2011

HINDUSTAN MOTORS TRAINING REPORT

ABSTRACT
The industrial training undertaken by Sri Chandan Kr Singh and Sri Mridul Kanti Das, a fourth year student of Mechanical Engineering Department, Saroj Mohan Institute of Technology, is hereby approved as a creditable study and presented in a manner satisfactory to warrant its acceptance as a requisite to the subject area for which it has been submitted. The work assigned to the trainee was purely observational in nature. It is to be understood here that by this approval, the undersigned personnel do not necessarily endorse or approve any statement made, opinion expressed or conclusions drawn therein, but approve the report which is submitted.

Name of the trainee

CHANDAN KR SINGH MRIDUL KANTI DAS 06th June 17th July, 2011 Mr. R BALA KRISHNAN 18th July, 2011 ACCU FORGE

Month of training Trained under Submitted on Assigned department

: : : :

_____________________________ (R BALA KRISHNAN)

ACKNOWLEDGEMENTS
The primary objective of this work is to present to the reader a very informative yet simple introduction to the Forge Division of Hindustan Motors Limited and I have tried my level best to achieve that goal. In my quest, I had the un-inhibited support of almost everyone associated to this plant I thank each and every one of them for making the past few weeks an intense learning experience for me. Especially, I am grateful to Mr. Adhikari, who has always appeased my queries with utmost patience and understanding. I am also thankful to Mr. Satish Kumar who has given me special access to the manuals of the different machines. Lastly, I would like to thank Mr R Bala Krishnan of the Head of department, for allotting me to train at the Forge Division of Hindustan Motors Limited. I wish all of them a very good life ahead.

PREFACE
The transition from having theoretical knowledge to application of that knowhow to the practical problems encountered in the industrial scenario is one of the most difficult phases of a persons career a true professional will vouch for that. This fact is most eminent in the manufacturing industries which are always in the middle of a dispute between the traditional methods and modern technologies. For smooth operation and achievement of optimum productivity, a compromise has to be reached. Now what to apply what to let go is a big question- certainly for someone who is an absolute newbie to the field. The situation was very similar for me when I went for month long summer training to the Forge Division of Hindustan Motors Limited, Hind Motor, Hooghly, and West Bengal. Suddenly, I was in this completely different world where both traditional and modern methods are working in perfect harmony. The very first hurdle that everyone faces is the discrepancy in the system of units we learn SI, they follow Imperial. Then there is always the question about methodology of application of technology. We learn to go about in a scientific step-by-step way, but in the industry empirical methods are dominant. But, close observations have often revealed that empirical methods are sometimes more scientific than scientific method itself. Technical personnel trained in modern techniques are often baffled by the way in which skill coupled with experience can achieve impossible feats after all the currency of experience still resigns supreme in this world. All this cannot be learnt from any literature available; one can only learn the secrets of the trade by experiencing the first-hand. In this work, I have attempted to unravel the methodologies that are used in this workshop and present them in an objective manner. This work is only meant as a very brief introduction to the Accu Forge Division.

OBJECTIVE
This thesis project examines cycle time of 6000 ton press machine of ACCU FORGE. The project shows that these reduction efforts cannot be addressed in isolation. Instead, they represent the outcome that results from improving the fundamental manufacturing processes across the supply chain. Through a series of different case studies, the project applies academic models to real situations at Hindustan Motors ACCU Forge. The models quantify the relationships between cycle time and inventory reduction. Reduced cycle time can translate into increased customer satisfaction. Quick response companies can launch new products earlier, penetrate markets faster, meet changing demand, and can deliver rapidly and on They can also offer their customers lower costs because quick response companies have streamlined processes with low inventory and less obsolete stock. According to empirical studies, halving the cycle time (and doubling the work-in-process inventory turns) can increase productivity 20% to 70% Moreover, quartering the time for one step typically reduces costs by 20%.

