TIPL

REPORT ON SUMMER VOCATIONAL TRAINING AT
TIL (TRACTORS INDIA LIMITED), KAMARHATTY WORKS, KOLKATA
NAME : ARKAJIT MITRA
COLLEGE : VELLORE INSTITUTE OF TECHNOLOGY
DEPARTMENT : MECHANICALENGINEERING (3rd
Semester)
REG. NO. : 14BME0760
DURATION : 10th
Dec. 2015 ---- 29th
Dec. 2015

ACKNOWLEDGEMENT
I would at first like to thank
Mr. Shyamal Dasgupta , on whose reference I got the
opportunityof performing my Vocational Training at TIL Ltd.,
Kamarhatty. This being my first, TIL gave me the taste of how
the atmosphere is and how a company actuallyworks. So on
this note, I would whole-heartedlylike to thank all the staff
of TIL Ltd. with whom I interacted and specially Mr.
Bappaditya Ghosh and Mrs. Piyali Ghosh, who have guided
me at each and every step of my training course.

CONTENTS :
 INTRODUCTION
 MARKETING DEPARTMENT
 ENGINEERING DEPARTMENT
 MANUFACTURING DEPARTMENT
 PRODUCTION PLANNING ANDCONTROL DEPARTMENT
 PURCHASE DEPARTMENT
 FABRICATION DEPARTMENT
 ASSEMBLY DEPARTMENT
 TESTING DEPARTMENT
 OSP
 CONCLUSION

INTRODUCTION TO
TIL as an organization, its attitude and philosophy is defined as
 TECHNOLOGY
 INNOVATION
 LEADERSHIP
For over 63 years TIL has been a growth partner to India’s infrastructure
sectors and is amongst the country’s leading providers of a wide range of technology
intensive equipment for infrastructure development that represent some of the finest in
global technology. In the material handling sector, TIL has always been the market leader.
TIL has continuously and successfully anticipated the future needs of the industry and
introduced state of the art products - with many firsts in the market. The plant at Kolkata is
the only purpose built manufacturing facility in this part of the world. Material handling
equipment from TIL are recognized as reliable, productive and efficient and over the years
TIL has emerged as the country’s foremost material handling equipment manufacturer and
service provider. This is evident from the company’s growth in recent years. TIL operates
through three Strategic Business Groups – Material Handling Solutions, Construction and
Mining Solutions, Power Systems Solutions having a well connected network of offices,
factories and product support centers in the country and overseas offices in Nepal and
Bhutan. TIL has long term technical and strategic alliances with leading Equipment
manufacturers in the world- Caterpillar Inc, Manitowoc crane Group, USA Famak S.A,
Poland and Paceco Corp, USA. TIL has two subsidiaries – Myanmar Tractors Ltd. and
Tractors Nepal Ltd.
The mantra at TIL is to consistently provide highest service accuracy
and introduce global best practices and innovation to raise the bar on customer satisfaction
and deliver beyond customer expectations. We are committed to deliver the “best value
proposition” by providing total solutions to all customers. Our passion remains to offer
excellence in product support initiatives, prompt customer response and to be the industry
benchmark as a Total Solutions Provider.

TIL products
TIL and Grove Cranes USA have an exclusive partnership to manufacture a range of
products to support the entire gamut of lifting needs. The range includes Rough Terrain,
Truck Mounted, Yard and Industrial Cranes. Lifting capacities ranging from 12 tonnes to 75
tonnes.
TIL markets and supports a complete and comprehensive range of wheeled and Lattice
Boom Crawler Cranes of Manitowoc Crane Group, USA for customers in India and
neighbouring countries. Lifting capacities range from 80T to 1300 T.
Our strategy is dictated by our ability to foresee tomorrow. Anticipating future needs, we
have collaborated with world leaders in material handling to add muscle to our range. Our
collaborations also include Paceco Corp. and Famak S.A. Paceco is the world leader in
design and manufacture of cargo container handling cranes. Famak specializes in bulk
cargo handling equipment.
TIL and HYSTER have entered into a dealership agreement for India, Nepal and Bhutan for
selling HYSTER Big Lift Trucks (above 8 Tonnes capacity), Container Handlers and Reach
stackers.
TIL and Astec Inc. USA have joined hand in an agreement to manufacture the entire range
of Double Barrel Hot Mix asphalt plants which incorporates a vibrant technology to make the
roads of the future India. Better roads better future.

