Internship at RNAIPL


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Basically it is a point point presentation of the work which I have done / observed during my internship at RNAIPL.

When I started making this PPT, I was in great confusion about how a internship PPT looks like. I think it would help many of you. Please let me know if there is any mistake in this PPT , so that I could make a note of it and would not repeat that mistake further.

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  •  chemical oxygen demand (COD) test is commonly used to indirectly measure the amount of organic compounds in water. Most applications of COD determine the amount of organic pollutants found in surface water (e.g. lakes and rivers) or wastewater, making COD a useful measure of water quality. It is expressed in milligrams per liter (mg/L) also referred to as ppm (parts per million), which indicates the mass of oxygen consumed per liter of solution.The basis for the COD test is that nearly all organic compounds can be fully oxidized to carbon dioxide with a strong oxidizing agentunder acidic conditions.B.O.D is the amount of dissolved oxygen needed by aerobic biological organisms in a body of water to break down organic material present in a given water sample at certain temperature over a specific time perioBOD is similar in function to chemical oxygen demand (COD), in that both measure the amount of organic compounds in water. However, COD is less specific, since it measures everything that can be chemically oxidized, rather than just levels of biologically active organic matter.
  • Here the reason was that foreign car generally moves with high speed thus there is a possibility that the paint may undergo oxidation and corrosion may occur on car body.
  • Internship at RNAIPL

    1. 1. INDUSTRIAL INTERNSHIP REVIEW (MEE 399) ON AUTOMOBILE MANUFACTURING Internship at Renault Nissan Automotive India Private Limited (RNAIPL) By : MAHENDRA SINGH SISODIA (11BME1051) MARCH 2014
    2. 2. Objectives of internship • To work cooperatively in the company for 28 days internship as required by the VIT University Chennai Campus. • To get acquaintance with the functional and operational activities of the company • To study about how various manufacturing concepts, tools and techniques that we studied are theoretically and practically applied in an industry.
    3. 3. About Renault-Nissan • The first dedicated Alliance between Nissans and Renaults. Renault–Nissan Alliance is a strategic Franco-Japanese partnership between automobile manufacturers Renault, based in Paris, France, and Nissan, based in Yokohama, Japan, which together sell more than one in 10 cars worldwide since 1999. It is a modern and highly efficient plant producing top quality cars. But there’s more which also produces zero emission cars. It’s now officially one of India’s safest and most environmentally-friendly factories, too. That’s according to the Confederation of Indian Industry (CII), which has given the plant its top award for excellence in Environmental Health and Safety. • In February 2008, the Renault-Nissan Alliance signed a MOU with Government of Tamil Nadu to set up a manufacturing plant at Oragadam, near Chennai with a minimum investment of Rs. 4500 Crore over a period of seven years. On March 17, 2010, the Renault-Nissan alliance plant was inaugurated in a record time of 21 months since its groundbreaking ceremony in June 2008. The Plant has an initial capacity of 2, 00,000 units per year and planned to reach 4, 00,000 units per year in full capacity.
    4. 4. Working Ideology RNAIPL gives very much importance to the following in production • Safety • Quality • Cost
    5. 5. Vehicles Manufactured at RNAIPL • Renault • Renault Fluence Renault Koleos • Renault Pulse • Renault Duster Renault Scala • Nissan • Nissan X-Trail Nissan Teana • Nissan 370Z • Nissan Micra Nissan Sunny
    6. 6. Renault Duster Nissan Micra Nissan Sunny
    12. 12. WTP (Water Treatment Plant) • It treats the raw and rain water. Rainwater are collected through surface ponds. • The First main step of WTP is pre-treatment of water before entering RO (Reverse Osmosis )system. • In WTP Actiflo method is adopted to remove the suspended solids.Actiflo method is a physico chemical treatment plant. This method has advantage of efficient removal of heavy metal from water. • Then the water is send to Press Sand Filter( PSF) and then to Activated Carbon Filter (ACF). • Then the water is send to MGF (Multi Grade Filter) , then to anti scalant dechlorination. The water is then is then send to micron cartride filter (5 micron). • And after first RO, it is feed to the 2nd R0 where every particle are removes and water for UV filtration is sent in UV Filtration is used to avoid micro organism growth. Its capacity is 10 micro /secs made free from everything and feed to pain shop for painting.
