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( starting from 23th JULY to 23th AUG., 2007 )Duration 31 days

SUBMITTED TO: GUIDED BY:

(BABULAL ) (BABULAL)

PERSONNEL OFFICER. PERSONNEL OFFIC

IST LTD.

(A UNIT OF DEFENCE APPLICATION)

SUBMITTED BY:SUNIL DHANIYAN

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Acknowledgement

I am extremely grateful to shri Babulal,

Personnel officer at Ist Ltd. Dharuhera (Rewari)

for giving me this opportunity to under go the

Industrial Training at their reputed premises.

I Pay thanks to Sh. Ankur Yadav Asst. and

all engg. Departments and engineers for their

inspiration, guidance, constant supervision and

constructive criticism in the success of this

Training.

I also express my sincere and heartful

gratitude to H.O.D of Mechanical Deptt. for

giving me this opportunity.

SUNIL DHANIYAN

Final Year(Mech.)

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L.I.E.T. Alwar

PREFACE#############

After going through theories for three years it was the time to go

through the practical exposure. I took training IST LTD. DHARUHERA

(REWARI). It is a very renowned name in factories.

Manufacturing the precision components, sub assemblies & defence

application. I got the practical exposure about various types of machines

such as CNC machines, lathe machines, grinding machines, milling

machine, various type of plating, measuring instruments & different

types of electronic devices. I learned also from other departments like

marketing, purchase, stock, excise, design etc.

Through I went to all departments carefully but I like quality

departments, the most. Because it is the department which determines

the quality of product.

SUNIL DHANIYAN

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INDEX

S. No. CONTENTS

1 COMPANY PROFILE

2 ISO CERTIFICATE

3 CUSTOMER FOCUS, QUAILITYPOLICY

4 OUAILITY OBJECTIVE

5 OUR MAJOR PRODUCTS

6 OUR MAJOR CLIENTS7 PRECISION STAMPING

8 FUEL INJECTION, EQUIPMENT PARTS

9 PRECISION COMPONENT FORASSEMBLIES

10 ORGANIZATION STRUCTURE

11 DEPTT. WISE DESCRIPTION

12 SPECIAL PRODUCT DIV.

13 CNC SHOP

14 SP ASSEMBLY

15 GEAR HOBBING DEPTT.16 PRESS SHOP

17 OIL JET ASSEMBLY

18 ELECTRO PLATING & HEATTREATMENT

19 QUALITY CONTROL

20 TOOL ROOM21 MAINTENANCE22 PPC & CONTROL23 PURCHASE

24 STORE SYSTEM25 SPECIAL INTERSTS26 CONCLUSION

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COMPANY PROFILE

IST Ltd. Is a public ltd. company promoted by Mr. Prem Gupta for more than

twenty eight years ago. This unit was established in technical collaboration

with world famous micro tech. Giants M/s RONDA SA, LA USEN, Switzerland

for manufactures of high precision mechanical watches movements, timers

and other precision parts. The company has diversified in various types of

manufacturing and export activities.

Location and infrastructures:

The complex is located in a fully landscaped lush green 490k square feet area

of which production area of 45k square feet.

The Plant is located on Delhi Jaipur high way no.-8, Kapriwas, Dharuhera

(Rewari) & about 55 km. from Delhi international airport & close to M/s HERO

HONDA MOTORS LTD. DHARUHERA. Engineering support for production is

provided by infrastructures facilities already available in complex which

include self owned power. Substation, diesel power generation sets, water

supply pollution control system and central air conditioning plant packed by

qualified and experienced personnel.

Tech. and manufacturing facility:

Our specialty is of manufacturing of micro precision mechanical parts, ass.

/sub ass. For all types of industrial electrical and electronic machinery

equipments which includes industrial products and consumer durable .We also

specialize in meeting defense

Industrys vital need for super precision timing system and components .We

manufacturing all verities of high precision, turned, hobbed, drilled, milled

,pressed and stamped components. The plant is designed for achieving a

production of US$50.00 million per annum and it can be conveniently

expanded diversified whenever need arises in the larded developed and likeTORNOS, PETERMANN, WAHLI, STRAUSAK, KARUSSEL, ESSA, KOLLER, and

IMOBERDORFAND WEILER & CITIZEN CNCs along with Indians machines of

reputed make.

We are also equipped with Swiss tool room, electro plating, and hardening and

passivation facilities.

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Man Power:

Having long Swiss association we have developed culture and have excellentback up of foreign trained engineers and technicians. Our supports work forces

of 390 persons have imbibed Swiss precision culture which makes it easy for

the company to win users commendation. Our work force is totally dedicated

and we have the best possible industrial relation with workers.

Quality Assurance:

While production high technical precision components strict quality control is

ensured at all stages of production. Our aim at manufacturing high quality

product for which expert supervision, sophisticated testing equipments &instruments are developed to ensure, fault free production of high standard in

conformance challenges.