ABOUT THE COMPANY

Hindustan Motors Limited, the flagship venture of the multi-billion-dollar C. K. Birla Group, was established during the pre-Independence era at Port Okha in Gujarat. Operations were moved in 1948 to Uttarpara in district Hooghly, West Bengal, where the company began the production of the iconic Ambassador. Equipped with integrated facilities such as press shop, forge shop, foundry, machine shop, aggregate assembly units for engines, axles etc and a strong R&D wing, the company currently manufactures the Ambassador (1500 and 2000 cc diesel, 1800 cc petrol, CNG and LPG variants) in the passenger car segment and light commercial vehicle 1-tonne payload mini-truck HM-Shifeng Winner (1500 cc diesel) at its Uttarpara plant. The first and only integrated automobile plant in India, the Uttarpara factory, popularly known as Hind Motor also manufactures automotive and forged components. The armouring division under Hindustan Motors Finance Corporation Ltd., a fully owned subsidiary of HM, is also based out of the Uttarpara plant. It is one of the leading bulletproof fabricators for Ambassador Cars and Mitsubishi Pajeros. The company also has operations in Pithampur near Indore in Madhya Pradesh where it produces 1800 cc CNG variant of Winner. Hindustan Motors has technical collaboration with Mitsubishi Motors Corporation of Japan and, under this license, produces premium passenger cars viz. Lancer, Pajero, Cedia, Montero, Outlander and Lancer Evolution X (Evo X) at its third plant situated at Tiruvallur near Chennai in Tamil Nadu. Hindustan Motors is committed to core values of quality, safety, environmental care and holistic customer orientation.

Plants
Hind motor, West Bengal (near Kolkata) Pithampur, Madhya Pradesh (near Indore) Thiruvallur, Tamil Nadu (near Chennai) Hosur, Tamil Nadu (near Bangalore)

Uttarpara Plant - West Bengal

The Uttarpara plant, which started operations in 1948, currently produces Ambassador (1500 and 2000 cc diesel, 1800 cc petrol and CNG & LPG variants) in the passenger car segment and light commercial vehicle 1-tonne payload minitruck HM-Shifeng Winner (1500 cc diesel). The first and only integrated automobile plant in India, the Uttarpara factory, popularly known as Hind Motor, also manufactures automotive and forged components. The armouring division under Hindustan Motors Finance Corporation Ltd., a fully owned subsidiary of HM, is also based out of the Uttarpara plant. It is one of the leading bulletproof fabricators for Ambassador cars and Mitsubishi Pajeros. The leading customers for this service include Union and state governments, police, defence services and Paramilitary forces. The setting up of the plant, which was followed by the establishment of the adjacent Hind Motor railway station by the government, had a profound impact on the socio-economic milieu of Uttar Para. A full-fledged township housing two schools, a hospital, shopping centres, ATM & bank, specialized sports academy, club, auditoria, lake, temples and other facilities provides the much needed amenities not only to the employees but also to residents of the entire locality. It is a live example of Hindustan Motors commitment to corporate social responsibility.

Automotive Components Division

Hindustan Motors components division comprises Accu Cast (casting unit) and Accu Forge (forging unit) which provide engines and transmission and axle components for HM vehicle business and also cater to established OEMs. I. Accu Cast

Accu Cast was established primarily for HMs internal consumption. Later on, it started catering to other well established OEMs. The manufacturing facility includes 2-tonne dual track induction furnace which can melt up to 1500 tonnes of metal per month. Moulding facilities include three pairs of ARPA 900 machines and three pairs of ARPA 450 machines which have capacity to mould 1200 tonnes of castings per month. Further, the unit possesses automated sand plant and facilities for fettling and machining. It also has a well-equipped laboratory with spectrometer apart from full-fledged testing facilities. The unit also possesses well established facility for machining. The unit currently manufactures all types of grey iron, SG iron, steel and aluminium pressure die castings for passenger cars, LCVs, HCV and tractor segments. Accu Cast specializes in manufacturing of intricate castings like 3-cylinder and 4-cylinder blocks, heads, gear box housings, manifolds, SG iron castings, cover, wheel hubs, aluminium gear box extension, steering arms etc. The unit can produce grey iron/ SG iron/ steel castings ranging from 5 kg to 500 kg unit weight and gravity die castings ranging from 1 kg to 25 kg unit weight. II. Accu Forge

Accu Forge too was established primarily for the companys own use. It has now started catering to well established OEM customers. The manufacturing facility includes 6000 T, 2500 T, and 1300 T presses with induction furnace and 5 up setter, and can, altogether, forge 1300 tonnes/month. The unit has in house facility for heat treatment, lab with spectrometer and all other necessary facilities. The unit has excellent facility for design, simulation and model development. The unit has a well-established die shop with VMCs and all dies are being developed in-house. The unit, currently, manufactures all types of profile forgings catering to passenger car, LCV, HCV and tractor segments and specializes in manufacturing intricate forgings like 2- cylinder, 3-cylinder, 4-cylinder crankshafts, camshafts, stub axles, spindles, draw hooks, all types of gears and shafts for reputed customers. The unit has the capacity to produce forgings ranging from 1 kg to 75 kg unit weight.

