equal height

3. 250T : 183.70 mm, 320T : 183.70 mm, 400T : 257 mm

4. Press ring up from machine bed (0.02 - 0.05 mm)

5. Setting of machine parameters acc; to the tool data sheet.(yes/no)

6. Using proper lubrication for guide pillar/ guide bush of tool.(yes/no)

7. Inner ring up from outer ring (0.02 - 0.05 mm)

8. Tool tightening with bolt in top & bottom bed.(yes/no)

9. Check tool guide rollers should be tight. (yes/no)

10. Check cutting oil (yes/no)

11. Coil is in the centre of tool.(yes/no)

12. Proper pressure on straightner rollers (flatness maintain)

13. Size of coil (width & thickness) as per requirement.(yes/no)

14. Scratch line mark, camber in coil.(yes/no)

15. Lubrication on straightner roller working. (yes/no)

16. No scratch, dent developed in straightner.

17. To check/ record batch number on coil. (yes/no)


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POWER PRESS MACHINE SHOP

N: of presses 64 (65T- 800T)


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Mechanical power press

The concept of the hydraulic press is based on Pascal's theory, whichstates that when pressure is applied on fluids in an enclosed system,the pressure throughout the system always remains constant. Insimple words, a hydraulic press is a machine that makes use of the

pressure exerted on the fluids to crush something.

Joseph Bramah invented the hydraulic press, hence it is also known as the Bramah Press .

Basic Operating Principles of Mechanical Power Presses

There are three types of power presses: mechanical, hydraulic, and pneumatic. Their control systemsmay be mechanical or electro-mechanical. Though these three major types of power presses sharesome common features, the mechanical power press is the most commonly used and is the type of

press on which the most research has been conducted.

The two major components of a mechanical power press are a stationary bed and a moving ram. The press shears, punches, forms, or assembles metal or other material by cutting or shaping; usingcombination dies attached to the ram and bed. The mechanical power press operates on areciprocating motion principle. The main components for power transmission are the clutch, flywheel,and crankshaft. A motor powers the rotation of the flywheel. A clutch is used to couple the spinningflywheel to the crankshaft. The crankshaft converts the rotary motion of the flywheel to the downwardand upward motions of the press ram. A work piece is fed into the lower die, either automatically ormanually, and the machine cycle is initiated. On the down stroke, the ram (with an upper die) movestoward the work area, or point of operation (see Figure 1) . When the upper and lower dies press

together on the stock material, a re-formed piece is produced. Once the down stroke is completed, thenewly formed work piece can be removed, a new work piece fed into the die, and the processrepeated.
http://www.cdc.gov/niosh/docs/87-107/#Figure%201http://www.cdc.gov/niosh/docs/87-107/#Figure%201


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FIG.1. MECHANICAL POWER PRESS

Clutches

Two different types of clutches are used on mechanical power presses: full-revolution clutches and part-revolution clutches. There are important differences between these two types of clutches withrespect to operator safety.

On presses with a full-revolution clutch, once the clutch is engaged, it remains engaged until thecrankshaft has completed a full cycle. The part-revolution clutch differs in that it can be disengaged atany point in the downward cycle; thus stopping for safety reasons before the crankshaft completes thedown stroke is possible. Since the full-revolution clutch makes a complete revolution before itdisengages, presses equipped with this type of clutch generally pose a greater hazard after a stroke isinitiated than presses equipped with a part-revolution clutch.


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Foot and Hand Controls

Initiation of the power press stroke can be either automatic or manual. On presses that are manuallyoperated, there are two popular modes for initiating machine motion: foot or dual palm-button (two-

hand) controls (see Figures 2 and 3). With foot controls, the press is activated by pressing down on afoot switch or pedal, leaving the hands free during the cycling of the press. Foot controls do notintrinsically separate the operator's hands from the machine's point of operation during the operatingcycle. Persons operating power presses with foot controls must be protected by safeguarding devicesnot always directly linked to machine operation. These safeguarding devices (e.g., barriers, gates,

pullouts) may have interlocks capable of controlling initiation of the stroke. However, it also may be possible to operate the press with safeguards removed or modified so that they do not function asintended.

