An

In-plant Training Report

MG ELECTRICA

(Duration of training from 11th June to 22nd July 2023)

Submitted By

Name of student
DHRUV MRINMOY

DUTTA

Mechanical Engineering Department

SANDIP FOUNDATION'S
SANDIP POLYTECHNIC

MAHIRAVANI, TRIMBAK ROAD, NASHIK-

422213 [2023-24]
 SANDIP FOUNDATION’S
SANDIP POLYTECHNIC
A/P: Mahiravani, Trimbak Road. Dist: Nashik - 422 213,
Approved by AICTE, New Delhi and Affiliated to MSBTE,
Mumbai Website: www.sandipfoundation.org Email-

This is to certify that, Mr Dhruv Mrinmoy Dutta has successfully completed the In-
plant training in “MG ELECTRICA” under my supervision, in the fulfillment of
Diploma in Mechanical Engineering.

Date: 2/8/2023
Place: Nashik

PROF. S.K.Aher PROF. J. R. Wadile

Staff Coordinator Head, Mechanical Engineering Department
 Acknowledgement
I am very thankful to MG ELECTRICA for giving me the opportunity to undertake my
summer In-plant training at their prestigious industry. It was very good learning experience
for me to have worked at this site .

I would like to convey my heartiest thanks to Mr.Mukesh Gupta sir. I would also like to
give my heart-felt thanks to Mr.Lakshmikant Visave sir, who heartily welcome me for the
training. He also guided and encouraged me all through the training and imparted in-depth
knowledge of company. I would like to thanks all department heads of MG ELECTRICA,
for giving their precious time and valuable guidance during my In-plant Training.

I am extremely thankful to Prof.J.R.Wadile (Head of Department, Mechanical Engineering)

Sandip Polytechnic, Nashik for providing me facility to work in without which this work
would not have been possible.

Last but not least; I would like to thank the staff of MG ELECTRICA family, for being so
helpful during this In-plant Training.

Name of Student:-

DHRUV MRINMOY DUTTA

HR SIGNATURE STAMP OF INDUSTRY

 CONTENTS
I. Cover Page
II. Certificate
III. Acknowledgement
IV. Course Completion Certificate
V. Introduction
VI. Company Profile
VII. Company Vision and Mission
VIII. Organization Structure
IX. Quality policy
X. Industrial Plant Layout
XI. Products
XII. Certifications
XIII. Esteemed Customers
XIV. Corporate Social Responsibility (CSR)
XV. Standards and Certifications
XVI. Policies and Annextures
XVII. Departments list
XVIII. Manufacturing processes
XIX. List of machines
XX. Specifications of machines
XXI. Various departments and their processes
XXII. Maintenance procedure followed
XXIII. Skills learnt during industrial training
XXIV. Conclusion
 INTRODUCTION:-
MG ELECTRICA is a leading Electrical component
manufacturing company based in Maharashtra, India since
2006. It has state of the art manufacturing facility based in
heart of the Industrial hub at Satpur in Nasik. It offers a wide
range of Electrical lugs & electrical connectors, which are
manufactured in conformance with various National and
International standards such as Indian Standards, DIN
Standards, Australian Standards & British Standards. We have
also tested our lugs from National Testing House (NTH),
Mumbai as per IEC 61238-1-2003 Standards. We are an ISO
9001, 14001, 18001 Certified Company. Our product range
includes copper ring type lugs, Pin, Fork Lugs, Copper
Tubular
Lugs, Aluminum Tubular Lugs, Copper Reducers, Copper Connectors, Aluminum
Reducers, Aluminum Connectors, End Sealing Ferrule, Chain Type Snap-On, Bimetallic
Lugs, Copper Press Parts, and Crimping Lugs etc.

The manufacturing process established by the company uses the latest technologies for all the
production process creating high efficiency in the working systems. We use the most
advanced machines for all our production processes & have all our systems with high quality
adherence. This constant updating in our machinery & process helps us in manufacturing
high quality products, reduction in wastage, meeting environmental norms, increase
productivity & produce tools and terminals with zero error possibilities. We always strive
hard to satisfy all the needs of our customers & maintain accuracy in all the products that we
deliver.

TECHNICAL DATA:-

Cable lugs are the devices used for connecting cable and wire conductors in electrical
installations and equipment. These are used when permanent, direct fastening methods are
not feasible or necessary. In general, lugs are fixed to cables and wires by inserting the
conductor/s into the barrel (tube) of the device and then barrel is either crimped, soldered or
welded onto the conductor for secure mechanical and electrical joint. The connection end of
the lug is then fastened to connection point by means of a bolt, screw, or spring clip.
Numerous sizes, configurations and material types are available to suit particular
applications.

