industrial visit -2005

Name of company: Jadhao gears industry

Type: small scale Management: individual Type of production: job order production Plant layout: process type layout Location: jadhao industries w-27, street no :5 MIDC amravati 444605 maharashtra, India.

* Quality policy *[objectives]

The main objectives of a quality central program conducted in an industry are:

1. Evaluation of quality standards of incoming material, product in the actual manufacture, and of outgoing product. 2. Judging the conformity of the process to the established standard and taking suitable action when deviations are noted. 3. Developing methods for effective utilization of scrap materials in minimum handing. 4. To improve quality and productivity by process control and experimentation. 5. Developing procedures for good employer employee relations. 6. Developing quality consciousness both within and outside the organization.

* Aim of the project *

The project has been undertaken keeping in view establishing an assembly shop, which supports continuous assembly line thus replacing the existing assembly.

Practice of job type for auto feeder at Jadhao gears, MIDC, amravati.

The company was facing a problem of not meeting the delivery dates in the peak season. At that time the production rate was 6 auto feeders per shift of 8 hours, thus to fulfill the demand they have to use 3 shifts. So it was decided that instead of batch wise production, a systematic approach towards continues production should be adopted. This necessitates the seed for assembly line and assembly shop. The target production rate was fixed at 20 auto feeders per shift.

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* Profile of industry *

jadhao Gears is a manufacturer of all types of reduction gear boxes, gears, conveyors spares, is located at MIDC, amravati.

The company is mainly involved with cotton processing systems, for which they produce following products on demand.

* Ginning machine. * Olicro feeder * Lint opener * Lint conveyors * Cotton pre-cleaner. * Cotton baling press. * Raw cotton suction system. * Preumatic cotton seed conveyor * Screw conveyor for raw cotton and cotton seed. Apart from above-mentioned products, there is regular production of auto feeder, a machine for feeding the cotton in the ginning machine.

The company motto: Excellence is not a destination, it is a continuous journey that never ends, has a very positive attitude towards the quality of its products.

In a very short future, it has received ISO 9002 certification; giving a self-identify to its products in the market.

A company, which believes in thought we have not arguments with competitors who charge less, but use readies what their product and service is worth.

Majority of the parts of auto feeder are been produced at Jadhao Gears and its sister concerns viz. Jadhao steel alloys , Jadhao agro pvt.ltd. etc. so in this sense, the company is self-sufficient.

In this company, near about 150 workers with quality consciousness produce quality products to provide best services to the customer.

* plant layout *

plant layout is a very important feature in today s industries. it is the arrangement of the desired machine and equipment of a plant established in a way which will permit the easiest flow of material at lowest cost and with the minimum handling in processing product from the receive of raw materials to the dispatch of the finished

industrial visit -2005

product. jadhav gears industries has the process type layout.

* departments of company *

the company is comprised of several departments, which work all together with good co-ordination.

y y y y y y y y y

machine shop cnc machine shop. design and drafting section. assembly shop. quality control department. warehouse department. account section. Purchase Department sales marketing section.

INTRODUCTION TO VARIOUS DEPARTMENTS

a. CNC MACHINE SHOP :cnc machine shop includes mainly two semi-automatic operated cnc machines. these are listed as bellows :

1. cnc - i on this machine, the ginning machine pin is finished and trued. the single point cutting tool is clamped automatically on turret head provided with eight tool stations. once the tool is set to proper position, it wasks automatically.

the loading and unloading of waskpiece (ginning pin) is done manually. as being semi-auto operated only 1 worker is required to operate the machine nicely and to get completed 1 job in 5 minutes.

2. cnc ii the required work piece tool position is get as above. on this machine, the swing lever clutch is true as shown in figure. this machine is capable of having 12 tools for different operations.

b. ASSEMBLY SHOP:c. o.e. & t. akola

industrial visit -2005

this shop includes various production sections. it comprises the production and assemblies of various parts of ginning machine.

1. this shop includes the assembling of ginning machine and different products of the company : the body of the ginning machine is placed on the rail conveyor. this is then proceeded further by attaching the various parts of the machine i.e. frame, roller, screw conveyor, motor, gear base, blower, etc.

it uses the product type layout

2. in this shop two production machines are placed : i) hydraulic shopping/bending machine. this machine is employed to cut or bend different shapes of angles, flat strips, bars, etc. ii) hydraulic press fitting machine :

this machine is used to press fitting of needle bearings into the hub. the loading and unloading of the hub is done manually. the raising and lowering of press stamp is totally manual.

