28-08-2014, 03:52 PM
SIX MONTHS
INDUSTRIAL TRAINING REPORT
AT
FEDERAL-MOGUL GOETZE (INDIA) LIMITED BAHADURGARH, PATIALA
Submitted in partial fulfillment for award of degree of
Bachelor of Technology
In
Mechanical Engineering
From
Punjab Technical University, Kapurthala
Submitted by
AJAYVEER SINGH
100491131008
Department of Mechanical Engineering
Ludhiana Collage of Engineering and Technology
Katani Kalan, Ludhiana.
Jan-June, 2014
ACKNOWLEDGEMENT
I am highly grateful to the Dr. J. S. Sohal, Director, Ludhiana College of Engineering & Technology Katani-kalan, for providing this opportunity to carry out the six month industrial training at FEDERAL-MOGUL GOETZE (INDIA) LIMITED BAHADURGARH, PATIALA.
The constant guidance and encouragement received from Dr. Pawan Kumar, Principal, has been of great help for me in carrying out the six month industrial training work and is acknowledged with reverential thanks.
I would like to express a deep sense of gratitude and thanks profusely to Er.Y.N. Gupta, HOD Mechanical Department, without the wise counsel and able guidance, it would have been impossible for me to complete the report in this manner.
I am also extremely thankful to Er. Arvind Sodhi (Head Training Coordinator, PMS-LVD) for guiding me in proper direction and assigning me productive jobs which made me learn things with more interest
Finally, I am indebted to all whosoever have contributed in this report work.
AJAYVEER SINGH
List of Figure
Figure No.
Title
Page No.
2.1.
Machining Of Blank To Rod
24
2.2.
Various Measuring Instrument.
26
2.3.
Formation Of Fixture Sheet.
27
2.4.
Oil Hole Drilling.
29
2.5
C.G. And Rough Bore
32
2.6.
Cavity Formation On Top
34
2.7.
Ring Formation.
35
2.8.
Valve Set Milling
37
2.9
Finish Outer Diameter
40
2.10.
Phasphating
44
2.10.
Screen Printing
45
3.1.
Dents On Crown Edges
52
3.2.
Dents On Ring Land
52
3.3.
Dents On Skirt
52
3.4.
Dents On Pin Hole
53
3.5.
Dents Or Chips On Fixture Sheet
53
3.6.
Dents On Crown
53
4.1.
Chips Present In Trolley With Piston
61
4.2.
Lining On Pin Hole
63
4.3.
Dent On Pin Hole
63
4.4.
Stamp Missing.
64
List of Tables
Table No.
Title
Page No.
2.1.
Machine Defects
48
2.2.
Material Defects
49
INDEX
Chapter 1 INTRODUCTION TO ORGANIZATION 1
1.1. Company Profile 2
1.1.1. Federal-Mogul Corporation 4
1.1.2. Milestones 5
1.2. Products of Patiala Plant 6
1.3. Main Competitors 6
1.4. Major Customers 7
1.4.1. Passenger Cars and Jeeps 7
1.4.2. Bi Wheelers 7
1.4.3. Compression / Air Conditioning 7
1.4.4. Tractors 8
1.4.5. Commercial Vehicles 8
1.4.6. Stationary Engines 8
1.5. Environment Policy 9
1.6. Introduction to Various Departments 10
1.7. Organisational Objectives 12
1.7.1. Primary Objectives: 12
1.7.2. Secondary Objectives 12
1.7.3. Major Losses 13
1.8. Introduction to the Plant 14
1.8.1. Piston Ring Foundry and Machine Shop 14
1.8.2. Goetze Manufactures Piston Rings For 15
1.8.3. Types of Coating on Pistons 15
1.8.4. Sections of Ring Machine Shop 15
1.8.5. Various Departments 16
Chapter 2 EQUIPMENT AND PROCESSES 17
2.1. Introduction to New Piston Machine Shop (PMS-LVD) 18
2.1.1. Light Vehicle Diesel Department Piston Machine Shop 18
2.1.2. Major Customers of Light Vehicle Diesel 19
2.1.3. Piston & Its Functions 19
2.1.4. Desirable Characteristics of A Piston 19
2.1.5. Materials of the Piston 20
2.2. Process Flow in LVD Shop 22
2.2.1. First Operation: - Rough Outer Turning 23
2.2.2. Second Operation: - Fixture Sheet / Spigot 27
2.2.3. Third Operation: - Oil Drill Hole 29
2.2.4. Fourth Operation: - Rough Bore and Cerclip Groove Diameter 31
