( starting from 23th JULY to 23th AUG.

, 2007 ) Duration 31 days

SUBMITTED TO: (BABULAL ) PERSONNEL OFFICER.

GUIDED BY: (BABULAL)

PERSONNEL OFFICER.

IST LTD. (A UNIT OF DEFENCE APPLICATION) SUBMITTED BY:

SUNIL DHANIYAN

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.)

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

INDEX
S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 CONTENTS COMPANY PROFILE ISO CERTIFICATE CUSTOMER FOCUS, QUAILITY POLICY OUAILITY OBJECTIVE OUR MAJOR PRODUCTS OUR MAJOR CLIENTS PRECISION STAMPING FUEL INJECTION, EQUIPMENT PARTS PRECISION COMPONENT FOR ASSEMBLIES ORGANIZATION STRUCTURE DEPTT. WISE DESCRIPTION SPECIAL PRODUCT DIV. CNC SHOP SP ASSEMBLY GEAR HOBBING DEPTT. PRESS SHOP OIL JET ASSEMBLY ELECTRO PLATING & HEAT TREATMENT QUALITY CONTROL TOOL ROOM MAINTENANCE PPC & CONTROL PURCHASE STORE SYSTEM SPECIAL INTERSTS CONCLUSION

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 like TORNOS, 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.

Man Power:
Having long Swiss association we have developed culture and have excellent back 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.

Customer focus:
In order to understand & meet the needs exceptions of the customer, top management 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 BY GOVERNMENT 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

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.

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.

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 3

rd

Ball Valve

Jet Component Piston Cooling Oil Jet Assembly Drive Gear Assembly Tooth Rack Stator Inner Yoke Sleeve Pump Nozzle Jet Holder

 Bushing Fuel Plunger Adaptor Crank Pin Push Road King Pin Pinion Drive Shaft Star Wheel Assembly Toggle Fuse 447 & 213

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

o ARMY o MOTOR INDUSTRIES CO. LTD.

DEPARTMEN T WISE DESCRIPTIO N

Special Product Division

S.P.D.TEAM:Manager - Mr.Dharambir Sharma Assistant Manager Mr. Suresh Chand Engineers-2 Supervisor-6 Workers-40

IST LTD. DHARUHERA

(S.P.D)

About S.P.D
There are many deptt./shops in IST Ltd. Dharuhera like electroplating, gear hobbing ,ebauche, cnc, quality control ,auto shop etc.-Special Product Division Is 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.D are Swiss made. Drilling machines -10 Lathe Machines -5 Fleury Machines-25 Engraving Machines-1

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

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

Inspection Process:-

During performing various operations of various components on Different types of machines, it is very necessary to check /inspect The components periodically. In addition to inspection report profile of Component is checked by profile projector

IST LTD. DHARUHERA

CNC SHOP Control) CNC SHOP TEAM:(Computerized Numerical

Dy. Manager- Mr. Bhagwat Swaroop Engineer Sh. Vireder Kumar Jr. Engineer- 3 Technical Assistant-3 Workers-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
SIEMENS

16i-TB, Oi Te

802D
Jet slow Strikers Firing pin Body Dome Arbor Material Brass Steel Rod Stainless Steel Stainless Steel Al. Alloy

MANUFACTURING COMPONENT:-

MATERIAL:Components Jet slow Striker Firing pin Arbor Body

Manufacturing System:Raw material (Rod) Operation (1st,2nd,3rd as required ) Dispatch Inspection Blank Deposit CNC

Programming:Some Examples of programming are given below: G0G90G54G95M3S1800X35.25F.2M8 G0 = Rapid Speed G 90 = Absolute G 54 = Zero offset G 95 = Spindle Speed in mm/revolution M 3 = Clockwise S = Speed F = Feed M 8 = Coolant on G0G40Z5M9 G0 = Rapid Speed G 40 = Compensation consillation Z5 = 5mm away tool from job on z axis M9 = Coolant off

IST LTD. DHARUHERA

S.P. ASSEMBLY
S.P. Assembly Team:Sr. Manager Mr. D.P.PUNIA Section Chief Sh. Yash Pal Singh Engineer 2 Technical Assistant 4 Workers -40

Introduction:There are many deptt. In IST LTD. Dharuhera like SPD, CNC Shop, Auto Shop, 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 of operations such as drilling, boring, deburring, rubbing, stamping, turning etc. These components are assembled after performing many tests like time regulation tests, torque tests, arming test, 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.