FIG. 2. FOOT CONTROLS

With dual palm-button controls, once a work piece is manually positioned in the press, both handsmust be removed from the point of operation to depress the palm buttons. Dual palm buttons require

both hands to be away from the point of operation when the press cycle is initiated.

FIG. 3. DUAL PALM-BUTTON CONTROLS

Operator productivity may be greater with foot switch operation than with dual palm-button operationsince the hands are free during the entire period of the press cycle. However, this freedom of handmovement also places operators using foot switches at greater potential risk of sustaining a point-of-operation injury.
http://www.cdc.gov/niosh/docs/87-107/#Figure%202http://www.cdc.gov/niosh/docs/87-107/#Figure%203http://www.cdc.gov/niosh/docs/87-107/#Figure%203http://www.cdc.gov/niosh/docs/87-107/#Figure%202


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PDI (Pre Dispatch Inspection)

It is the final inspection of any materials or a product; before it handed over to the customerhands.

Following steps in PDI deptt;

1. Grinder.2. Vibro.

I. Stone.II. Dryer.

3. Visual dimensionally.4. If need counter then counter operation is done.5. Stamp

DOCUMENTS IN PRODUCTION


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Production report.

Loss time report.

Rejection report.


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MAINTENANCE DEPT;

Maintenance dept. is responsible for the machine problems & itsrepairing.

The maintenance of press machine & fine blanking are:-


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Feeder problem arises due to the following reasons:-

No input command go the plc or relay panel If command is ON then check the output signal If output/input is OK then check the voltage signal on the valve, also check the pump supply

of feeder Also check & adjust the timer sensors switches & its timing

Check the pipes leakage Remove the dirt or other unwanted the particles near the cylinder of feeder

Chopper problems:-


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V-ring counter

No input command go the plc or relay panel If command is ON then check the output signal If output/input is OK then check the voltage signal on the valve no: V-ring & for counter

Ejection problems also check from the counter valve & check its parameters.

Stroke not taken: -

also check the INPUT/OUTPUT signal on plc or relay panel

Misalignment of coil


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This problem arises due the de-coiler problems:-

Pump not properly working

Strainer rollers setting not proper

Fluctuates in voltages & oil supply

Control panel of electricity for machine


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1. main supply switch

2. main pump motor for counter,v-ring,holding pressure etc.

3. pump motor for feeder and chopper.

4. emergency OFF for electric supply of machine.


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Methodlogy follow:-

5 S

The main principle of 5 s

SortingEliminate all unnecessary tools, parts, and instructions. Go through all tools, materials, and so forth inthe plant and work area. Keep only essential items and eliminate what is not required, prioritizing

things per requirements and keeping them in easily-accessible places. Everything else is stored ordiscarded.

Straightening or Setting in Order

Arranging tools, parts, and instructions in such a way that the most frequently used items are theeasiest and quickest to locate. The purpose of this step is to eliminate time wasted in obtaining thenecessary items for an operation.

Sweeping or ShineClean the workspace and all equipment, and keep it clean, tidy and organized. At the end of eachshift, clean the work area and be sure everything is restored to its place. This makes it easy to knowwhat goes where and ensures that everything is where it belongs.

Standardizing All work stations for a particular job should be identical. All employees doing the same job should beable to work in any station with the same tools that are in the same location in every station. Everyoneshould know exactly what his or her responsibilities are for adhering to the first 3 S's. Synonym:Systematize

Sustaining the PracticeMaintain and review standards. Once the previous 4 S's have been established, they become the newway to operate. Maintain focus on this new way and do not allow a gradual decline back to the oldways. While thinking about the new way, also be thinking about yet better ways. When an issue arisessuch as a suggested improvement, a new way of working, a new tool or a new output requirement,review the first 4 S's and make changes as appropriate. It should be made as a habit and becontinually improved.