Experience in consumer durable manufacture:

We are manufacturing high precision components for timers, auto mobiles and

electromechanical equipments. We have extensive land & readymade building

for future expansion needs.

Experience in assembly of finished product:We have vast experience in micro assembles in any product as we have done

assy. Work for mechanical, quartz, watches, timers & other products.

Experience in automotive components manufacturing:

We are manufacturing automotive precision parts for GENERAL MOTORS

(POWER TRAIN) USA, ESCORTS, YAHAMA, MICO, SIEMENS, KEIHINFIE, SUZUKI,

POWER TRAIN INDIA LTD. & back precision. We are further diversifying our

clients both in India & abroad.

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Customer focus:

In order to understand & meet the needs exceptions of the customer, topmanagement demonstrates leader ship in & to the following activities:-

Understanding current & the future customer needs & the exceptions in

addition to requirements.

Translate, identified & exceptions into requirements.

Communicating the requirements through out the organization & focus

on process improvement to ensure value for the customer & users.

Managements ensure that organization has the knowledge of statutory &regulatory requirements that apply to its product, process & activities. Top

management during management meeting review informative related to

customer satification & use this information for improving the performance of

the organization.

Quality Policy

WE SHALL MANUFACTURE PRODUCT WHICH CONFORMS TO CUSTOMER

STANDARDS & SPEFICATION & MEET REQUIREMENTS OF QUALITY. WE

SHALL CONTINUE IMPROVE OUR PROCESS, PLANT & PERSONNEL TO

ENHANCE CUSTOMER SATIFICATION.

WE SHALL COMPLY WITH ALL REGULATORY & STATUTORY REQUIREMENTS

GOVERNING OUR INDUSTORY & PRODUCT AS ESTABLISHED BYGOVERNMENT OR ACCERDITING BODY.

This policy is displayed at factory premises & communicated verbally in the

local language through various informal & formal channels to insure its clear

understating. This quality policy is implemented & maintained by everyone

through the implementation of this quality management system which

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complies with ISO/TS-16949-2002. Quality system standard represented by

this manual. As with other business policies, the quality policy is reviewed

periodically for continue suitability.

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Quality objectives

Based on organization, strategic planning & the quality policy top

management establishes achievable quality objectives within a defined time

period, including those needed to meet requirements for product & customer

exceptions. These objectives are included in the organizations business plan.

To support the company wide quality objectives, functional quality objectives

are established at relevant function & levels in the organization. These

objectives are capable of being measured in order to facilitate an effective &

efficient review by management. When establishing these objectives

management consider:-

Current & future needs of the organization & the markets served.

Relevant finding from management review.

Current products & process performance.

Levels of customer satisfaction.

Self assessment results.

Bench marketing, competitor, analysis, opportunities for

improvement.

Resources needed to meet the objectives.

The quality objectives are communicated in such a way that the people in the

organization can contribute to their achievements. Objectives are

systematically reviewed as necessary.

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LIST OF OUR PRODUCTS

Jet Slow

Impulsion Tube

Shaft Throttle KSPO

Shaft Throttle c75

Valve Seat

Nozzle

E-ring

Pilot Jet Blank

Jet

Needle Assembly

Pin

Bushing 3rd

Ball Valve

Jet Component Piston Cooling

Oil Jet Assembly

Drive Gear Assembly

Tooth Rack

Stator

Inner Yoke

Sleeve

Pump Nozzle

Jet Holder

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Bushing Fuel Plunger

Adaptor Crank Pin

Push Road

King Pin

Pinion

Drive Shaft

Star Wheel Assembly

Toggle

Fuse 447 & 213

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LIST OF OUR CLIENTS

o A.R.D.E

o BECK PISTON

o ALLISON TRAMISSION POWER TRAIN-USA

o MARUTI UDYOG LTD.

o ESCORTS

o AIR FORCE

o GENERAL MOTORES

o FLAT POWER TRAIN

o GIMELLI LAB

o KEIHIN FIE(P) LTD.

o COUPLED PRODUCTS INC

o NAVY

o SIEMENS LTD.

o IRDE

o CENTRAL, ELECTRONICS LTD., SAHIBABAD, GAGIABAD

o SWISS PACIFIC WORKS

o TRIGONA

o UCAL

o AVALON TECH. PVT. LTD. CHENNAI

o ELECTRONICS CORP. OF INDIA LTD. ECIL

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o ARMY

o MOTOR INDUSTRIES CO. LTD.

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DEPARTMEN

T WISE

DESCRIPTION

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IST LTD. DHARUHERASpecial Product Division (S.P.D)

S.P.D.TEAM:-Manager - Mr.Dharambir SharmaAssistant Manager Mr. Suresh ChandEngineers-2Supervisor-6

Workers-40About S.P.DThere are many deptt./shops in IST Ltd. Dharuhera like electroplating, gearhobbing,ebauche, cnc, quality control ,auto shop etc.-Special Product DivisionIs one of them .This deptt. Plays a great role in manufacturing of fuze 213&447 .Mainly secondary operations are preformed in this deptt.

