28-08-2014, 12:45 PM
I did my six month Industrial training at Rockman industry limited.Rockman Industries Ltd was set up in 1960, with production of bicycle chains in India. In 1996, with the help of Japanese Technology, the plant was expanded for the manufacture of automotive chains. Subsequently, in 1999, its operations were expanded to manufacture Aluminum Die Casting, Machined, Painted and Sub Assembled Components. 2008 Started Low Pressure and Gravity Casting in Haridwar. Current Rapid growth in volume and variety. An in-house modern tool room. Present production level 12 million motorcycle chains per annum and 20 million motorcycle hubs per annum
Chapter-1
INTRODUCTION TO ORGANIZATION Rockman Industries Ltd was set up in 1960, with production of bicycle chains in India. In 1996, with the help of Japanese Technology, the plant was expanded for the manufacture of automotive chains. Subsequently, in 1999, its operations were expanded to manufacture Aluminum Die Casting, Machined, Painted and Sub Assembled Components. 2008 Started Low Pressure and Gravity Casting in Haridwar. Current Rapid growth in volume and variety. An in-house modern tool room. Present production level 12 million motorcycle chains per annum and 20 million motorcycle hubs per annum. World largest producer with exports to over 30 country globally. With a team of designers with over two decade of experience in designing, Rockman combines together the latest technologies/platforms and rich experience. Once the tool design is complete, the design data is converted into machining data using software’s and this data is transferred directly to High Speed and High Precision Machining Centers. We can produce tools upto a weight of 5 tons . Rockman also designs complex machining fixtures for CNC Machining of components. The key to customer delight is timely execution of projects and project management plays the most important goal in delivering the right product, at the right time and at the right location. The Cross Functional Team takes care of the complete Process of Project Management right from defining the project goal and targets, till the final PSW Submission. A close interaction is maintained with the customer throughout the development process. Process Development is the key to ensure timely identification and deployment of all the necessary resources not only in terms of machines but also inspection facilities, trained manpower, utilities etc to ensure smooth development, trial, inspection and submission. The use of advanced simulation and testing software’s give Rockman the advantage of testing all the tool designed for cast fill, gate design, over flow design by doing mould fill simulations and thermal analysis of the designs at actual production parameters. This not only avoids number of tool corrections required but also ensures good castability as optimum machine parameters are already known. Rockman has over 20 years of experience of exporting to the Global customers in Europe including Germany, Italy, France, UK, Latin America, USA, etc. Fig. 1.1 Global Customers 1.1 FACILITIES & SERVICES 1. Aluminum High Pressure Die Casting: With 9 years of experience in High Pressure Die Casting, Rockman has developed in-house expertise in this field. Not only we have developed systems for handling multiple alloys, but have mastered the art of large scale mass production. We produce over 30,000 die cast components/day from our machines ranging from 150T to 800T locking force capacity. The HPDC machines are fully automatic with real time controls to ensure uniform quality. Customer’s quality requirements are continuously increasing. Pressure-tight castings free from pores are the order of the day. Rockman has the experience and expertise in such castings. Our expertise in processes, ability to offer creative solutions, always meeting the timeline and offering the entire range of services have made us what we are today. 2. Low Pressure Die Casting: Rockman produces 1.2 Million Cylinder Heads per annum for Motorcycles. Rockman has in-house facility for fully computerized Heat Treatment process. 3. Machining: Ability to design High Speed SPMs in our Group Company gives us the edge for mass production and rapid ramp capabilities. A combination of precision CNC lathes, CNC processing centers and component – specific machines gives us the right amalgamation of highly automated, flexible and cost effective machining cells. With capability of machining castings under very close tolerances for critical safety parts and parts for transmission systems for the automotive industry, Rockman ensures defect free castings. CNC machining with in-housed designed fixtures ensures flatness of 0.005mm to 0.01mm and parallelism of 0.02mm. Post machining, the parts are thoroughly cleaned to keep the residual levels to a minimum so that the parts are used directly on customer’s line. Machined castings are pressure tested by automated process and impregnated if necessary. 4. Assemblies and Modules: A wide supplier base for Sheet Metal Parts, Forgings, Springs, Sintered Products, Seals, Plastic Parts, Bearings, Friction Material, etc. gives Rockman the expertise to supply full assemblies and modules to OEMs . Rockman produces over 15,000 assemblies on a daily basis including highly critical and safety related applications like Brake Drum Assembly, Wheel Hub Assembly for customers like Hero. Integrating casting, machining, painting and assembly is our key to driving up quality whilst driving down lead times and cost. 1.2 DEPARTMENTS 1 Pressure Die Casting (PDC): The plant has 35 machines out of which 23 fully automatic die casting machines equipped with Auto Sprayer and Auto Ladle & Auto extractors to produce consistent high quality castings. 1250Ton (ZITAI) 800Ton (TOSHIBA) 730 Ton (ZITAI) 660Ton (HMT) 650Ton (ZITAI) 560Ton (ZITAI) 500Ton (ZITAI) 500Ton (TOSHIBA) 420Ton (ZITAI) 400Ton (LK) 400Ton (HMT) 350Ton (TOSHIBA) 250Ton (TOSHIBA) 2 Machine Shop Department: There are 32 VMC machines, 24 CNC machines and 47 SPM machines. In this shop different machining operation performed by the machines on the product. There are different types of machine are as below: CNC Turning centre Vertical Milling centre Judicious mix of standard SPM & CNCs. Cellular layout with single piece flow. Machining in close tolerance. 3 Paint Shop: Rockman has modern paint shop with complete pre-treatment line & electrostatic guns to produce components of the highest quality standard. Fully pressurized shop ensuring zero dust environment. Environment friendly process with zero discharge. Powder coating plant in Ludhiana by Dec 09. 4 Standard Room: In standard room calibration has been done of the measuring instruments time to time and different type of hardness test has been done there. There different types of machines are: CMM (Co-ordinate Measuring Machine) Spectrometers Micro hardness testing machine Surface Finish tester Profile Projector 5 Tool Room: One of the biggest strength of Rockman is the state of the art tool room & design facilities, to provide high precision quality components. Latest high-speed vertical CNC machining centers like Deckle Maho,Agma & Harford are the back bone for the accurate tool manufacturing. Tool room also has wire-cut machine from Fanuc & Sodick, EDM & Spark Erosion machine. 