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Additional S's

Three other phases are sometimes included: safety, security, and satisfaction. This is however not atraditional set of "phases". Safety for example is inherent in the 5S methodology and is not a step initself. Therefore the additions of the phases are simply to clarify the benefits of 5S and not a different

or more inclusive methodology.

Safety A sixth phase, "Safety", is sometimes added. There is debate over whether including this sixth "S"promotes safety by stating this value explicitly, or if a comprehensive safety program is underminedwhen it is relegated to a single item in an efficiency-focused business methodology.

Security A seventh phase, "Security", can also be added

. To leverage security as an investment rather than an

expense, the seventh "S" identifies and addresses risks to key business categories including fixedassets (PP&E), material, human capital, brand equity, intellectual property, information technology,assets-in-transit and the extended supply chain.

Satisfaction An eighth phase, "Satisfaction", can be included. Employee Satisfaction and engagement incontinuous improvement activities ensures the improvements will be sustained and improved upon.The Eighth waste Non Utilized Intellect, Talent, and Resources can be the most damaging waste ofall.

It is important to have continuous education about maintaining standards. When there are changesthat affect the 5S program such as new equipment, new products or new work rules, it is essential tomake changes in the standards and provide train

Kaizen

The cycle of kaizen activity can be defined as:

Standardize an operation and activities.

Measure the operation (find cycle time and amount of in-process inventory)

Gauge measurements against requirements

Innovate to meet requirements and increase productivity

Standardize the new, improved operations

Continue cycle


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The five main elements of kaizen

Management teamwork

Increased labour responsibilities

Increased management morale

Quality circles

Management suggestions for labour improvement

STATISTICAL PROCESS CONTROL

Statistical Process Control (SPC) can be applied to software development processes. A process has one or more outputs, as depicted in the figure below. These outputs, inturn, have measurable attributes. SPC is based on the idea that these attributes have twosources of variation: natural (also known as common) and assignable (also known asspecial) causes. If the observed variability of the attributes of a process is within therange of variability from natural causes, the process is said to be under statisticalcontrol. The practitioner of SPC tracks the variability of the process to becontrolled. When that variability exceeds the range to be expected from natural causes,one then identifies and corrects assignable causes.


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SPC is a powerful tool to optimize the amount of information needed for use in makingmanagement decisions. Statistical techniques provide an understanding of the business

baselines, insights for process improvements, communication of value and results of processes, and active and visible involvement. SPC provides real time analysis to establishcontrollable process baselines; learn, set, and dynamically improve process capabilities; andfocus business on areas needing improvement. SPC moves away from opinion-baseddecision making.

These benefits of SPC cannot be obtained immediately by all organizations. SPC requiresdefined processes and a discipline of following them.

The key steps for implementing Statistical Process Control are: Identify defined processes Identify measurable attributes of the process Characterize natural variation of attributes Track process variation If the process is in control, continue to track If the process is not in control:

- Identify assignable cause- Remove assignable cause- Return to Track process variation

DETAI LED DESCRI PTION


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Statistical Process Control (SPC) can be applied to software development processes. A process has one or more outputs, as depicted in Figure 1. These outputs, in turn, havemeasurable attributes. SPC is based on the idea that these attributes have two sources ofvariation: natural (also known as common) and assignable (also known as special) causes. If

the observed variability of the attributes of a process is within the range of variability fromnatural causes, the process is said to be under statistical control. The practitioner of SPCtracks the variability of the process to be controlled. When that variability exceeds the rangeto be expected from natural causes, one then identifies and corrects assignable causes. Figure2 depicts the steps in an implementation of SPC.


