27-08-2014, 12:12 PM
SIX MONTHS
INDUSTRIAL TRAINING REPORT
AT
EMSON GEARS Ltd.
G.T. Road, Sahnewal
Submitted in Partial Fullfillment of award of Degree of
Bachelor of Technology
In
Mechanical Engineering
From
Punjab TechnicalUniversity, Jalandhar
Submitted by:
Paramjeet Singh
100491131040
DEPARTMENT OF MECHANICAL ENGINEERING
Ludhiana College of Engineering and Technology
Katani Kalan, Ludhiana
May, 2014
TABLE OF CONTENTS
S. No. Topics Page No.
1. Introduction 1
2. Introduction To Gears 21
3. CNC Opertions 28
4. Gear Cutting 40
5. Heat Treatment 50
6. Quality Control 56
7. Project 71
ACKNOWLEDGEMENT
The real spirit of achieving a goal is through the way of excellence and strict discipline. We would have never succeeded in completing our task without the co-operation, encouragement and help provided to us by various personalities.
This formal piece of acknowledgement may not be sufficient to express my feelings of gratitude towards the people who helped me in successfully completing my training with regards to EMSON GEARS LTD.
We are thankful to Mr.ASHOK DHALL M.D., who permitted us for the six months industrial training for a training period of JAN 2014 to June 2014. We are also thankful to MR. N.K VERMA, heat treatment incharge, for providing me continuous encouragement during my training.
In the end, I am really impressed from the management and the working of the EMSON GEAR LIMTED Who have established such a marvelous enterprises in Ludhiana, which provides chance of training to a number of engineering students like me and render all their help, assistance and cooperation to them and established a great name in gear manufacturing of their service of the Nation.
PARAMJEET SINGH
100491131040
CHAPTER 1:- INTRODUCTION
1.1 The Company
Located in Ludhiana, the industrial hub of Punjab, Emson Group are the pioneers in manufacturing precision auto components for renowned OEMs of Cars, MUV, LCV, MCV, HCV and tractors. A modest beginning in 1970 and over 3 decades of expertise coupled with technical excellence enables the group to support its customer’s requirements and deliver the product with impeccable quality at a very competitive cost.
With a current turnover of over 100 crores, the group has three state-of-the-art plants,EmsonGears Ltd, Osho Forge Ltd, Osho Gears and Pinion Ltdspread over an area of 20 Acres. The facilities house dedicated lines for producingCrown Wheel and Pinion, Transmission Gears, Axle Shafts, Synchro Assembly and Vital Engine Components with Captive Forge Shop.
The kind of success and growth Emson Group has experienced over the past three decades can only be attributed to its Engineering excellence, its dedicated employees, innovative technology, impeccable quality and its commendable customer services. The group has a work force of over 1000 nos. consisting of professionals, engineers, technocrats and highly skilled workmen. To keep them abreast with the changing trends and Technologies, the company imparts training at periodical intervals.
The company is expanding its horizons by venturing into Auto Subassemblies including Complete Axle Shaft Assembly, Transmission Gear Boxes and Syncro Assembly. The group is poised to achieve a turnover of over 300 Crores by 2012-13.
1.2 Mission
To provide superior value for money to customers through quality and cost effective products by improving level of efficiency and productivity.
Core Values
Ø Honesty and Integrity.
Ø Customer delight.
Ø Innovation & Creativity.
Ø Transparency.
1.3 Management
Mr. Ashok Dhall -Managing Director
Mr. Ashok Dhall is an engineering graduate from a premier institute with over three decades of expertise in manufacturing, designing, planning and metal treatment of precision auto components. He is the guiding spirit to over thousand dedicated employees of the Emson Group.
Mr. Vimal Dhall- Joint Managing Director
Mr. Vimal Dhall is a Management Graduate with over 30 years of exposure in finance, purchase and human resource management. Through his dynamic leadership, the company is setting newer parameters in the industry.
Mr. Gautam Dhall- Director
Mr. Gautam Dhall is a young engineer with youthful ideas and a fresh outlook to management. With a right blend of engineering excellence, enthusiasm and marketing skills he is steering the company to the pinnacle of achievement.