6 Assembly Shop: In house development of SPMs for the higher productivity. Daily production of over 25000 assemblies. Assemblies of higher critical safety like Brake Drum, Brake Panel Assembly and Wheel Hub Assemblies etc. Fig. 1.2 Assembly of Panel 7 Auto Chain Department: Auto Chain Plant was imported from lzumi chain manufacturing company of Japan with installed capacity of 4000 motorcycle drive & 1000 chains a day. Production of critical engine cam chains & drive chains for motorcycle. Annual capacity of million chains Fig 1.3 Auto chain 1.3 CUSTOMERS OF ROCKMAN INDUSTRIES LTD 1. HERO HONDA MOTORS LTD. (GURGOAN , DHARUDERA) 2. HONDA MOTORCYCLE AND SCOOTER INDIA PVT. LTD. (MANESAR) 3. TYCO ELECTRONICS (IRELAND) 4. UNIMACTS (USA) 5. GETRAG (GERMANY) 6. ELECTROLUX (ITALY) 7. IWIS MOTOR SYSTEM (GERMANY) These are the customers of rockman industries ltd of all branches. The parts here are sub-assembled and then exported. . International Fig 1.4 International Customers Domestic Fig 1.5 Domestic Customers 1.4 THE VISION We, at the Hero Group are continuously striving for synergy between technology, systems and human resources to provide products and services that meet the quality, performance, and price aspirations of the customers. While doing so, we maintain the highest standards of ethics and societal responsibilities, constantly innovate products and processes, and develop teams that keep the momentum going to take the group to excellence in everything we do. 1.5 THE ACHIEVEMENTS The Group and its management have acquired a number of accolades and achievements over the years: • Hero Group Management style has been acclaimed internationally by World Bank and BBC, UK. Hero Group is discussed as a case study at London Business School, UK and INSEAD, France. World Bank has acclaimed Hero Cycles as a role model in vendor development based on a world-wide study. The London Business School, UK, has done a case study on the Group as model of entrepreneurship. • Boston Consulting Group has ranked Hero Group as one of the top ten Business Houses on Economic value, in India. • HSBC-Merril Lynch has estimated Hero Group to be amongst the top value creators in the five years 2001-05. • The Hero Group is recognized as a long term partner and an ideal employer: • Hero Group's partnership with Honda Motors, Japan is over 20 years old • Hero Group's Partnership with Showa Manufacturing Corporation, Japan is over 18 years old. • Group Chairman, Mr. Brijmohan Lall Munjal received the coveted "Ernst & Young Entrepreneur of the Year" award for 2001. • Hero Cycles was ranked 3rd amongst top Indian companies Review 2000 - Asia's leading companies award (2003) by Far Eastern Economic Review. • Hero Cycles is the World's largest manufacturer of Bicycles with annual sales volume of over 4.8 million cycles. 1.6 PLANT LAYOUT Fig 1.6 Plant Layout Chapter 2 TRAINING GIVEN DETAILED STUDY ABOUT ASSIGNED DEPARTMENT 2.1 Introduction to Machine Shop The shop where most of the work is performed on different machine is called machine shop. In machine shop, the casting material machined with the help of machines. Different machine used in machine shop are: • CNC Vertical Machining Centre Machine • CNC Horizontal Machining Centre Machine • CNC Special Purpose Machine for Leakage Test • CNC Special Purpose Machine for Drilling • CNC Special Purpose Machine for Grinding • CNC Special Purpose Machine for Facing • CNC Special Purpose Machine for Taping • CNC Spinner Machine • Special Purpose Rotary Milling Machine There are 32 VMC machines, 24 CNC machines and 47 SPM machines. In machine shop there are number of operation done on different number of machines. In this shop the component can be manufactured with in divided lines. In machine shop different types of tool used like drill, reamer, spot face, chamfer, tapping, etc. There is an also different type of inserts used in turning centers and vertical machine centers. In VMC inserts used for the milling operations. 2.2 PROCESS FLOW THE MACHINE SHOP DIVIDED INTO THE LINES. THE MACHINING OF DIFFERENT COMPONENT DONE IN DIFFERENT LINES. 1. Crank Case Cover Right Line: This line deals with the machining of the crank case cover right (CCCR). In this line machining of four type of CCCR (P17, P21, KSTG, KWAG) done. The various operations done in this line listed below: S.No. Name of Operation 1. Face milling 2. Dowel hole drilling 3. Oil pipe and Lifter hole drilling 4. Dip stick hole drilling and tapping 5. KSS hole step drilling 6. Mounting hole drilling(6 hole) 7. Clutch lever hole drilling/reaming 8. Plug cone hole drilling 9. Cross oil hole drilling 10. Washing 11. Assembly (plug cone and oil pipe) 12. Leakage testing Table 2.1 2. Panel Rear Brake Line: This line deals with machining of panel rear brake. The various operations done in this line listed below: 3. S.No. Name of Operation 1. Burnishing 2. Facing and outer dia. Grooving 3. Facing and cam hole drilling 4. Reaming Table 2.2 4. Flange Final Driven line: This line deals with machining of Flange Final Driven. The various operations done in this line listed below: S.No. Name of Operation 1. Outer dia. Turning 2. Boring 3. Drilling and tapping 4. Assembly (Stud, Bearing, Sprocket, Nut) Table 2.3 5. Cylinder Cover Head Line: This line deals with machining of Cylinder Cover Head. The various operations done in this line listed below: S.No. Name of Operation 1. Drilling and tapping 2. Drilling 3. Assembly (Jointed, Gaskit, Plate, Screw) 4. Leakage testing Table 2.4 6. Cover Oil Pump Line: This line deals with machining of Cover Oil Pump. The various operations done in this line listed below: S.No. Name of Operation 1. Turning 2. Boring 3. Grooving 4. Drilling 5. Tapping 6. Spot facing Table 2.5 7. Hub Rear Wheel Line: This line deals with machining of Hub Rear Wheel. The various operations done in this line listed below: S.No. Name of Operation 1. C.I Ring Turning 2. Boring 3. Grooving 4. Spokes hole drilling (18 hole) Table 2.6 8. Hub Front Wheel Line:- This line deals with machining of Hub Front Wheel. The various operations done in this line listed below: S.No. Name of Operation 1. C.I Ring Turning 2. Boring 3. Grooving 4. Spokes hole drilling (18 hole) Table 2.7 9. Cylinder Head Line:- This line deals with machining of cylinder head. The various operations done in this line listed below: S.No. Name of Operation 1. Drilling 2. Reaming 3. Tapping 4. Chamfering 5. End milling 6. Leakage testing Table 2.8 10. Tensioner Housing: - This line deals with the machining of tensioner housing. The various operations done in this line listed below: S.No. Name of Operation 1. Drilling 2. Reaming 3. Tapping 4. Chamfering 5. End milling 6. Leakage testing Table 2.9 2.3 MACHINING OPERATIONS 1. Face Milling: A milling operation in which the surface of the workpiece is perpendicular to the spindle axis. Face milling primarily is used to mill the top surface of the part. 2. Drilling: The drilling process is an extensively used machining operation by which through or blind holes are cut or originated in a work piece. The drilling tool is called a drill which is a multi-point cutting tool. The hole is produced by axially feeding the rotating drill into the work piece. 