2.2.5. Fifth Operation: - Crown Facing and Cavity Formation 33
2.2.6. Sixth Operation: - Groove Finish 35
2.2.7. Seventh Operation: - Valve Set Milling 37
2.2.8. Eight Operations: – Finish Outer Diameter Turning 39
2.2.9. Ninth Operation: - Finish Pin Hole Diameter. 41
2.2.10. Washing 42
2.2.11. Phosphating 43
2.2.12. Molybednum Coating/ Screen Printing 45
2.2.13. Bonding Ok Testing 46
2.2.14. Final Inspection 47
2.3. Various Defect and There Code 48
2.3.1. Machine Defect 48
2.3.2. Material Defect 49
Chapter 3 PROJECT WORK 50
3.1. Overview of Project 51
3.1.1. Project – A 21 51
3.1.2. Various Type Defects on Piston 51
3.1.3. Dents on Pistons 52
3.2. Objective Of Project 54
3.3. Causes 54
3.4. Visual Inspection 55
3.5. Various Remarks Area 55
3.6. Methodology/ Procedure 56
3.7. Process 58
Chapter 4 RESULTS AND DISCUSSION 60
4.1. Analysis of General Finding 61
4.2. Recommendations 65
Chapter 5 Conclusion 67
Bibliography 69
INTRODUCTION TO ORGANIZATION
1.1. COMPANY PROFILE
Federal-Mogul Corporationis a global supplier of automotive components, systems and modules serving the world's original equipment manufacturers and theglobal aftermarket. The companyutilizes its engineering and materials expertise, proprietary technology, manufacturing skill, distribution flexibility and marketing power to deliver products, brands and services ofvalue to its customers. Federal-Mogul is focused on global profitable growth to create valuefor and bring greater satisfaction to its customers, employees and stakeholders.
FEDERAL MOGUL GOETZE INDIA LIMITED, BAHADURGARH was set up in 1954 with the collaboration of M/S GOETZE WERKE, GERMANY, which started its production of Piston Rings for automobile industry in 1957.
Considering the need of complete PISTON assembly ESCORTS LIMITED ventured into manufacturing of Pistons. In 1958 with the collaboration of M/S MAHLE, GERMANY, this delivered the Indian automobile industry its Piston in 1960. ESCORTS entered in collaboration with M/S SUKO, GERMANY, for Piston Pins in 1967 and manufacturing started in 1968.To meet the increasing demand of market, in 1977 a parallel unit for manufacturing Pistons and Pistons Pins was set up in BANGLORE .In October 2006 name changed “Goetze (India) Limited” to “FEDERAL-MOGUL GOETZE (INDIA) LIMITED” because majority stake holding acquisition by Federal-Mogul Corporation. Federal-Mogul Goetze (India) Limitedis the largest manufacturerof pistons and piston rings in India Pistons are varying from 30mm to 300mm diameter. The most modern production facilities at Federal-Mogul Goetze (India) Limited Patiala is certified TS 16949, ISO14001 and OHSAS 18001.
The Escorts Group, with Escorts Limited as its H.P. Nanda & Rajan flagship company is among India's largest (1917-99) Nanda corporations operating in the diverse fields of Agri machinery , telecommunications, information technology , healthcare, bi- wheelers, construction & material handling equipment, automotive & railway ancillaries and financial services.
The Group has 19 modern manufacturing facilities & an extensive marketing network spread across the country .The major global alliances of the Group include: JCB - UK, Yamaha -Japan, Claas, Mahle and Goetze - Germany, Carraro -Italy, Long CA, Vistaar & i2 -USA, First Pacific -Hong Kong, IFS -Sweden and POL-MOT -Poland. The genesis of Escorts goes back to 1944 when two brothers, Mr. H. P. Nanda and Mr. Yudi Nanda launched a small agency house, Escorts Agents Ltd. in Lahore. The next 50 years saw Escorts surge ahead and become one of India's largest conglomerates.
