REPORT Ayush Choudhary 0901AU171023
REPORT Ayush Choudhary 0901AU171023
REPORT Ayush Choudhary 0901AU171023
INTERNSHIP REPORT
A Project Report for the Internship From
“NHK Spring India Ltd”
(1 MARCH – 30 APRIL 2021)
By
AYUSH CHOUDHARY
ENROLL.NO.- 0901AU171023
MADHAV INSTITUTE OF TECHNOLOGY AND SCIENCE
GWALIOR-474005, MADHYA PRADESH
Submitted to
“STABILIZER BAR”
ACKNOWLEDGEMENT
AYUSH CHOUDHARY
CANDIDATE’S DECLARATION
The work reported in this dissertation has not been submitted by me for
award of any other degree or diploma.
Date:
Place: Gwalior
CERTIFICATE
India is 2nd fastest growing economy, also growing as hub for auto
manufacturing industry. Most of global auto manufacturing leaders
and producers are moving towards Indian market. Autocomponent
Industry could be the future base for Indian economy. The study in
this report is on the internship done in NHK spring India Ltd. It
consists topic ranging from History of the Company to their Quality
Control.
This study focusing on 3 aspects –
1. Situation Of Automotive Component Manufacturing Companies
In India
2. About NHK Spring India ltd. And their Stabilizer bar production
line.
3. Brief Analysis .
Table of Contents
ACKNOWLEDGEMENT ........................................3
CANDIDATE’S DECLARATION ............................................................................................................. 4
ABSTRACT ..........................................................6
CHAPTER – 1 ......................................................9
INTRODUCTION ................................................................................................................................ 10
1. Market Overview ...................................................................................................................... 10
2. Export Scenario ......................................................................................................................... 10
3. Key Product Categories and Segments for Exports................................................................... 11
4. Major Characteristics ................................................................................................................ 12
5. Major Findings........................................................................................................................... 13
6. Challenges faced by Indian auto component industry .............................................................. 16
CHAPTER-2 ....................................................... 18
COMPANY PROFILE .......................................................................................................................... 19
NHK spring India LTD. POLICIES ....................................................................................................... 22
Quality policy ................................................................................................................................ 22
Laboratory quality policy ............................................................................................................. 22
Environmental Management System Policy ............................................................................... 23
Key Management Philosophy / Shared Value System .................................................................. 24
BRIEF HISTORY OF NHK Spring INDIA LTD ....................................................................................... 25
PLANTS IN INDIA............................................................................................................................... 27
PRODUCT RANGE.............................................................................................................................. 28
1. Coil Springs: -......................................................................................................................... 28
2. Stabilizer bar :- ...................................................................................................................... 29
3. Hollow Stabilizer bar :- .......................................................................................................... 30
4. Vehicle Seat Plan:-................................................................................................................. 31
5. Leaf Spring............................................................................................................................. 31
• CUSTOMERS.............................................................................................................................. 32
ORGANIZATION CLUSTER OF MANESAR PLANT............................................................................ 33
2. Export Scenario
COMPANY PROFILE
COMPANY PROFILE
NHK Spring India Ltd. has been a major supplier to Maruti Suzuki,
Honda Cars, Mahindra & Mahindra, Toyota Kirloskar, Nissan,
Renault, Ford, Ashok Leyland, Daimler, Tata Motors, ISUZU, Yorozu
etc.
The company is drawing upon the strength of its joint venture
partners to upgrade its systems, skills and production values to offer
its customers the finest quality in its product category.
Quality policy
NHK Spring India Ltd. is an ISO 14001 certified Company since 2003.
It is striving, as a good global corporate citizen, to make
environmental preservation efforts in all steps of production.
NHK Spring India Ltd are committed to protect the environment
and continually improve the environmental performance by:
• Prevention of pollution and reduction of waste in production
processes
• Recycling of waste and Conservation of natural resources
through sustainable resource use
• Fulfilling the applicable environmental, legal and statutory
requirements
• Providing awareness on environmental impact to employees
through environmental education and participation
Key Management Philosophy / Shared Value System
TIMELINE
un. 1936 Established as Shibaura Spring Seisakujo.