    13. 13. WWTP (Waste Water Treatment Plant) • The WWTP gets water from paint shop, water used for hand wash and remaining water from central kitchen is collected at GA &GB tank. • Then waste water in the tank is uniformly mixed by supplying air. The waste water then moves to the DAF (Dissolved Air flotation) for oil separation. Then lime and alum is added as PH booster. • Then the polyelectrolyte is added for coagulation. It is kept for 5 hours as the retention time. This water is feed to clarriflocculator (combination of flocculator and the clarifier), this is done to remove heavy metals like zinc, phosphates. Sludge water is moved to the sludge deposit bed where where sludge is removed , then filteration takes place and water is again fed to the collection tank. Then the ferric chloride is added for PH neutralization. • It is feed to biological tank / aeration tank, here microbial activity takes place. This is done to reduce COD(Chemical Oxygen Demand), BOD (Bio chemical Oxygen demand).COD is reduced to less than 250 and BOD is reduced to less than 20
    14. 14. • The water is then send to MDR (membrane separation) where suspended particle is removed. To reduce smell we use carbon filter. Then the water is send to MGF (Multi Grade Filter) , then to anti scalant dechlorination. The water is then is then send to micron cartride filter . • At last water is send to RO plant.The WWTP treated water is used in cooling tower and car washing before painting and for toilet flushes. The sluges are collected to bags and given to govt for disposal. Clarriflocculator
    15. 15. BMS (Building Management System) A Building Management System (BMS) is a computer-based control system installed in buildings that controls and monitors the building’s mechanical and electrical equipments. It consists of hardware's and software's. All the information about utilities (driers, compressors etc.) like operating status, present conditions (pressure, temperature, and flow rate) is transmitted through sensors to BMS. In BMS five displays are using that display the operating status of the all utilities. One main display is used for main control. For safety automatic alarm system is there. If any problem occurs in any utility system then alarm rings and displays show the place where problem occurs. It also display’s about the problem. It is very fast and time saving system because through these system we can easily know the location of problem, so it’s easy for any specific person to go there and solve the problem so it helps in avoiding the checking of all utilities.
    16. 16. BMS LPG yard details
    19. 19. COIL STAMPING SHOP BODY SHOP TRIM AND CHASIS SHOP CAR Manufacturing process of a car goes under these process. This process is also known as VEHICLE CHAIN
    20. 20. Stamping Shop In stamping shop body parts of the car are manufactured using steel sheet alloy. Following sequence is followed in the stamping shop. 1. Blanking 2. Pressing and Piercing 3. Quality checking
    21. 21. Layout of blanking line
    22. 22. Blanking Process 1. Coil-Car: Coils of steel sheet is pick up by crane and transferred to coil-car that transfer the coil to uncoiler. 2. Uncoiler and advance correction machine: It sets the inner diameter of coil to the center of the line by holding device that remove rolling habit of the tip of the coil. 3. Washing: The device that removes the foreign material that has adhered to the coil which is done by oil with the help of roller. 4. Leveler: used for levelling the blank by correcting the shape of the steel sheet and makes it smooth. It works on the principle of less than 1 mm tollerence . 5. Looping: In this process steel plate is stretched into the pit and all the bends are removed. 6. Feeder: Device that adjusts the coil material to press cycle and set the cutting length and sends it to piler. 7. Press: It press the steel sheet and cut the steel into required dimension. Press can be rotated at required angle to cut the steel plate at any angle. 8. Piler: The device that piles the cut material with accuracy. From here cut material are transferred to pressing line. There are Two Piler zone here.
