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    Industrial Training Report: Dronacharya College of Engineering

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    KshitijKumar
    The document summarizes an industrial training report submitted by Kshitij Kumar at Dronacharya College of Engineering. It discusses the trainee's learning at a manufacturing company that produces sheet metal components. The key learnings included different types of welding guns and processes used at the plant, the concept of poka-yoke for reducing defects, and laser cutting machines. Ganging multiple dies on a single press was proposed as a project to increase productivity by performing multiple operations simultaneously.

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    Industrial Training Report: Dronacharya College of Engineering

    Uploaded by

    KshitijKumar
    443 views26 pages
    The document summarizes an industrial training report submitted by Kshitij Kumar at Dronacharya College of Engineering. It discusses the trainee's learning at a manufacturing company that produces sheet metal components. The key learnings included different types of welding guns and processes used at the plant, the concept of poka-yoke for reducing defects, and laser cutting machines. Ganging multiple dies on a single press was proposed as a project to increase productivity by performing multiple operations simultaneously.

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    jbm

    Original Title

    JBM PRESENTATIUON

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    The document summarizes an industrial training report submitted by Kshitij Kumar at Dronacharya College of Engineering. It discusses the trainee's learning at a manufacturing company that produces sheet metal components. The key learnings included different types of welding guns and processes used at the plant, the concept of poka-yoke for reducing defects, and laser cutting machines. Ganging multiple dies on a single press was proposed as a project to increase productivity by performing multiple operations simultaneously.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    443 views26 pages

    Industrial Training Report: Dronacharya College of Engineering

    Uploaded by

    KshitijKumar
    The document summarizes an industrial training report submitted by Kshitij Kumar at Dronacharya College of Engineering. It discusses the trainee's learning at a manufacturing company that produces sheet metal components. The key learnings included different types of welding guns and processes used at the plant, the concept of poka-yoke for reducing defects, and laser cutting machines. Ganging multiple dies on a single press was proposed as a project to increase productivity by performing multiple operations simultaneously.

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    © All Rights Reserved
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    Download as pptx, pdf, or txt
    of 26

    INDUSTRIAL TRAINING REPORT

    DRONACHARYA COLLEGE OF
    ENGINEERING SUBMITTED BY:
    KSHITIJ KUMAR
    ME ( 20331)
    ABOUT THE
    COMPANY
    Multi unit,multi product group that deals in broad range
    of sheet metal assemblies,die casting components and
    forging for the domestic and export markets.
    Jbm group began its engg. Activity in 1983 with the
    establishment of gurera gas cylinder ltd and entered the
    auto component industries with the inception of
    SUZUKI AUTO INDIA.
    Four plants in NCR.
    OUTLOOK OF PLANT
    OUTLOOK OF
    THE PLANT J1
    MAJOR LEARNINGS IN ENGINEERING
    DEPARTMENT
    • Types of Welding and guns used.

    • Study of poka yoke.

    • Study of laser cutting machine.


    TYPES OF WELDING AND GUNS USED

    Resistance welding

    • Spot welding
    • Multi spot welding
    • Stationary spot welding
    • Portable spot welding

    Projection welding

    • Nut projection welding


    • Stud projection welding
    RESISTANCE SPOT WELDING
    • 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 consequently solidifies under the
    pressures of the two electrodes, thereby
    joining the two sheets at the spot that was
    under the two electrodes.
    TYPES OF GUN USED IN SPOT WELDING
    • X- TYPE GUN

    Also known as "scissors" or "pinch"

    • C-TYPE GUN

    C guns are generally the cheapest


    and the most commonly used.
    PROJECTION WELDING
    Nut projection welding
    • Projection Welding Is A Type OfResistance
    Welding.

    • High current in less time is the main


    feature of this welding.

    Stud projection welding

    • Stud is a form of spot welding where a bolt or


    nut is welded on another metal sheet.
    STUDY OF POKA
    YOKE
    Poka Yoke = Zero Defect
    • Basically the poke yoke is the Japanese technology. It is used to reduce the
    manufacturing defects in the parts to zero.

    • Poka Yoke sense that bolt then that process will occur otherwise that processwill not
    occur.
    Type of Defects for which Poka- Yoke can be
    used

    • Part Miss, Nut Miss, Spot, Miss Hole miss.

    • Part Shift.

    • Nut Welded at wrong place.

    • Color Difference.

