LAYOUT CHANGE & SKILL CENTER

SUBMITTED BY:RAJKUMAR
ME(Auto) 7th Sem.
ROLL NO. 13MEBLAO18
SHOOLINI UNIVERSITY

Contents

1.Decleration3
2.Acknowledgement.4
3. Abrastract.5
4.Company overview6-14
5.Project Detail
6. Project-01................................................................................................................................................
7. Project-02................................................................................................................................................
8. Project-03................................................................................................................................................
9. Project-04................................................................................................................................................
10. References..

DECLARATION
I

hereby

declare

that

TRANSFORMATION

the
&

project

MADE

work

entitled

DEXTERITY

SHOP

FLOOR

CENTER

(SKILL

CENTER) it is record of my own work carried out at MAHLE FILTERS

SYSTEMS INDIA LIMITED as requirements of two months project semester
for the award of degree of B-tech. (ME, Automobile), Shoolini University, Solan,
under the guidance of Mr. KAMAL PANDA during 8th June 2015 To 8th Aug
2015.

DATE:- ______________

RAJKUMAR
13MEBLA018

Certified that the above statement made by the student is correct to the best of our
knowledge and belief.

Mr. Munish Sethi

(Mechanical department)

Mr. KAMAL PANDA

(PRODUCTION DEPTT.)

Company Overview
Mahle filter system is the largest manufacturer and exporter of Automotive and filtration solution for
the automotive filtration, railways and aviation of India a joint venture between MAHLE Filter
System Gmbh Germany Globe leader in Engine Systems and Filtration Solutions and Anand, India.

Mahle Filter System GMBH:The Mahle unit with its two business unit Engine System and component as well
as and Filtration and Engine peripherals , rank amongst the top three system
suppliers worldwide system for piston systems,cylender components, valve train
systems ,air management system, and liquid management systems.
MAHLE has local presence in all major world market. Approximately 48,000
employees work at over 100 production plants and 7 research and development
centers in Stuttgart, Northampton,
Detroit ,Tokyo and Shanghai.
Around the world, approximately 2,400 development engineers technicians
are working forward-looking concepts, product and system for the ongoing
development of vehicle power trains.
The industry business unit bundles the MAHLE Groups industrial activities.
These include the area of large engines, industrial filtration as well as cooling and
air conditioning systems for Railway and special vehicles, buses, ships,
construction and agriculture machinery, the aerospace industry, and stationary
large engine for power generation. The aftermarket business unit serves the
independent spare part market with MAHLE products in OE quality

Anand Group:
Anand group has been operating in India since 1961. Anand is a group
of 19 companies that have been set up over a period spanning five
decades. It is no mean achievement that ever Anand Company is either a
market leader or rank among the top three in the country in its field of
operation. Integrating this multifarious units an operation with a drive
world force spread across 50 locations into a power full unified entity,
has made Anand the large conglomerate that it is today.
The Anand group is present almost in every part of the world.

The khandsa plants manufacture air filters, fuel filters and oil filters. The product range
is highlighted below.

Leading Automotive Filter Supplier:

MAHLE Filter Systems India, as the leading Automotive Filter supplier
in the country has consistently invested in research & development to
develop filtration media, new filter geometries, constructions and
systems.

Market Leading Brands in the After Market: Purolator &

MAHLE:
The company is the largest in its segment in the Aftermarket as well and
its products are marketed under the brands MAHLE and Purolator.

Indias Leading Exporter, OEM and After Market Supplier:

With the widest range of automotive and industrial filters in the country,
MAHLE is the principal supplier to both the OEM segment and the
Aftermarket with a sizeable presence in overseas markets as well.
The company has four state-of-art filter plants, located at Parwanoo
(Himachal Pradesh), Pune (Maharashtra), Khandsa (Haryana) and
Chennai (Tamil Nadu). The Khandsa facility is equipped with an ultramodern filter paper impregnation plant, the largest of its kind in the
country.

Originally known as Purolator India Limited:

The company was originally known as Purolator India Limited, set up as
Joint Venture in 1964 between Purolator, USA and Anand. MAHLE
Filter Systems India was established in 2005.