    23. 23. Pressing and piercing Line Here are three pressing lines. Pressing Lines Line-3 (5400 ton) L-Line (2400 ton) XL-Line (5400 ton) For pressing of larger parts For pressing of larger parts For pressing of small parts
    24. 24. Pressing and piercing Line Cont. Each line have 4 presses. PB: By this press,shape is given to steel plate by using specific die according to drawing. PC: By this press side or extra material is removed. PD: By this press Piercing is done. PE: By this press specific holes is made. XL LINE AND LINE-3 PB PC PD PE 2400 ton 1000 ton 1000 ton 1000 ton L-LINE PB1200 ton PC400 ton PD400 ton PE400 ton
    25. 25. Layout of stamping line
    26. 26. BODY SHOP • Place where the main manufacturing of car body takes place. The car body design manufacturing is done by skilled engineer who have their work divided. • The parts which have been designed in the stamping shops come here for assembling. engine compartments and mounting points, chassis, hood, front cabin, rare cabin etc are made in the stamping shop while others are supplied by vendors like JBM, Unipress, Technico. Unipress is the major supplier. • Most of the parts are welded using spot welding while MAG welding is done for filling. • Most of the welding is done manually but welding of few parts are done using Robots.
    27. 27. • Body shop consist of two main line, six sub lines and 290 sub stations. • The main base of the car is not manufactured or designed , rather the sill plate is supplied by the supplier in three pieces which are welded to the part they have designed. • In the first sub line the engine compartment, the front cabin and the rear cabin are assembled using spot welding which is manually done. • In the second sub line nearby parts of engine, doors, hoods are assembled using welding and nuts. • In main assembly line side doors, back doors, hood is assembled using automatic nut runner machine. Finally quality checking is done of car body. • Each car is given with the serial number which corresponds to the paint colour. • The body is sent to the metal line, where the aesthetics, finish doors, any bumps or the dent or spots are check, If found the body is sent to the sideways where it is sent or tested for the faults. Finally the car from the body shop is sent to paint shop.
    28. 28. Paint shop • The car body after the body shop is move to this shop for painting. Car body is moved on hanger. • In paint shop there are two lines i.e. Line: 1 and Line: 2. both lines does the same work.
    29. 29. Pre treatment line 1. Pre-Degreaser-Washing using chemicals and safely removal of oils, greases, fats and carbon deposited on the car body. 2. Degreaser-2 .- Final washing with chemicals of car’s body. 3. Pre-Raw water Rinse. -Here, car body is washed using raw water of specific ph. 4. Raw water Rinse - Again washed with raw water of specific ph. 5. Conditioner- It is used to make the car body surface rough. Because at rough surfaces coating more adheres. 6. Phosphate treatment zone- car body is coated with phosphate for providing metal cleanliness and corrosion protection to the surface of the car body. 7. Pre-DI (Deionized) water Rinse zone- DI water bath is given to car body. For DI Water rinse Fresh de-ionized water is used that is cleaner than drinking water. If any contamination remains on the surface before the ED coating, it will cause the application issue and raise the potential for product failure. 8. DI water Rinse (D/P). -Final DI water bath is given to car body.
    30. 30. Electro Deposit Line (ED-Line) It has 3 stages. 1. ED-Bath-At this stage car body is covered with ED Paint. ED (Electro-deposition) paint (cationic) is used as a primer for car bodies. It imparts rust resistance and chipping resistance to the car body. 2. UF-(Ultra Filtrate)-1-The paint bath can be contaminated with pre-treatment chemicals like e.g. phosphates, chlorides, and chromates. So, a part of ultra-filtrate has to be leaded out to avoid contamination of the paint bath with these chemicals. This process also removes excess paint. 3. Fresh water and Tilting stage-After UF stage car body is washed with fresh water. After washing the car body is tilted to remove all the water and waste paint from the car body. Then car is tilted back to its initial position. Here ED Line ends. Cont.
    31. 31. ED-OVEN Sealant is applied at every exterior edge of the car. Sealant is used to resist the leakage through the car body. Then car body passes through the Sealer Oven for drying the sealant. Temperature of the varies 150 to 200 degrees. Sealer-Zone Then car body passes through the ED Sanding Zone. Here, extra paint is removed to make ED paint layer uniform. This process is completely manual. First workers check the ED paint layer and then remove extra paint using Sanding paper. ED sanding zone Car body passes through the ED Oven for drying the ED paint. First, air is heated and passed through oven chamber then car body passes through the chamber. Thus ED paint is dried by hot air. The temperature at the oven varies from 170 C to 200 C. Again after the oven the thickness of the paint is checked manually.