Under the guidance of Mr. D.S Sharma, Suresh Chand I have learnt the

Following data:-

About Machine:-Most of machine available in S.P.Dare Swiss made.Drilling machines -10Lathe Machines -5Fleury Machines-25Engraving Machines-1

Operation performed:-Milling (slot, flat, v-slot, angular milling) Drilling, CounterBoring, Reaming, Tapping, Rubbing, Grinding, Turning, Marking, Marking etc.

Milling Cutters Used:-Side & face milling Cutter, Angular Milling Cutter, end MillingCutter, Form Milling Cutters etc.

Inspection Process:-

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During performing various operations of various components onDifferent types of machines, it is very necessary to check /inspectThe components periodically. In addition to inspection report profile ofComponent is checked by profile projector

IST LTD. DHARUHERACNC SHOP (Computerized NumericalControl)

CNC SHOP TEAM:- Dy. Manager- Mr. Bhagwat Swaroop

Engineer Sh. Vireder KumarJr. Engineer- 3

Technical Assistant-3Workers-16

OPERATIONS PERFORMED:-Turning, drilling, boring, threading(B.S.W ,Metric

Thread), parting, Knurling etc.

ABOUT MACHINES:-Total Number of CNC Machines-16

CNC Sliding head machines-8(CINCON) CNC Turning machines-6(ACE-CUB)

Automat Traube M/C-2

CNC CONTROLS:- FANUC 16i-TB, Oi Te

SIEMENS 802D

MANUFACTURING COMPONENT:- Jet slow

Strikers

Firing pin

Body

Dome

ArborMATERIAL:-

Components MaterialJet slow BrassStriker Steel RodFiring pin Stainless SteelArbor Stainless SteelBody Al. Alloy

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Manufacturing System:-

Raw material (Rod) Blank CNCOperation

(1st,2nd,3rd as required ) Inspection DepositDispatch

Programming:-Some Examples of programming are given below:-

G0G90G54G95M3S1800X35.25F.2M8G0 = Rapid SpeedG 90 = AbsoluteG 54 = Zero offsetG 95 = Spindle Speed in mm/revolutionM 3 = ClockwiseS = SpeedF = Feed

M 8 = Coolant on

G0G40Z5M9G0 = Rapid SpeedG 40 = Compensation consillationZ5 = 5mm away tool from job on z axisM9 = Coolant off

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IST LTD. DHARUHERA

S.P. ASSEMBLYS.P. Assembly Team:-

Sr. Manager Mr. D.P.PUNIASection Chief Sh. Yash Pal SinghEngineer 2Technical Assistant 4Workers -40

Introduction:-There are many deptt. In IST LTD. Dharuhera like SPD, CNC

Shop,AutoShop, Tool Room, Gear Hobbing etc .S.P. Assembly Deptt. Is one of them. In

this deptt.Various components comes from various shops after performing a lot ofoperations such asdrilling, boring, deburring, rubbing, stamping, turning etc. These componentsare assembledafter performing many tests like time regulation tests, torque tests, armingtest, pull test etc.to achieve a single unit i.e. fuse. Fuse is a product of defense. From this deptt.Fuse is sent to

defense store

Various Types of assembly:- Pallet assay. With hair spring

Third wheel & third pinion

Train assay.

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Device/ machines available in S.P Assembly:-

Digital Stroboflash:-

A digital stroboflash for determination ofthe rotation speed sha or motors .The Xenon tube flash rate can be set using acoarse/fine adjust potentiometer to match a rotating object which will appearto freeze its motion. An electronic display indicates R.P.M and flash rate. It canbe used to determine the rotational speed of motors, fans, pump conveyorsetc.

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Impact press:-

Impact press is suitable for riveting, staking, flaring, numbering,stamping anOther assy work. This press is very easy to operate and unskilled Labour canbe employedProfitably for working this machines

Spinning Machine:-Spinning machines are designed developed tosimulate

Performance condition of object revolving at high speed (up to 25000 rpm)and to test the

Functional characteristics of the object.

Technical Specification:-

Arm turbine maximum rpm 25000 rpm

Max. Load carrying 2kg.

Digital tachometer flange with two trip setting accuracy = + 1% Power supply = 230 volt-250 volt

Various Types of test Performing in S.P. Assv. :-

Arming test

Time regulation test

Pull test

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Assembly TreeMech. Assy. Final

Spacer Mech. Assy.Hand Spring

Bridge Screw Stage 2 Bridge PinHand Screw

HandBridge

Hand Center

Holding Screw Mech. Ass. Stage 1 Pin Long Lever PivotClick

Top platePlunger Locked Bolt closing Disc pinPlunger Spring Closing DiscPlunger

Click Spring screwStriker Spring

StrikerClick Spring

Barrel PlateBottom Plate

Barrel

Cover PlateMain Spring

Rivit Center Wheel 3Regulator

Regulator ScrewCenter Arbor

Pillar

Centre Wheel Escapment Assy.Copper Plate Screw 2Train Plate Copper Plate

PalletShort Pin

Pallet Assy..Pallet Arbor

Third Wheel

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Pallet Wt. TrainAssay.