3. the assembly shop is associated with many material handling equipments. the various material handling devices are :

* fork lift truck :-it is widely used for stacking the materials. similarly it is used for carrying the scrap sheet metals, bass, angles throughout the various departments. the company has the two medium sized truck.

* jib crane :-this crane is used for lifting and displacing the heavy objects like steel bars, plates, dies, etc. within the shop. for a smooth and continuous work of assemblies and sub-assemblies 3 jib cranes are employed in the assembly shop. the cranes has the oscillating movements. * overhead crane :-this crane has both transverse and longitudinal movements. the crane hook thus moves in a rectangular area and can reach to any part of rectangular floor or yard. it is used for displacing and lifting the frames, steel rolls of ginning machine within the shop.

the 1 overhead crane is employed in assembly shop.

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industrial visit -2005

* rail lines :-a very small rail line is installed within the shop for conveying the ginning machine through the various sub-assemblies sections of assembly shop. c. MACHINE SHOP I: This shop includes various production machines. Different assemblies and Sub-assemblies are manufactured in this shop. Various operations like facing, turning, Drilling grinding, etc. are performed in this department.

Following machines are placed in the machine shop.

1. Centre lathe machine. 2. Drilling machine. 3. Grinding machine. d. Fabrication shop and sheet metal shop: In street metal shop sheets are cut or bended according to design considerations. This department plays an important rate since many machines are made of different sheet metals.

The complete bodies of various machines are manufactured by this section : (1) Channels, (2) circular bars, (3) panels, (4) angles of small sections can be manufactured by various machines like nibbling machine and bending machine. The Welding machines are used for joining the different parts of sheet metals.

Main store building:This building is having the following departments:

1) Machine shop ii This shop is equipped with production machines like milling and lathe machines. in this section, connecting rod casting is processed. The small end of connecting rod is drilling on milling machine. Various machining and finishing operations on different castings are done in this department.

Following machines are placed in machine shop ii :

(I) Gang milling machines (3) (ii) Centre lathe machines (3)

b. production shop

This shop plays on vital role in designing and manufacturing of gears. As the company s name suggests, this department has its own important.

The following machines are placed in production department.

(1) Key way milling machine : On this machine the keyway i.e. slot on the ginning pin is produced by end mill cutter. The parts keyed on this machine are:

(I) Eccentric shaft, (ii) Clutch,

(iii) Gear 39t, 46t and long bars.

(2) slotter machine : The slotting machine or slotter has its own importance for a few particular classes of work. This is mainly used in cutting different types of slots and it certainly pored to be most economical, so far as this kind of work is concerned. its other uses are in machining irregular shapes, circular surfaces and other remarked profiles, both internal as well as external.

3) planer machine :

Planning is one of the basic operations performed in machining work and is primarily intended for machining large flat surfaces. These surfaces may be horizontal, vertical or inclined. the jobs which are almost impracticable to be machined on a shaper or milling machine are machined on planning machine. In the production shop are planning machine is satisfactorily being used for machining flat surface or rails. The material feeding is manual.

4) grinding machine :

This machine is used for removing material by the abrasive action of a revolving abed on the surface of hardened ginning pin .it is a finishing operation and on ginning pin uses a cylindrical grinder bath for internal and external grinding.

5) Gear hobbing machines:

In this process, the gear blank is rotted with a rotating cutter called hob. a majority of involutes gears are produced by this method. Spur helical and herring bone gears and many other shaper like splines and gear sprockets etc.can be cut by hobbing process.

4 hobbing machines are placed for gear hobbing process in the production department.

6) gear burnishing : This process used for finishing the gear teeth and is employed on gears after cutting. the gear is mounted on a vertical reciprocating shaft in mesh with three hardened and ground burnishing gears. These gears are power driven. the three gears are fed into the cut gear and rotated through a few turns in both directions. this makes the gear teeth surfaces smooth and also imparts a little hardness to them. the required bad is provided by hydraulic means.

* after gear burnishing : the gear meshing and run out operations is done by hydraulic means for proper alignments of gears. d. sheet metal or press working : In this shop streets are cut or bended according to design considerations. the shop is associated with bending and press machines. channels, panels, hopper for auto feeder, etc. are manufactured in this shop as per the required capacity and design.

c. store department : The finished and non finished parts, raw materials, in process inventories, spare parts of machines, etc.are stored in store departments. to be precisely, junctions of stores are as follows :

1. to maintain record of incoming and outgoing materials from store. 2. to maintain record of issued materials, equipment etc. 3. to prevent materials from erosion or any other such type of fatigue. 4. to keep record of quantity of materials remaining; and from this record, to inform purchase department that which goods need to purchase. management:

1) production manager :- mr. vijayrao deshmukh. 2) managing director :- mr. sanjay jadhav. 3) q.c.c.manager :- mr. mahure 4) marketing executive :- mr. deshmukh assembled in this section.

