24-09-2014, 02:44 PM
ABSTRACT I would like to express my sincere thanks to my Project Guide, Mr. Uttampal Singh. For his guidance and support throughout my training at MAJESTIC AUTO LIMITED, LUDHIANA. His calm willingness to teach has been a great help to me for successfully completing the project. My learning has been immeasurable and working under him was a great experience. I extend my sincere thanks to all the staff members of Mufler production line, M.A.L for providing a very hospitable and helpful work environment and making my training an exciting and memorable evenjectt. In my training period I was allotted with the following proje ct �TO REDUCE THE CONSUMPTION OF MIG WELDING WIRE IN MUFFLER PRODUCTION LINE� Without their continuous help the project would not have been materialized in the present form.. A special thanks to Mr. M.C Munjal (M.D. Majestic Auto Limited.) for facilitating me with all tools and equipment. I also acknowledge heartfelt gratitude to Shyam Sunder Dogra who helped me in doing this project successfully. Finally, I thank my inst
1. PROJECT REPORT
TO REDUCE THE CONSUMPTION OF MIG WELDING WIRE IN MUFFLER PRODUCTION LINE
Description- At MAL silencers (mufflers) are manufactured for Hero Moto crop and MIG welding is one of the most repeatedly occurring processes in the line. Consumable mild steel wire is used as an electrode in MIG welding process. The aim of my project was to analyze how much amount of mild steel wire is consumed in each welding process per muffler and to find methods
by which wire consumption can be reduced.
Steps-
1. The weight of the wire roll was measured before the starting of welding process in morning
2. The number of silencers welded were counted
3. Weight of wire roll was again measured after the end of the shift
4. Net weight of wire consumed = weight of wire roll before welding- weight of wire roll after Welding
5. To cross check he observations and also to determine the amount of wire wasted in the form of oxidation and grinding, the total weight of all the components used in muffler was measured
6. After that, weight of the completed silencers were measured using average
7. The difference between above mentioned two weights gave the amount of wasted wire
Salient features
1. Department- Muffler section C-48 plant
2. Line- CDN line
3. Model- AAD
4. Time period- 6 NOV.2013 To 27 NOV 2013
Following are the reports of the study showing the consumption of wire as well as amount of
wasted wire in the processes.
MUFFLER SECTION MIG WELDING WIRE STUDY
SUBMISSION DATE
CDN LINE
28/11/2013
PART - 1 ( AAD MODEL ALL PROCESSES)
S. NO.
PROCESS
MODEL
DATE
MASS OF WIRE ROLL BEFORE OBSERVATION
MASS OF WIRE ROLL AFTER OBSERVATION
MASS OF WIRE CONSUMED
NUMBER OF PIECES
WIRE CONSUMED PER PIECE
1
DIFFUSER WELDING
AAD
6/11/2013
10990 g
10470 g
520 g
75
6.93 g
2
INNER SUB ASSEMBLY WELDING
AAD
8/11/2013
6620 g
1970 g
4650 g
645
7.21 g
3
STAY PATCH WELDING
AAD
9/11/2013
17820 g
15630 g
2190 g
437
5.01 g
4
STAND STOPPER WELDING
AAD
12/11/2013
19260 g
18090 g
1170 g
409
2.86 g
5
STAY A , STAY B AND HOOK PROTACTOR WELDING
AAD
14/11/2013
1350 g
740 g ( EMPTY ROLL)
610 g
118
5.16 g
6
EXHAUST PIPE WELDING
AAD
16/11/2013
13330 g
12620 g
710 g
90
7.88 g
7