    32. 32. Body arranging zone It has 3 lines. • Side line • Main Line • Repair Line
    33. 33. Body arranging zone contd. Cont. When car body enters at storage are then barcode of car body is scanned, a paper having code is given at the ED sanding shop , the scanned data is sent to the CCR (central control room) panel. Then the end of ED sanding involves 3 lines. In First and second line the body are arranged according to FIFO(First In First Out) technique, in which the car body of same color are arranged first for time management. If any car body of different color comes in that line then it will be shifted to side line till it groups with another bodies of same color. It is fully automated process according to the color car bodies are arranged automatically in their respective line. If after the ED Sanding stage body paint is not uniform or if some other faults are found in ED paint then car body is transferred to repair line. From here body is sent to repair zone for repairing.
    34. 34. Dust Off zone Dust from the body is removed before painting. So that dust doesn’t contaminate the paint. Feathers of Emu bird are used for dust removal. The reason behind using EMU bird feathers is that the feathers has long life. • ACC (Anti corrosion Coating) (only for foreign country vehicle) • Primer coat (Sprayed by robots) (35 micron thickness) • Primer Paint (Manually for more accuracy) • Primer flash off zone (Drying of primer paint) • Base Zone (For main paint, first sprayed by robots ,then manually) (70 micron thickness) • Base flash off zone (Drying of base paint) • Clear Zone (For clearing car surface for shining, First by robots then manually for more shining purpose.) TOPCOAT Zone In this zone car is painted through following zone. Car body is transferred to Trim & Chassis shop
    35. 35. The main purpose of this shop is to mold the parts. The parts include the bumper, mirror cover and finisher. The waste plastic material is again used in order to avoid wastage. The waste material which is used for the first time is called virgin material and the waste material which is used for more than one time is called reused material. The process starts from the plastic i.e. polypropene (PPE) which is supplied by the supplier is stored. The pure polypropene and the grinded body part that has produced by grinding the defected parts is sent to the drying chamber where the moisture is removed. The PPE are then passed to the blending machine which uses vaccum to transfer the PPE. The two purpose of blending machine are that it act as a carrier between the dryer and extrusion machine just like an intermediate and it also mixes the pure and impure The PPE are then moved to the intrusion machine. There are three intrusion machine in the plastic shop two are mechanically operated while one is electrically operated. In the extrusion machine the necessary operation take place like plasticizing the PPE and mold into the shape take place. The temperature for plasticizing is 200 C. Plastic shop
    36. 36. The heating takes time till the temperature reaches the melting point of PPE ,thus it will be time consuming hence production will be effected. So the heating is done before the die is loaded to the extrusion chamber. Cooling is done using water as coolant. The coolant control system is placed near the extrusion machine for quick accesses. • Electrical molding machine is preferable because it requires less maintenance and works with good accuracy. In both types of machines hydraulic forces are applied. • The time for extruding the one part is 28 seconds approximately. The time require for changing the mold is 8 minute 20 seconds approximately which is a programmed technique for changing the die. . For changing the mold for different units QMC (Quick Mold Change) System is used. It is completely automated and controlled by PLC. The parts has been produced are collected by the robot which places them on to the conveyor. At the end of manually the defects are checked and then the parts are then send to the plastic paint shop.