FORGING
Forging is the process by which metal is heated and is shaped by plastic deformation by suitably applying compressive force. Usually the compressive force is in the form of hammer blows using a power hammer or a press. Forging refines the grain structure and improves physical properties of the metal. With proper design, the grain flow can be oriented in the direction of principal stresses encountered in actual use. Grain flow is the direction of the pattern that the crystals take during plastic deformation. Physical properties (such as strength, ductility and toughness) are much better in a forging than in the base metal, which has, crystals randomly oriented.

Forgings are consistent from piece to piece, without any of the porosity, voids, inclusions and other defects. Thus, finishing operations such as machining do not expose voids, because there aren't any. Also coating operations such as plating or painting are straightforward due to a good surface, which needs very little preparation. Forgings yield parts that have high strength to weight ratio-thus are often used in the design of aircraft frame members.

A Forged metal can result in the following: Increase length, decrease cross-section, called drawing out the metal. Decrease length, increase cross-section, called upsetting the metal. Change length, change cross-section, by squeezing in closed impression dies. This results in favourable grain flow for strong parts.

Advantages of forging process Some common advantages of forging are given as under 1. Forged parts possess high ductility and offers great resistance to impact and fatigue loads. 2. Forging refines the structure of the metal. 3. It results in considerable saving in time, labor and material as compared to the production of similar item by cutting from a solid stock and then shaping it. 4. Forging distorts the previously created unidirectional fiber as created by rolling and increases the strength by setting the direction of grains. 5. Because of intense working, flaws are rarely found. 6. The reasonable degree of accuracy may be obtained in forging operation. 7. The forged parts can be easily welded. Press forging Forging of parts by presses involves slow squeezing of plastic metal in closed impression dies, instead of applying repeated severe blows by hammers. Usually two types of presses are used in press forging. Hydraulic Presses (e.g.: 6000 tons) are used for heavy work and Mechanical Presses (e.g.:2500 tons, 1300 tons, 600tons, 200tons, 100 tons) for light work. Hydraulic presses are designed to provide greater squeezing force then mechanical presses. Also production of forging by hydraulic presses is faster than that by hammers, because the whole operation is complicated in a single squeezing action.

CYCLE TIME REDUCTION IN 6000 TON PRESS

DEFINATION Time based competition is an operational strategy focusing on compressing total throughput time in an organization. Compressing time has a cascading effect on quality and cost. As cycle times are reduced, productivity increases proportionally. A fifty percentage reduction in cycle time and a doubling in work-in-process inventory turn cause productivity to increase from 20-70 percentages. As productivity increases, resource capacity is freed. Two things happen: costs decline, and the organization becomes capable of producing significantly more output with less resources: a winning combination.

CYCLE TIME REDUCTION Cycle Time Reduction is identifying and implementing more efficient ways to do things. Reducing cycle time requires eliminating or reducing non-value-added activity, which is defined as any activity that does not add value to the product. Examples of non-valueadded activity in which cycle time can be reduced or eliminated include repair due to defects, machine set-up, inspection, and test and schedule delays. Reducing cycle time will have a significant impact on a company's bottom line when implemented.

BENEFITS OF CYCLE TIME REDUCTION Reduced costs Increased throughput Streamlined processes Improved communications Reduced process variability Schedule integrity Improved on-time delivery

MACHINE SPECIFICATION
Machine Name Manufactured by Primary Function Input : : : : 6000 TON National Maxi Press National Pressing machine Billet of 42Cr4Mo2 steel Weight 67 Kg Length 660 mm Machine capacity Function of machine in plant Production Work force requirement Total no. of similar machine Location : : : : : : Pressing power 6000 ton. Forging of crank shaft. 125pcs/shift 3 min. (1 operator + 2 for handling & setting) 1 Forge Line.

WORKING PRINCIPLES OF 6000 TON FORGING MACHINE

Mechanical press work by the motor through triangular large pulley belt drive (usually doubles as a flywheel),press machine after a pair and clutch slider-crank mechanism driven, so that slider and punch straight down. Mechanical press in the forging process after the completion of the slider up, clutch automatic turn press machine off and the crank shaft at the same time the automatic device connected so slider only stop in the vicinity. Each slider-crank mechanism known as a "Point". The simplest mechanical press that only a slider-crank mechanism. Some big face mechanical press is to enable the bottom slider force uniform and sporting a smooth and rapid.

Schematic illustration of the principles of 6000 Ton Press forging machine. (a) Hydraulic press. (b) Mechanical press with an eccentric drive; the ec entric shaft can be replaced by a crankshaft to give the up-and-down motion to the ram.