Connector end of lug is typically chosen for its compatibility to the terminal type. Fork or U-
shaped lugs are used for screw terminals; closed-ring or O-type lugs are used for bolt-on
applications; and pin lugs are used for press-on terminals.
 COMPANY PROFILE:
NAME OF THE COMPANY:- MG ELECTRICA

ADDRESS:- C-13/1, NICE Industrial Area, MIDC Satpur

Colony, Nashik-422007, Maharashtra, India.

YEAR OF ESTABLISHMENT:- 2006

MAJOR CUSTOMERS:- ABB Limited

Larsen & Turbo Limited

Legrand Limited

Siemens Limited

Crompton Greaves Ltd

MANUFACTURED PRODUCTS:- Copper Ring, Pin, Fork Type Lugs

Aluminum Tubular Lugs

Aluminium Reducers

Din Channels & End Clamps

Bimetallic Lugs & End Sealing

Ferrules

ANNUAL TURN OVER:- Above 25 Crore

 COMPANY VISION AND MISSION - MG ELECTRICA:-

VISION:-

‘Creating a Global brand, earning Customers, Goodwill & Respect across the globe’.

MISSION:-

The Mission of MG ELECTRICA is to create an creative, robust & ethical organization that
works towards manufacturing & distributing World class products by following the principles
of excellent customer service, high quality production & competitive pricing structure to all
our customers’.

ORGANIZATION STRUCTURE:-

QUALITY POLICY:-

Our highly qualified & dedicated staff, efficient process designs & constantly updated technology
systems have always helped us in being committed to timely & qualitative production. We are
committed to satisfy all our customers with quality products that meet requirements on time & follow
strict ethical code of conduct. We follow strict Quality norms as per the guidelines of National and
International standards such as Indian Standards, DIN Standards, Australian Standards & British
Standards. We have also tested our lugs from National Testing House (NTH), Mumbai as per IEC
61238-1-2003 Standards. We are an ISO 9001, 14001, 18001 Certified Company.
INDUSTRIAL PLANT LAYOUT:-

Plan-1

Plan-2
 PRODUCTS:-

END SEALING FERRULE CRIMPING TOOLS COPPER RING, FORK, COPPER PRESS PARTS

PIN TYPE LUGS

COPPER REDUCERS COPPER TUBULAR COPPER CONNECTOR CHAIN-TYPE SNAP ON

LUGS

BIMETALLIC LUGS ALUMINIUM TUBULAR REDUCERS CONNECTORS

LUGS

END CLAMP MCB BUSH BAR (SINGLE POLE) DIN CHANNEL

 CERTIFICATIONS:-

ISO CERTIFICATION ROHS CERTIFICATION MECON CERTIFICATION

IEC TEST CERTIFICATE NTPC CERTIFICATE CE CERTIFICATION

UL CERTIFICATE IATF CERTIFICATE EOCH (EMS & OHSAS)

ESTEEMED CUSTOMERS:-
 CORPORATE SOCIAL RESPONSIBILITY (CSR):-

Being an EMS 14001, OHSAS 18001 Company, we at MG ELECTRICA define CSR as

conducting business in ways that provide social, environmental and economic benefits for the
communities and geographies where we operate.

SOCIAL RESPONSIBILITY

MG ELECTRICA looks to create a workplace that values, improves and energises people.
We also seek to create links with local communities which promote and support our mutual
goals.

SAFETY IN OPERATION

Both with regard to the performance of our products and in terms of our manufacturing,
distribution and support operations, safety is our top priority at all times.

ENVIRONMENTAL RESPONSIBILITY

MG ELECTRICA looks to create a workplace that values, improves and energises people.
We also seek to create links with local communities which promote and support our mutual
goals.

CORPORATE RESPONSIBILITY

MG embraces the need to take on the challenge of new technologies which deliver added-
value to its range of products and services.