    37. 37. Bumper Paint Shop In this mainly the plastic body like bumper, finisher and mirror cover are painted as well as finishing ,mostly in the same way as main body. Here, punching and drilling operation are done for generating holes in bumpers In this zone bumper is painted through following zone. • Heating Zone (Low speed conveyor) (bumper is heated. For heating fire is applied by the two robots. Fire flame length is 250 mm) • Dust off zone (air is applied to bumper surface for clean the dust.) • Primer coat (Sprayed by robots) • Primer Paint (Manually for more accuracy) • Primer flash off zone (Drying of primer paint) • Base Zone (For main paint, first sprayed by robots ,then manually) • Base flash off zone (Drying of base paint) • Clear Zone (For clearing car surface for shining, First by robots then manually for more shining purpose.) • Backing Zone 1 & 2- (High Speed Conveyor) Both backing zones are maintained at 120 degree Celsius temperature. By passing hot air in banking chamber paint is dried. Then bumper is shifted from high speed conveyor to low speed conveyor
    38. 38. Bumper Paint Shop Cont.• Quality checking-Here, quality inspection is done. If any fault found in bumper then it is sent for repair. If no fault is found then bumper is unloaded from low speed conveyor and sent to vehicle chain. After final painting process piercing robot is used to generate holes in bumper Robots generate small holes in bumper by drilling operation. Holes are used for placing small sensors in bumper. Rare punching machine: It is used to generate big holes in bumper. These holes are used for placing little big sensors, lights and other components. Front punching machine: It is used for generate big holes in rare bumper and Front punching machine is used for generate big holes in front bumper
    39. 39. Trim and Chassis shop • Here all the components of car are assembled. In this department the body from the paint shop is brought into the trim and chassis department. • Initially the body is under the PBS( paint body storage). The body from the paint body is stored. The body is brought under the conveyor which is under the CCR (central control room). • SCM (Supply chain Management) area contains all the parts which are supplied by CCR (Central Control Room). • The green signals are passed whether the parts are been supplied for the body are for Micra, Duster or any other and thus help is avoiding mishandling.
    40. 40. There are two main lines Line-1 and Line-2. Both lines are same. • At each line total 31 stations are there. • At each station 3-4 parts are assembled in car body. • There are six sub lines in each main line:  Primary line  Trim Line  Chassis Trim line  Engine assembly  Pre final  Tester Line Cont.
    41. 41. Cont.  Primary line- Car body comes from paint shop. Doors are separated.  Trim Line- Interior components are assembled manually. Ex. Seat belt, floor cover ,Front and rear glass ,CMM (Speedometer, Tachometer etc.). CCR controls the assembly.  Chassis and Engine Assembly line – Exterior parts are assembled. Ex. engine, suspension system, exhaust system, fuel tank, exhaust heat observer, brake system Chassis and Trim line- All assembled components are checked. front and rear wheels.  Pre-final line- pre final line brake oil, fuel and coolant are filled using combo filling machine. (The brake oil depend on the countries climatic conditions and thus chosen accordingly.)  Final Line- Doors are assembled.  Tester Line- wheel alignment, Speed, braking system, Leakage are tested. Test Drive and Sale
    42. 42. Internal component assembly
    43. 43. Engine fitting in car at Trim and Chassis shop
    44. 44. Tester Line
    45. 45. Power Train Line Three Lines are here • JXX gear box assembly line • Engine Line:1 • Engine Line:2
    46. 46. Cont. Gear box assembly Line Process 1. Gear box Scanning 2. Assembly of gears. 3. Gear shifter (for 1st and 2nd gear) attached to secondary shaft 4. Primary shaft, secondary shaft with gear shifter and differential are assembled in clutch housing 5. Gear shifters for 3rd, 4th and reverse gear are assembled with both shafts. 6. Differential housing is assembled with clutch housing 7. By using mechanical housing tire side of the gear box is closed 8. In gear box a magnet is placed
    47. 47. Cont. Gear box assembly Line Process 9. Primary shaft thickness measurement 10. Sealant Deposition 11. Then mechanical and clutch gear boxes are fixed and closed using nut 12. Gear Box leakage testing by pressurized air. 13. Final Testing of gear box by assemble it with engine. 14. First gear box is scanned. 15. All tests are control by a PC. 16. maximum speed at different gears, Noise level (Manually) Speed at different torques, power required at different slops at different speed are tested. It is a one time process. 17. unloaded at gearbox area. 18. Testing of machine by blue and red gear box. 19. All blocks for gear box are imported from Renault France
    48. 48. Cont. Engine Shop Line • At line-1 K9K (Diesel) engine is manufactured. • At line-2 XH (petrol) engine is manufactured Gear Box leakage testing by pressurized air.