Device/ machines available in S.P Assembly:Digital Stroboflash:A digital stroboflash for determination of the rotation speed sha or motors .The Xenon tube flash rate can be set using a coarse/fine adjust potentiometer to match a rotating object which will appear to freeze its motion. An electronic display indicates R.P.M and flash rate. It can be used to determine the rotational speed of motors, fans, pump conveyors etc.

Impact press:Impact press is suitable for riveting, staking, flaring, numbering, stamping an Other assy work. This press is very easy to operate and unskilled Labour can be employed Profitably for working this machines

Spinning Machine:Spinning machines are designed developed to simulate 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


Assembly Tree
Mech. Assy. Final
Spacer Hand Spring Bridge Screw Bridge Pin Hand Screw Hand Bridge Hand Center Holding Screw Pin Long Lever Pivot Click Top plate Plunger Locked Bolt Plunger Spring Closing Disc Plunger Click Spring screw Striker Spring Striker Click Spring Barrel Plate Bottom Plate Barrel Cover Plate Main Spring Rivit Center Wheel 3 Regulator Regulator Screw Center Arbor Pillar Centre Wheel Copper Plate Screw 2 Train Plate Copper Plate Pallet Short Pin closing Disc pin

Mech. Assy. Stage 2

Mech. Ass. Stage 1

Escapment Assy.

Pallet Assy.

.Pallet Arbor
Third Wheel

Pallet Wt. Assay. Hair Spring Third Pinion Copper Wire Fourth Wheel

Train

Fourth Pinion Escape Wheel

Escape Pinion Movement Screw

FUSE ASSY. FINAL

LOCKING PIN 3 MAGAZINE CAP SPRING SAFETY CAP ASSY. RIVIT CAP 1 PIN POWER DISC SAFETY CAP POWER DISC TENSIONING SCREW SHEAR WIRE RING WIRE STOP PIN LOCKING WEIGHT HEAD STRIKER PIN LUG SAFETY LUG SAFETY

FUSE ASSY. STAGE-

DOME ASSY. HEAD ASSY.

NEEDLE DOME CUP STRIKER AL DISC WASHER HEAD

MECH & BODY ASSY.

L.D HOLDER SCREW L.D HOLDER SCREW SEC. MECH.3 BOX CLOTH WASHER D/PIN BODY MECH. ASSY.FINAL BODY

BODY ASSY.

IST LTD. DHARUHERA

GEAR HOBBING DEPTT.
Assistant Manager-Mr. I. M. Sharma Section Chief- R. S. Kanudal Foreman = 2 Technical Assistant = 1 Workers = 40+10 =50

Introduction to Gear Hobbing:Gear hobbing deptt. has its on value. Teeth are cut blan with the help of different types of machine . In addition to teeth cutting , shaft throttle (KSPO & C75) IS manufactured by performing various operation like linear milling , 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 standard machines is equipped for three different cycles of operation i.e. dive milling ,through milling or dive and through milling combined . A special inclined milling attachment for cutting bevel teeth is available on request .

Technical Specifications: Max. length between centers 80 mm

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 Thread Rollin Inspection Linear milling Rough flat milling Final Flat milling Rough grinding(ebauche) Drilling ,counter sinking & tapping Radius slitting Angular milling Chamfering on slitting Process store Inspection Process store Grinding Process store Inspection Brushing Process store Final Inspection Packing & Dispatch

IST LTD. DHARUHERA EBAUCH DEPTT.