Creating A Successful And Sustainable Business Is About More Than Financial Results.
 STANDARDS AND CERTIFICATIONS:-
DIN:- 46235, 46234, 46239, 46267

BS:- 4579

ISO:- 8309:1993 ISO 9001:2008; ISO 14001:2004; ISO 9001:2015; ISO 14001:2015

IS:- 8394:1977; IS 1359:1992; IS 3651:1985; IS 3965:1981

IATF:- 16949:2016

OHSAS:- 18001:2007

IEC:- 60715

(DIN-Deutsches Institut fur Nurming German Institute for

Standardization) (BS-British Standards)

(ISO-International Organization for Standardization)

(IS-Indian Standards)

(IATF-International Automotive Task Force)

(IEC-International Electrotechnical Commission

Standard) (QMS-Quality Management System)

(IMS-Integrated Management System)

(ROHS-Restriction of Hazardous Substances)

(UL-Underwriters Laboratory Unilisted)

(CE-Conformite Europeenee EEA European Economic Area)

NTPC

MECON

(EOCH-Environmental Occupational Health and Safety

Policy) (EMS-Environmental Management System)

 COMPANY CULTURE:-
A customer is satisfied with quality product and timely service which is the result of
company culture. The manufacturing process adapted by us is well set to provide efficiency
in our working system. We believe in equality and treat our team as assets. By building trust
in our employees we have bought up a culture where all employees feel that they are the
integral part of the MG ELECTRICA Family.

COMPANY POLICY:-
Committed to meet customer requirements in terms of quality, on time delivery and customer
satisfaction, committed towards our society, employees and environment.

POLICIES AND ANNEXTURES:-

1) Quality Policy
2) No child/Forced Labor Policy
3) Anticorruption and Bribery Policy
4) Ethical Conduct Policy
5) Whistle Blowing Policy (Misconduct such as Criminal activity, Respect, Fairness,
Abuse to staff, Non discloser of Interest)
6) Health and Safety Policy

ANNEXTURE A:- Organization Chart

ANNEXTURE B:- Process Interaction and Evaluation Matrix

ANNEXTURE C:- Roles, Responsibility and Authority

ANNEXTURE D:- Quality and CSR Policy

ANNEXTURE E:- Needs and Expectations of Interested Parties

ANNEXTURE F:- Communication Matrix

 VARIOUS DEPARTMENTS OF MG ELECTRICA:-
1) Development (DVP)
2) Human resources (HR)
3) Maintenance (MNT)
4) Marketing (MKT)
5) Production (PRD)
6) Production, Planning and Control (PPC)
7) Sales and Dispatch (SLS)
8) Stores (STR)
9) System coordination (SC)
10) Purchase (PUR)
11) Quality (QA)
12) Toolroom (TLR)
13) Trading (TRD)
14) Accounts (AC)

MANUFACTURING PROCESSES:-
1) PO from Customer
2) Book and Extract PO from Tally
3) Redefine Re-order level
4) Planning
5) Work order/Production schedule
6) Issue of Raw Material
7) Cutting
8) Vibrating
9) Chamfering
10) Anneling
11) Washing
12) Forging (R-Cutting, Holling, Piercing, Stamping, Slotting, Notching, Finishing)
13) Plating
14) Sorting
15) Weighing (counting)
16) Packing
17) Labelling,
18) Dispatch.
 LIST OF MACHINES:-
1) Single Manual Power Press Machine
2) Progressive Power Press Machine
3) Shearing Machine
4) High Speed Machine
5) Holling and Grinding machine
6) Drill Machine
7) Belt Grinding Machine
8) Anneling Furnace
9) Vibrating Machine
10) Dryer Machine
11) High Speed Automatic Cutting Machine
12) Automatic Chamfering Machine
13) Din Channel Machine
14) Auto Terminal Welding Machine
15) Automatic Brazing Machine
16) Automatic Sleeving Machine
17) Lathe Machine
18) Surface Grinder Machine
19) Turret Milling Machine
20) Digital Temperature Controller Furnace

