Professional Documents
Culture Documents
name of company
jadhav gears industry
type : small scale
management : individual
type of production : job order production
plant layout : process type layout
location : jadhav 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 – employer 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 jadhav gears, m.i.d.c. amravati.
the company was facing a problem of not meeting the delivery dates in the
peak season. a 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.
* profile of industry *
“jadhav gears” is a manufacturer of all types of reduction gear boxes,
gears, conveyors spares, is located at m.i.d.c. 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 redies what their product and service is worth.”
majority of the parts of auto feeder are been produced at “jadhav gears”
and its sister concerns viz. “jadhav steel alloys”, “ jadhav 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
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.
* machine shop
* cnc machine shop.
* design and drafting section.
* assembly shop.
* quality control department.
* warehouse department.
* account section.
* 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:-
* 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.
in this process, the gear blank is rotted with a rotating cutter clled hob. a
majority of involute 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.
the blower of medium to large sized capacities are completely
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 :-
(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.
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.