Ebauch Deptt. Team:Assistant manager Mr. Umesh Kapil Foreman Mr. Gajraj Singh Technical Assistant- 1 Total 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 machine Like micro drilling machine , center less grinding machine ,multi spindle drilling machine

About machines:Most of machines available in this shop are Swiss made. Total number of machines 37 Fleury machines(hydraulics & pneumatics) 5 Sensitive drilling press 8 Slitting machine 6 Centerless grinding machine 3 Hand press 3 Emery belt rubbing machine 1 Gang drilling machines 9 Drilling machines 1

Process flowgram for Jet:Raw material Inspection Auto blank Process store Inspection Process store Dia. 2.0mm drilling(ebauche) Dia. A drilling(ebauche) Final Inspection Packing & Dispatch.

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

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 to 20000 rpm. It is designed to match virtually any precision drilling requirements Including all types of material such as steel, s.s , non ferrous metal ,plastics ,P.C.B and diamond drilling in ceramics sapphire and glass .

Technical Specifications:-

1. Power supply 115 volt AC ,60 Hz

2. Spindle speed Low range- 200 to 400 rpm Higher speed 1000 to 20000 rpm

Center less grinding machine:Center less grinding machine is used to grind the dia meter of works Piece without using centers . Hi-life center less grinders satisfy the demands of modern Industries for high accuracy, economical operation and reliability of Performance for through feed grinding of various metallic & non metallic cylindrical parts.

Technical Specifications:1. Grinding dia. Max. -85mm 2. Grinding wheel size 350100127 3. Regulating wheel size 23010076 4. Grinding wheel speed 1700rpm 5. Regulating wheel speed 30 to 80 rpm

IST LTD. DHARUHERA

Press Shop Press Shop Team:Dy . Manager Sh. D.P. Arora Engineer Sh. Virender Yadav Workers 5

Available Machine:Kollar Press 6 Ton Essa Power Press 1.5 Ton May Press 63 Ton Basant Power Press 50 Ton

Operations 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 H Frame type 70t programmable 350 mm 300 mm/sec 0-50t

63 Ton May Press Specification:Type:-

1. Upper ram:Max. Witdrawal capacity capacity Ram stroke: programmable Fast approach speed:

2. Lower ram:Max. Upward capacity programmable

Max. Downward Hydraulic system Electric motor Tank capacity Electrical system Power supply 415V, 50Hz

0-50t 50hp 1000 lt. 3 Phase AC,

IST LTD. DHARUHERA

Introduction to oil Jet Assembly:In this department oil jet assembly is prepared After performing various operation and sub assemblies. This oil jet component is utilized 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, block and bracket process store inspection process store copper pasting of tube, block and bracket cooper brazing of tube, block & bracket process store inspection process store ultrasonic cleaning crimping (oil jet assy.) process store inspection process store flow test ultrasonic cleaning process store final inspection Packing & Dispatch

Copper Pasting:1. Before using the dispensing unit first cleans the unit properly 2. Switch on dispensing unit 3. Fill the copper paste in needle cylinder of dispensing unit upto the specified limit

4. Maintain input pressure from 5-6 kg. S/cm2 and dispensing unit
pressure 20-25 psi. 5. Bring the needle near to area to component where copper pasting required. 6. Press the foot-paddle and move the needle uniformly around the copper pasting area. 7. Ensure that copper past is uniformly distributed and its weight 0.01 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 complete process control for precise, repeatable fluid dispensing.

Main Features:-

1. All digital multification control display with simultaneous

read out of air Pressure, time, vacuum, deposit, shot count and time of day. 2. Unique air management reservoir and high speed solenoid system for Consistent, 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.

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

Filling procedures for pour able low and medium viscosity 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 white smooth flow piston and carefully press down until it contacts the fluid. The syringe barrel is ready for use.

IST LTD. DHARUHERA

Electroplating & heat treatment:Section chief Sh. Rajbir Tommer Foreman 2 Workers 10 Electroplating & HT ploy a great role for coating the component. Various types Of plating i.e. zinc plating. Nickel plating, tin plating, Copper plating is applied on the Component. Anodising & painting are also employed. In acidition to plating surface hardening is done in components by using various types of furnaces. A brazing furnace is used for brazing the copper pasting.

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

Various types of plating

Zinc plating:Zinc plating is being used on increasing scale particularly in the electrical inclusiry for components which would formly have been cadmium plated. In recent years electrode position of zinc has made rapid strides and is now used extensively for finishing all manner of iron and steel products including casting. Forgings and sheet steel pressings.