FORGING OPERATION
1. Billet Heating: At first billet is heated by Oil furnace or induction heater at temperature 1220 C to 1300 C. 2. Corner Breaking: Red hot billet is carried to press machine where it is first pressed to break corners. This step only done in rectangular billet where as in the case of cylindrical billet it is not required. 3. Block Finishing: Very next to the corner breaking is Block finishing die. Here both side of block is press to give primary structure of crank shaft. Then it is carried by conveyor to 600 Ton punching machine. 4. Trimming: Under 600 ton punch machine waste flash is trimmed out of crank shaft. 5. Hot padding: Last step of whole procedure is hot padding where it is make sure that the crank shaft is straight.

Time consumption in each step

We have split the total cycle time in the given steps. 1. Time consumed in carry of billet from furnace to 6000 ton pressing machine. 2. Time taken in corner breaking. 3. Time taken in block finishing. 4. Time consumed in carry crank shaft to 600 punching machine and trimming. 5. Time consumed after trimming to padding.

DATA COLLECTED OF TIME CONSUMPTION IN EACH STEP

No of Reading 1 Step 1 Step 2 Step 3 Step 4 Step 5 Total Time 122

25

11

12

47

27

37

52

40

144

10

16

16

49

47

138

17

26

45

39

133

Average

22

15

11

48

38

134

(Time consumption is recorded in sec.)

60

50

40

Reading 1 Reading 2

30

Reading 3 Reading 4

20

Average

10

0 Step 1 Step 2 Step 3 Step 4 Step 5

(Time consumption of each step shown in bar)

DATA ANALYSIS
From above table and chart we conclude the following. 1. Maximum Time Consumed: In step 4. Which is time consumed in carry crank shaft to 600 punching machine and trimming. Probable Reason: i) Man handling Its difficult to lift and carry 67 kg in proper direction and alignment. ii) Conveyor Improper arrangement of conveyor. iii) Limitation of crane Small crane used to carry crank from trimming to padding is limited in extension.

2. Minimum Time Consumed: In step 3 i.e. time taken in block finishing.

DAY WISE PRODUCTION OF GMI CRANK SHAFT

Date Production Date Production

28th June

250

29th June

200

30th June

360

3rd July

150

4th July

435

5th July

360

6th July

250

7th July

224

13th July

84 (No of GMI crank produce on given dates)

500 450 400 350 300 250 200 150 100 50 0 Actual Production Machine Capacity

(Date v/s Production graph)

CALCULATION
No. of observation days MACHINE CAPACITY Per shift production Per Day production Total production of 17 days Actual Production Percentage of production : : : : : 125 pcs 125 3 = 375 pcs 17 375 = 6375 pcs 2313 pcs (2313 6375) 100 = 36.28 % : 17

CONCLUSION
SUMMARY Cycle time represents a vital competitive dimension for the Forging Division and for Hindustan Motor Company as a whole. Through a series of case studies that gradually expand in scope, this thesis has addressed cycle time reduction every level of detail. Each case study examined the concept of inventory and their effect on production, scheduling, and cost. Inventory fundamentally reflects the way the business is being run and how well it is against the competition. The central themes that unite the case studies in their efforts to reduce cycle time include: The need to understand the fundamental manufacturing process and incorporate that knowledge into the problem solving approach. The importance of finding the right level of detail to address the problem at hand. The value of looking across the entire supply chain and recognizing the effect that one departments decisions can have across the system. RECOMMENDATIONS
Rapid cycle times provide a competitive weapon for satisfying the customer, reducing cost, and improving quality. Each business, each division, and each machine team needs to translate how the companys cycle time vision applies to their scope of activities. Then analysis and models such as those presented in this thesis can help assess the impact of particular actions and prioritize improvement opportunities. On a more focused level, the recommendation is to expand on the following critical areas discussed in the thesis case studies. For the Single Product Analysis, the benefits of setup time reduction and lot sizing can be emphasized and encouraged by implementing the following.

USE OF INDUCTION HEATER Use of induction heater can increase the rapidity of production. Temperature control and consistency from the surface to the core, as well as over the length of the product, is usually a prime requirement can be full filled by this. Hence cycle time can be reduced. CONVEYOR ALIGNMENT Conveyor with less number of turns can reduce the time consumption between press (Block Finishing) and punching (Trimming) machine. DIE HEATING BY INFRARED HAETER IR heaters are used in industrial manufacturing processes including billet heating for forging shrink tunnels, heating of plastic prior to forming, plastic welding. They are used when high temperatures are required, fast responses or temperature gradients are needed or products need to be heated in certain areas in a targeted way. Their application is difficult for objects with undercuts.

BLIOGRAPHY
1. Manufacturing and Technology by Poovendan 2. A Course in Workshop Technology Vol. I by B. S. Raghuwansi 3. Manufacturing and Technology by Kalpakjain

4. www.hindmotor.com
5. www.wikipidea.com 6. www.scribd.com