 Industrial cranes
Industrial Cranes are highly useful while operating in and out of workshops and
sheds, doing small lifting jobs due to its compactness.
 Rough-terrain Hydraulic Crane :-
 RT 880 :
 Maximum Capacity (out riggers)- 75T at 3m radius (85% rating) 360*
slew
 Maximum Capacity (on tyres)-34.4T 3m radius (85% rating) over front
 Boom-4Sec trapezoidal 11m-34.6m
 Maximum road speed -30Km/hr
 Carrier-4x4 wheel drive with whel steer
 HYSKY 640M :
 Maximum Capacity (out riggers)-40T
 Maximum Capacity (on tyres)-33T
 Boom options-3Sec 10m to 24.5m centres, 4Sec 10.5m to 32.25m
centers.
 Maximum hook ht-38.4m with lattice extra & fly jib (3Sec Boom),41.0m
with lattice extension (4Sec Boom)
 Carrier 4x4 wheel drive with 4 wheel steer
 Maximum road speed-30Km/hr

 RT 670 :
 Maximum Capacity (out riggers)- 55T at 3m radius (85% rating)
360*slew.
 Boom-4Sec trapezoidal 10.8m-33.5m
 RT 745 :
 Maximum Capacity (out riggers)- 45T at 3m radius (85% rating)
360*slew
 Boom-4Sec trapezoidal 10.3m-31.7m
 HUSKY 620S :
 Maximum Capacity (out riggers)- 18.15T at 3m radius (85% rating)
360*slew
 Maximum Capacity (on tyres)-16T over font with standard tyres.
 Boom options-3Sec 8.8m to 21.2m centers, 4Sec 8.5m to 14.7 centers.
 Maximum hook ht-29m with 8m lattice extension.
 Carrier 4x4 wheel drive with 4 wheel steer.
 HYSKY 635 :
 Maximum Capacity (out riggers)-36.3T
 Maximum Capacity (on tyres)-33T
 Boom options-3Sec 10m to 32.25m centers, 4Sec 10.25m to 32.25m
centers.
 Maximum hook ht-38.4m with lattice extra & fly jib (3Sec Boom),41.0m
with lattice extension (4Sec Boom)
 Carrier 4x4 wheel drive with 4 wheel steer.

 Maximum road speed-30Km/h
 RT 630C :
 Maximum capacity (out riggers)-30T at 3m radius (85% rating) 360*
Slew.
 Maximum Capacity (on tyres)-11.72T 3m radius (85% rating) over
front.
 Boom-4Sec 8.8-29m
 Carrier-4x4 wheel drive with 4 wheel steer.
 RT 422 :
 Maximum capacity (out riggers)-20T at 3m radius (85% rating) 360*
Slew.
 Maximum Capacity (on tyres)-12.4T at 2.5m radius (85% rating) over
front.
 Boom-3Sectrapezoidal 8.3m-21.4m.
 Maximum road speed-35Km/hr.
 Carrier-4x4 wheel drive with 4 wheel steer.
 RT 620M :
 Maximum capacity (out riggers)-20T at 3m radius (85% ratting) 360*
Slew.
 Maximum Capacity (on tyres)-11.22 at 2.5m radius (85% rating) over
font.
 Boom-3Sec 9.4m-22.9m
 Carrier-4x4 wheel drive with 4wheel steer.
 Industrial Diesel Hydraulic Crane
 AP 418(S) :
 Maximum capacity-20m.
 ,, hook hight-29.2m