Major R&D Achievements at MAHLE Filter Systems India:

Involved in several research projects like the development of a high

efficiency multi-layered filter media using nano fibers for use in fuel
filters of commercial diesel vehicles.
Involved in the development of all-plastic Air Intake systems for HCV
applications for improved aesthetics and noise control.
Innovative design of a heavy duty air filter element with minimum metal
parts
New non-woven air filter media for passenger cars with increased
service life
Design, Development and Installation of Fuel rig, Collapse rig, and Fly
ash test rig for Mahle, China.
Development of air filter rig (Life & Efficiency) for Guard filter,
Pakistan.
Pressure sensors for air filtration.
Diesel water separation media.
Software development for the prediction of permeability in filter media
and efficiency / DHC in a oil filter test rig.
Oil Filter Systems for turbo-charged engines
Eco-friendly Metal-Free Fuel Filters
Oil Filters Turbo-fan Dry type Air Filters
New Pleating technology to reduce spin-on filter sizes
New dual-layered filtration medias for fuel and oil application

R&D CAPABILITIES:
Designing of new generation portfolios validated by CAE:
The designing of new generation portfolios validated by CAE,
comprising of Plastic Air Intake Manifolds, Integrated Head Covers with
Oil Mist Separators & complete Plastic Air Intake Systems with
snorkels, pre-cleaners and plastic air cleaners with polyurethane
elements, using special filter media with respect to change over lifetime
and efficiency as required by the new generation engines.

Design & Simulation capabilities with a range of advanced

software
Design & Simulation capabilities with a range of advanced software to
produce 3d acoustic calculation; optimize Air Intake Systems and
Resonator performance; generate accurate results of air borne noise in
front of orifices; obtain an accurate result of structure borne noise in a
defined point above the surface of interest; all-round solution for
measurement, analysis, and evaluation of sound and vibration signals.

Advanced Testing Infrastructure & Facilities

MAHLES advanced testing Infrastructure includes test facilities for
advanced product lines with the latest environmental control equipment
like Salt spray testing and a Thermal chamber; dust feeder in the air test
rig which helps controlled feeding of test dust; street test bench to aid
correlation of field performance of the air filter; validation of the
simulated acoustic results with a NVH facility; OMS testing apparatus
for testing separation efficiency of the Oil Mist Separator.

KAIZEN
Kai means continuous and Zen means improvement so Kaizen is Continuous improvement
over current processes. This continuous improvement can occurs for machinery, materials, labor
utilization, and production methods through applications and ideas of company teams.

OBSERVATIONS
MPFI Line
1. COILING MACHINE
Coiling machine make element coil for the filter. The main parts are :- centre tube
and filter paper.
Number of Coil = 12+/-1
Coil Height = 40+/-0.8
Hot melt Weight = 3.5 to 5.5 gm.
Fold Height = 8 mm+/-1
Paper gap = 3 mm max
Hot melt Distance = 6 mm+/-1
Hot melt width = 4 mm+/-1
Temperature of hot melt = 250 to 260C
Total time required per piece = 20 sec
Time required by the machine = 7 sec

Time per Piece Table:S.no

Loading Time

Machine Time

Unloading Time

1.

7:50

4:49

18:99

2.

8:00

5:05

20:05

3.

7:43

5:25

19:68

4.

8:00

5:20

20:20

5.

8:00

5:35

20:35

6.

7:56

4:20

18:78

7.

8:05

5:10

20:15

Average time required by 1 piece = 20sec (approx)

Total cycle Time

2. EPOXY MACHINE
Epoxy machine is used up to fill the gap between the coil and the bowl by using an
Adhesive like structure Ana bond .
1.
2.
3.
4.
5.

Vaccum gauge pressure = 2-3 bar

Pressing gauge = 2-3 bar
Machine inlet pressure = 6-7 bar
Dispensing time = 1000-2000 ms
Shot weight = 3-3.4 grams
Coil insertion in the bowl till the dead centre is also done in the epoxy
machine.

HEAT OVEN
Heat oven is used for the hardness of Ana bond by providing a high temperature.
It has three heating coils to provide heat.
1. Temperature = 150 +/-10 degree C
2. Time = 10-15 min
Inspection of adhesive hardness is manual. Pin holes are also checked.
Pin holes or improper hardness of the adhesive is considered under rejection.

3. SEEMING MACHINE(AUTO-3)
LOCTITE DISPENSING
The process of this machine is to dispense a sticky substance which we call as loctite.
Loctite is used to cover up the gaps and prevent the leakage after the bowl and covering is
seemed.
1. Pressure = 0.3 0.69 bar
2. Time = 2 3 sec

SEEMING
Seeming machine is used to join the bowl and the upper covering. It has four rollers, 2 to
roll up and 2 to seem.
1.
2.
3.
4.
5.
6.

Seeming O.D = 67.0 +/-1

Sean Width = 4.5 +/-0.5
Total ht = 60 +/-0.8
Seam hook overlap = 1 mm Min
Pipe height = 28 +/-0.8
Pressure = 3-5 kg/sq.cm
Poka yoka in it is hand body detecting sensors. If any part of body is inside the
working area than the machine stop working and save that person from any harm.