3. Tapping: It is the operation of cutting an internal thread in a drilled hole with an externally threaded tool called a tap. For tapping in a drilling machine, special tapping attachment holds the tap and is rotated by the spindle of the drilling machine. 4. Reaming: It is the operation of sizing and finishing the inside of a drilled hole using a reamer which has several cutting edges. A drill will not produce a hole having sufficiently good qualities of finish and accuracy for many purposes. Therefore, when a very accurate smooth hole is required, the hole is first drilled a little undersize. Then it is reamed to the correct size. 5. Facing: The operation of finishing the ends of the work to make the end flat and smooth and to make the piece of required length is called facing. 6. Grooving: The process of cutting a narrow channel or passageway into the outside or inside diameter of a cylindrical work piece. 7. Turning: It is the operation of remove material from the outside diameter of a work piece to obtain a finished surface. The finished surface may be of continuous diameter, stepped and tapered. 8. Boring: The operation of enlarging an already existing drilled hole with the help of boring tool is known as boring. 9. Chamfering: The operation of beveling the external edge of the workpiece with the help of chamfering tool is known as chamfering. 10. End Milling: This operation is used to machine flat surfaces either horizontal, vertical or at an angle using an end mill as cutter. The cutter removes material with the teeth on the periphery. 11. Spot facing: A spot face or spot face is a machined feature in which a certain region of the work piece (a spot) is faced, providing a smooth, flat, accurately located surface. 2.4 CONVEYORS USED IN ROCKMAN INDUSTRIES Gravity-roller conveyors consist of a series of parallel rollers fastened to a metal frame supported at intervals. The frame can be inclined slightly for gravity flow, but objects and packages may also be rolled along manually. Gravity-wheel conveyors are similar but consist of skate wheels instead of rollers and are usually used for lighter loads. Gravity conveyor do not require a motor, use wheels, rollers and the pull of gravity to move materials along a conveyor. Power conveyors unlike gravity conveyors, require a pneumatic or an electrical power source. Power is transmitted from a drive system to drive pulley, which is fastened to drive shaft. The drive pulley then transmits the power to the conveyor belt, which moves the conveyor bed, upon which the materials rest. 2.5 MACHINE USED 1. Vertical Machining Centre (VMC): Toshiba Machine Tool offers the highest quality in the today market. This provide dual opening front door. This ensures easy and complete access for front loading or overhead loading of stock. Fig.2.1 VMC Every VMC machine is designed from the casting up with all of the customer desired features engineered as standard equipment. Standard Feature of VMC • High speed control system • High speed axis motor • Automatic tool changer • 10,000 RPM, 20 HP continuous, spindle system • High speed rigid tapping • Dual front door • Dual coolant pumps • Fully enclosed, sound absorbing machine cabinet • Programmable wash down • Work light • Spindle load meter • Optional stop Available Option in VMC • chip conveyor • Dust collection system • Rotary table • Coolant through tool • Auto loaders • Tool changer • Auto door • Display system • Tool holder 2. Multi Spindle Drilling Machine : Multi spindle head are designed for almost all type of drilling and tapping machine. Multi spindle head will increase the production as you increase number of spindles. The internal construction of multi spindle drilling is made of planetary of gears which gets drive from main spindle to gear in multi spindle drilling head connected to ”N” number of spindle required in drilling. Fig. 2.2 Multi spindle drilling machine Multi spindle heads are the best method to do drilling and tapping when the holes are close or in affixed PCD. This can divided into two Adjustable Multi Spindle Drilling Heads and Fixed or Special purpose drilling Heads. Adjustable multi spindle drilling heads can be used in many components where you can change the center distance to some range. It will increase your drilling capacity in single special purpose machine. With capability of machining castings under very close tolerances for critical safety parts and parts for transmission systems for the automotive industry, Rockman ensures defect free castings. CNC machining with in-housed designed fixtures ensures flatness of 0.005mm to 0.01mm. Post machining, the parts are thoroughly cleaned to keep the residual levels to a minimum so that the parts are used directly on customer’s line. Machined castings are pressure tested by automated process and impregnated if necessary. 3. Special Purpose Machine (SPM): Special Purpose Machines are Precision's main business. It produces state-of-the-art precision special purpose machines to meet the manufacturing challenges. It takes specification and requirements from initial design study and concept through to full scale special purpose machine design and build. Fig. 2.3 SPM This is generally one-off special purpose machine developed to their full potential with Precision with the manufacturing facility for Limited capable of Batch Production. 4. Washing Machine: After machining this process is performed. An appropriate cleaning solvent (sometimes ordinary tap water) to clean delicate items. Sometime for washing the component coolant is also used. In this hot water or coolant is used and temperature of coolant is 60°c to 70°c. Hot solvent is used because of the impurities, oil etc from the component is removed . Fig. 2.4 Washing machine 2.6 System of Machine The system used in the machines are basically pneumatic and hydraulic : 1. Pneumatic System: Pneumatic systems used compressed gas such as air or nitrogen to perform work processes whereas hydraulic system uses liquids such as oil and water to perform work processes. Pneumatic systems are open systems, exhausting the compressed air to atmosphere after use whereas hydraulic system are closed systems, recalculating the oil or water after use. The reason for using pneumatics, or any other type of energy transmission on a machine, is to perform work. The accomplishment of work requires the application of kinetic energy to a resisting object resulting in the object moving through a distance. In a pneumatic system, energy is stored in a potential state under the form of compressed air. Working energy (kinetic energy and pressure) results in a pneumatic system when the compressed air is allowed to