INDUSTRIAL TRAINING REPORT
AT
FEDERAL-MOGUL GOETZE (INDIA) LIMITED BAHADURGARH, PATIALA
Submitted in partial fulfillment for award of degree of
Bachelor of Technology
In
Mechanical Engineering
From
Punjab Technical University, Kapurthala
Submitted by
AJAYVEER SINGH
100491131008
Department of Mechanical Engineering
Ludhiana Collage of Engineering and Technology
Katani Kalan, Ludhiana.
Jan-June, 2014
ACKNOWLEDGEMENT
I am highly grateful to the Dr. J. S. Sohal, Director, Ludhiana College of Engineering & Technology Katani-kalan, for providing this opportunity to carry out the six month industrial training at FEDERAL-MOGUL GOETZE (INDIA) LIMITED BAHADURGARH, PATIALA.
The constant guidance and encouragement received from Dr. Pawan Kumar, Principal, has been of great help for me in carrying out the six month industrial training work and is acknowledged with reverential thanks.
I would like to express a deep sense of gratitude and thanks profusely to Er.Y.N. Gupta, HOD Mechanical Department, without the wise counsel and able guidance, it would have been impossible for me to complete the report in this manner.
I am also extremely thankful to Er. Arvind Sodhi (Head Training Coordinator, PMS-LVD) for guiding me in proper direction and assigning me productive jobs which made me learn things with more interest
Finally, I am indebted to all whosoever have contributed in this report work.
AJAYVEER SINGH
List of Figure
Figure No.
Title
Page No.
2.1.
Machining Of Blank To Rod
24
2.2.
Various Measuring Instrument.
26
2.3.
Formation Of Fixture Sheet.
27
2.4.
Oil Hole Drilling.
29
2.5
C.G. And Rough Bore
32
2.6.
Cavity Formation On Top
34
2.7.
Ring Formation.
35
2.8.
Valve Set Milling
37
2.9
Finish Outer Diameter
40
2.10.
Phasphating
44
2.10.
Screen Printing
45
3.1.
Dents On Crown Edges
52
3.2.
Dents On Ring Land
52
3.3.
Dents On Skirt
52
3.4.
Dents On Pin Hole
53
3.5.
Dents Or Chips On Fixture Sheet
53
3.6.
Dents On Crown
53
4.1.
Chips Present In Trolley With Piston
61
4.2.
Lining On Pin Hole
63
4.3.
Dent On Pin Hole
63
4.4.
Stamp Missing.
64
List of Tables
Table No.
Title
Page No.
2.1.
Machine Defects
48
2.2.
Material Defects
49
INDEX
Chapter 1 INTRODUCTION TO ORGANIZATION 1
1.1. Company Profile 2
1.1.1. Federal-Mogul Corporation 4
1.1.2. Milestones 5
1.2. Products of Patiala Plant 6
1.3. Main Competitors 6
1.4. Major Customers 7
1.4.1. Passenger Cars and Jeeps 7
1.4.2. Bi Wheelers 7
1.4.3. Compression / Air Conditioning 7
1.4.4. Tractors 8
1.4.5. Commercial Vehicles 8
1.4.6. Stationary Engines 8
1.5. Environment Policy 9
1.6. Introduction to Various Departments 10
1.7. Organisational Objectives 12
1.7.1. Primary Objectives: 12
1.7.2. Secondary Objectives 12
1.7.3. Major Losses 13
1.8. Introduction to the Plant 14
1.8.1. Piston Ring Foundry and Machine Shop 14
1.8.2. Goetze Manufactures Piston Rings For 15
1.8.3. Types of Coating on Pistons 15
1.8.4. Sections of Ring Machine Shop 15
1.8.5. Various Departments 16
Chapter 2 EQUIPMENT AND PROCESSES 17
2.1. Introduction to New Piston Machine Shop (PMS-LVD) 18
2.1.1. Light Vehicle Diesel Department Piston Machine Shop 18
2.1.2. Major Customers of Light Vehicle Diesel 19
2.1.3. Piston & Its Functions 19
2.1.4. Desirable Characteristics of A Piston 19
2.1.5. Materials of the Piston 20
2.2. Process Flow in LVD Shop 22
2.2.1. First Operation: - Rough Outer Turning 23
2.2.2. Second Operation: - Fixture Sheet / Spigot 27
2.2.3. Third Operation: - Oil Drill Hole 29
2.2.4. Fourth Operation: - Rough Bore and Cerclip Groove Diameter 31