1943 Ina First Plant opened and started manufacturing of precision springs
1998 Bought into the Jamna Group, an Indian automotive suspension coil
manufacturer,
to which the Company had provided technical assistance for the last 10
years.
1999 Best Quality Supplier Award from Honda Siel cars India ltd.
2011 Established NHK Automotive Components India Pvt. Ltd., acquiring the
precision spring business from India-based Bombay Burmah Trading
Corporation Ltd.
2013 Established NHK F. Krishna India Automotive Seating as a joint venture with
the Krishna Group based in Chennai India.
2014 Rs. 300 crore investment plant in Sricity, Varadaiah Palem Mandal,
Chittoor, Andhra Pradesh
NHK Spring India Ltd. Has offered world class quality suspension
components for passenger cars and jeeps to its customers. And are
committed to rapid expansion of our product range and clientele by
continuously investing in contemporary and environment friendly
technology
PLANTS IN INDIA
1. Coil Springs: -
Manufacturing Capabilities of Coil Spring Plant
Spring Diameter: 80 mm ~ 200 mm
Wire Diameter: 8 mm ~ 18 mm
Free Height: 200 mm ~ 550 mm
Type of Springs: Cylindrical, Conical, Single Pig, Tail, Double Pig
Tail,
L Shape Coil Spring (Side Force Control Springs)
Production Capacity: : 11.50 Million/Year (Four Lines)
Coil springs and coil spring manufacturing in NHK manesar
2. Stabilizer bar :-
Stabilizer Bars
Manufacturing Capabilities of
Stabilizer Bar Plant
Bar Diameter: 15 mm ~ 60 mm
Outer Diameter: 15 ~ 45 mm
5. Leaf Spring
Leaf Spring Plant Outline of Leaf Spring Plant
Production : 13200
Capacity: MT/Year with
WSSP Technologies
Manufacturing Leaf Spring
Capabilities of Leaf
Spring Plant
Leaf 45 mm ~
Width: 80 mm
Leaf 4 mm ~ 16
Thickness: mm
Leaf 700 mm ~
Length: 1600 mm
• CUSTOMERS
ORGANIZATION CLUSTER OF MANESAR
PLANT
The company has 5 directors and 2 reported key management
personnel.
The longest serving director currently on board is Toru Kadowaki
who was appointed on 30 August, 2008. Toru Kadowaki has been on
the board for more than 12 years. The most recently appointed
director is Shinichi Kozawa, who was appointed on 01 December,
2020.
Toru Kadowaki has the largest number of other directorships with a
seat at a total of 3 companies. In total, the company is connected to
2 other companies through its directors.
05 April, 2007
RAJESH KUMAR
Secretary
30 August, 2008
TORU KADOWAKI
Managing director
10 September, 2014
SANJEEV BHATIA
CFO
25 May, 2015
MIO EGUCHI
Director
24 November, 2018
JUNICHIRO MIZUTANI
Director
01 April, 2019
JIRO OYAMA
CHAPTER – 3 STABILIZER
BARS
What Is Stabilizer Bar?
A stabilizer bar (anti-roll bar ,roll bar, anti-sway bar, sway bar),
is typically a u-shaped metal bar connected to the strut or
control arm, located by each of the vehicle’s wheels. Not every
vehicle has a sway bar, and there are multiple types.
➢ Sometimes sway bars don’t come in their typical “u shape” and
some sway bars are solid while others are hollow. While a sway
bar’s exact physical appearance can vary, sway bars all serve
the same purpose.
1. Cutting
2. Turning :
3. Coining :
The low-bed press applies 260 tons of force and makes the first
forging process for this bar. “Coining” flattens the end of the bar and
punches a hole where an end link or bushing will connect it to the
vehicle. Based on applications, this process can also happen after
several other bending procedures. Stabilizer bars offer adjustable
spring rates depending on which hole is used to attach to the
vehicles.
Coining process on Sway bar
4. Bending
Here’s what a batch of sway bars look like after those two forming
processes have been done to each side.
5. Quenching
Bars go back into a forge, this time the whole thing is heated until
they reach 1500-1600 degrees before workers moves them first into
one forming die, and then another, before the bar is dropped into a
quench tank. The quench tank holds thousands of gallons of oil and is
surrounded by a water jacket that keeps it at the proper
temperature. Water is routed to a radiator outside and then back to
the tank once it’s been cooled.
