1bi20ei042intr Organized
1bi20ei042intr Organized
1bi20ei042intr Organized
INTERNSHIP REPORT
On
STUDY OF PRODUCTION OF PRESS AND WELD ASSEMBLY PARTS
Submitted in the partial fulfillment of the requirement for the award of the degree of
BACHELOR OF ENGINEERING
In
ELECTRONICS AND INSTRUMENTATION ENGINEERING
Submitted by
SUPRITHA S
1BI20EI042
Internship carried Out at
JBM OGIHARA AUTOMOTIVE INDIA LIMITED
Toyota Kirloskar Motor Pvt ltd, Bidadi Industrial Area,
Ramanagara District, Bengaluru 562109.
Internal Guide: External Guide:
Dr. Aswathappa P. Mr. BABU R H
Associate Professor and HOD, Assistant Manager,
Department of EIE, BIT. JBM Ogihara Automotive Limited.
CERTIFICATE
This is to certify that the Internship, carried out by SUPRITHA S bearing USN 1BI20EI042, a
bonafide student of Bangalore Institute of Technology in partial fulfillment for the award of
Bachelor of Engineering in Electronics & Instrumentation Engineering under
Visvesvaraya Technological University, Belagavi during the academic year 2023-2024. It is
certified that all corrections/suggestions indicated for Internal Assessment have been
incorporated in the report. The report of the Internship has been approved as it satisfies the
academic requirements in respect of Mandatory Internship prescribed for the said degree.
EXTERNAL VIVA
NAME OF EXAMINER SIGNATURE WITH DATE
1.
2.
ACKNOWLEDGEMENT
The satisfaction and euphoria that accompany the successful completion of any task would be
incomplete without the mention of the people who made it possible, whose constant guidance and
encouragement crowned the efforts with success.
I would like to express my deepest sense of gratitude to Mr. BABU R H, Assistant Manager, JBM
Ogihara Automotive India Limited,for his constant support and honest guidance throughout the
Internship.
I express my sincere sense of gratitude to my Guide Dr. ASWATHAPPA P., Associate Professor
and Head of the Department, Department of Electronics and Instrumentation Engineering, B.I.T.
for her constant support and guidance throughout the course.
I would like to express my deepest sense of gratitude to our Internship Coordinator Prof.
NEETHASHREE N R, Assistant Professor, Department of Electronics and Instrumentation
Engineering, BIT, for her initiative, support, and guidance throughout the course.
I extend my whole hearted thanks to Dr. ASWATHAPPA P., Associate Professor and Head of
the Department, Electronics and Instrumentation Engineering B.I.T. who in his capacity gave us
all possible support and assistance for the completion of the course.
I would also like to sincerely thank Dr. J PRAKASH, Vice Principal, B.I.T. for his constant
support during the internship and the guidance which has immensely aided in the completion.
I would like to acknowledge Dr. M U ASWATH, Principal, B.I.T. for his invaluable support
during this endeavor and the timely support in all forms.
I wish to express my profound gratitude to everyone who provided their valuable time and
assistance in helping us to bring out the best.
SUPRITHA S
1BI20EI042
CONTENTS
CHAPTER 1: ABOUT THE COMPANY
1.1 Company Profile 1
CHAPTER 2: INTRODUCTION
2.1 Introduction to the Production Department 4
5.1 Applications 13
5.2 Advantages 14
5.3 Disadvantages 14
6.2 Outcomes 15
CHAPTER 7: CONCLUSION 16
LIST OF FIGURES
CHAPTER 1
ABOUT THE COMPANY
• Manufacturing department: All pressing machines are automatically controll nut, bolt are
attached by different welding processes.
• Quality department:The main work is to ensure that product will be perfectly fit location and
are performed to make products defect free.
CHAPTER 2
INTRODUCTION
The plant has total ten lines comprising of different forging machines of different tones and the
main reason JBM is developing very fast is because of innovative technology they are using in
their industries which are totally automatic and are less dependent on human power. All pressing
machines are imported from Japan companies like KOMATSU, ISGEC etc. Out of all 10 lines
only one line has Hydraulic pressing machine and rest 9 are mechanically pressing machine.
Hydraulic pressing is very slow process and is used for component which require large bending.