expand. For example, a tank is charged to 100 PSIA with compressed air. When the valve at the tank outlet is opened, the air inside the tank expands until the pressure inside the tank equals the atmospheric pressure. Air expansion takes the form of airflow. To perform any applicable amount of work then, a device is needed which can supply an air tank with a sufficient amount of air at a desired pressure. This device is positive displacement compressor. A positive displacement compressor basically consists of a movable member inside housing. The compressor has a piston for a movable member. The piston is connected to a crankshaft, which is in turn connected to a prime mover (electric motor, internal combustion engine). At inlet and outlet ports, valves allow air to enter and exit the chamber. Fig. 2.5 Pneumatic circuit A: Compressor: a pump which compresses air, raising it to a higher pressure, and delivers it to the pneumatic system (sometimes, can also be used to generate a vacuum. B: Check valve: one-way valve that allows pressurized air to enter the pneumatic system, but prevents backflow (and loss of pressure) into the compressor when it is stopped. C: Accumulator: stores compressed air, preventing surges in pressure and relieving the duty cycle of the compressor. D: Directional valve: controls the flow of pressurized air from the source to the selected port. Some valves permit free exhaust from the port not selected. These valves can be actuated either manually or electrically (the valves typically provided in the FIRST kits use dual solenoids to change the direction of the valve, based on input signals from the control system). E: Actuator: converts energy stored in the compressed air into mechanical motion. A linear piston is shown. Alternate tools include rotary actuators, air tools, expanding bladders, etc. 2. Hydraulic System: Hydraulic system uses liquids such as oil and water to perform work processes. Pneumatic systems are open systems, exhausting the compressed air to atmosphere after use whereas hydraulic system are closed systems, recalculating the oil or water after use. Hydraulics is used to do work in the same way as a lever or gear does work. All of these systems transmit energy or force. Because energy cannot be created or destroyed, these systems only redirect energy to perform work and do not create more energy. Work is the amount of force applied and the distance over which it is applied. Force is power working against resistance; it is the amount of push or pull exerted on an object needed to cause motion. We usually measure force in the same units that we use to measure weight: pounds or kilograms. Pressure is the amount of force exerted onto a given surface area. Therefore, pressure equals the applied force (measured in pounds or kilograms) divided by the surface area (measured in square inches or square centimeters) that is receiving the force. In customary English units, pressure is measured in pounds per square inch (psi). In the metric system it can be measured in kilograms per square centimeter, but the preferred metric pressure measurement unit is the Pascal. The pressure of a liquid in a closed system such as a brake hydraulic system is the force exerted against the inner surface of its container, which is the surface of all the lines, hoses, valves, and pistons in the system. Pressure applied to a liquid exerts force equally in all directions. If the hydraulic pump provides 100 psi, there will be 100 pounds of force on every square inch of the system .When pressure is applied to a movable output piston, it creates output force. If the system included a piston with an area of 30 square inches, each square inch would receive 100 pounds of force. This means there would be 3,000 pounds of force applied to that piston. The use of the larger piston would give the system a mechanical advantage or increase. 2.7 TYPES OF CHIPS 1. Discontinuous Chip : These types of chips are usually produced when cutting more brittle materials. These materials lack the ductility necessary for appreciable plastic chips formation. The material ahead of the tool edge fails in a brittle fracture manner along the shear zone. This produces small fragments of discontinuous chips. Since the chips break up into small segments, the friction between the tool and chips reduces resulting in better surface finish. These chips are convenient to collect, handle and dispose of. Discontinuous chips are also produced when cutting more ductile materials under the following conditions: • Large chip thickness • Low cutting speed • Cutting with the use of a cutting fluid 2 Continuous Chips : These types of chips are produced when machining more ductile materials. Due to large plastic deformations possible with ductile materials, longer continuous chips are produced. This type of chip is the most desirable, since it is stable cutting resulting in good surface finish. On the other hand, these chips are difficult to handle and dispose off. The chips coil in a helix and curl around the work and tool and may injure the operator. Also this type of chip remain in contact with the tool face for a longer period resulting in more frictional heat. These difficulties are usually avoided by attaching to the tool face a chip breaker which break the chips. The following cutting conditions also helps in the production of continuous chips: • Small chip thickness • High cutting speed • Reducing the friction of chip along the tool face by imparting high surface finish to the tool face, use of good cutting fluid. 3 Continuous Chips With Built Up Edge : When machining ductile materials condition of high local temperature and extreme pressure in the cutting zone and also high friction in the tool chip interface, may cause the work material to adhere or weld to the cutting edge of the tool forming the built up edge. Successive layers of work material are then added to the built up edge. When this edge becomes larger and unstable , it breaks up and part of it is carried up the face of the tool along with the chip while the remaining is left over the surface being machined, which contributes to the roughness of the surface. The built up edge changes its size during the cutting operation. It first increases, then decreases, then again increases etc. This cycle is a source of vibration and poor surface finish. Low cutting speed contributes to the formation of the built up edge. Increasing the cutting speed, increasing the rake angle and using a cutting fluid contribute to the reduction or elimination of built up edge. Fig. 2.6 Types of chips 2.8 TOTAL PRODUCTIVE MAINTANCE (TPM) TPM A manufacturing improvement method that increases production and reduces waste through continuous attention to the condition of machines and processes To full fill requirements of customer & to achieve our business goal we are going to start a new journey in our Rockman Ludhiana Plant which will be known as TPM. Fig. 2.7 Pillars of TPM 1 STEPS OF TPM STEP 0 • Team • Safety Mapping • Safety Instruction • Cleaning Tools • What to look for