1.4 Corporate Social Responsibility
Emson Group is a socially responsible organization. It has taken significant initiatives for environmental safety, development of human resource and the welfare of society in large. The company complies with all industrial norms and follows all statutory requirements for environmental management taking into interest the welfare of mankind. While conducting its business operations, the company never overlooks its duties towards the society. Emson Gears understands well that no development process can be a meaningful one without upliftment of society and it guides its corporate policies keeping in mind the all round development of the people. The company is committed to contribute to the prosperity of the country by taking various initiatives.
1.5 COMPANY CLIENTS
Tata Motors Ltd. Ashok Leyland Ltd. Eicher Motors Ltd.
Mahindra & Mahindra Ltd. Swaraj Mazda Ltd. Iran Khodro Ind. Group
Continental Engines Ltd. International Tractors Ltd. TVS Motor Co. Ltd.
Tafe Motors & Tractors Ltd. Punjab Tractors Ltd. Greaves cotton Ltd.
1.6 COMPANY POLICY:-
Emson Gear Limited is committed to enhance customer satisfaction and strives to achieve the goal of perfection by implementing quality management system ISO/TS 16949:2002 by manufacturing cost effective safe and quality products. Emson commits itself to render customer services of international standards by improving levels of intellect efficiency and productivity within its organization.
1.7 COMPANY MOTTO:-
“CUSTOMER ORIENTED QUALITY ASSURANCE”
1.8 PRODUCTS MADE BY THE COMPANY
Ø Oil seal - differential
Ø Differential housing
Ø Speed sensor - instruments
Ø Dowel
Ø Oil seal - selector rod
Ø Boot
Ø Selector rod
Ø Thrust washer - sun gear
Ø Sun gear
Ø Thrust washer - planet pinion
Ø Planet pinion
Ø Pinion shaft
Ø Ball bearing - differential
Ø Final drive gear
Ø Roll pin - differential pinion shaft
Ø Differential casing
Ø Ball bearing - differential
Ø Selective shim
Ø Clutch release arm
Ø Oil seal - clutch release arm
Ø Selector rod guide
Ø Dowel bolt and washer.
Ø Magnet
Ø Detent cap bolt, ball and spring - selector rod
Ø oil guide plate
Ø Parallel roller bearing - countershaft
Ø Countershaft
Ø 26. Selective thrust washer - 1 st gear end float
Ø Needle roller bearing - 1st gear
Ø 1st gear
Ø Synchro ring - 1 st gear
Ø Synchro spring
Ø Synchro hub - lW2nd gear
Ø Synchro sleeve - lW2nd gear
Ø Synchro spring
Ø Synchro ring - 2nd gear
Ø Selective collar - 2nd gear end float
Ø Needle roller bearing - 2nd gear
Ø 2nd gear
Ø 3rd gear
Ø 4th gear
Ø 5th gear
Ø Roller bearing - countershaft
Ø Ball bearing - countershaft
Ø Washer
Ø Countershaft nut - L.H. thread
Ø Circlip
Ø Reverse idler shaft
Ø Thrust washer - reverse idler gear
Ø Roll pin - reverse idler shaft
Ø R8v8t'Se idler Q8a
Ø Reverse fork
Ø Oil seal - mainshaft
Ø Ball bearing - mainshaft
Ø Mainshaft
Ø Needle roller bearing - 3rd gear
Ø 3rd gear
Ø Synchro ring - 3rd gear
Ø Synchro spring
Ø Synchro hub - 3rd/4th gears
Ø Synchro sleeve - 3rd/4th gears
Ø Synchro spring
Ø Synchro ring - 4th gear
Ø 4th gear
Ø Needle roller bearing - 4th gear
Ø Distance collar - 4thEth gears
Ø Needle bearing - 5th gear
Ø 5th gear
Ø Synchro ring
Ø Synchro spring
Ø Synchro hub - 5th gear
Ø Synchro sleeve - 5th gear
Ø Ball b8ariftg - mainshaft
Ø Selective snap rings - mainshaft end thrust
Ø Belville washer - mainshaft end thrust
Ø Oil guide plate
Ø Gearbox casing
Ø Reverse idler shaft bolt and washer
Ø Breather pipe
Ø Breather pipe bracket
Ø Oil seal - differential
Ø Filler/level plug
Ø Drain plug
Ø Access plug - countershaft bearing circlip
1.9 PLANT LAYOUT
Plant layout
1.10 DEPARTMENTS
§ Production
§ Production Planning & control (PPC)
§ Production & Control (P&C)
§ Drawing Office (Engineering Department)
§ New Product Development (NPD)
§ Quality Office
Ø Production: - The purpose of the production is to ensure that all the production is carried out as per plan in controlled conditions. The head of the production department is Mr Amarjeet singh.