 ,, road speed-30Km/hr.
 Carrier-4x2 wheel drive.
 Boom options-2Sec 8.5m to 14.7m 3Sec 8.8m to 21.2m.
 AP 415M :
 Maximum capacity-20T.
 ,, hook hight-12.5m
 ,, road speed-30Km/hr.
 Carrier options-4x2 wheel drive, 4x4 wheel drive.
 Boom options-2Sec5.5m to 9m centres ,3 Sec 5.5m to 12.5m centers.
 Truck Mounted Hydraulic Crane:-
 HYDRA 830M :
 Maximum capicity-30T.
 ,, hook hight-22m(3Sec Boom)
 OCTAG 870 :
 Maximum capicity through full 360* slew circle 75T to 85% rating.
 Octay Boom-4Sec 11.3m to 35.3m.
 Carrier-8x4.
 HYDRA 830 :
 Maximum capacity-30T.

 Boom options-3Sec 8.7m to 21.2m centres.
 Maximum hook height-33m.
 Carrier Mounted Hydraulic Crane
 HYDRA 45/50T :
 Maximum capacity (out riggers) 50T at 3m radius (85% rating) 360*
Slew.
 Boom-4Sec trapezoidal 10.6m-33.5m.
 Carrier-8x4 drive.
 TMS 750B
Maximum capacity (out riggers) 50T at 3m radius (85% rating) 360* Slew
Boom-4Sec trapezoidal 10.6m-33.5m.
Maximum road speed-50Km/hr
Carrier-8x4 drive.
Reach Stackers:
 RST45
Capacity -45T.

OVERVIEW OF TIL
INCORPORATEDIN THE YEAR : 1944
HEAD OFFICE : KOLKATA,INDIA
REGIONAL OFFICES : KOLKATA,DELHI, MUMBAI & CHENNAI
BRANCHES : FORTY ONE
OVERSEASOFFICES : PHUNTSHOLING(BHUTAN),KATHMANDU (NEPAL)
FOREIGN SUBSIDIARY : YANGON (MYANMAR/BURMA)
MANUFACTURININGPLANTS : KOLKATA-CRANES,REACHSTAKERS,SAHIBABAD-CATERPILLER
GENSETS
OPERATINGDIVISIONS : MATERIAL HANDLINGGROUP (MHG),
CONSTRUCTION & MING SOLUTIONS(CMS),
POWERSYSTEM SOLUTIONS(PSS)
NO. OFEMPLOYEES : OVER 1500
TECHNICALCOLLABORATION : MANITOWOC CRANEGROUP FORMOBILE CRANES,FAMAK.
POLANDFORELECTRIC LEVEL LUFFINGCRANES(ELL). NACCO,
NETHERLANDSFOR HYSTER REACHSTACKER
QUALITY SYSTEMS : ISO 9001:2000 APPROVEDORGANISATION,
AWSD14.1, AWS A5.28, ISO- 3834 WELDING
CERTIFICATIONS

ORGANISATIONAL STRUCTUREOF TIL
TIL
IT ACCOUNTS MARKETING DEPT.
ADMN. DEPT. PLANNING DEPT.
MANUFACTURING
DEPT. FABRICATION DEPT.
SHOP-1 SHOP-2
SHOP-5 SHOP-6
SHOP-7 SHOP-8
ASSY. DEPT.
ASSY SHOP-3 SOT BLSTING SHOP
ASSY SHOP-4 TEST BED
PAINT SHOP
QUALITY CONTROL
DEPT.
SCM
PURCHES STORE
DESIGN DEPT.