while Cleaning STEP 1 • Fugai list (abnormality list) • Fugai matrix • Fugai Tag status • JH Audit form STEP 2 • Initial Cleaning • Countermeasures for contamination sources and hard to access areas • Source of Contamination list • Hard to Access Area List STEP 3 • Fugai Status • Daily safety Monitoring • Autonomous maintenance sheet OTHER • JH Status • Break down • OEE 2 Types of Abnormality Tag:-The abnormality tag is divided into two types Red tag for maintenance related activity and Blue tag for operator related activity. Fig. 2.8 Type of tags 3 Types of Abnormalities • Broken • Crack • Damage • Dirty • Leakage • Loose • Missing • Not proper • Not Working • Unsafe • Unwanted • Worn 4 Benefits of TPM Fig.2.9 Benefits of TPM 2.9 INSPECTION AND QUALITY CONTROL 1 Inspection: Inspection is closely associated with quality control. It is often said that no two things can ever been exactly alike. This also hold true with manufactured parts. Even through certain variations are accepted, parts are liable to rejection if the deviations go beyond the specified quality. Some procedure must therefore be set up to detect errors so that the manufacture of faulty parts does not go uncorrected. The job of the inspection department is to interpret the specifications properly, inspect whether or not job confirms to those specifications and convey the information obtained to the production department for necessary corrections to the process. There are three basic areas of inspection: • Receiving inspection • In process inspection • Final inspection In the receiving inspection, inspections are performed on all incoming materials and purchase parts. In the in process inspection the products are inspected as they are in process. In the final inspection, all finished products are finally inspected prior to sending them to the customer. 2 Quality Control:-The word “QUALITY” as used in manufacturing implies the best for the money invested and does not necessarily mean the best. Quality is the relative term and is generally explained with reference to the end use of a product. A component is said to be of good quality if it works well in a particular situation for which it is meant while in other situation it may not work well and it is said to be of bad quality. The word control implies observation and manipulation. The basic philosophy of quality is both “preventing” and “remedial”. It ills through quality control that some measures are taken to see that defective items are not produced at all ad when they do occur, corrective action must be taken to prevent further recurrence. Inspection is considered to be a tool of quality control. It checks the product while quality control attempts to bring the variable factors under control. 3 Quality Control Inspection M/C Shop:- • Gauge and fixture should always clean • Ensure the lubrication cards are properly filled up. • Ensure that the being used are calibrated. • Check the components visually and dimensionally. • Check the critical parameters. • If found major defect in the process report immediately to the concerned supervisor. • If any new change in the machine setting ensures that the machine setting is ok 2.10 Quality Control System Used In RIL : • KAIZEN • 5-S RULE • KANBAN SYSTEM • CAUSE – EFFECT DIAGRAMS • PROCESS QUALITY CHECKSHEET • DAILY PROCESS CHECKSHEET 1. KAIZEN : KAIZEN - SIMPLER, FASTER, BETTER For standardization, easy to understand and implement. According to KAIZEN-Making improvement with own ideas by all employees in a continuous basis, creates an assets which cannot be purchased. KAIZEN forces the employees to contribute to the every part of the company with their innovation and creativity in simpler, faster and better way. KAIZEN Strategies: Elimination of the seven wastes: • Overproduction • Down Time • Transportation • Inappropriate Processing • Unnecessary Inventory • Unnecessary Motions • Defects Benefits of KAIZEN: • Makes the job: • Easier • Safer • Less unpleasant • More efficient • Saves money and time • Stimulates workers • Creates an atmosphere of harmony and a strong sense of community, family, and belonging. 2. 5-S RULE : Although 5 ‘s’ have become so popular in japan that many companies simply use 5 ‘s’ as the title of their programme some companies does post the original words of 5 ‘s’ in Japanese characters. 1. Seiri A sorting what you have , identifying the needs and throwing out those unnecessary. 2. Seiton Making things in order. Example include keeping shelves in order , keep storage area in order , keeping work place in order. Keeping worktables and the office in order. 3. Seiso Having a clean workplace , equipments , etc. 4. Seikesu Maintaining equipments and tools. 5. Shitsuke Following the rules and making them a habit Table 2.10 THESE 5 ‘S’ WHEN TRANSLATED INTO ENGLISH ARE :- • Sorting Out • Systematic Arrangement • Shine Everything • Standardization • Self Discipline 3. KANBAN SYSTEM: A kanban system or pull system production control system uses simple , visual signals to control the movement of materials b/w work centre as well as the production of new material to restock those sent downstream to the next work center .originally , the name kanban referred to a Japanese shop sign that communicated the type of product sold at the shop through the visual image on the sign. In rockman industries ltd , there is a tag in every components’ trolley written over there. ` PART NAME – PNF/PNR/FFD/HRW/HFW/CCCR/CCCL/GBS/OPC MODEL – P-17/P-21/P-27/P-40/P-70/P-90/P-91/KSTG/KVNA/KWAG OPERATION COMPLETE – CASTING – MACHINING – BUFFING – PAINT – ASSEMBLY STATUS : OK / NOT OK Table 2.11 Check sheets are used to collect data that will be used towards solving the problem selected .This TQM tool is important , as it provides the facts .The document is typically a blank form that is designed for the quick , easy and efficient recording of the desired information, which can be either quantitative or qualitative. A defining characteristic of a check sheet is that data is recorded by making checks on it. 4. CAUSE – EFFECT DIAGRAM : A cause and effect diagram is an analysis tool that provides a systematic way of looking at effects and the causes that creates or contribute to those effects . It was developed by Dr. Kaoru Ishikawa of Japan in 1943 and is sometimes referred to as an Ishikawa diagram or a fishbone diagram because of its shape. The fishbone is easy to construct and invites interactive participation . Here is a cause and effect diagram. Fig. 2.10 Cause Effect Diagram Steps in constructing and analyzing a cause and effect diagram:- Step 1 : Identify and clearly define the outcome or effect to be analized Step 2 : Use a chart pack positioned where everyone can see it. Draw the spine and create the effect box. Step 3 : Identify the main causes contributing to the effect std. Step 4 : For each major branch , identify other specific factors which may be the caused of the effect. Step 5 : Identify increasingly more detached level of causes and continue organizing them under related cause or categories . you can do this by