    SIGNALS
    PANEL
    LASER CUTTING
    MACHINE
    • Six axis robotic machine worth rs I crore(abb
    company).
    • Yetteribium laser is used.
    • Yetteribium crystal produces light by photoelectric
    effect.
    • Laser light get passed to robotic head through
    optical fibre cable(TIR).
    • Yetteribium crystal contained in box which is placed
    in room maintained at 22degree c.
    • Chiller cools laser head using distilled water.
    • FRL removes moisture of air
    • Working temp.of robotic head is 3000-4000 degree celsius.
    • Used to cut elliptical cross section of axle to spiral.
    • Oxygen helps in burning.
    • Nitogen takes care so that burr do not cover the laser head.
    • Dot test performed once in six months to centralize the
    laser beam.
    • There is ups which can run the laser machine for half an
    hour after electricity is cut.
    • Spiral profile gas 21 control points
    • Nitrogen pressure= 7 bar approx.
    • Oxygen pressure= 3.7 bar approx.
    • Air pressure= 5.40 bar approx.
    • Avg operating power= 1000W.
    MISSION

    TO MAKE JBM A SYNONYM FOR WORLD CLASS


    ORGNISATION EXCELLENCE IN SHEET
    METAL TECHNOLOGIES
    VISION
    EXPANDING LEADERSHIP IN OUR BUSINESS
    THROUGH PEOPLE, KEEPING PACE WITH
    MARKET TRENDS AND TECHNOLOGY
    PRODUCT
    MANUFACTURED
    SKIN PANEL
    BODY IN WHITE PARTS
    CHASSIS & SUSPENSION PARTS
    WELDED ASSEMBLIES
    EXHAUST SYSTEMS
    SEAT BELTS
    FRONT/ REAR AXIS
    WHEEL RIM
    PROJECT UNDERTAKEN

    TO INCREASE THE PRODUCTION OF PRESS SHOP


    WITH THE HELP OF GANGING OF DIES.
    INTRODUCTION OF
    PROJECT
    • Here in this project we are concentrating
    on only on factor i.e. Increase in
    productivity. Here we are using a method
    of ganging of dies in which two similar dies
    are mounted on a press machine. This help
    us reduction of productivity time. Which will
    enhance the productivity. So this method is
    very much effective in increase the
    productivity of the material. This is cost and
    time saving method which will help in the
    betterment of the industry.
    EXPLAINING PROJECT WITH AN EXAMPLE
    PART NO.-DZ161013
    PART NAME : GUSSET HEAD

    Gusset head is generally a BAJAJ part which are used in platina bikes.
    These parts gives the support to the engine.
    TABLE
    Process Description Incoming source of Product Expected/actual
    variation characterstics strokes (per
    hour)
    Receiving Inspection Wrong size 1.5+/-0.1
    Wrong grade 260*1250 +/-2mm
    Visual defects
    Blanking Improper profile Free from
    Dent/scratch Burr
    Dent 250/150
    Crack
    Forming Incomplete bend Free from
    Scratch Burr
    Crack Crack 250/160
    Dislocation Scratches
    Piercing Dim us/os Free from
    Hole/slot size Burr 250/170
    Location Crack
    Visual defects
    Bending-trimming No thinning Free from
    Incomplete profile Burr
    Scratch Crack 250/180
    burr Thinning
    NOW IFAPPLY 2 DIES IN SAME PRESS THEN THE OPERATION CAN
    BE PERFORMED AT FASTER RATE

    TO USE GANGING OF DIES THE FOLLOWING THINGS SHOULD BE


    TAKEN INTO CONSENDERATION

    Power of the press.


    Size of the bluster bed.
    Size of the dies.
    Shut height of the die.
    Shut height of the press.
    Tonnage required for the die.
    CALCULATION :- (COST
    ESTIMATION)
    Procurement for the metal sheet- 45 rupees per kg
    Dimensions of sheet -1230x260mm
    Weight of on sheet- 1.020 kg
    Thickness of the sheets- 1.5mm
    Scraps cost -25 rupees per kg
    Now according to table
    Cost estimated for blanking- 2x150=Rs300
    Cost estimated for forming-
    2x160=Rs320 Cost estimated
    for percing-2x170=Rs340
    Cost estimated for bending-trimming- 2x180=Rs360

    Total cost-Rs1320
    This is a rough calculated cost in this hidden cost are not involved like maintainace, worker availability
    etc. are not included.
    Now if re plan our process and mount 2 dies in one press
    For example
    Blanking and forming at a time in a single press having different dies. This will save time as well as
    machine cost.
    And similarly at the same time piercing and bending trimming operation can be done.
    Now the calculation of cost
    Cost for blanking and forming-2x150=Rs300
    Cost for piercing and bending-2x170=Rs340
    Total cost=Rs640
    This is a rough calculated cost in this hidden cost are not involved like maintainace, worker availability
    etc. are not included.
    ADVANTAGES OF
    GANGING OF DIES
    Cost saving
    Time saving
    Man power saving
    Less press machine required
    Utility of press machine increases
    Pace of work is fast
    Production is high
    DISADVANTAGES

    Require bigger bluster bed


    May require a dummy cushion when one die require cushion
    and other’s didn’t so dummy cushion is given to the second
    die in order to balance it.
    Tonnage of press should be greater or equal to the die required.
    Shut height of both the dies should be same and should be in
    press shut height range.
    CONCLUTION

    This method is very much effective in increasing the


    production rate. This works quite efficiently. By
    using this method we can cover some parameter
    which is very much important for every industry.
    THANK YOU

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