    49. 49. Cont. Process 1. Cylinder block scanning. 2. Oil jet is fixed in cylinder by Oil jet press (2 Hydraulic and 4 Pneumatic) 3. Marking of engine code on cylinder block. 4. Oil level indicator assembly. 5. metal pieces are assembled in cylinder block support the crank shaft. These metal pieces work as a bearing. 6. Then D dimension machine measure the height between bottom dead center and top dead center for selecting the proper piston. 7. then crankshaft, piston, connecting rod are assembled in cylinder block 8. oil filter, oil pump and oil pan is fixed 9. In H dimension machine piston is inspected that the piston is perfect or not for the corresponding bore.
    50. 50. Cont. Process 10. cylinder head is fixed on the cylinder block using nut bolt. 11. Then Cam shaft is fixed. Then fuel injector and high pressure fuel pump is fixed. 12. Timing Pulley and Timing belt is fixed. 13. Timing belt and gear transfer the power or motion from crank shaft to other engine accessories like cam shaft, high pressure fuel pump. Fuel pump, cam shaft and other accessories are synchronized with crank shaft. 14. Flywheel, vacuum pump ,Fuel pipe line, EGI harness cable, Intake manifold, exhaust manifold , Then EGR (exhaust gas recycle) unit stabilizer, exhaust air intake ,exhaust air filter, Clutch kit (clutch plate and disk), friction plate are assembled. 15. Engine Testing 16. Then quality of engine is checked and visual inspection of engine is done. If any fault is found then engine is sent for repair. Then finally engine is sent to the SCM (supply chain management).
    51. 51. Casting Shop In casting shop cylinder head and cylinder blocks are manufactured by casting process. In this shop two casting machines are here. 1 HPDC (High Pressure Die casting): Cylinder blocks are manufactured by High Pressure Die Casting because they are heavy in weight. 2 LPDC (Low Pressure Die Casting): Cylinder heads are manufactured by Low Pressure Die Casting Process. HDPC process is same as LDPC. Only difference is that pressure and die moving velocity is higher in HDPC i.e. 60-70 Mpa and 308 m/s.
    52. 52. • The furnace capacity was 1.5 ton means 1.5 tones is melted per hour. The material of ingot which is fed is (ACD 12 Al alloy Rectangular rods). • The ingot is melted in moving furnace which is LPG operated (1 bar) then it is moved to holding furnace (maintains temp 70 C) while air is fed using blower. • Then the molten metal is moved to degassing unit where poisonous gases are removed by forcing nitrogen through carbide rod. Then the molten metal is moved to LPDC machine which moves it to electric heaters for re melting and while LPG heaters maintains temperature. • Then the core will be placed in the die and the molten metal will be poured into the die. Near each die casting machine there is shell core machine which prepare the sand core thus eliminating the need of die to be destroyed if the new model comes. • The castings are then air cooled at temperature 100 to 150 degree Celsius. The other coolant like water is not used because others will drastically reduce the temperature which will be harmful for the castings while air reduces the temperature gradually. • Then the casting goes to the knockout machines where 90 – 95% of the sand will be removed which removed and by vibration. After that it goes for finishing operation where runner and riser are removed. • Then it goes for heat treatment process at 495 C which also helps in removing remaining sand. Then it is quenched using water at 60 C. After that it again goes for hardening process at 200 C and after that it is air cooled. After that Quality checking for cracks, Visual inspection ,Air leakage checking LPDC (Low Pressure Die Casting)
    53. 53. Overall this internship was very useful in providing enormous experience about how a engineering is applied in industries. I have gained new knowledge, skills and met many new people. I got insight into professional practice. I learned the different facets of working. I have experienced how every second is important for a manufacturing company and they work in minimizing it. I have learnt that work management, is an important factor for the progress of projects. Regarding the engineering related subject I have learnt about the stamping shop, body shop , casting shop and welding. This company gives very much importance to safety of workers and quality of product. Every worker in the company was aware of what their life means. Energy conservation is very important aspect of this company. From energy audit to waste water treatment plant , it shows the importance of reducing the consumption of it. At last this internship has given me new insights and motivation to pursue a career in automotive field. Conclusion