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F igur e 2: H ow to Perf orm SPC

In practice, reports of SPC in software development and maintenance tend to concentrate on afew software processes. Specifically, SPC has been used to control software (formal)inspections, testing, maintenance, and personal process improvement. Control charts are themost common tools for determining whether a software process is under statistical control. Avariety of types of control charts are used in SPC. Table 1, based on a survey [Radice 2000 ] of SPC usage in organizations attaining Level 4 or higher on the SEI CMM metric of processmaturity, shows what types are most commonly used in applying SPC to software. The

combination of an Upper Control Limit (UCL) and a Lower Control Limit (LCL) specify, oncontrol charts, the variability due to natural causes. Table 2 shows the levels commonly usedin setting control limits for software SPC. Table 3 shows the most common statisticaltechniques, other than control charts, used in software SPC. Some of these techniques areused in trial applications of SPC to explore the natural variability of processes. Some areused in techniques for eliminating assignable causes. Analysis of defects is the mostcommon technique for eliminating assignable causes. Causal Analysis-related techniques,such as Pareto analysis, Ishikawa diagrams, the Nominal Group Technique (NGT), and

brainstorming, are also frequently used for eliminating assignable causes.
https://www.goldpractices.com/practices/spc/index.php#_[Radice_2000]https://www.goldpractices.com/practices/spc/index.php#_[Radice_2000]https://www.goldpractices.com/practices/spc/index.php#_[Radice_2000]https://www.goldpractices.com/practices/spc/index.php#_[Radice_2000]


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GLOSSARY

c-Chart A control chart displaying counts per item where the range of the counts

is fixed. Contrast with a u-chart.CE Diagram Cause and Effect diagram. A diagram, developed by Kaoru Ishikawa

that resembles a fish skeleton. The diagram shows the causes and subcauses leading to an effect.

CMM Capability Maturity Model

Control Chart A graph with limit lines that is used to detect changes in the processfrom the graphed data is collected. [Ishikawa 1982]

FishboneDiagram

See CE Diagram.

Histogram A graph showing for defining intervals, the number of values in asample or the percentage in that interval. A visual display of a

probability distribution.

IshikawaDiagram

See CE Diagram.

Kiviat Chart A chart in the shape of a circle with evenly spaced radii, where eachradius represents the value of a (non-negative attribute). Attributes areoften plotted with respect to user-defined thresholds.

LCL Lower Control Limit. Used in constructing a control chart.

NGT Nominal Group Technique

Pareto Analysis The use of a bar chart that displays by frequency, in descending order,the most important defects. Proper use of this chart will have thecumulative percentage on a second y-axis (to the right of the chart). Ifthe Pareto principle is evident, about 20% of the categories on the farleft will have about 80% of the impact on the problem.

p Chart A control chart in which a fraction formed from the ratio of discretevariables (e.g., fraction of items defective) is plotted against time.

Pie Chart A graph in which the percentage in one of a small number of categories

is displayed as an area in a circle.Radar Chart See Kiviat Chart

RegressionAnalysis

A statistical technique for determining the best mathematical expressiondescribing the functional relationship between one response and one ormore independent variables.

Run-Chart A performance measure of a process over a specified period of timeused to identify trends or patterns.

Scatter Diagram A plot in which two attributes of the data are plotted, one on theabscissa and the other on the ordinate. Useful for detecting a

relationship between the two attributes.


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SEI Software Engineering Institute

SPC Statistical Process Control

u-Chart A control chart displaying counts per item (e.g., total defects perthousand source lines of code) where the range of the counts is not

fixed. Contrast with the c-chart.UCL Upper Control Limit. Used in constructing a control chart.

X-Chart Individual control chart

Xbar Chart A control chart in which the average for subgroups of data is plotted bysubgroup.

Xbar-mR Chart A control chart in which both the average and the range for subgroupsof data are plotted by subgroup.

XmR Chart Individual and Moving Range control chart.

z-Chart A control chart in which the plotted data has been transformed to befrom a normal distribution if the process is under control.


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THANKS

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