Machine shop where the manufacturing of various parts of the tractor such as Front axle hub, Hydraulic lift Housing, Transmission Casing for the various companies such as Mahindra and Mahindra, Escort, Tafe are discussed.

1. KLE DR. M. S. SHESHGIRI COLLEGE OF
ENGINEERING AND TECHNOLOGY, BELAGAVI
590008
A INTERNSHIP REPORT PRESENTATION ON,
ASHOK IRON WORK JAI HIND PLANT
Submitted by,
ABHISHEK TURAMANDI USN: 2KL17MDE01
Under The Guidance of
Dr: D. C. Patil
Department of Mechanical Engineering
2018-19
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2.  CONTENTS
 Introduction to the industry
 Company Profile
 Detail profile of each department
 Products
 Layout study
 Receiving inspection plan
 Hard Automation
 Process Planning
 Flexible Fixturing
 Coordinate Measuring Machine
 Leak Testing Method
 Conclusion
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3.  INTRODUCTION TO THE INDUSTRY
 Ashok iron work private limited company established in 1974 foundry to make
iron castings.
 Shri. Ashok. S. Humbarwadi and Shri. Vasudev. P. Hanji were he partners.
 It has three foundries and six machines shops.
 Fully integrated setup from a 3D casting model as a input to design and
manufacturing of tools.
 Largest producer and market leader of heavy duty engine blocks and heads.
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4.  COMPANY PROFILE
NAME Ashok iron work Pvt. Ltd.
REGISTERED
ADDRESS
Ashok Iron Work Pvt. Ltd. 689/1, Udyambhag, Belgaum,
Karnataka.
CORPORATE OFFICE Mazagoan Road, Udyambhag, Belgaum-590008, Karnataka.
E-MAIL enquiry@ashokairon.com
WEBSITE www.ashokairon.com
TYPE OF OWNER SHIP Partnership (Beginning) Private Co. Ltd. (Presently)
TYPE OF INDUSTRY Foundry,Casting,Machinery and Assembly work.
[Manufacturing]
YEAR OF
ESTABLISHMENT
1974
WORKING HOURS 1ST Shift 8.00AM to 4.30PM
2ND Shift 4.30PM to 1.00AM
3RD Shift 1.00AM to 8.00AM
GENERAL SHIFT 8.00AM to 4.30PM 4

5.  VISSION
Committed to serve the interests of all our stockholder by being top with
exceptional moral and business ethics.
 MISSION
To be develop expertise in technology of maintaining various components to
support the foundry business.
 QUALITY POLICY
To aim at customer’s delight by exceeding his expenditure through an
exceptional blend of quality cost, delivery of products and services that they provide.
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6.  SWOT ANALYSIS
 STRENGTH
• AIW Company is strongly export oriented.
• Top class fine castings.
• On time salary.
• Availability of basic raw material around the nation.
• Cheap and excess labour force.
• Experienced staff, latest technology, three shifts in all foundries.
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7.  WEAKNESS
• High cost of production.
• Decentralisation of raw material.
• Welfare activities not up to mark.
 OPPORTUNITY
• High demand both at domestic and global level.
• Permanent and new customers.
• Global market place and good technological advancement.
 THREATS
• Stiff competition from china and others.
• Environmental policy and restrictions.
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8.  DETAIL PROFILE OF EACH DEPARTMENT
 Functions of human resource department
• Recruitment and selection.
• Industry training.
• Wage and salary administration.
• Sanctioning of bonus.
 Functions of administration department
• Keeping land records in terms of area.
• Asset record like building and machinery.
• Internal and external mail correspondence.
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9.  Functions of production department
• Receiving plan from the marketing department, for the month. Based on plan
workout material requirements, manpower requirements, cutting tools, packaging
material etc.
• Rectifying the rejection work.
• Monitoring the 7 numerical control machines.
 Function of stores department
• Receiving of materials ordered.
• Proper stacking of materials.
• Issuing of purchase indent to material department.
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10.  Functions of purchase department
• Receives purchase indent from stores in charge.
• Selection of appropriate vendors and scrutinizing.
• Negotiation and finalisation of commercial terms like price, payment, discount,
credit etc.
• Preparing and forwarding purchase order.
 Functions of account department
• Recording day to day transactions.
• Coordinating to bank transactions like cheque deposits and withdrawals.
• Preparation of cash budget.
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11.  Functions of Marketing Department
• Sales planning and dispatch.
• Packaging and forwarding.
• Customer complaint analysis.
 Functions of quality department
• Inward inspection
• Final inspection
• Rejection meeting
• Communication with foundries.
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12.  PRODUCTS
1. Mahindra and Mahindra transmission casing 2. VTU(Hydraulic lift
housing)
(MMTC)
12Fig.1: MMTC Fig.2: Hydraulic lift housing