SPECIFICATIONS OF MACINES USED:-

POWER PRESS MACHINE:-

CAPACITY:-10, 20, 30, 50, 75, 100TON

RPM-1440

HP-5

STROKE-76mm

DATE OF ISSUE-15/7/2017

YEAR OF PURCHASE-2007

KILOWATT-1KV

VOLTAGE-415V

CURRENT-1.5A

HERTZ-50Hz
HIGH SPEED MACHINE:-

DATE-1995

SR.NO-022672

CAPACITY-25TON

STROKE OF SLIDE-30mm

STROKE PER MINUTE-300mm

DIE HEIGHT-210mm

BOLSTER VOLUME-600mm

SLIDE AREA-300mm

BED HOLE DIAMETER-600mm

MOTOR-5HP

WEIGHT-2500Kg

FEED ANGLE-180 Degree

FEED LENGTH-60mm

POWER-380V

AIR PRESSUURE-5-6Kg

ANNELING FURNACE MACHINE:-

R-PHASE CURRENT-28.95A

Y-PHASE CURRENT-29.64A

B-PHASE CURRENT-26.53A

TEMPERATURE-490 Degree

ENERGY METER-2.194KWH

VIBRATING MACHINE:-

VIBRATING CAPACITY-120Kg

SPEED-1440RPM
AUTOMATIC CUTTING MACHINE:-

MOTOR SUPPLY-7.7KW, 50Hz, 380V, 2.5A

COOLING PUMP MOTOR POWER-90W

AIR PRESSURE-0.6MPA

MOTOR-2/4 POLE 3.0KW

YEAR OF PURCHASE-2012

AUTOMATIC CHAMFERING MACHINE:-

VOLTAGE-380V/50Hz

YEAR OF PURCHASE-2014

MOTOR-2 POLE 1.1KW, 1.5HP

MAXIMUM CHAMFER CAPACITY-1.5 TO 16 SQ.MM

AMPERE-3.33A

RPM-1420

AUTOMATIC BRAZZING MACHINE:-

YEAR OF PURCHASE-2010

BRAZING CAPACITY-1.5 TO 6sq.mm RS TYPE LUG

LPG GAS PRESSURE-20 TO 22 PSI

OXYGEN GAS PRESSURE-40 TO 50 PSI

VOLTAGE-220V/50Hz

DRILL MACHINE:-

VOLTAGE-415V

POWER-0.75KW

HP-1

EFFICIENCY-

75%
LATHE MACHINE:-

SR-2040

YEAR OF MANUFACTURE-2009

4 JAW CHUCK

DIRECT DRIVE-950A 280D

BACK GEAR DRIVE-140A 45B

SURFACE GRINDER MACHINE:-

SR NO-1021

YEAR OF PURCHASE-2010

VOLTAGE-380V, 50HZ, 15A

TURRET MILLING MACHINE:-

SPINDLE SPEED LOW-80 TO 650RPM

SPINDLE SPEED HIGH-670 TO 5440RPM

DRO MILLING MACHINE

 VARIOUS DEPARTMENTS AND ITS PROCESSES:-
1) QUALITY DEPARTMENT:- (QA)

 TYPES OF LUGS:-
1) PIN TYPE LUGS
2) RING TYPE LUGS
3) FORK TYPE LUGS

 LUG TERMINOLOGY:-
1) Stud hole (E)
2) Inner diameter (A)
3) Outer diameter (C)
4) Thickness (F)
5) Barrel length (B)
6) Total length (J)
7) Palm length (D)
8) Distance from center of stud hole to palm end (L-1)
9) Distance from sleeve end to center of stud hole (C-1)
10) Sleeve outer diameter (J-1)
11) Sleeve inner diameter (A-1)

INPUT (RAW OUTPUT

PROCESS
MATERIAL) (FINISHED
PRODUCT)

 TYPES OF INSPECTION:-
1) Material Inward
2) Work in Progress (WIP)
3) Finished Goods (FG)

 INSTRUMENTS USED IN THE QUALITY DEPARTMENT:-

1) Profile Projector
2) Vickers Hardness Tester
3) Conductivity Tester
4) Pull Tester
5) Plating Thickness Tester
6) Bend Tester
  TEST CERTIFICATE:-

A test certificate is a verified document which is provided by NABL certified laboratories

which gives us the information about the Raw material which is been used in the production.
The test certificate contains the following information:-

1) Conductivity
2) Hardness
3) Weight
4) Thickness
5) Width
6) Length
7) Chemical composition
8) Dimensional report
9) Mechanical property
10) Electrical property

 GOODS RECEIPT NOTE (GRN):-

The goods receipt note is a document written by the quality material inspector who checks all
the parameters of the raw material. It is a type of a challan generated at the quality material
inward department. The GRN contains the following information:-

1) Raw material exporter address

2) Company address
3) Item code
4) Item name
5) TC number
6) Quantity weight
7) Challan quantity
8) Received quantity
9) Authority signature

 STANDARD OPERATING PROCEDURE (SOP) CHART OF

TESTING EQUIPMENTS:-

1) Load test by Pull Tester:-

LOAD APPLY (IN KGF) SQ. MM OF WIRE
9 1.5
15 2.5
24 4
36 6
60 10
96 16
SPECIFICATIONS:-

DATE OF CALLIBRATION- 7/12/2022 (NABL)