4. MAGNIFYNG, SCREENING
Magnifying is done check the cracks, sharper edges etc. If cracks or something that may
have damaged the filters are found than that piece is sent to rejection.
Screening is done to provide names, dates or as per the company requirement. There
should be no smudges, if there than the part is reworked and then sent to next station for
next process.

5. WATER LEAK TESTING - 1

Water leak testing is done to check out leakages in seemed part. This is a must required
process because it is possible that we can see outer cracks through magnification but the
leaks cant be seen through magnifying glass thats why we perform water leak testing
operation.
Water leak testing is performed by putting the filter inside the water and passing a high
pressure gas inside the filter. If bubble formation is there then we get the rejection piece.
Time = 30 sec
Pressure = 5-6 kg/sq.cm
Operator coding properly visible
Poka yoka = Hutter for blocked piece
= bubbles for leaked piece

PAINT SHOP

LOADING OF BOWLS
ON CONVEYER BELT

BOWLS PASSES
BLOW OF MACHINE
TO BLOW OFF
WATER

IR(PAINT STARTS
MELTING IN THIS
AREA)

DEGREASING OF
BOWL BY CHEMICAL
MIXTURE

BOWLS NEXT
PASSES FROM
WATER DRY OVEN

PCO(PAINT CURE
OVEN) PROVIDE A
SHINING FINISH TO
BOWL

WASHING OF
BOWLS TO REMOVE
CHEMICALS FROM
IT

PAINT SPRAY
BOOTH(SOLID PAINT
SPRAYED ON BOWL)

UNLOADING
(INSPECTION)

The loading to unloading process of one bowl take approximate 1.5

hours.
Solid powder paint is used instead of liquid paint because liquid paint
starts flowing down and form an uneven layer of paint on the bowl and
we cant get the desired result.
Degreasing is done to remove the oily surface that is there on the filter
bowl so that the paint can be easily got on it.

1ST PROJECT
SHOP FLOOR LAYOUT CHANGE:The project is provided to me by Mr. Kamal Panda sir and I thank
him for giving me this opportunity.
In the shop floor layout change, the main purpose is to get the extra
space out from the shop floor area so as to increase WIP and 5S.
For changing the layout we measure the shop floor area and
AUTO1 is taken as the reference for the layout arrangement. After
taking the area of the shop floor, all the machine area is also
noticed so as to arrange the machines in the desired area.

DRAW LAYOUT CLICK

After taking all the dimensions a layout is made on the paper sheet.
After making the layout it is checked by Kamal Panda sir and then after
the approval it is applied. Machines are shifted as per the reference line
is provide.
The toughest job was of shifting of packing line, but is an interesting and
learning project.

LAYOUT CHANGING WORK:-

Reference line

Unadjusted trolleys during layout change.

After the change of layout WIP and 5S is improved. Not only this but it also help
in increasing my knowledge and made me to learn some new thing. Its teaches me
that nothing is perfect so once we should also try ourselves to make things perfect
so as to get a benefit from them.
The extra space we have for keeping our bins and trolley without disturbing our
5S. Now the uneven lying of material is no more there and we also have space to
keep the desired material at desired machine so the movement is also decreased.

KEY LEARNINGS:

Safety measures
How to behave with your team mates
Working procedure in a company
About kaizen
Time wastage study
Quick solution of some common occurring problem
How to improve 5S in a company and whats the importance of 5S
How to increase productivity

Benefits:

5S of plant improve very well.

Space for WIP increase.
Conjunction of line decrease.
Plant looks neat & clean.
Manpower movement decrease.

AFTER LAYOUT CHANGED:-

SHOP FLOOR APPEARING VERY WELL

PROJECT NO.-2
DEXTERITY CENTER:Dexterity center means skill center, where
we give same working condition as at work floor to the new employees.
Here employees learn about companys goals, mission, vision, product,
process, machine, equipments, safety & maintenance etc.

PICTURES OF SKILL CENTER

DOCUMENTS BOARD

ACKNOWLEDGEMENT
Training as teaching is an essential part of an individuals future career.
The learn while you work attitude is a very practical touch in the
complete tenure of a personal life. Training bridges the gap between the
learnt and the happening. During this phase the trainer or guide or the
supervisor is the one who can help make the most of this golden
opportunity.
I would like to put forth my regardful thanks to all those who have and
are making it a remarkable attempt in guiding me and making me learn
the most during my training at MAHLE FILTERS SYSTEM INDIA
LTD. KHANDSA GURGAON
I also pay my special thanks to Mr. KAMAL PANDA (PRODUCTION
HEAD) who cared to give out an ample amount of time to me,
regardless of being extremely busy at their work. Ahead I put my special
regards to the management, workers and my co-trainees at MAHLE
FILTERS SYSTEM INDIA LTD. KHANDSA GURGAON who have
always been so supporting, loving and always ready to help. I have been
in close touch with them since the beginning of my training at MAHLE
FILTERS SYSTEM INDIA LTD. KHANDSA GURGAON. And I
appreciate the relationship they all have developed with me