Ø PPC: - Master Schedule for each month is prepared on the basis of consolidated order sheet/job order/ shortage raised by the store. Daily calculation of production is compared with the plan. OEE calculation is done on the regular basis. Setting time of the product is noted down daily and if the setting is taking more time than target given for it, then it is referred to the team who takes some appropriate actions by decreasing the Non Value added activities and also the required non value added activities.
Ø Production & Control (P&C):- Calculation of OEE (overall equipment efficiency) is done on the daily basis, weekly, monthly and yearly. Timely dispatching of goods and direct contact with the purchaser’s and vendors of the company.
Ø Engineering department:- Designing of new products, their drawing making, new program development, die making, analysis of the parts etc activities are done by engineering section. Auto CAD, Pro/Engineer, NX Software’s are used for the products to follow up the activities.
Ø NPD (New Product development): - In this department samples of new products are developed. The company produces samples for their customers according to their demand. After a no of testing’s, if the sample is passed, then on the customer demand the plan has to be set up and production of the product is setup.
Ø Quality office:-In quality office, the quality of the product is analyzed They directly contact with the customers to know about their quality rate. Our company has got first prize in the Quality of the products in Ludhiana.
1.11. PRODUCTION procedure
1. Purpose: - The purpose is to ensure that production is carried out as per plan under controlled condition.
2. Scope: - This procedure is applicable to all production area.
3. Process
Master schedule for each month is prepared on the basis of consolidated order sheet/job order/shortage raised by stores. For all cnc stations, monthly booking of machine wise plan is made as per standard cycle time and issued. This is updated on regular basis. Production plan for the week is prepared on the basis of master schedule and finalized by the last working day of the previous week. Section i/c approves production plan after reviewing with planning. Daily machine schedule for each day is finalized by the evening of previous day on the basis of weekly production plan. Production lots within a section are controlled by allocating a section specific lot no at the first operation stage. Lot no are recorded in lot control register It is ensured that the latest revision process sheet is available before planning a production lot Execution of production as per production plan is monitored & reviewed daily. Amendments if, any are authorized by HOD P&C. I/C section ensures that the required tools, jigs and fixture, gauges and instrument AS PER PROCESS sheet are available for all operations before the production work is taken up. Master list is available within section and updated on regular basis Forging blanks are obtain from WIP store and consumable tools form consumable store against requisition slip Details of all incoming and outgoing material in the section. Are maintained in issue receipt register. First piece approval is done before the start of production for all critical operations specified in process sheet. Production is done at every stage as per process sheet and the applicable procedure. It is ensured that for processes having established process parameters adhered to. Proper cards are used (accepted, rework, rejected and non conforming) On completion of production in the section material is inspected before releasing to next operation stage Daily production details are recorded and updated in electronic media. Hourly production on all machines are recorded and monitored. Daily final production report is submitted to the planning for updating planning. All material move through the move ticket.
1.12 SHOP WISE PROCESSES
1.12.1 TESTING
Fig.no.1 testing lab
Emson Gears has complete testing facilities for inspection of components at various stages of manufacturing right from steel analysis to forging processes, machining accuracies and metallurgical parameters. Gear accuracies are checked on Lead & Profile testers of world renowned makes like Klingenberg, Hofler and Maag Gear analyzers.
1.12.2 QUALITY
Fig.No.2 Quality checking
Emson Group strives to achieve excellence by maintaining the highest quality standards in all its manufacturing units. The entire production process is carried out under strict vigilance and quality checks. The company has ISO-9001: 2000 Quality Management System Certification from DNV and it is in the process of receiving TS-16949 certifications.