2.2.5. Fifth Operation: - Crown Facing and Cavity Formation 33
2.2.6. Sixth Operation: - Groove Finish 35
2.2.7. Seventh Operation: - Valve Set Milling 37
2.2.8. Eight Operations: – Finish Outer Diameter Turning 39
2.2.9. Ninth Operation: - Finish Pin Hole Diameter. 41
2.2.10. Washing 42
2.2.11. Phosphating 43
2.2.12. Molybednum Coating/ Screen Printing 45
2.2.13. Bonding Ok Testing 46
2.2.14. Final Inspection 47
2.3. Various Defect and There Code 48
2.3.1. Machine Defect 48
2.3.2. Material Defect 49
Chapter 3 PROJECT WORK 50
3.1. Overview of Project 51
3.1.1. Project – A 21 51
3.1.2. Various Type Defects on Piston 51
3.1.3. Dents on Pistons 52
3.2. Objective Of Project 54
3.3. Causes 54
3.4. Visual Inspection 55
3.5. Various Remarks Area 55
3.6. Methodology/ Procedure 56
3.7. Process 58
Chapter 4 RESULTS AND DISCUSSION 60
4.1. Analysis of General Finding 61
4.2. Recommendations 65
Chapter 5 Conclusion 67
Bibliography 69
INTRODUCTION TO ORGANIZATION
1.1. COMPANY PROFILE
Federal-Mogul Corporationis a global supplier of automotive components, systems and modules serving the world's original equipment manufacturers and theglobal aftermarket. The companyutilizes its engineering and materials expertise, proprietary technology, manufacturing skill, distribution flexibility and marketing power to deliver products, brands and services ofvalue to its customers. Federal-Mogul is focused on global profitable growth to create valuefor and bring greater satisfaction to its customers, employees and stakeholders.
FEDERAL MOGUL GOETZE INDIA LIMITED, BAHADURGARH was set up in 1954 with the collaboration of M/S GOETZE WERKE, GERMANY, which started its production of Piston Rings for automobile industry in 1957.
Considering the need of complete PISTON assembly ESCORTS LIMITED ventured into manufacturing of Pistons. In 1958 with the collaboration of M/S MAHLE, GERMANY, this delivered the Indian automobile industry its Piston in 1960. ESCORTS entered in collaboration with M/S SUKO, GERMANY, for Piston Pins in 1967 and manufacturing started in 1968.To meet the increasing demand of market, in 1977 a parallel unit for manufacturing Pistons and Pistons Pins was set up in BANGLORE .In October 2006 name changed “Goetze (India) Limited” to “FEDERAL-MOGUL GOETZE (INDIA) LIMITED” because majority stake holding acquisition by Federal-Mogul Corporation. Federal-Mogul Goetze (India) Limitedis the largest manufacturerof pistons and piston rings in India Pistons are varying from 30mm to 300mm diameter. The most modern production facilities at Federal-Mogul Goetze (India) Limited Patiala is certified TS 16949, ISO14001 and OHSAS 18001.
The Escorts Group, with Escorts Limited as its H.P. Nanda & Rajan flagship company is among India's largest (1917-99) Nanda corporations operating in the diverse fields of Agri machinery , telecommunications, information technology , healthcare, bi- wheelers, construction & material handling equipment, automotive & railway ancillaries and financial services.
The Group has 19 modern manufacturing facilities & an extensive marketing network spread across the country .The major global alliances of the Group include: JCB - UK, Yamaha -Japan, Claas, Mahle and Goetze - Germany, Carraro -Italy, Long CA, Vistaar & i2 -USA, First Pacific -Hong Kong, IFS -Sweden and POL-MOT -Poland. The genesis of Escorts goes back to 1944 when two brothers, Mr. H. P. Nanda and Mr. Yudi Nanda launched a small agency house, Escorts Agents Ltd. in Lahore. The next 50 years saw Escorts surge ahead and become one of India's largest conglomerates.