1. 6 MONTH INTERNSHIP AT
MADE BY - ADITYA THOMBARE
SYMBIOSIS INSTITUTE OF TECHNOLOGY
PRN- 1700121158
2. INSIGHT OF THE COMPANY
KIRLOSKAR BROTHERS LTD, (KBL) incorporated in 1920 is a acknowledged
leader in fluid handling and largest manufacturer and exporter of pumps in
India.
The company's product range includes a wide range of Centrifugal Pumps
for Agriculture, Domestic, Industrial process , general applications , large
vertical pumps , concrete volute pumps for Power Projects, Water Supply
and Irrigation schemes ranging from Domestic Pumps of 0.375 Kw to
concrete volute pumps of 4500Kw.
KBL’s Global Network includes Regional Offices in all the major cities in
India and offices and representatives posted in various countries in Europe,
Middle East and South East Asia.
Its products and services are exported to over 70 countries across five
continents. On both the national and international fronts.
3. DEPARTMENTS WITHIN THE COMPANY
HRMC
PATTERN
SHOP
FOUNDRY
MACHINE
SHOP
PUMP
TESTING
PACKING
DISPATCH
5. PROCESS DETAILS
IT STARTS WITH THE DESIGN DEPARTMENT providing the drawing of the related
pump with all details , then the CAD engineer analyses and produces the pattern
and necessary core for making a casting.
The Manufacturing of a pattern is also decided on the basis of how frequently
they would be utilised-
Temporary- Thermacol pattern
Few castings- Wood
Large requirement – Aluminium
Besides even dies(Aluminium) are made for making highly finished castings.
These patterns after their use are stored in pattern store where they can be
reproduced as in when the customer order is generated.
6. INSIGHT OF THE PATTERN PROCESS
A casting is made from 2 basic things = Pattern + Core box
The cores are separated as per convenience for easy casting
removal.
7. PROJECT DETAILS
The company assigned 3 projects which included :
Pattern Management System ( Material Management)
Angular Drilling machine stand (Jig to guide the drill in any angle)
Reverse Engineering of a impeller
Out of which :
Pattern Management System took about-- 3 months
Drilling machine stand took about -- 2 months
And reverse Engineering project – 1 month
All the 3 project had different impact providing knowledge of various works of
Mechanical Engineering.
8. PATTERN MANAGEMENT SYSTEM
NEED FOR MANAGEMENT-
Patterns and Core boxes form the basics of manufacturing a simple casting.
They both are developed on the basis of the requirement or order placed
by the consumer. Pattern along with the core box made is sent to the
foundry for making a casting.
These patterns and core boxes need to be maintained with proper care so
that they can be re-used when required again. If not maintained, they
further have to be made again which is not at all cost efficient. Thus
maintaining a pattern and its core box is very essential as it is a major asset
to the company, which can cause a great deal of loss.
Further if not kept at the right place or in a right manner it becomes very
difficult to search or find the necessary pattern when needed. This leads to
panic or dependency of the company to a particular person or authority. To
avoid all such problems, a proper systematic arrangement or a management
is necessary which guides every related employee of the company to search
the required equipment when in need. (Equipment= patter +core box)
9. SOLUTION PROVIDED
To avoid all above problems a project of pattern
management was adopted to minimize the effort
Initially layouts of the stores containing the patterns
were drawn to know the area well and to plan and
utilize the space efficiently
These storage areas were given particular names and
rack system was adopted to simplify the problem
11. Besides the details of the racks were calculated including
dimensions and giving names to all of them.
12. Also in order to create a database of the patterns and core
boxes the equipments were counted manually along with the
name, material, size, date of manufacturing of the pump.
On the basis of noted data an excel database of about 4000
pieces of both patterns and core boxes were found
With help of such database the patterns came to be sorted out
on the basis of condition of it.
After all the data collection the used and unused patterns were
separated and the unused were disposed to the scrap yard and
all the frequently used ones were collected together.
13. It was decided to arrange them in the racks on the basis of their sizes
and need.
Each of the top and bottom and their core boxes were arranged in such a
way that all the work could be done by coming into one store.
The top were kept in one rack their other half i.e. its bottom was kept in
the rack in front of the earlier rack and their core boxes were kept
below the racks for their easy removal.
Besides color coding system was to be adopted to recognize particular
equipment.
So on the basis of series decided the patterns were colored with specific
colors along with their core boxes and a signboard indicating the color
code was put up at the entrance of the pattern store.