asking a series of WHY questions . Table 2.12 5. POKA-YOKE : Poka-yoke is a Japanese term that means "mistake proofing". It is anything that helps people to avoid mistakes. The goal is to prevent a mistake before it occurs so you don’t have to deal with the after-effects of the mistake .The goal of manufacturing is to produce value-added products in a timely manner, which is free of defects. Poke Yoke is applied in fundamental areas. The main objective of Poka Yoke is to achieve zero defects. It is used to create a system that prevents defects from occurring, and it used as a system to catch defects, which have just occurred and prevent them from continuing through the system. Poka-yoke helps people and processes work right the first time. Poka-yoke refers to techniques that make it impossible to make mistakes. These techniques can drive defects out of products and processes and substantially improve quality and reliability. The basic concept of this is avoiding the problems by correcting the process. Poka yoke is implemented by using simple objects like fixtures, jigs, warning devices to prevent people from committing mistakes, even if they try to. No defective part will be passed to the next process. So at the end of the process you can trust that you have a good quality parts on your hand. Poka yoke is one of the critical steps in the lean journey. Benefits of Poka Yoke • Reduced rework • Reduced defects • Reduced wastes • Increased safety - Prevents accidents before they happen • Improved customer satisfaction 2.11 CLASSIFICATION OF MEASURING INSTRUMENTS: 1. Digital Vernier Caliper : The Digital Vernier Caliper is a precision instrument that can be used to measure internal and external distances extremely accurately. They give a direct reading of the distance measured to high accuracy. The example shown below is a digital caliper as the distances/measurements, are read from a LCD display. The most important parts have been labeled. Earlier versions of this type of measuring instrument had to be read by looking carefully at the imperial or metric scale and there was a need for very good eyesight in order to read the small sliding scale. Manually operated vernier calipers can still be bought and remain popular because they are much cheaper than the digital version. Also, the digital version requires a small battery whereas the manual version does not need any power source. Digital calipers are easier to use as the measurement is clearly displayed and also, by pressing the inch/mm button the distance can be read as metric or imperial. Fig. 2.11 Digital Vernier Caliper 2. Digital Height Gauge : A digital height gauge is a high accuracy measuring device developed specifically for measuring the difference in height of two points. High specification electronic height gauges can carry out different measuring tasks including step heights, internal/external diameters and centre-line distances. The electronic height gauge is extremely precise up to 0.001. Fig 2.12 Digital height Gauge 3. Gauges : Gauges are used for checking the size, shape and relative positions of various parts but not provided with graduated adjustable members. Gauges are therefore understood to be single size fixed-type measuring tools. 2.12 CLASSIFICATION OF GAUGES Gauges are classified as standard and limit. Standard gauges are made to the normal size of the part to be tested and have the measuring member equal in size to the mean permissible dimension of the part to be checked.Limit gauges or “go” and “no go” gauges are made to the limit size of the work to be measured. One of the sides or ends of the gauges is made to correspond to the maximum and other to the minimum permissible size. The function of limit gauges is to determine whether the actual dimensions of the work are within or outside the specified limits. A double end gauge has “go” member must pass into or over an acceptable piece but the “no go” member should not. Different types of gauges are : I. Plug Gauges : These gauges are referred to as plug gauges; they are used in the manner of a plug. They are generally assembled from standard parts where the gauge portion is interchangeable with other gauge pieces (obtained from a set of pin type gauge blocks) and a body that uses the collet principle to hold the gauges firmly. To use this style of gauge, one end is inserted into the part first and depending on the result of that test, the other end is tried. Fig 2.13 Plug Gauges II. THREAD PLUG GAUGES: Thread plug gages are used to check an internal threaded hole. Fig 2.14 Thread Plug Gauge III. SNAP GAUGES : Snap gauges are oftentimes used when a large quantity of work pieces must be inspected. The snap gauge has four anvils or jaws, the first one or pair (outermost) are set using the upper limit (tolerance) of the part and the inner set adjusted to the lower limit of the part. A correctly machined part will pass the first set of jaws and stop at the second end of test. In this manner a part may be checked in one action, unlike the plug gauge that needs to be used twice and flipped to access the second gauge. Fig 2.15 Snap Gauge IV. RING GAUGES : A ring gauge is a cylindrical ring of steel whose inside diameter is finished to gauge tolerance and is used for checking the external diameter of a cylindrical object. Ring gauges are used for comparative gauging as well as for checking, calibrating, or setting of gauges or other standards. Fig 2.16 Ring Gauge 2.13 PRODUCTS MANUFACTURED BY ROCKMAN INDUSTRIES 1 Domestic Products Crank Case Cover Rear Panel Panel Flange Assembly Hub Front Wheel Hub Rear Wheel Fig. 2.17 Products Manufacture 2 EXPORTS PRODUCTS Tensioner Housing Gear Shift Fork Assemblies Gear Cover Housing Differential cover housing Fig 2.18 Export Products Chapter 3 PROJECT 3.1 INTRODUCTION TO PROJECT I did my training at Rockman Industries Ltd. Focal Point, Ludhiana I did my training at Rockman Industries Ltd. Focal Point, Ludhiana. I was assigned particularly in Machine Shop where I got the opportunity to undertake various live projects and learnt many new techniques and methods of doing various tasks efficiently in an industry. Initially in Machine Shop I was asked to know and understand all the machines and processes used in that department to get the production done in scheduled time. In this context, my first step was to go through the detailed study of each and every process done to manufacture the components of that section. Here, I was able to know how the number of processes used on a single component to manufacture and in what sequence. After spending the enough time in doing so, I was given a task to increase the production of any component if I find some scope to increase the production of any component. There I got a opportunity to apply my engineering skills in that section. In this department, I worked their engineers and tried to do the project: 1. Productivity improvement from 1300 pcs./day to 1500 pcs./day In CCCL KTRM line :- By doing the analysis of process flow of crank case cover left KTRM and finding the way to increase productivity. 