RANGE- 0 TO 1000N

LEAST COUNT- 0.1N

CALLIBRATION FREQUENCY- 1 YEAR

2) Plating Thickness Tester:-

SPECIFICATIONS:-

DATE OF CALLIBRATION- 4/11/22

CALLIBRATION FREQUENCY- 1 YEAR

RANGE- 0.1 TO 999.9 MICRON

LEAST COUNT- 0.1 MICRON

3) Conductivity Tester:-
MATERIAL CONDUCTIVITY UNIT
COPPER TUBE 97% IACS
COPPER STRIP 97% IACS
ALLUMINIUM 60% IACS
COPPER SHEET 97% IACS

SPECIFICATIONS:-

CALLIBRATION FREQUENCY- 1 YEAR

INSTRUMENT ID:- MGCM-001

IACS- International Anneled Copper Standard

 4) Hardness Tester:-
MATERIAL HARDNESS UNIT APPLIED LOAD
(KG)
COPPER STRIP 90-100 VPN 5
COPPER TUBE 100-110 VPN 5
COPPER SHEET 75-80 VPN 5
ALLUMINIUM 21-25 VPN 1
ANNELED COPPER 40-52 VPN 5

SPECIFICATIONS:-

DATE OF CALLIBRATION- 4/7-2022

CALLIBRATION FREQUENCY- 1 YEAR

MAXIMUM CAPACITY- 50KGF

 BATCH CARD:-

It contains all the details of the material part code machine to be used, die to be used,
operations to be performed, material final dimensions, Tolerances, inspection. The
batch card contains the following data:-

1) Inner Diameter
2) Outer Diameter
3) Total Length
4) Palm Length
5) Palm Width
6) Barrel Length
7) Palm Thickness
8) Hole Diameter
9) Hole Center Distance To Palm Radius
10) Operations To Be Followed
11) Machine To Be Used
12) Die To Be Used
13) Final Inspection With Dimensions

The batch card is derived from the process manual and the quality manual in which all the
details are mentioned about all the manufacturing process to be done from material
receiving to dispatch.
  RAW MATERIAL BATCH STICKER:-
1) Batch number
2) Part code
3) Raw material length
4) Raw material thickness
5) Inner diameter
6) Outer diameter
7) Weight in kg

 DAILY QUALITY REVIEW:-

1) Problem faced while production and quality check.
2) Solution found, action taken
3) Inner diameter found undersized
4) Deep chamfer
5) Crack found on palm
6) Palm bend

 FINISHED GOODS INSPECTION CATEGORIES:-

1) Hole run-out
2) R-cutting Out
3) Insufficient plating
4) Blackness
5) Sorting product issue
6) Dents
7) Cracking

 FINISHED PRODUCT INSPECTION:-

1) Dimensions
2) Tolerances
3) Item code
4) Plating thickness
5) Plating vendor
6) Bending test
7) Crimping test
8) Sorting person name
9) Packing person name
10) FG batch number
11) Report number
12) Date of inspection
13) Date of packing
14) Visual inspection
  PROBLEM RECORDING SHEET
 REJECTION SHEET
 ANALYSIS SHEET
 TEST REPORT
 REWORK SHEET
 REWORK REPORT

TYPES OF LUGS:-

QUALITY TESTING INSTRUMENTS:-

Hardness Testing Meter Conductivity Meter Bending Test

Pull Tester Plating Thickness Tester Sorting Process

2) NEW PRODUCT DEVELOPMENT:- (NPD)

 PRODUCT RESEARCH AND DEVELOPMENT

1) LUGS
2) DIN CHANNEL
3) MCB BUSH BARS
4) STICKING SADDLE
5) END CLAMPS
6) NEUTRAL LINKS
7) COMPRESSION GLANDS

 PROCEDURE FOLLOWED:-
1) Checking all the available manufacturers who manufacture the product and acquire
the knowledge about the company.
2) What are the different types of products and its categories manufactured.
3) Check all the certifications and collecting various data and product catalogue.
4) Creating and developing the new product with suitable specifications.
5) Checking which type of test can be performed on the final product. Test depends upon
the standard mentioned and the product.
6) Decide the testing parameters and check the various testing labs which can do the
testing.
7) Verify all the test parameters on the product to get certified test certificate of
that product.

 DIE MAKING AND TOOL MAKING NPD:-

1) As per the requirement of the product take the samples.
2) Samples are tested and all dimensions are calculated.
3) The actual die design part design starts in the development. Also
checking whether the die and tool is feasible for development.
4) Using NEXX and AUTOCAD 3d development and 2d design of the
product is made.
5) Drawing is made keeping all the dimensioning details.
6) Reffering the drawing, the tool and ide is prepared. After development
of the die it goes for the trail. If the trial is successful, the die is then
used in the production line.