*costing department* this shop is located 1 km away from the annexure building. the various assemblies and sub-assemblies are casted with proper technique and design. the different sub-departments of casting shop are as below :a)

pattern making department :

the process of making pattern is known as pattern making. the pattern making is a primary stage of making casting. in this section various types of pattern are made by skilled workers. wood is widely used because of ease of availability and being cheaper.

b) foundry shop :

in this shop metallic products are formed by melting the metal into different furnances, poured it into a cavity known as mould and allowed it to solidity. The various works performed in foundry shop are : i) the preparation of sand includes (i) mixing of sand, (ii) tempering of sand (iii) sand conditioning. i) mixing of sand :it means the mixing of various moulding materials to ensure uniform distribution of clay, moisture and other constituents between the sand grains. the moulding sand is ordered from kanhan plant dist. nagpur maharashtra. ii) tempering of sand :in this process sufficient moisture is added to the moulding sand by adding water.

iii) Sand conditioning: New sand as well as used sand is properly conditioned before being used. Proper binders and additives are added to impart strength and other properties to the sand.

Most of the conditioning of moulding sand is done by hard. besides, a sand muller is used for sand mixing.

2) Moulding procedures : most of the sand moulds are made by hand. one moulding machine is employed in large lot and mass production of moulds. highly skilled workers has been appointed for making the moulds.

The moulding procedures used in jadhavo industries is ; i) based on the type of material of which the mould is made is green sand moulds . ii) the method used in making the mould is floor moulding .

the graphite powder (black in colour) is provided over the moulds to develop special properties in the moulds and consequently in casting. it also helps to provide smooth surface on the castings. moulds like cover plate, frame, rails etc.are produced.

iii) Core making: Core making consists of the following operation: (I) core sand preparation (ii) core moulding (iii) baking and (iv) core finishing.

A core is a body made of refractory materials which is set into the prepared mould before closing and pouring it, for forming through holes recesses, undercuts, Internal cavities. All these core making operations are done manually.

(3) Melting: Various types of melting furnaces are used, depending upon the quantity of metal to be melted at a time, and the nature of work that is carried out in the shop. The following furnaces used for melting are: i) cupola : this furnace is used in foundaries for melting and refining pig iron along with scrap. ii) the continuous show cupolafurnace is used and has the capacity of 3 tonnes/hour. iii) q oiled fired furnace : this furnace is used for mase production and has the capacity of 1

tone/hour.

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industrial visit -2005

(5) casting : casting is the solidified piece of metal taken out of the mould. different castings like crucibles, frames, rails, cover plates and many others small pieces are conventionally casted.

c : shot blasting : this is the process machining and filling the cavities left in castings. this is done by the blow of small metal balls on the castings; which are kept on the rotary table, operated in the closed chamber.

an double doored shot blasting machine is used for this purpose.

d. surface grinding and primer coating : after from blasting the castings are grinded to get the more finishing. the pneumatic grinders are used for surface grinding. the finished castings are than shifted for primer coating. the coatings are used for the purpose of decoration, surface protection corrosion resistance and the providing of a hard surface.

the coated castings are then shifted to various departments for further operations.

* design and drafting section* design is considered as a primary key in the production by different machines.

advanced parameters are considered while designing any machines. various comments, past experiences, different results are taken into consideration to provide the best services to both the customers and consumers. the factors like capacity of machine, cast, ease of availability, purpose, handling and maintenance, etc. are considered before designing and drafting of machine. all these are recorded by means of charts, tables, cd s, floppy s etc.

it helps to meet customer satisfaction and to improve quality of products.

if adds the company s status to be longer.

*production planning and control section*

advanced planning of flow of materials, operations to be performed on raw

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industrial visit -2005

material, material handling maintenance are made on the charts, tables and graphs. by using these charts, tables, graphs various operations are performed.

it results in saving of times, easy central of production, prevention from breakdown of machines. due to this systematic method required processing time is reduced. it causes increase in production rate as well as profit.

*inspection department*

it is the main department in all manufacturing companies. inspection leads to improvements in metallurgy and raw material manufacturing due to demands of high accuracy and precision. inspection has also introduced a spirit of competition and led to production of quality products in volume by eliminating tooling bottle necks and better processing techniques. the method of inspection depend upon method of manufacturing.

for assembly line production in line inspection is used. similarly in casting department in line inspection is used.

but in line inspection is not possible in job order production. because of being job order production the inspection is done in different shops while manufacturing.

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