2. To control effect of noise pollution & provide sufficient light range in machine shop. 3.2 Project Work And Methodology Once I was familiarized by the works carried out in different departments and the people responsible for carrying out processes, I was involved in the various live projects for stipulated period of time. Along with the above projects I was also involved in the daily issues of the department like Inline Inspection. The projects were carried out under the guidance of my mentors who guided me and helped in sorting out any problems or knowing the way the work was to be done. Theme 1:-Productivity improvement from 1300 pcs./day to 1500 pcs./day In CCCL KTRM line. Fig. 3.1 CCCL KTRM Customer demand: - 1500 pcs. Achieved: 1300- pcs. Difference: - 200pcs Customer demand Vs existing line capacity QTY (Nos). Fig 3.2 Customer demand v/s existing cappacty CAUSE & EFFECT DIAGRAM Fig 3.3 Cause and effect diagram The main problem is that the cycle time of the machine is not good to achieve the costumers demand. Also we have to check the line layout. The first step is how to reduce the cycle time of the line. The line having machine 7 machines as shown below. LINE LAYOUT Fig 3.4 Line Layout In this line lay out there is total 7 machines. 5 SPM and 2 vmc . The following are operation perform on this line. • Rotary Milling • Dowel hole • Mounting hole • Spot Facing (M6&M30) • Leakage Test Cycle Time Study of CCCL KTRM Line MACHINE NO. OPERATION AVG CYCLE TIME (sec) PRODUCTION P/H PRODUCTION P/Shift@85% Production/Day Actual Production SPM 36 Rotary Milling 46 78 532 1596 VMC 42 DOWEL HOLE 103 35 238 714 1321 VMC 1 DOWEL HOLE 121 30 203 607 SPM 77 MOUNTING HOLE 13 277 1833 5649 SPM 73 SPOT FACING (M14) 21 171 1166 3498 SPM 34 SPOT FACING (M30) 21 171 1166 3498 SPM 75 LEAKAGE TEST 28 129 1210 3630 Table 3.1 From the above cycle time study it is seen clearly that the Production capacity of CCCL KTRM line is of Approximate 1300 pieces per day. But customer demand having 1500 pieces. So to meet the customer need some step should be taken. The formula to drive the maximum cycle time of machine in line to achieve the target is given below Takt is Germany word means the suitable cycle time to meet the requirements. It means cycle time of every machine in CCCL KTRM line Should be below 49 sec to get the target of 1500 pieces. But here the cycle time of VMC 01 & VMC 42 was 121 & 141. But these two machine having same operation. The maximum capacity of machine is to produce 1321 piece according to graph. Fig 3.5 Bar graph of cycle time of line VMC 01 & VMC 42 are bottleneck machine having cycle time much larger then takt time. Know we have to generate production bar chat of CCCL KTRM line Production bar chat Fig 3.6 Bar graph of production Activity plan to achieve takt time Reduced the cycle time of machine by increasing the feed and RPM Sn Machine Activity CT reduced/ Add Remark 1 VMC42 (103sec) Dowell Hole Drilling Reduce 02sec 02Nos 2 O.D .Boring Reduce 16.5sec 02 Nos 3 Drilling of 5*8*9 Reduce 4.9sec 03Nos Total cycle time reduction 23.4sec Final Cycle time 79.6sec Final capacity 1534 Table 3.2 Step 1:- Reduced the cycle time of machine by increasing the feed and RPM Before After OPERATION DESCRIPTION RPM FEED MM/MIN TIME RPM FEED MM/MIN TIME Load/Unload 8 8 Index 3 3 Dowel hole drilling 3800.00 400.00 8 4000.00 573.00 7 Dowel hole drilling 3800.00 400.0 6 4000.00 573.00 5 Dowel hole drilling 3800.00 400.0 6 4000.00 573.00 5 Dowel hole drilling 3800.00 400.0 6 4000.00 573.00 5 Rough OD boring 800.00 20.0 14 2000.00 54.0 8 Rough OD boring 800.00 20.0 12 2200.00 54.0 6 Finish OD boring 2000.00 15.0 19 2000.00 54.0 9 Finish OD boring 2000.00 15.0 18 2000.00 54.0 7 Spot facing 2500.00 250.0 5 2500.00 250.0 5 Spot facing 2500.00 250.0 3 2500.00 250.0 3 Spot facing 2500.00 250.0 3 2500.00 250.0 3 Spot facing 2500.00 250.0 3 2500.00 250.0 3 Pre drill for M6 3000.00 300.0 7 6000.00 573.0 6 Pre drill for M6 3000.00 300.0 6 6000.00 573.0 4 Pre drill for M6 3000.00 300.0 6 6000.00 573.0 4 Pre drill for M6 3000.00 300.0 6 6000.00 573.0 4 Pre drill for M6 2500.00 300.0 7 6000.00 573.0 6 Pre drill for M6 2500.00 300.0 5 6000.00 573.0 4 Pre drill for M6 2500.00 300.0 5 6000.00 573.0 4 Pre drill for M6 2500.00 300.0 5 6000.00 573.0 4 M6 tapping 1592.00 1592.0 5 1592.00 1592.0 5 M6 tapping 1592.00 1592.0 3 1592.00 1592.0 3 M6 tapping 1592.00 1592.0 3 1592.00 1592.0 3 M6 tapping 1592.00 1592.0 5 1592.00 1592.0 5 M6 tapping 1592.00 1592.0 3 1592.00 1592.0 3 M6 tapping 1592.00 1592.0 3 1592.00 1592.0 3 Drilling 2800.00 350.0 6 2000.00 250.0 6 Drilling 2000.00 350.0 4 2000.00 250.0 5 Index 3 3 Total 200/2 = 103 159/2 = 79 Capacity 714 927 Table 3.3 The RPM and feed of operation Dowel hole, Rough drilling, and finished boring has been changed to achieve the target. The change is RPM and Feed are only for Trail to see its result, if any problem occur it will be changed as much as needed After process Optimization Fig. 3.7 After process optimization With the increase in feed and RPM production goes up to 927 pieces of VMC 42 & 607 from VMC 01, so total production increases up to 1534 pieces/day. Problems Facing during trail implementation Tool life decreases. Quality related problem occurs. 5W & 2H analysis of problem of Tools break down Who:- Operator and Supervisor What:- Tool Breakdown When:- 2nd Week of April Where:- At VMC 24 Why:- Due to Change in machine Input How:- Because of increase in RPM and Feed How Much:- 3 tools within a week Table 3.4 Solution for tool break down problem Carbide through coolant drill ø 6 mm replaced with HSS drill ø 6 mm in vmc-42 Fig 3.8 Drill changed from HSS to Carbide Production has not much valve in Industries. The main thing is productivity. Due to high feed and RPM tool life has reduced and rejection increases . but every proplem having solution, So to increase the tool life we deceded to change the tool material hhs to carbide through coolant flow from above as shown below. Quality related Problem Data collection Quality related problem occur after increasing the feed and RPM. Because of Load on piece and tool. The data collected by gauge checking of 100 pieces. The machine having 4 operations. Rejection data S. No. Defects No. of Pieces % w.r.t Total Cumulative % 1 Dowel HOLE 79 79 79 2 OD boring 12 12 91 3 Spot Facing 6 6 97 4 Taping M6 3 3 100 Table 3.5 Pareto Diagram Fig 3.9 Pareto diagram From the above Table and Pareto diagram it is show that main problem is OD Boring. We have to take action on feed And RPM of dowel Hole. Decreased the feed 573mm/min to 500mm/mm in all 4 operation of dowel hole. There is very small difference in cycle time it reduces only 5 sec. now Cycle Time of VMC 42 is of 82 sec. which is sufficient to achieve takt time. 82 sec is below the Takt time. 1502 Pieces produced in 24 hours. Process Capability Chart Before Standardization the FEED and RPM of Machine we have to Check that the process is capable or not. 50 pieces was checked on CMM machine as shown below Table 3.6 The value of Cpk is 1.4387 means the process is