Divisioninto Departments :
For the effectivefunctioningof the factoryithas beendividedintoanumberof departmentseachof
whichhas its owndutiesandall of themare totallyinter-related.
The departmentsare :
 Marketing
 Engineering
 Manufacturing
 ProductionPlanningandControl
 Purchase
 Fabrication
 Assembly
 QualityAssessmentandTesting
Thisdivisionintodepartmentsisverymuchhelpfulforthe organizationin
a numberof ways.These are :
1. Thisdivisionleads toamuch greaterefficiency.Eachdepartmentisallottedaparticular
task that suitsthe skillsof the peopleinthe departmentthusensuringbetterandquick
completionof the task.
2. It alsofacilitatesmassproduction :Large scale productionprovideseconomiesinthe use of
resources,suchas raw materials,labor,tools,etc.Optimumuse of meansof production
helpstoreduce cost of production.
3. Thisdivisioncreateslessstrain:The divisioneffectivelyreducesamuchcomplicatedjobinto
short simple fragmentswhichmake iteasierforthe workerstocomplete the jobina short
time withgreaterprecision andefficiency.
4. Alsothe societyisbenefitteddue to:
a) Reducedcoston account of large scale production
b) Higherproductivitywhichleadstoeconomicgrowth
c) Betterqualityof goodsandservicesforconsumers

TIL mainly operatesinthe following :
a) Material Handling Solutions(MHS)
b) Equipment andProjects Solutions(EPS)
c) Construction andMining Solutions(CMS)
d) PowerSystemSolutions(PSS)
Customers: ONGC,SAIL,INDIAN ARMY,NTPC,PORT, IOCI,IFFCO
Competitors: ESCORTS,TATA, HITACHI,VOLTAS

MARKETING DEPARTMENT
Definition:
The activitiesof a companyassociatedwithbuyingandsellingaproductor service.Itincludes
advertising, sellinganddelivering productstopeople.Peoplewhoworkinmarketingdepartmentsof
companiestryto getthe attentionof targetaudiencesbyusingslogans,packagingdesign,celebrity
endorsements andgeneral mediaexposure.
The marketing mix isa businesstool usedin marketing andbymarketers.The marketingmix is
oftencrucial whendeterminingaproductor brand'soffer,andis oftenassociatedwiththe fourP's:
price, product,promotion,and place.In service marketing,however,the fourPsare expandedto
the sevenP'sor sevenP's to addressthe differentnature of services.
Product : A productisseenas an itemthatsatisfieswhataconsumerdemands.Itisa tangible
goodor an intangibleservice.Tangible productsare those thathave anindependentphysical
existence.Typical examplesof mass-produced,tangible objectsare the motorcar andthe
disposable razor.A less obviousbutubiquitousmass-producedservice isacomputeroperating
system.
Everyproduct issubjecttoa life-cycle includingagrowthphase followedbyamaturityphase and
finallyaneventual periodof decline assalesfall.Marketersmustdocareful researchonhow long
the life cycle of the producttheyare marketingislikelytobe and focustheirattentionondifferent
challengesthatarise asthe productmoves.
The marketermustalso considerthe productmix.Marketerscanexpandthe currentproductmix by
increasingacertainproductline'sdepthorby increasingthe numberof productlines.Marketers
shouldconsiderhowtopositionthe product,how toexploitthe brand,how toexploitthe
company'sresourcesandhowto configure the productmix sothat each productcomplementsthe
other.The marketermustalsoconsiderproductdevelopmentstrategies.
Price : The amounta customerpaysfor the product.The price isvery importantas itdetermines
the company'sprofitand hence,survival.Adjustingthe price hasaprofoundimpacton the
marketingstrategyand,dependingonthe price elasticityof the product,oftenit will affect
the demand and salesaswell.The marketershouldsetaprice thatcomplementsthe otherelements
of the marketingmix.
Whensettinga price,the marketermustbe aware of the customerperceivedvalue forthe product.
Three basicpricingstrategiesare: marketskimmingpricing,marketpenetrationpricing andneutral
pricing.The 'reference value'(where the consumerreferstothe pricesof competingproducts) and
the 'differential value'(the consumer'sview of thisproduct'sattributesversusthe attributesof other
products) mustbe takenintoaccount.