A conveyor lifts the parts from the quench tank and cleans off the oil
before they move through a 1000-degree tempering oven for an
hour to reduce their hardness and make them less brittle. A part is
pulled every two hours and tested for hardness to ensure the
hardening and tempering process is working properly.
Experimental verification
• Pre-damage caused by Impact Simulator
• Corrosion in alternating cycle tests
• Tests with original stabilizer bar bearings in instillation
position
• Statistical validation through systematic testing
Technical data
• Test Specimens:
all types of passenger vehicle stabilizer bars,
one or two bars can be tested simultaneously.
• Stabilizer bar diameter: d = 15 to 60 mm
• Stabilizer bar length: L ≤ 1200 mm
• Test frequency: f = 2 to 25 Hz
• Loading conditions:
constant and randomly variable amplitudes (block
program), constantly alternating loads
• Installation:
P el equates to 1 kW, on a level ground surface
• Weight / Measurements of the machine:
3,2 tons, L = 4500 mm, W = 1500 mm,
H = 1800 mm
OTHER TESTS
Apart from testing on the Stabilizer bar testing machine the
following tests are performed.
Mechanical testing
• Load, rate and profile measurement
• Slip force, stress measurement
• Environmental Bushing Noise
• Performance, corrosion, and environmental
fatigue
Comprehensive metallurgical investigation
• Hardness (HBD, HRC, HV)
• Decarburization
• Microstructure
• Shot peening coverage
• Weld bead and weld flow
• Surface profile
• Residual stress
• Chemical composition
• Failure investigation
Coating evaluation
• Film thickness
• Cold/room temperature
• Chipping
• Adhesion
• Pre-treatment evaluation
• SST and CCT
• Humidity resistance
• Fluid immersion
CHAPTER – 4
ANALYSIS &
RECOMMENDATIONS
CHARACTERISTICS OF PRODUCTION LINE AT
NHK MANESAR
COST-EFFICIENT PRODUCTION
Productivity
1) Productivity of workers low because of lack of training.
Quality
NHK Spring India is known for quality for more than 25 years, but
their amount of scrap & Wastages is too high.
Customer Relation
1) NHK Spring India ltd. have supplier relations with almost all
the auto manufacturers.
Cost concern
1) Electricity & Raw material cost is major concern
2) Raw material cost is another major cost concern for
company.
POSSIBLE SOLUTIONS
For productivity
1) H.R. department should continuously evaluate labour
performance & their satisfaction level, training & development
programme should be organized, special training will be given
to those employees whose productivity is less than basic
standard.
2) Company should make change in CPSR line of stabilizer line.
They could use hydraulic robots and more CNC controlled
machines, by using these quantity of wastages will leads to
very low.
3) They can take technical help from their North American partner
NHK New Mather Metals, because their technical knowhow is
very advance.
For Quality
Company is already known for their quality standard, they follow
TQM standard (total quality management) they need to focus on
speed of processes.
Company should conduct R&D to improve the quality of component
& processes.
NHK Spring India Ltd is the major supplier of Spring to almost all the
auto manufacturers and maintain relation for 20 years , now it’s time
to get benefits from these relations because various foreign
companies enters in Indian market.
Cost control
1) Company should use solar generators in all their plants to save
huge electricity cost, that is one time investment but it can save
& saves electricity cost for long term.
2) Company Should try to find out new cheaper source of raw
material.
LIMITATIONS &
BIBILOGRAPHY
LIMITATIONS OF STUDY
Broader topic.
Being a large company, I think NHK Spring India Ltd should have a
better Website of their own. Since there is no one specific place
or website for information , it is quite difficult to find data
related to all the aspects of this project.
Duration of study
Time given was enough to complete the internship and find all the
related data. But due to lockdown issues study could not be
completed properly.
Communication barriers
I collected Some information from different employees of NHK
Spring India Ltd. The major problems is that they have too busy
schedule, it wasted my lots of time to wait for them, they have
very little time for interaction, so find out relevant information
in very short interaction is another major barrier of my study.
BIBLIOGRAPHY