Hair Spring

ThirdPinionCopper Wire

Fourth Wheel

Fourth Pinion

Escape Wheel

Escape PinionMovement

Screw

FUSE ASSY. FINAL

LOCKING PIN 3MAGAZINE

CAP SPRING SAFETY CAP ASSY.RIVIT CAP FUSE ASSY. STAGE-

1 PIN POWER DISCSAFETY CAPPOWER DISC

TENSIONING SCREWSHEAR WIRE

RING WIRE

DOME ASSY.STOP PINLOCKING WEIGHT

HEAD STRIKER HEAD ASSY.PIN LUG SAFETY

LUG SAFETY

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NEEDLE

DOMECUP STRIKER

AL DISC

WASHERHEAD

MECH & BODY ASSY.L.D HOLDER SCREWL.D HOLDER

SCREW SEC. MECH.3 BODY ASSY.BOX CLOTH WASHERD/PIN BODYMECH. ASSY.FINALBODY

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IST LTD. DHARUHERAGEAR HOBBING DEPTT.

Assistant Manager-Mr. I. M. SharmaSection Chief- R. S. KanudalForeman = 2Technical Assistant = 1Workers = 40+10 =50

Introduction to Gear Hobbing:-Gear hobbing deptt. has its on

value. Teeth are cut blanwith the help of different types of machine . In addition to teeth cutting , shaft

throttle(KSPO & C75) IS manufactured by performing various operation like linearmilling ,rough milling , flat milling ,slitting ,tapping ,counter sinking ,drilling,chamfering ,Brushing etc.

About Machines:- WHALI- 20

ACIERA MILLING MACHINES= 3

FLEURY MACHINES = 1 TWIN SPINDLE SLITTING MACHINWS = 2

TORNOS MACHINES =2

ABOUT WHALI:- WHALI machines are Swiss made. The standardmachines is equipped forthree different cycles of operation i.e. dive milling ,through milling or dive andthrough

milling combined . A special inclined milling attachment for cutting bevel teethis available onrequest .

Technical Specifications:-

Max. length between centers 80 mm

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Max. cutting length 50mm

Max. work dia. 40 mm

Number of teeth cut 6 to 200 teeth

Return speed 3m/min.

Cutter spindle speed 660, 1450, 1850, 2500,3000,5300rpm

Max. cutter dia. = 32mm

Net weight of machines = 445kg

Process Flowgram for shaft throttle(KSPO):-Raw material Inspection Auto blank Inspection ThreadRollinInspection Linear milling Rough flat milling FinalFlat milling Rough grinding(ebauche) Drilling ,counter sinking & tapping

Radius slitting Angular milling Chamfering on slittingProcess store Inspection Process store Grinding Processstore Inspection Brushing Process store FinalInspection Packing & Dispatch

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IST LTD. DHARUHERA

EBAUCH DEPTT.Ebauch Deptt. Team:-

Assistant manager Mr. Umesh KapilForeman Mr. Gajraj SinghTechnical Assistant- 1Total workers 37

Introduction to Ebauch:-In this deptt. Mainly secondary operations are

done such as micro drilling, counter drilling, slitting, cross drilling

etc.In this deptt. Jet. Is manufactured by using different type of machineLike micro drilling machine , center less grinding machine ,multispindledrilling machine

About machines:-Most of machines available in this shop are

Swiss made.Total number of machines 37

Fleury machines(hydraulics & pneumatics) 5Sensitive drilling press 8Slitting machine 6Centerless grinding machine 3Hand press 3Emery belt rubbing machine 1Gang drilling machines 9Drilling machines 1

Process flowgram for Jet:-Raw material Inspection Auto blank Process store Inspection

Process store Dia. 2.0mm drilling(ebauche) Dia. Adrilling(ebauche)

Final Inspection Packing & Dispatch.

Precision sensitive Drill Presses :-Servo Products Company offers the finest and most comp line ofPrecision sensitive drill presses and accessories in the industry .

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Ideally suited to small hole drilling in the range of 0.004

Inch (0.1mm) to 1/8 inch (3.2mm) with a speed range from 200 to20000 rpm.It is designed to match virtually any precision drillingrequirementsIncluding all types of material such as steel, s.s , non ferrousmetal ,plastics ,P.C.B and diamond drilling in ceramics sapphireand glass .

Technical Specifications:-

1.Power supply 115 volt AC ,60 Hz2. Spindle speed -

Low range- 200 to 400 rpmHigher speed 1000 to 20000 rpm

Center less grinding machine:-

Center less grinding machine is used to grind the dia meter ofworks

Piece without using centers .