 QUATATION MAKING
 FEASEABILITY
 TOLERANCES
 DRAWING SHEET DESIGN
 DESIGNING SOFTWARES
  DESIGN:-

Design is the basic step before manufacture of the actual product. Design of tool and die is
essential so that the final product should be manufactured easily and in standardized way.

1) Tool design
2) Die design
3) Lug design
4) Gland design
5) Din channel design
6) Mould design
7) MCB Bush bar design
8) End clamp design

 ESSENTIAL PARTS OF A DRAWING SHEET:-

1) Drawing number
2) Revision number
3) Scale
4) Company brand and address
5) Drawing title
6) Part name and code
7) Tolerance chart
8) Dimension chart
9) Drawing views
10) Drawing prepared
11) Drawing checked
12) Dimensioning symbols views and naming

3) SALES AND MARKETING DEPARTEMNT:- (MKT)

 DIGITAL MARKETING:-
1) Marketing of the company and its products in a digital platform.
2) Marketing websites for dealers and customers.
3) Login your company on the website and upload product image, description, technical
drawing and specifications.
4) Provide company details and contact details for dealers and customers.
5) Upload images, product catalogue and after inquiry get inquiry and Quatation details.
6) Digital marketing may also proceed in various social networking websites.
7) For digital marketing create a digital card of the company and a digital catalogue
with templates.
  INQUIRY
 QUATATION
 TAX INVOICE
 PERFORMA INVOIVE (PI)
 PURCHASE ORDER (PO)
 LEDGER
 INQUIRY

TRACKING APPLICATIONS OF

LUGS:-

1) Control panels
2) Switch gears
3) Power generation industries
4) Electronic industries
5) Railway industries
6) Automobile industries
7) Steel industries
8) Aeronautical industries

USES OF LUGS;-

1) Installation, maintenance and repair of electric devices.

2) Link and connect two wires together.
3) Connect fuse sockets, load switches and electrical equipments.
4) Electrical vehicles and transformers.

LUG MANUFACTURING BRANDS:-

1) MG
2) TT
3) HEX
4) BRACO
5) CHETNA
6) ALSON
7) ENER

EXPORTS:-

1) Documentation
2) Bill of lading (enables customer to take shipments)
3) Order booking
4) Order dispatch
5) Shipment details
6) Enquiry generation
7) Access the enquiry
8) Customer follow-up
9) PO Booking
10) Production of the material
11) Dispatch preparation
12) Transportation
13) Documentation
14) Payment follow-up

4) STORES DEPARTMENT:- (STR)

Various terms and processes are executed in the store department. The store
department also plays a vital role in the company and helps in the proper functioning
of the company before the start of the production.

 ORDER BOOKING
 BILLING ORDER
 ORDER STORAGE
 PURCHASE ORDER BOOKING
 Using the TALLY PRIME software for the PO Booking.
 VOUCHERS
 DISPATCH
 E-INVOICE
 TAX INVOICE
 TALLY INVENTORY
 TRANSPORTATION
 STOCK SUMMARY
 BILLING DEPARTMENT PROBLEMS AND ACTION TAKEN
 LOGISTIC ISSUE
 BOOKING ISSUE
 PAYMENT PROBLEM
 EXECUTION PROBLEM

PACKING AND STORE DEPARTMENT OF MG ELECTRICA

 5) TOOLROOM DEPARTMENT:- (TLR)
Die making is necessary for the lug production. Single die and progressive die can be
used in high speed machines and press machine for the production of lugs.

 PROCEDURE FOLLOWED IN DIE MANUFACTURING:-

1) Drawing provided by the customer.
2) Raw material
3) Facing and turning
4) Drilling as per drawing
5) Tapping
6) Hardening
7) Grinding
8) Right angle
9) Wire cutting
10) Assembly
11) Trial
12) Handover to production department.

 TYPES OF DIE:-
1) Single operation die
2) Progressive die
3) Forging die
4) Blanking tool die
5) RHS die (R-cutting, Holling, Stamping)
6) Holling die
7) Rounding die
8) Bending die
9) Notching die
10) Flattening die
11) Straight cut die
12) U-cut die
13) RS type piercing die

 RAW MATERIAL FOR DIE:-

WPS Material (Tungstun, Chromium, Carbon, Vanadium)

High toughness

High strength

Corrosion free
 VARIOUS DIE PARTS:-
1) Die plate
2) Punch holder plate
3) Stripper plate
4) Stamping punch
5) Piercing punch
6) Trimming punch
7) Side chamfering punch
8) Ejector
9) Liner
10) Guide bush
11) Guide pillar
12) Sleeve
13) Bush
14) Ball cage
15) Coil spring
16) Allen bolts
17) Dowel pin