14. Some of the images here describe the related work :
15. On the basis of color coding a layout containing the
equipments was made to easily guide any related person
within the company -
16. ANGULAR DRILLING MACHINE STAND
REQIUREMENT :
The Pattern shop along with manufacturing of Patterns and
Core Boxes also produces dies(Aluminium) for making
Thermacol patterns used for producing high finish castings.
17. These dies are made of aluminium and have intricate parts
which are machined on the VMC by using programming.
These dies need air passages for adding steam in the die to
fuse the Thermacol balls by using a process called REPLICAST
to generate a high finish casting.
These air passages were manually drilled earlier.
The parts of the dies have hydraulic shapes of the vane,
casing etc. On which manual drilling caused a lot of problems
like breaking of the drill ,change in the angle in which the
drill has to be drilled and much more.
In order to overcome all these problems a concept of
making an angular drilling machine stand was generated in
the department which was to be fulfilled.
18. With the guidance of the Sir Dhananjay Sankpal (Ass.Manager)
the concept was understood and the 3-D drawing of the concept
was made initially.
A drawing of the 3-model is shown below-
19. By help of this 3-D model a 2-D model was generated and
machining and other tolerances were added by the
MED(Manufacturing Engineering Division) division
20. As the stand needed to be sturdy – steel was selected
as the material to be used (WBC)
The material was searched through the scrap yard and
the material was re-used from the scrap out of which 2
parts were casted out in the ACS foundry by making
Thermacol pattern of each of them.
All the collected parts were then started to be
machined by considering all the machining allowance
and tolerances.
21. Following were the manufacturing processes used –
Facing
Turning
Parting
Drilling
Milling
Key way slotting
Welding
Grinding
22. • After machining it was assembled together and a table having
T-slot was found from scrap yard and the assembly was
mounted on the table creating a fix position.
23. Later, on testing it was found that modification was necessary
and thus use of linear bearings was done for the smooth
movement of the sliding arm holding the hand drilling machine.
24. COSTING -
Approximate cost estimation of the project was done to
calculate the investment done in manufacturing and
show the savings.
25. This is the detailed costing of each part of the
assembly :
26. REVERSE ENGINEERING
A systematic methodology for analyzing the design of an
existing device or system, either as an approach to study the
design or as a prerequisite for re-designs.
The process of duplicating an existing component,
subassembly or product, without the aid of drawings,
documentation, or computer model is known as reverse
engineering.
Reverse engineering can be viewed as the process of
analyzing a system to:
Identify the system's components and their
interrelationships.
Create representations of the system in another form or
a higher level of abstraction.
Create the physical representation of that system
27. Need of Reverse Engineering:
Some bad features of a product need to be design out.
To strengthen the good features of a product based on
long-term usage of the product.
To analyze the good and bad features of the competitors
product. To explore new avenues to improve product
performance and features.
To gain competitive benchmarking methods to
understand competitor's products and develop better
products.
28. Reverse Engineering is done in 4 stages:
Stage 1: Evaluation and verification
Stage 2: Technical data generation
Stage 3; Design verification
Stage 4: Project implementation
DATA CAPTURE DATA SEGMENTATION 3D CAD MODEL
29. AREAS IN WHICH REVERSE ENGINEERING IS APPLICABLE:
Lost documentation: Reverse engineering often is done because the
documentation of a particular device has been lost (or was never written), and
the person who built it is no longer available. Integrated circuits often seem to
have been designed on obsolete, proprietary systems, which means that the
only way to incorporate the functionality into new technology is to reverse-
engineer the existing chip and then re-design it.
Product analysis. To examine how a product works, what components it
consists of, estimate costs, and identify potential patent infringement.
Digital update/correction. To update the digital version (e.g. CAD model) of an
object to match an "as-built" condition.
Acquiring sensitive data by disassembling and analyzing the design of a system
component [3]
Military or commercial espionage. Learning about an enemy's or competitor's
latest research by stealing or capturing a prototype and dismantling it.
Creation of unlicensed/unapproved duplicates.
Academic/learning purposes.
Curiosity
Competitive technical intelligence (understand what your competitor is
actually doing versus what they say they are doing)
Learning: learn from others' mistakes. Do not make the same mistakes that
others have already made and subsequently corrected
32. THESE WERE THE METHODS FOLLOWED FOR
VERIFICATION OF A PARTICULAR DESIGN
33. BESIDES THE PROJECTS GIVEN –THERE WERE SOME 5S
AND KAIZEN INITIATIVES TAKEN ON THE SHOP FLOOR
KAI ZEN
“Kai” in Japanese means
“Change” and “Zen” means
good.
The literary meaning of Kaizen
is
“change for good”