Hi-life center less grinders satisfy the demands of modernIndustries for high accuracy, economical operation and reliabilityofPerformance for through feed grinding of various metallic & nonmetallic cylindrical parts.

Technical Specifications:-

1. Grinding dia. Max. -85mm2.Grinding wheel size 3501001273.Regulating wheel size 230100764. Grinding wheel speed 1700rpm5. Regulating wheel speed 30 to 80 rpm

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IST LTD. DHARUHERAPress ShopPress Shop Team:-Dy . Manager Sh. D.P. AroraEngineer Sh. Virender YadavWorkers 5

Available Machine:-Kollar Press 6 TonEssa Power Press 1.5 TonMay Press 63 Ton

Basant Power Press 50 TonOperations Performed:- Blanking

Bending

Shouing

Notching

Embossing Piercing Etc.

Various type of press tools:- Conpound Tool/Die

Progressive Tool/Die

Draw Tool/Die

Bending Tool/Die

Blanking Tool/Die

Piercing Tool/Die

63 Ton May Press Specification:-Type:- H Frame type

1.Upper ram:-Max. Witdrawal capacity 70t programmable

capacityRam stroke: 350 mmprogrammableFast approach speed: 300 mm/sec

2.Lower ram:-Max. Upward capacity 0-50tprogrammable

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Max. Downward 0-50t

Hydraulic systemElectric motor 50hpTank capacity 1000 lt.Electrical systemPower supply 3 Phase AC,415V, 50Hz

IST LTD. DHARUHERA

Introduction to oil Jet Assembly:- In this department oil jetassembly is preparedAfter performing various operation and sub assemblies. This oil jet

component isutilized in diesel engine for MARUTI UDYOG LTD.

Various Types of Assembly:- Block, bracket & tube assy.

Block & click assy.

Process Flogram For Jet Component Piston Cooling:-

Ultrasonic cooling of oil jet assy. Parts (electroplating) assy. of tube, blockandbracket process store inspection process store copperpasting of tube, blockand bracket cooper brazing of tube, block & bracket process storeinspection

process store ultrasonic cleaning crimping (oil jet assy.) process storeinspection process store flow test ultrasonic cleaningprocess store finalinspection Packing & Dispatch

Copper Pasting:-1. Before using the dispensing unit first cleans the unit properly

2.Switch on dispensing unit3.Fill the copper paste in needle cylinder of dispensing unit upto

the specified limit

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4.Maintain input pressure from 5-6 kg. S/cm2 and dispensing unitpressure 20-25 psi.

5. Bring the needle near to area to component where copperpasting required.

6. Press the foot-paddle and move the needle uniformly aroundthe copper pasting area.

7.Ensure that copper past is uniformly distributed and its weight0.01 gm. Each and even press.

8.Handle the component carefully and use proper bins system.

Ultra 2400 Series Dispensing Work Station:-The ultra 2400 work station is designed to provide completeprocess control for precise, repeatable fluid dispensing.

Main Features:-

1.All digital multification control display with simultaneousread out of airPressure, time, vacuum, deposit, shot count and time of day.

2. Unique air management reservoir and high speed solenoid

system forConsistent, repeatable deposits.

3. Time increments as small as 0.0001 seconds for precise

deposit control.

Technical Specifications:-

1. Cabinet Size (14.318.117.3cm)

2. Weight 2.3kg.

3. Power Supply 100 to 240 volt AC, 47 to 63 Hz.

4. Time range programmable from 0.0001 to 999.99 sec.

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5. Ambient operating condition Temp. 5 c to 45c

Filling procedures for pour able low and mediumviscosity fluids :-

If the fluid you are dispensing is pour able take the syringe barrel.Twist on an orange tip cap and pour your fluid in insert a whitesmooth flow piston and carefully press down until it contacts thefluid.

The syringe barrel is ready for use.

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IST LTD. DHARUHERA

Electroplating & heat treatment:-Section chief Sh. Rajbir TommerForeman 2Workers 10

Electroplating & HT ploy a great role for coating the component. VarioustypesOf plating i.e. zinc plating. Nickel plating, tin plating, Copper plating is appliedon theComponent. Anodising & painting are also employed. In acidition to platingsurfacehardening is done in components by using various types of furnaces. A brazingfurnace isused for brazingthe copper pasting.

About Machines & Furnaces:-Turbula 2Poly Service 1P 10 3Rotal 1Sand blashing machine- 2Hardening furnace solo 1Hardening furnace simplicity 1

Ammonia Crocker - 2Brazing furnace 1Centrifugal 2

Various types of platingZinc plating:-

Zinc plating is being used on increasing scale particularly in theelectrical inclusiry for components which would formly have been cadmiumplated. Inrecent years electrode position of zinc has made rapid strides and is now usedextensively

for finishing all manner of iron and steel products including casting. Forgingsand sheetsteel pressings.