 DAILY TOOLROOM REVIEW MEETING:-

1) Tool design report problem
2) Die design report problem
3) Part design problem
4) Urgent points
5) Maintenance
6) Die preparation
7) Die selection
8) Design of die
9) Tool design
10) Tool maintenance
6) ACCOUNTS DEPARTMENT:- (AC)
 JOB WORK CHALLAN
 CHALAN NUMBER
 HSN CODE
 SERVICE CODE (SAC CODE)
 GOODS AND SERVICE TAX (GST)
 CREDIT NUMBER AMOUNT
 DEBIT NUMBER AMOUNT
 CAPITAL
 RAW MATERIAL

HSN code is important to understand which type of product and its processes. HSN code is
different for different processes.

 HSN CODE EXAMPLES:-

8538 9967

8536 8413

8544 9988

8209 9968

9636 8855

8569 7852

8265 8863
  TAX PERCENTAGE:-
I. 5%
II. 12%
III. 18%
IV. 28%
V. N/A

 LOGISTIC RECEIPT
 CHECK LIST AGAINST JOB WORK
 PURCHASE CAPITAL GOODS VOUCHER
 PURCHASE EXPRESS GOODS VOUCHER
 TAX COLLECTING SOURCE (TCS)
 TAX DEDUCTING SOURCE (TDS)
 INTEGRATED GOODS AND SERVICE TAX (IGST)
 STATE GOODS AND SERVICE TAX (SGST)
 CENTRAL GOODS AND SERVICE TAX (CGST)

 TDS CHART RATE (A.Y. 2023-24):-

SR.NO CATEGORY RATE SECTION
1 Interest on bank 10% 194A
2 Winning from lotteries 30% 194B
3 Winning from horse race 30% 194BB
4 Contractor 1% 194C
5 Life insurance policy 5% 194DA
6 Commission on lottery 5% 194G
7 Commission on brokage 5% 194H
8 Rent on land, building 10% 194(b)
9 Rent on machinery 2% 194(a)
10 Purchase of goods 0.1% 194Q

 TCS CHART RATE (A.Y. 2023-24):-

SR.NO CATEGORY RATE SECTION
1 Scrap 1% 206CE
2 Parking lot 2% 206CF
3 Toll plaza 2% 206CG
4 Sale of motor 1% 206CL
5 Mining and quarring 2% 206CH
 SALARY STRUCTURE:-
1) Name of employee
2) Days
3) Rate
4) Amount
5) Provident fund (PF)
6) Gross rate
7) ESIC (Medical)
8) Professional tax
9) Net salary
10) Net salary in hand

 SALARY SHEET:-
1) Employee name
2) Net payment
3) Account number employee
4) Account number company
5) Bank name
6) IFSC code
7) Bank branch
8) Mobile number of Employee

 PROVIDENT FUND (PF) SHEET:-

1) Yearly order
2) GST monthly return
3) TDS quarterly return
4) Income tax return
5) Bill checking

GST

IGST CGST SGST

  MAINTENANCE PROCEDURE IN THE INDUSTRY:-
DAILY PREVENTIVE MAINTENANCE RECORD:-

1) Machine name and number

2) Machine nomenclature
3) Monthly record
4) Checklist (Points of Maintenance)
5) Operation
6) Operator name
7) Signature

CHECKLIST MAY CONTAIN INFORMATION LIKE:-

1) Checking oil/Grease leak

2) Lubrication of machine
3) Check loose bolts, nuts
4) Check for moving, rotating parts

SAFETY PREVENTION WHILE OPERATING MACHINES:-

1) Wear safety shoes

2) Wear safety goggles
3) Wear hand gloves
4) Wear apron
5) Avoid hand motion near moving parts
6) Stay away from machine, keep safe distance.

OVERALL EQUIPMENT EFFECTIVENESS (OEE):-

1) Daily basis
2) Monthly basis

Helps us to decide and maintain the efficiency of the worker.