Promotion : All of the methodsof communicationthatamarketermayuse to provide information
to differentpartiesaboutthe product.Promotioncompriseselementssuchas: advertising, public
relations,salesorganisation andsalespromotion.
Advertisingcoversanycommunicationthatispaidfor,fromcinemacommercials,radioandInternet
advertisementsthroughprintmediaandbillboards.Public relationsiswhere the communicationis
not directlypaidforandincludespressreleases,sponsorshipdeals,exhibitions,conferences,
seminarsortrade fairsandevents.
Afterweb2.0, the capacity of the customerstell aboutthe productsthat theyhave bought,making
reviewsandtestimonialsrelatedtotheiruse experiences,are examplesof publicrelation,aswell.
Thiskindof behaviourtakesthe disseminationof the productinformationoverthe internetspace
and createsthe phenomenonknownasword-of-mouth. Word-of-mouthisanyapparentlyinformal
communicationaboutthe productbyordinaryindividuals,satisfiedcustomersorpeople specifically
engagedtocreate word of mouthmomentum.Salesstaff oftenplaysanimportantrole inwordof
mouthand publicrelations.
Price : Referstoprovidingthe productat a place whichisconvenientforconsumerstoaccess.
Various strategiessuchasintensive distribution,selective distribution,exclusive distribution
and franchisingcanbe usedbythe marketertocomplementthe otheraspectsof the marketingmix.
Physical Evidence : The evidence whichshowsthataservice wasperformed,suchasthe delivery
packagingfor the item deliveredbyadeliveryservice,orascar leftbya surgeon.Thisremindsor
reassuresthe consumerthatthe service tookplace,positivelyornegatively.
People : The employeesthatexecutethe service,chieflyconcerningthe mannerandskill inwhich
theydo so.
Process : The processesandsystemswithinthe organizationthataffectthe executionof its
service,suchasjob queuingorqueryhandling.

Functions of Marketing Department :
 Gathering and Analyzing Market Information
 Marketing Planning
 Product Designing and Development
 Standardization and Grading
 Packaging and Labelling
 Branding
 Customer Support Service
 Pricing of Products
 Promotion
 Physical Distribution
 Transportation
 Storage or Warehousing

ENGINEERING DEPARTMENT :
Important Terminologies :
 Safe Working Load --- Safe Working Load (SWL) sometimes stated as the Normal
Working Load (NWL) is the mass or force that a piece of lifting equipment, lifting
device or accessory can safely use to lift, suspend, or lower a mass without fear of
breaking.
 Tail Radius --- It is the maximum distance between the centre of rotation to the tail of
rotation of the superstructure.
 Outreach --- It is the horizontal distance between the centerline of lifting hook to the
nearest point on the chassis. This is measured when the crane is on level ground
with load suspended.
 Job Length --- It is the shortest distance between the fulcrum of the job to the
centerline of job held on pulley.
 Boom Angle --- It is the angle between the boom base and the horizontal after lifting
the rated load at the rated radius with rated boom length.
 Height of Lift –-- It is the vertical distance between the floor level and the lowest
point of the throat of the hook when hook is in highest working position.
 Load Moment Indicator --- It means a system which aids the crane operator by
sensing the overturning moment on the equipment, i.e. load multiplied by radius.
 Duty Chart --- It is a set of performance data. It indicates the lifting capacity of crane
in static and mobile condition. It includes both the lifting capacity on tires and on
outriggers.
 Block Duty --- A set of load lifting capacities of a Crane when it is on outriggers and
wheels are off the ground.
 Rubber Duty --- A set of load lifting capacities of a Crane when it is resting on the
ground on tires. The duties are of two types – Stationary and Mobile.
 Blocking-up Base --- The effective span of the supporting base when outriggers,
jacks or blocks are used to increase stability by virtue of making contact with the
ground at points further from the center line of the crane than the normal wheels or
tracks.