Solution:-- ZNO- NaCN- NaOH

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Operating Condition:-Cathodic current denisty 1.5 to 6.5 amp/dm2Voltage 4 to 5V , Temp. - 30c

Tin plating:-The chief application of tin plating is for products which will come into contactwithfoodstuffs. Tin plating is also used in the nitriding of steels .

Tin plating solution:-- Potassium stannate- Stannous sulphate- Stannous flouborate

Operating conditions:-- Cathode current denisty- 1.5 to 20amp/dm2- Anode current denisty 1 to 2amp/dm2- Voltage 3 to 4V- Temp. 60 to 80c

Equipment:-For this a plain welded steel tank is generally employed. The tankbeing

fitted with the necessary anode and cathode rods are provided with means of

solutionheating.

Copper plating:-Copper plating is particularly useful as a pre coating for soft, soldered work,pewter andzinc alloy die castings before the depostion of nickel, gold or silver.

Copper plating Solution:-- Cyanide copper solution- Acid copper sulphate solution

Equipment:-For cyanide plating solution a welded steel tank is normalyemployed

alternatively, rubber or plastic lined equipment is used. It is essential that therubber us anapproved grade.

Operating conditions:-- Cathode current denisty- 2amp/dm2

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- Voltage 1 to 2V- PH value 11.5 to 12.5- Temp. 55 to 60C

Nickel Plating:-

Application machined parts, electroforming of gramophone masters, presstools andmoulds.

Nickel Plating Solutions:- Nickel salt, nickel sulphate, sodiumchloride, boric acid, water.

Operating conditions:-

- Cathode current density- 1 to 8.5 amp/dm2 (Normal)

-4 to 6.5 amp/dm2 (Higher)- PH - 4 to 4.8- Temp. 55 to 65C- Agitation - Vigorous air agitation

Passvation:-The purpose of passivation is to protect zinc or cadmium platedsurface

and in some cases zinc base die castings from corrosion so that their maintask ofSacrificial protection to steel is not reduced.

Ultrasonic Cleaning:-In ultrasonic cleaning the penetration power of the solvent cleaner isaccerlated byemploying the high frequency energy of sound waves. Microscopic cavities areprogressively created and collapsed in the cleaning medium producing apowerful andpenetrating scrubbing action. Any stubborn soil present on the componentsbeing cleanedand efficiently removed.

Anodising:-Anodising is used where a high resistance to corrosion required.Solution:-

- Chromic acid

Operating conditions:-Anodising current density - 0.3amp/dm2

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Voltage 0 to 40 VoltTemp. 40 min. to 59 min

Brazing Furnace:-Associated furnace pvt. Ltd. makes mesh belt conveyor or furnace forcopper brazingwith bright annealing.

Method:-The ammonia will be heated up be heated up to 950C in a separate furnaceand at this temp. the liquid Ammonia will be crecked , became gas ofHydrogen and Nytrogrn will be fed to theFedder and hydrogen will be burnt at the exit of the cooling pond. Nickelcatalysts will be

Used in a seald retort to crack Ammonia.

IST LTD. DHARUHERAQuality Control Deptt.

Q.C. Team:-Sr .Manager-Sh. Ashok Kumar SharmaSr. Engineer N .C. MandalEngineers 2

Foremen 2Workers 30

Introduction to quality Control Deptt.:-Quality Control Deptt. is the deptt. which determines the quality of theproduct.As thename suggest this department is related to the quality aspects in the productof the company.The department works in the critical points in the whole working areas of theplant. It mainly checks the quality standers for components received fromoutside and inside the plant.

The major area in which the QC department is most activelyParticipate are:

Good receipt and dispatch (GR & D)

Assembly line

Pre dispatch inspection (PDI).

Various types of Measuring Instruments:-Most of available measuring instrument are made by MITUTOYO ASIAPACIFIC PTE. LTD.

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MITUTOYO ASIA PACIFIC PTE.LTD.is a part of Mitutoyo a globalorganization that leads theway in precision measuring technology. Mitutoyo has facilities in 120 countriesaround the world all dedicated to seeking perfection in precision instruments.

1.Digital Caliper:-Mitutoyos new ABS DIGIMATIC CALIPER MYCAL ABSOLUTE keeps track of itsorigin pointonce set. Whenever turned on the large LCD screen displays the actual sliderposition ready start measurement. No more repeated zero setting isnecessary.

Features:-- Large and clear LCD screen.

- Display zero setting at any slider position along the scale forincremental comparison measurements.

- With SPC Data output.

Least count:- 0.01mm

2.Vernier caliper:-Features:--Plain and basic design-Permitting four types of different measurements (internal, external, depth andstep)-With clamping screw atop the slider

Least count:-0.02mmRange:-0-1500-2000-3000-6000-1000

3. Height Gauge:-

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To determine the height of any component.

Features:--Easy to use-Double column structure ensure high measuring stability

-Function include: zero setting, inch/mm conversion, coarse/fine feed switchingover speedalarm-Carbide tipped scriber

4.Digital Micro Meter:--Extra large LCD read out with 0.001mm revolution.-With SPC data output.-Light weight design.-Two types of constant forces devices are available ratchet stop and ratchetthimble.