DOCUMENTS BOARD

OUR PRODUCT (OIL FILTER)

INLET HOLES

OUTLET HOLE

15 FACETS TO TIGHTEN THE FILTER WITH TOOL

CHILD PART OF OIL FILTER WITH FUNCTION

Gasket retainer

Sealing gasket

Function: Hold the gasket and join

with

Function: Provide sealing between filter and

engine block

housing through seaming

process

CV gasket

Cover plate

Function: Act as sealing

between clean and
dirty oil.

Function: Provide threads to

assemble with mating part and
able to sustain under vibration and
pressure

Center tube
Function: Act as
support to filter media
and allow

End plates
Function: Act as support the filter
and provide sealing from both
ends with the help of bonding
adhesive

oil to flow
through holes
Housing (Bowl)
Function: Act as
canister and join with
cover assy.

Adhesive
Function: Bonding of paper from
both ends
with end plated
Relief valve

Bottom spring

Function: Act as safety valve when filter is

chocked and allow oil to pass through to avoid
any Engine seizer or damage.

Function: Act as support to filter element

and ensure no mixing of clean and dirty oil

FUNCTION FLOW DIAGRAM OF OIL FILTER

OIL INLET THROUGH HOLE

OIL
FLOW

OIL OUTLET THROUGH CENTER HOLE

PICTURES OF SKILL CENTER

SAMPLES OF PRODUC

WATER LEAK TESTING M/C

SAFETY MAN WITH PROPER PPES

OBJECTIVE OF SKILL CENTER:Objective of skill center is to

provide working environment to the new employees of the company.

As show in above pictures, in the skill center we used machines,

measuring instruments, process flow charts, safety man with proper
equipments, assembly tables and moulding fixture etc.

To provide working environment on skill center as at shop floor.

To provide practical during induction training.
To provide knowledge about our product, company process,
machines & measuring equipments.
To be friendly with machines & equipments.
To provide knowledge about safety equipments, how to use &
benefits of safety equipments.
Practical knowledge about how to make the filter at seaming
machine, how to perform water leak testing & then what is the
procedure of packing & how it will?

BENEFITS OF SKILL CENTER: During seven days induction training new

employees know more

effectively about the company.

They

get practical knowledge about product & machines before

come to the shop floor.

Surprise about machine mechanism & operation almost hide.

New employees try to learn very effectively.
They perform & learn about the machine.
They can differentiate the good & reject piece.
They know very well about the quality concern.
They awake about safety & safety equipments.
During induction new employees learn through the practical which
they will perform.

Quality at Mahle:Our professional project management system identifies possible source

of defects already during the initial phases of development. In this way,
we prevent problem that could be expensive later on.
Consistent control procedures during the development process monitor
timing and achievement of the project targets.
All Mahle plants are certified according to the international quality
standard of the automotive industry.

Quality at Mahle:Our professional project management system identifies possible source

of defects already during the initial phases of development. In this way,
we prevent problem that could be expensive later on.
Consistent control procedures during the development process monitor
timing and achievement of the project targets.
All Mahle plants are certified according to the international quality
standard of the automotive industry.

Training as teaching is an essential part of an individuals future career. The learn while you
wthe gap between the learnt and the happening. During this phase the trainer or guide or the
supervisor is the one who can help make the most of this golden opportunity.
I would like to put forth my regardful thanks to all those who have and are making it a
remarkable attempt in guiding me and making me learn the most during my training at MAHLE
FILTERS SYSTEM INDIA LTD. KHANDSA GURGAON
I also pay my special thanks to Mr. KAMAL PANDA (PRODUCTION HEAD) who cared to
give out an ample amount of time to me, regardless of being extremely busy at their work. I
would also like to appreciate that they gave me experience of almost every cell of the company.
so, that I could utilize every single minute in the company.
Ahead I put my special regards to the management, workers and my co-trainees at MAHLE
FILTERS SYSTEM INDIA LTD. KHANDSA GURGAON who have always been so
supporting, loving and always ready to help. I have been in close touch with them since the
beginning of my training at MAHLE FILTERS SYSTEM INDIA LTD. KHANDSA
GURGAON. And I appreciate the relationship they all have developed with me.
Finally, I express my indebtedness to all who have directly or indirectly contributed to the
successful completion of my industrial training.