Solution:ZNO NaCN NaOH

Operating Condition:Cathodic current denisty 1.5 to 6.5 amp/dm2 Voltage 4 to 5V , Temp. - 30c

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

Tin plating solution:Potassium stannate Stannous sulphate Stannous flouborate Cathode current denisty- 1.5 to 20amp/dm2 Anode current denisty 1 to 2amp/dm2 Voltage 3 to 4V Temp. 60 to 80c

Operating conditions:-

Equipment:For this a plain welded steel tank is generally employed. The tank being fitted with the necessary anode and cathode rods are provided with means of solution heating.

Copper plating:Copper plating is particularly useful as a pre coating for soft, soldered work, pewter and zinc 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 normaly employed alternatively, rubber or plastic lined equipment is used. It is essential that the rubber us an approved grade.

Operating conditions:Cathode current denisty- 2amp/dm2

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

Nickel Plating:Application machined parts, electroforming of gramophone masters, press tools and moulds. Nickel Plating Solutions:- Nickel salt, nickel sulphate, sodium chloride, 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 plated surface and in some cases zinc base die castings from corrosion so that their main task of Sacrificial protection to steel is not reduced.

Ultrasonic Cleaning:In ultrasonic cleaning the penetration power of the solvent cleaner is accerlated by employing the high frequency energy of sound waves. Microscopic cavities are progressively created and collapsed in the cleaning medium producing a powerful and penetrating scrubbing action. Any stubborn soil present on the components being cleaned and efficiently removed.

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

Solution:Chromic acid

Operating conditions:Anodising current density - 0.3amp/dm2

Voltage 0 to 40 Volt Temp. 40 min. to 59 min

Brazing Furnace:Associated furnace pvt. Ltd. makes mesh belt conveyor or furnace for copper brazing with bright annealing.

Method:The ammonia will be heated up be heated up to 950C in a separate furnace and at this temp. the liquid Ammonia will be crecked , became gas of Hydrogen and Nytrogrn will be fed to the Fedder and hydrogen will be burnt at the exit of the cooling pond. Nickel catalysts will be Used in a seald retort to crack Ammonia.

IST LTD. DHARUHERA

Q.C. Team:Quality Control Deptt.
Sr .Manager-Sh. Ashok Kumar Sharma Sr. Engineer N .C. Mandal Engineers 2 Foremen 2 Workers 30

Introduction to quality Control Deptt.:Quality Control Deptt. is the deptt. which determines the quality of the product.As the name suggest this department is related to the quality aspects in the product of the company. The department works in the critical points in the whole working areas of the plant. It mainly checks the quality standers for components received from outside and inside the plant. The major area in which the QC department is most actively Participate 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 ASIA PACIFIC PTE. LTD.

MITUTOYO ASIA PACIFIC PTE.LTD. is a part of Mitutoyo a global organization that leads the way in precision measuring technology. Mitutoyo has facilities in 120 countries around the world all dedicated to seeking perfection in precision instruments.

1.Digital Caliper:Mitutoyos new ABS DIGIMATIC CALIPER MYCAL ABSOLUTE keeps track of its origin point once set. Whenever turned on the large LCD screen displays the actual slider position ready start measurement. No more repeated zero setting is necessary.

Features:Large and clear LCD screen. Display zero setting at any slider position along the scale for incremental 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 and step) -With clamping screw atop the slider Least count:- 0.02mm

Range:0-150 0-200 0-300 0-600 0-1000

3. Height Gauge:-

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 switching over speed alarm -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 ratchet thimble. -Carbide tipped measuring faces. Least count:-0.001mm

Range:0-25 25-50 50-75 75-100

5. Outside Micro Meter:-Stain-chrome finished frame tapered on the anvil side for hard to reach place. - 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

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 of specification. 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.

-Designed to be operated efficiently with one hand.

Least Count:-0.01mm
Range:0-25 25-50 50-75 75-100

6.Dial indicator:Mitutoyos series 4 dial indicator gives user the advantage of an accurate and durable gauging device that include easy reliability. There large dial face makes them perfect for application where reduced lighting or discharge makes reading difficulty.