In the production department of JBM Ogihara, a meticulous and coordinated approach drives the
manufacturing process forward. It all starts with detailed planning and scheduling, where the team
orchestrates the production timeline based on customer demands and internal capacities. Procuring
the necessary materials follows suit, with a focus on maintaining reliable supply chains and timely
deliveries. Once materials are secured, the department focuses on tooling and setup, ensuring that
machinery and equipment are calibrated and ready for operation. Then, production kicks into gear,
with skilled teams executing metal stamping, welding, assembly, and other fabrication processes
with precision and efficiency. Throughout this process, rigorous quality control measures are
implemented to uphold the company's high standards and meet regulatory requirements.
against environmental variables, and seamless integration with cutting-edge technologies like
infotainment systems and driver-assist functionalities.
harshness (NVH), and enhance overall vehicle performance. JBM Ogihara's underbody
components undergo thorough testing to ensure compliance with safety and regulatory standards,
as well as integration with other vehicle systems such as suspension and drivetrain components.
CHAPTER 3
STUDY ON HYDRAULIC PRESSES AND
MECHANICAL PRESSES
3.1 HYDRAULIC PRESSES
A Hydraulic presses are a powerful class of machine tools, they derive the energy they deliver
through hydraulic pressure. Fluid pressure, in a particular chamber, can be increased or decreased
by the use of pumps, and valves. Sometimes devices and systems may be used to increase the
capacity of the pumps in more powerful presses.
Presses are chosen based on the characteristics of the manufacturing process. Mechanical
press machine tools are commonly used in metal forging manufacture, and sheet metal
working. The desired application of force will dictate the type of machine required. Extrusion
will often necessitate a more consistent force over a longer distance. However, a mechanical
press may often be a good choice for impact extrusion, since a fast, quickly repeatable
application of force over a limited distance is what is needed for that type of manufacturing
process. The most powerful mechanical presses in modern manufacturing industry will have
a press capacity of about 12,000 tons.
Parting: This separation of the formed plate or component into two distinct parts along a
designated dividing line or plane. Parting may utilize a specialized die set or cutting tool designed
to cleanly separate the material along the desired dividing line.
CHAPTER 4
WELDING DEPARTMENT
4.1 WELDING
The Welding is a fabrication process that joins material usually metals or thermoplastics, by using
high heat to melt the parts together and allowing them to cool, causing fusion. Melting is distinct
lower temperature metal joining techniques such as brazing and soldering, which do not melt the
base metal.
4.1.1 RESISTANCE SPOT WELDING
A Resistance welding is a welding process which join the metals with the heat obtained from
resistance offered by the work to the flow of electrical current through the parts being joined.
A pair of copper alloy electrodes conducts electrical current through the two sheets pressed
between the interface. The two sheets offer maximum resistance to the flow of current, this
generates heat, the interface melts and consequences solidifies under the pressures of the two
electrodes, thereby joining the two sheets at the spot that was under the two electrodes.
Projection welding is commonly used in various industries for joining components in automotive
manufacturing, appliance production, electrical equipment, and more. It offers advantages such as
high speed, consistent quality, and suitability for mass production.
C TYPE GUN: Specific configuration of a spot welding gun where the electrodes are arranged
in a C-shaped pattern and welding guns are essential tools in resistance spot welding processes,
where two or more metal sheets are joined together at specific points by applying pressure and
passing an electric current through the workpieces.
CHAPTER 5
APPLICATIONS, ADVANTGES AND DISADVANTAGES
5.1 APPLICATIONS
• Manufacturing Industry: Presses and weld assembly parts are fundamental in
manufacturing various products across industries like automotive, aerospace, electronics,
and consumer goods.
• Product Assembly: Presses are used to assemble components by pressing them together,
while welding is used to join metal parts permanently. Understanding these processes helps
in efficient and effective assembly line operations.
• Quality Control: Studying presses and weld assembly parts assists in quality control by
ensuring that the assembled parts meet the required specifications and standards.
• Design Optimization: Knowledge of press and weld assembly techniques aids in
designing products for manufacturability, helping engineers optimize designs to minimize
production costs and maximize efficiency.
• Safety Standards: Understanding these processes is crucial for implementing safety
standards in manufacturing environments to prevent accidents and ensure worker safety.
• Prototype Development: Presses and welding techniques are utilized in the development
of prototypes to test the feasibility of designs before full-scale production, allowing for
refinement and optimization.
• Repair and Maintenance: Understanding press and weld assembly parts is essential for
repairing and maintaining machinery and equipment in manufacturing facilities, ensuring
smooth operations and minimizing downtime.
• Art and Sculpture: Beyond industrial applications, presses and welding are used in art
and sculpture to create intricate metalwork and installations, showcasing the versatility of
these processes in creative endeavors.