capable. It is under 2s so we can standardize the new input of machine. Standardization of machine new input S.NO. Activity Q S P Method Why it is reqd to be done Remarks 1 Dowel hole drilling P In program Parameter optimization RPM 4000 and FEED 500 mm/min 2 Rough OD boring P In program Parameter optimization RPM 2000 and FEED 54 mm/min 3 Pre drill for M6 P In program Parameter optimization RPM 6000 and FEED 573 mm/min Prepared By Issued By Table no 3.7 The new standard develop for the vmc 42 , to achieve the takt time to full fill the customer recruitment. Theme 2: To control effect of noise pollution & provide sufficient light range in machine shop. Safety is very necessary in Industry. Each employee is responsible to follow established polices and procedures. Regular attendance is required of all. Following directions is critical. Responsibility does not end with just taking care of you. Unsafe working conditions and acts must be reported to management. It is the responsibility of each employee to work in a professional and safe manner. Problems due to noise pollution 1. Noise can cause stress and interfere with concentration. It can cause chronic health problems and it can also cause accidents by interfering with communication and warning signals. 2. Short-term exposure to excessive noise can cause temporary hearing loss. 3. Exposure to noise over a longer period of time can cause permanent hearing loss 4. Workers exposed to noise may complain of nervousness, sleeping problems and fatigue (feeling tired all the time). 5. Excessive exposure to noise can also reduce job performance and may cause high rates of absenteeism 6. The following chart gives recommended limits of noise exposure for the number of hours exposed. 7. The Continues noise is very dangerous to health. Its effects can be seen after the long years. The following chart gives recommended limits of noise exposure for the number of hours exposed No. of hours exposed Sound level dB 8 90 6 92 4 95 3 97 2 100 1.5 102 1 105 0.5 110 0.25 or less 115 Table 3.8 In rockman industry working Hour is of 24 hours. But operators are changed after 8 hours, means every shift is of 8 hours. So according to this upper limit of noise is 90 db. Problems due to low LUX Range in workshop Accidents In comfort to workers Defect in eyesight of of worker in the long run Generate unpleasantness and leads to less out put More Fatigue more accidents and more rejection Normal Range of LUX: - 500 to750 Data collection about the problem Range of LUX and decibel in machine shop LINE M/C NO. LUX LEVEL SOUND LEVEL CCCR 100 CC SPM-09 480 202 78.8 99.2 VMC-43 207 220 75 95 VMC-15 360 420 71 91 VMC-10/ 09 320 350 74 88 SPM-01 465 475 78 86 VMC-06 508 525 72 88 VMC-04 460 480 75 83.9 SPM-03 497 510 75 87 SPM-16 510 532 78 86.2 ASSEMBLY 350 360 75 80 L/TESTING 565 580 77 82 L/TESTING 200 215 76 81 TROLLEYS CCCR 150 CC SPM-86 850 875 83.3 97.5 VMC-19 520 531 82.1 92.2 VMC-20 180 200 81.6 84 VMC-21 78 85 70 81 VMC-22 78 90 74.1 80 SPM-91 75 85 77 81 SPM-98 80 98 84 88 SPM-115 95 115 83 87 WASHING 94 108 82 85 ASSEMBLY 72 78 78 80 L/TESTING-117 100 111 85 90 CCCL 150 CC VMC-18 44 50 81 84 L/TESTING-118 274 284 78 85 VMC-23 968 974 77 87 VMC-24 128 132 74 90 SPM-90 58 64 82 102 SPM-97 50 58 81 100 CCCR P-91 SPM-37 62 70 80 83 VMC-41 31 46 81 86 VMC-08 42 50 78 85 VMC-37 50 58 77 84 SPM-50 47 50 80 90 SPM-53 80 84 81 92 L/TESTING-56 111 124 82 91 CCCL P-91 SS SPM-37 62 70 85 105 VMC-01 86 90 81 103 VMC-42 90 100 83 102 SPM-79 128 140 80 100 SPM-77 127 140 82 98 SPM-34 118 120 84 99 L/TESTING-75 116 122 86 100 CCCL L/F KSTK SPM-37 62 70 93 103 VMC-12 78 84 92 100 VMC-13 110 120 90 96 SPM-71 110 122 81 87 WASHING 285 310 84 92 CAP ( CCCL/F KSTK & P-91 SS) 510 550 82 91 CCCL KWAG SPM-99 1350 1422 83 88 VMC-35 630 650 82 86 VMC-33 235 245 84 87 SPM 13 140 160 85 88 CCCL KVHH SPM-110/ 99 1350 1422 85 107 VCM-35 630 650 83 87 VMC-33 235 245 81 88 WASHING 175 193 78 82 CAP FIITING CCCL KWAG/CCCL 150 CC 490 510 83 85 C.C.H. K06A VMC-38 210 225 82 86 SPM-116 210 250 84 87 CCCR KZAA SPM-110 1350 1422 81 89 VMC-48 380 460 82 86 VMC-49 290 340 80 85 SPM-123 270 275 83 88 SPM-96 512 550 80 87 WASHING 1192 1227 81 85 ASSEMBLY 875 890 78 83 L/TESTING-128 410 422 78 86 CCCL KZAA SPM-110 420 460 84 104 VMC-29 430 470 82 87 SPM-124 512 252 86 93 SPM-92 425 450 81 87 L/TESTING-136 460 478 77 82 C.C.H. KZAA VMC-40 490 520 70 84 L/TESTING-128 380 400 76 80 C.H. LEFT SIDE SPM-125 460 478 77 83 PNR P-90/70 SPM-10 375 388 81 84 TC-07 434 450 80 85 SPM-78 312 325 81 85 PNR P-17 SPM-41 288 312 82 88 TC-09 125 132 84 90 SPM-65 350 360 81 90 SPM-64 388 400 85 98 PNF P-90/KTRM/AAD SPM-12 430 440 84 90 SPM-54 430 450 85 89 SPM-55 388 400 84 92 TC-08 145 160 82 90 TC-19 325 345 82 91 SPM-52 338 350 86 90 SPM-53 480 510 98 103 FFD P-70/KZAA TC-03 410 430 85 91 TC-18 440 470 80 87 SPM-59 570 590 81 85 SPM-60 480 516 83 90 SPM-127 (KZAA) 390 410 84 91 FFD P-90/ KWAG/KSTG TC-01 510 530 80 85 TC-14 480 525 84 90 SPM-25 490 535 90 96 FFD KSTG TC-02 478 514 83 87 SPM-24 450 500 78 84 SPM-63 570 560 82 88 COVER HEAD SPM-105 437 480 80 85 SPM-15 545 590 80 84 PN-03 477 500 80 84 SPM-104 550 590 81 83 COVER OIL PUMP TC-04 477 510 81 89 VMC-02 440 500 81 85 L/TESTING-138 557 573 81 87 HFW KSTG SPM-61 447 493 84 89 TC-17 530 570 85 90 TC-26 375 400 82 87 TC-16 240 260 81 86 SPM-66 387 400 82 87 HRW P-90 TC-12 273 310 83 89 TC-25 448 550 80 88 SPM-44 387 480 82 87 HRW P-17/KSTG TC-06 347 400 83 87 TC-04 478 490 80 86 TC-05 380 420 81 86 SPM-45 577 610 82 87 SPM-62 488 503 86 92 GBS KVEA/ K06A/P40 SPM-18 367 390 81 87 TC-13 479 489 82 86 TC-15 587 599 78 83 SPM-21 470 493 80 83 SPM-22 467 481 81 84 PNF KZAA SPM-18 578 598 78 82 TC-20 387 403 82 93 TC-17 368 375 80 85 SPM-57 577 589 80 87 SPM- CCCLF KSTK SS SPM-99 488 501 84 98 VMC-60 477 489 79 89 VMC-59 568 582 67 78 VMC-61 378 380 80 87 VMC-58 367 396 79 85 CAP FITTING 476 493 78 80 Buffing m/c 80 85 98.9 100.8 Buffing Adda 1 200 206 88.2 90 Buffing Adda 2 250 266 89 92 Buffing Adda 3 150 158 87 93 Buffing Adda 4 240 250 88 91 Table no 3.9 Device used for Data Collection 1. LUX METER 2. DECIBLE METER LUX Meter Decibel Meter Fig 3.10 LUX meter & decibel meter Result 1. After the Data collection it is noticed that every Rotary face milling machine produced sound more than 90 db. The Operator which is works on Machine L.H.S and R.H.S to rotary machine also affected by the noise pollution. And Buffing adda also have produced more noise. 2. There are many lines where not proper range of light reached. Many machines at having LUX range Below the normal Range Solution of problem:- 1. By Provided ear safety Plug to operators of rotary face milling and same to its L.H.S and R.H.S machine operators 2. By provided proper lighting in PNR P-17, PNF P-90/KTRM/AAD, C.C.H. K06A and CCCL L/F KSTK Chapter 4 CONCLUSION After successfully completing of project related to productivity quality and safety I observed that both productivity quality and safety are the main pillars of industries. The basic causes of low productivity, bad quality, and accidents are the same