-Carbide tipped measuring faces.

Least count:-0.001mm

Range:-0-2525-5050-7575-100

5. Outside Micro Meter:--Stain-chrome finished frame tapered on the anvil side for hard to reachplace.- Carbide tipped measuring faces.

MAINTENANCE

Maintenance in simple words is to maintain a machine. In any industry,

whether it may be small or large scale, maintenance plays an impartment role.

Almost in every industry there is separate department made for maintenance.

The main task of this department is to maintain the entire machine.

Maintenance not only means to repair or replace the damaged machine parts,

but it also contains periodic of any problem that will supposed to come a

period of time i.e. it also contains a regular checkup of machine.

Careful maintenance will increase life & efficiency of machine. A regular

cleaning is very necessary for any machine in continuous use. It pays to check

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an adhere to the lubricating instructions for time to time & any defect however

small it is, should be immediately rectified, other wise this will lead to a

measure breakdown of the machine resulting in loss of production & high cost

of repair.

It is necessary to check the electrical outfit in every six months & clean

particularly the contact points melting or burn strips should be removed & the

links lubricated carefully. The ball bearing of the motor requires cleaning &

refilling will grease once a year.

To perform this:-

The covers are removed.

The bearing shields are removed to leave then

both accessible on the shaft. They are washed

with benzol. Then bearing mare fitted clean

bearing quality grease. The dismantled parts are

to be reassembled carefully.

When replacing the damaged bearing & new bearing should be oil heated &

mounted on the shaft & greased. This is important to prevent any damage to

any part either while removing or during reassembly.

The oil filter & the pump are to be cleaned once in a year the oil is to be

drained out. The sumps are to be cleaned before refilling them with fresh oil ofspecification.

The general survey of the lubricating system may restricted to observation of

oil level marks refilling oil periodically & to daily lubricating of all openly

moved mechanism & links & guide ways.

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-Designed to be operated efficiently with one hand.

Least Count:-0.01mm

Range:-0-2525-5050-7575-100

6.Dial indicator:-Mitutoyos series 4 dial indicator gives user the advantage of an accurate and durable

gauging devicethat include easy reliability. There large dial face makes them perfect for applicationwhere reducedlighting or discharge makes reading difficulty.

7. Snap Gauge:-Snap gauge is a convenient gauge for inspecting the outer dia meter of a cylindricalwork piece.It is easy to use and therefore widely employed on the machine shop floor. However itis requires an expanded period of inspection time skill for accuracy control.

8.Black Granite Surface Plate:-- Natural granite seasoned for thousands of years is free from deterioration.- Granite surface plate many advantage over cast iron surface plate.

- Minimal changes in dimensions due to Temp. change.- Long life and rust free.

9.Tool Measuring Microscope (T.M.M):-It is a microscope well suited for measuring dimensions and angles of machinedmetals.It can also be used to check the shape of screws and gears by attaching an optionalreticle.Its compact body makes it ideal for use on shop floor with limited space.

10.Profile Projector:-It is an electronic instrument with a huge screen used for measurement the profile ofany component.

Features:--Vertical illumination system-D.R.O screen (zero setting protractor)-Angled screen allows projected images to be easily traced or compared with atemplate.

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11.Rockwell Hardness Tester (Manual):-It is a device which is used to determine the hardness of any material.

Features:-

- Diamond and 1/16 diameter steel boll indenters are provide asstanders.

- Large working space for easy measurement of large specimens.

PRODUCTION PLANNING AND CONTROL (PPC)

PPC is an important section of a company and any companygrowth rely on the performance of the planning section i.e. howefficiently they plans & implements it to complete an order or

production target proceeding of PPC department are explained inbrief here.

First of all preparation and updating ofbill of material is done on the basis of the chassis speciation andthe target production of various chassis. Then based onmonthly/quarterly production plan the department drive therequirement of the various material which are used on theassembly line, the next step is to send schedules to the differentunits, ancillaries & suppliers who are responsible for the

fulfillment of the raw material requirement the next material thenext step of PPC department is to update material position basedupon receipt & transit details & also to prepare critical partsrequirement it also include daily follow up of critical parts withsuppliers/units.

One most important function of PPCdepartment is to reschedule the requirement in case if there ischange in production planning. Another function of PPC

department is goods receipt & dispatch after doing the planningof requirement of raw material according to production planning,requisitions are made to different units/suppliers and in theresponsibility of PPC department to receive & also if some good isto be send back it also came under the control of PPC departmentto dispatch these goods.

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After the material is reach in thepremises of company & giving the receipt note to the transporternow PPC department is also responsible for the proper storagethese material or for managing the stores.

PPC department also have the responsibility of rectification ofstored material if the is any sort of problem with there use & toissue the material to various departments according to variousproduction plan established.