13. 13
3. Continuous Running Power Take Off (CRPTO)
Six types
1. 11×11
2. H-DOME
3. H-1
4. H-2
5. Antifriction
6. Arjun
Fig.7: CRPTO

14. 4. Tafe Centre Housing (TAFE CH) 5. Tafe Transmission Casing (TAFE TC)
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Fig.3: TAFE CH Fig.4: TAFE TC

15. 6. ESCORT AXLE HUB 7. ESCORT FRONT AXLE
SUPPORT
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Fig.5: ESCORT AXLE HUB Fig.6: ESCORT FRONT AXLE SUPPORT

16.  LAYOUT STUDY
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Jai hind plant is a Machine shop
• 7 zones
• 150 machines
• 5 to 6 CNC.
E.g.: 1. J-DX-08
DX= Duplex milling
2. J-SPT-05
SP= Special purpose machine
T= Tapping
Fig.8: Plant Layout

17.  RECEIVING INSPECTION PLAN
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Fig.9: Receiving Inspection Plan

18.  HARD AUTOMATION
 Power-head Production Units
• Consisting of a frame, electric drive motors,
gearboxes, and tool spindles, these units are
self-contained.
 Transfer Machines
• Consisting of two or more powerhead units,
these machines can be arranged on the shop
floor in linear, circular, or U-shaped patterns.
 Transfer Lines
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Fig.10: Power Head
Fig.11: Pallet

19.  PROCESS PLANNING
• Selecting methods of production: tooling, fixtures, machinery, sequences
of operations, and assembly.
• Computer-aided process planning (CAPP) accomplishes the complex task
of process planning by viewing the total operation as an integrated
system, so that the individual processing steps are coordinated and
performed efficiently and reliably.
• CAPP is a powerful tool for efficiently planning and scheduling
manufacturing operations.
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20.  FLEXIBLE FIXTURING
• In describing work-holding devices for the manufacturing
operations the words clamp, jig, and fixture often were used
interchangeably and sometimes in pairs.
• Clamps are simple multifunctional work-holding devices.
• Jig is clamping device and fixture is a holding device.
• Modular Fixturing
• Tombstone Fixtures
• Bed-of-nails Device
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Fig.12: Jig and Fixture

21.  COORDINATE MEASURING MACHINE
• Coordinate-measuring machines are very versatile and
capable of recording measurements of complex profiles
with high resolution and high speed.
• Built rigidly to resist environmental effects in
manufacturing plants, such as temperature and
vibration.
• With a touch probe and computer-controlled three-
dimensional movement are suitable for use in small
shops and generally cost under $20,000.
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Fig.13: Coordinate-measuring machines

22.  LEAK TESTING METHOD
 Testing Criteria
• Leak testing method: Differential pressure
measurement
• Testing pressure: 1 Bar
• Allowable leak rate: 15 cc / min
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Fig.14: Leakage Test Setup

23.  CONCLUSION
• I found that it is one of the leading industries in Foundries, manufacturing and
designing.
• The team work of the company is the main backbone of the success.
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24. THANK YOU
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