7. Snap Gauge:Snap gauge is a convenient gauge for inspecting the outer dia meter of a cylindrical work piece. It is easy to use and therefore widely employed on the machine shop floor. However it is 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 machined metals. It can also be used to check the shape of screws and gears by attaching an optional reticle. 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 of any component.

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

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 as standers. Large working space for easy measurement of large specimens.

PRODUCTION PLANNING AND CONTROL (PPC)

PPC is an important section of a company and any company growth rely on the performance of the planning section i.e. how efficiently they plans & implements it to complete an order or production target proceeding of PPC department are explained in brief here. First of all preparation and updating of bill of material is done on the basis of the chassis speciation and the target production of various chassis. Then based on monthly/quarterly production plan the department drive the requirement of the various material which are used on the assembly line, the next step is to send schedules to the different units, ancillaries & suppliers who are responsible for the fulfillment of the raw material requirement the next material the next step of PPC department is to update material position based upon receipt & transit details & also to prepare critical parts requirement it also include daily follow up of critical parts with suppliers/units. One most important function of PPC department is to reschedule the requirement in case if there is change in production planning. Another function of PPC department is goods receipt & dispatch after doing the planning of requirement of raw material according to production planning, requisitions are made to different units/suppliers and in the responsibility of PPC department to receive & also if some good is to be send back it also came under the control of PPC department to dispatch these goods.

After the material is reach in the premises of company & giving the receipt note to the transporter now PPC department is also responsible for the proper storage these material or for managing the stores. PPC department also have the responsibility of rectification of stored material if the is any sort of problem with there use & to issue the material to various departments according to various production plan established. Generally PPC department keep the inventory of 21 days for smooth running of assembly line according to production plans if there is any sort of problem regarding transportation services.

PURCHASE DEPTT.
Purchase of the following Raw material

Consumable

Spares

Packing Item

Tools

Fabrication Calibration Job

Working of Purchase Deptt MKT

PPC

Purchase

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

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: max basis. Powders store gives the demand on the basis of

2. Consumables: These include the material which is being consumed after each month such as lubricants, oils etc.

3. Spares: machine, furnace,

Spares include all the accessories parts of the 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: marketing deptt.

These include the cartoon boxes, packing

cover/bags, the slips (quality approval). This demand is given by

5. Tools: -

Maintenance department is consultation with

marketing department give the demand of tool the purchase department. Purchase department import (die & punches) from TAIWAN.

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.

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.

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

SPECIAL INTRESTS

About 5s
Ja panese Word Seiri E lishm ning ng ea Sorting

1S

T skto be done for im a plim enta tionof 1 S Preparation of list of itms Sorting of items into "Required & Not Required" Ja nese Word pa E lishm ning ng ea Seiton Arranging T skto be done for im a plim enta tionof 2 S Allocation of space for "Required & Not Required" items Preparation of layout showing the space allocated Keeping items at allocated space Tagging "Not required" items Ja nese Word pa E lishm ning ng ea Seiso Cleaning T skto be done for im a plim enta tionof 3 S Finding abnormamalites Tagging abnormalities Process of closing abnormalities Ja nese Word pa E lishm ning ng ea Seiketsu standardization T skto be done for im a plim enta tionof 3 S Spreading of awareness among workmen Ja nese Word pa E lishm ning ng ea

2S

3S

4S

5S

Shiksuke

Self-Displine

T skto be done for im a plim enta tionof 3 S We have to discipline ourselves for maintain our place

INDUSTRIAL SAFETY
The importance of industrial safety was realized because every year millions of industrial 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. 2. 3. 4. Increasing rate of production. Reducing producing cost. Reducing damage to equipment & machinery. 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, and 2. 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. 2. 3. 4. 5. 6. 7. Always wear safety helmet or goggles. Keep your work place clean before & after works. Always use right type of tools which is in good condition. Provide proper ventilation & lighting in work area. Before commencing any new work made a check list. Know the location of safety & fire fighting appliances in your work area. 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.

11. 12.

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