Generally PPC department keep the inventoryof 21 days for smooth running of assembly line according toproduction plans if there is any sort of problem regardingtransportation services.

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PURCHASE DEPTT.

Purchase of the following

Raw material

Consumable

Spares

Packing Item

Tools

Fabrication

Calibration Job

Working of Purchase Deptt

Marketing deptt in consultation with PPC-Vender (production Planning &

control) gives the list of requirement of the purchase deptt. The list is made on

the basis of the maximum-minimum basis. This max-min basis says that

MKT PPC

Purchase

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requirement is divided into a certain level. We can not go beyond a certain

unit (max) & one demand which are at least required.

Topic wise details of the purchasing:-

1. Raw material: - Powders store gives the demand on the basis ofmax basis.

2. Consumables: - These include the material which is beingconsumed after each

month such as lubricants, oils etc.

3. Spares: - Spares include all the accessories parts of the

machine, furnace, press etc. The maintenance department gives the

list of the spares of the brake down parts of the purchase department

duly signed by their HOD.

4. Packing item: - These include the cartoon boxes, packingcover/bags, the slips (quality approval). This demand is given by

marketing deptt.

5. Tools: - Maintenance department is consultation with

marketing department give the demand of tool the purchase

department. Purchase department import (die & punches) from TAIWAN.

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6. Calibration: - Calibration is the rectification of the machine

tool time to time for standardization. Calibration time is fixed for each

machine/press. The expense is taken by purchase department.

7. Fabrication: - Any fabrication work like shading, welding,

sheet, metal job etc. is also whelmed by purchase department.

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8.

STORES SYSTEM

Stores are the places where excess of the raw material and accessories items

are being kept for further use. The material which is in kept stores room

includes powders, lubricants, tools, parts/spares of each machine press

actually for easiness in use coding is done for each m/c & its components. Let

say there are presses, furnace, grinding machines, CNC machine etc. They are

coded let say a, b, c &d etc. then each main component is sub coded. Hence

we can directly access to that component.

Colour coding is an important factor in the storage. Different colours are

allotted according to the month. The stickers are glued on the boxes of the

spares. These colours help us to identify which part to be used first stores

system uses the formula LIFO & FIFO. LIFO stands for last in first out & FIFO

stands for first in first out. The materials are divided into these two categories

& these are used accordingly.

There is a regular check up by being done by store system according to the

calibration date and the material is revalidated accordingly. Materials are also

stored on max-min basis. There is a particular limit of the raw material. We

cant store beyond a certain extent and also has to store a minimum quantity.

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Thus, we can say that a store house acts as a reservoir of all the required

material of the factory.

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SPECIAL

INTRESTS

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About 5sJapanese Word English meaning

Seiri Sorting

1S Task to be done for implimentation of 1SPreparation of list of itms

Sorting of items into "Required & Not Required"

Japanese Word English meaning

Seiton Arranging

Task to be done for implimentation of 2S

2S Allocation of space for "Required & Not Required" items

Preparation of layout showing the space allocated

Keeping items at allocated space

Tagging "Not required" items

Japanese Word English meaning

Seiso Cleaning

3S Task to be done for implimentation of 3S

Finding abnormamalites

Tagging abnormalities

Process of closing abnormalities

Japanese Word English meaning4S Seiketsu standardization

Task to be done for implimentation of 3S

Spreading of awareness among workmen

Japanese Word English meaning

5S Shiksuke Self-Displine

Task to be done for implimentation of 3S

We have to discipline ourselves for maintain our place

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INDUSTRIAL SAFETY

The importance of industrial safety was realized because every year millions ofindustrial accidents occur which results in either death or in temporary and

permanent disablement of the employs & involve a good amount of costs,

such as resulting from wasted man-hours, machine hour etc.

NEED FOR SAFETY

1. Increasing rate of production.2. Reducing producing cost.3. Reducing damage to equipment & machinery.4. Preventing premature death of talented workers who are an asset to the

society.5. Preventing needless pain & suffering to its employs.

SAFETY RESULTS

1. From safe plants, processes, and operation, and2. by educating & training workers & supervisors regarding safe practices

on the shop floor.

**In an industry, safety may be considered from the mechanical side or

from legal angles of workmens compensation or even as a matter of

training in & motivation towards safe work practices for workers**

SAFETY PRECAUTIONS

1. Always wear safety helmet or goggles.2. Keep your work place clean before & after works.3. Always use right type of tools which is in good condition.4. Provide proper ventilation & lighting in work area.

5. Before commencing any new work made a check list.6. Know the location of safety & fire fighting appliances in your work area.7. Familiarize yourself & workers with methods of use of all safety & fire

fighting appliances.8. Clean the spillage of grease, oil & acid immediately.9. Machine guard should be in its position while the machine is moving

condition.10. Use ear plugs where the sound level is high.

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11. Ground all electrical equipments.12. Switch off all electrical equipments while fueling.