5.2 ADVANTAGES
• Efficiency: Presses and welding processes can automate assembly tasks, leading to
increased production efficiency and reduced labor costs.
• Strength and Durability: Properly executed press and weld assembly parts often result
in strong and durable joints, critical for ensuring the reliability and longevity of the final
product.
• Versatility: Presses and welding techniques can be applied to a wide range of materials,
including metals, plastics, and composites, making them versatile for various
manufacturing needs.
• Customization: These processes allow for the customization of parts and products,
enabling manufacturers to meet specific customer requirements.
• Joint Integrity: Properly executed press and weld assembly parts often result in joints
with high integrity, resistant to mechanical stresses and environmental factors, enhancing
the overall reliability of the assembled components.
• Time Efficiency: Presses and welding processes can significantly reduce assembly time
compared to traditional methods like bolting or adhesive bonding, increasing overall
production throughput.
• Material Conservation: Welding allows for the efficient use of materials by creating
strong bonds between parts, minimizing material waste in the manufacturing process.
5.3 DISADVANTAGES
• Resource Intensive: Conducting a comprehensive study on presses weld and assembly
parts requires significant time, effort, and resources.
• Complexity: Manufacturing processes can be complex, and analyzing them may require
expertise in various areas such as engineering, materials science, and production
management.
• Resistance to Change: Implementing changes based on the study findings may face
resistance from employees accustomed to existing processes.
• Initial Investment: Improving processes or equipment based on the study may require
initial investment in new technology, training, or infrastructure.
• Confidentiality Concerns: Sharing detailed information about manufacturing processes
may raise concerns about intellectual property and confidentiality.
CHAPTER 6
REFLECTION AND OUTCOMES
During my tenure as an intern at JBM Ogihara Limited, I had to opportunity to involve my
academic background and practical skills to support the team in achieving its objectives in the
conducting research, analyzing data, the development of new products and also got an opportunity
to study various fields based on this my reflection note as follows.
6.1 REFLECTION
As an intern at JOAI Limited, Bengaluru, my internship has resulted in the following
reflections:
The company's manufacturing operations through meticulous analysis, gained insights into
the intricacies of the production processes, revealing both strengths and areas ripe for
enhancement. Our study unveiled opportunities for process optimization, enabling us to
streamline workflows, reduce waste, and enhance overall efficiency. By implementing
targeted improvements and witnessed tangible outcomes such as reduced cycle times,
improved product quality, and optimized resource utilization.However, this endeavor was
not without its challenges. The complexity of manufacturing processes demanded
interdisciplinary expertise and thorough investigation, consuming significant resources and
time. Resistance to change emerged as a hurdle, requiring effective communication and
change management strategies to garner buy-in from stakeholders. Additionally, ensuring
confidentiality and safeguarding proprietary information posed challenges in sharing detailed
findings with external parties.
6.2 OUTCOMES
It has underscored the importance of continuous innovation and meticulous attention to detail in
ensuring the reliability and functionality of essential manufacturing tools.the impact of
technological advancements in automation and robotics on the production of tools and
advancements with the on safety measures and quality control mechanisms.By embracing change
and leveraging insights gleaned from the analysis, we have fortified our competitive position in the
market. Enhanced process efficiency has enabled us to deliver high-quality products to customers
in a more timely and cost-effective manner. Moreover, our commitment to continuous
improvement and innovation remains steadfast, driving sustained growth and resilience in an ever-
evolving industry landscape and this topic has deepened my appreciation for the skilled workforce
involved in the manufacturing sector and expertise and craftsmanship of engineers, technicians,
and workers are instrumental in the creation of high-quality presses and welding assembly delving
into the production of presses and welding assembly.
CONCLUSION
My internship at JOAI Limited has been profoundly enlightening, offering me invaluable insights
and a comprehensive immersion in the industry. The company's steadfast dedication to innovation
and technological excellence resonates throughout all its departments, creating a dynamic and
enriching learning environment. This experience has notably broadened my knowledge and honed
my skills within the automation sector. I am sincerely appreciative of the chance to learn from
seasoned professionals in the field, whose practical expertise has significantly contributed to my
professional growth. The internship has provided me with indispensable insights and hands-on
experiences that will undoubtedly shape my future endeavors. I commend JOAI Limited for its
pioneering role in the automation landscape, driving the industry's evolution. Overall, my
internship at JOAI Limited has been an immensely rewarding and enriching journey.