1) Operator name
2) Operator shift
3) Operation
4) Start time, End time
5) Machine number
6) Part item code
7) Efficiency %
8) Production quantity
 HOUSEKEEPING AND 5-S REPORT (JUNE-2023):-

LOCATION STATUS PERCENTAGE

INWARD STORES OK 73.02%
INWARD INSPECTION IMPROVE 78.85%
RM/FG STORE OK 82.69%
DISPATCH OK 78.85%
QUALITY LAB GOOD 88.46%
PRODUCTION OFFICE OK 80.77%
PACKING OK 88.69%
POWER PRESS GOOD 84.62%
HIGH SPEED PRESS OK 78.85%
VIBRATING/WASHING IMPROVE 71.15%
ANNELING OK 80.77%
CUTTING GOOD 78.85%
FINISHING OK 78.85%
HAND PRESS OK 80.77%
TOOLROOM OK 80.77%
BRAZING OK 76.92%

 HOUSEKEEPING AND 5-S REPORT (JULY-2023):-

LOCATION STATUS MARKS PERCENTAGE

100 75 50
INWARD STORES IMPROVE 3 5 3 75.00%
INWARD INSPECTION GOOD 5 6 0 86.36%
RM/FG STORE OK 3 8 0 81.82%
DISPATCH OK 2 9 0 79.55%
QUALITY LAB GOOD 5 6 0 86.36%
PRODUCTION OFFICE OK 4 6 1 81.82%
PACKING GOOD 5 6 0 86.36%
POWER PRESS GOOD 3 8 0 81.82%
HIGH SPEED PRESS GOOD 5 6 0 86.36%
VIBRATING/WASHING GOOD 2 5 4 70.45%
ANNELING OK 4 6 1 81.82%
CUTTING OK 2 8 1 77.27%
FINISHING OK 1 10 0 77.27%
HAND PRESS OK 5 6 0 86.36%
TOOLROOM OK 2 8 1 77.27%
BRAZING OK 0 11 0 75.00%
 SKILLS LEARNT DURING THE INDUSTRIAL TRAINING:-
1) Learn about the various processes of various departments like the
PRODUCTION, QUALITY, STORES, SALES, TRADING,
MARKETING, TOOLROOM, NEW PRODUCT DEVELOPMENT,
ACCOUNTS, HR, SYSTEM CORDINATOR, etc.
2) Learn about the Standards and Certifications of the industry and got to learn about
various international standards like ISO, IATF, OHSAS, ROHS, CE, DIN, UL,
MECON, EMS, QMS, IMS, TQM.
3) Learn about the SOP of various machines such as the AUTO BRAZING
MACHINE, HIGH SPEED MACHINE, AUTO CHAMFERING MACHINE,
AUTO SURFACE GRINDER, AUTO CUTTING MACHINE, POWER PRESS,
DRO MILLLING MACHINE, DRILLING MACHINE, LATHE MACHINE.
4) Learn about various documentations like the TAX INVOICE, QUATATION
RFQ, GRN, TEST CERTIFICATE, PERFORMA INVOIVE, PURCHASE
ORDER, BATCH CARD, LEDGER, PPAP PROCESS FLOW CHART,
DILEVERY CHALLAN.
5) Learn about the organisation structure and plan layout of the industry.
6) Learn about various RANKS and POSTS like the CEO, HR, GM, HOD,
SUPERVISORS, EMPLOYEES and WORKERS with their Roles and
responsibilities.
7) Learn about the QUALITY NORMS of the production and FINAL INSPECTION
of the product.
8) Learn about the various MAINTENANCE PROCEDURES followed in the
industry.
9) Learn about the various SAFETY AND POLLUTION CONTROL norms
followed in the industry.
10) Learn about the various INDUCTION TRAINING and WORKER
ORIENTED TRAINING programs.
11) Learn about the DAILY REVIEW MEETINGS and ERP server meetings.
12) Learn about various 5-S and HOUSEKEEPING procedures for cleanliness.
13) Learn about the PRODUCT CATALOGUE and MARKETING
STRATEGIES with respect to the product.
14) Learn about the APPLICATIONS and USES of the LUGS in various fields
and industries.
15) Improved TEAM WORK and INDIVIDUAL personal development skills
and grabbed vast practical hands-on knowledge and skills.
16) Developed skills for PRODUCTION PLANNING and SMART USE of
the LIMITED RAW MATERIALS to earn MAXIMUM PROFIT.
 CONCLUSION:-
The vast knowledge and experience of industry and development in the field of
engineering is the key to success which was received by me in this industrial training. I
got to learn new things related to the industry which would really help me in the future.
Various standards and certifications with the detailed idea about the procedure followed
in the production method gave me a whole new experience about the industrial skills.
This industrial training really helped me to gain much more of the practical hands-on
knowledge and skills. Learning about the various automatic machines was fun and
interesting. Learning about the marketing strategies to attract more customers was
among some soft skills which I got to learn. Overall this industrial training was a very
beneficial experience for me.