Crane :
A crane is a type of machine,generallyequippedwithahoistrope,wire ropesor chains,and
sheaves,thatcan be usedbothto liftandlowermaterialsandtomove themhorizontally.Itismainly
usedforliftingheavythingsandtransportingthemtootherplaces.Itusesone or more simple
machinestocreate mechanical advantage andthusmove loadsbeyondthe normal capabilityof a
human.Cranesare commonlyemployedinthe transportindustryforthe loadingandunloadingof
freight,inthe constructionindustryforthe movementof materialsandinthe manufacturing
industryforthe assemblingof heavyequipment.
Cranesexistinanenormousvarietyof forms – each tailoredtoa specificuse.Sizesrange fromthe
smallestjibcranes,usedinside workshops,tothe tallesttowercranes,usedforconstructinghigh
buildings.Mini-cranesare alsousedforconstructinghighbuildings,inordertofacilitate
constructionsbyreachingtightspaces.Finally,we canfindlargerfloatingcranes,generallyusedto
buildoil rigsandsalvage sunkenships.
Some liftingmachinesdonotstrictly fitthe above definitionof acrane, butare generallyknownas
cranes,such as stackercranes andloadercranes.

Mechanical Principles :
There are three majorconsiderationsinthe designof cranes.First,the crane mustbe able to liftthe
weightof the load;second,the crane must nottopple;third,the crane mustnot rupture.
Lifting capacity
Cranesillustrate the use of one ormore simple machinestocreate mechanical advantage.
Lever : A balance crane containsa horizontal beam(the lever) pivoted aboutapointcalledthe
fulcrum.The principle of the leverallowsaheavyloadattachedtothe shorterendof the beamto be
liftedbyasmallerforce appliedinthe oppositedirectiontothe longerendof the beam.The ratioof
the load'sweighttothe appliedforce isequal tothe ratioof the lengthsof the longerarmand the
shorterarm, and iscalledthe mechanical advantage.
Pulley: A jibcrane containsa tiltedstrut(the jib) thatsupportsa fixedpulleyblock.Cablesare
wrappedmultipletimesroundthe fixedblockandroundanotherblockattachedto the load.When
the free endof the cable ispulledbyhandor bya windingmachine,the pulleysystemdeliversa
force to the load thatis equal tothe appliedforce multipliedbythe numberof lengthsof cable
passingbetweenthe twoblocks.Thisnumberisthe mechanical advantage.
Hydraulic Cylinder: Thiscan be useddirectlytoliftthe loador indirectlytomove the jiborbeam
that carriesanotherliftingdevice.
Cranes,like all machines,obey the principle of conservationof energy.Thismeansthatthe energy
deliveredtothe loadcannotexceedthe energyputintothe machine.Forexample,if apulleysystem
multipliesthe appliedforce byten,thenthe loadmovesonlyone tenthasfaras the appliedforce.
Since energyisproportional toforce multipliedbydistance,the outputenergyiskeptroughlyequal
to the inputenergy(inpractice slightlyless,because some energyislosttofrictionandother
inefficiencies).
The same principle canoperate inreverse.Incase of some problem, the combinationof heavyload
and greatheightcan accelerate small objectstotremendousspeed(seetrebuchet).Suchprojectiles
can resultinsevere damage tonearbystructuresandpeople.Cranescanalsogetin chainreactions;
the rupture of one crane may in turntake outnearbycranes.Cranesneedtobe watchedcarefully.
Stability
For stability,the sumof all momentsaboutthe base of the crane mustbe close to zeroso that the
crane doesnotoverturn.[36] Inpractice,the magnitude of loadthatis permittedtobe lifted(called
the "rated load"inthe US) is some value lessthanthe loadthatwill cause the crane to tip,thus
providingasafetymargin.

Under US standardsfor mobile cranes,the stability-limitedratedloadfora crawlercrane is 75% of
the tippingload.The stability-limitedratedloadfora mobile crane supportedonoutriggersis85%of
the tippingload.These requirements,alongwithadditional safety-relatedaspectsof crane design,
are establishedbythe AmericanSocietyof Mechanical Engineers[1] inthe volume ASMEB30.5-2014
Mobile andLocomotive Cranes.
Standardsfor cranesmountedonshipsor offshore platformsare somewhatstricterbecauseof the
dynamicloadon the crane due to vessel motion.Additionally,the stabilityof the vesselorplatform
mustbe considered.
For stationarypedestal orkingpostmountedcranes,the momentcreatedbythe boom, jib,andload
isresistedbythe pedestal base orkingpost.Stresswithinthe base mustbe lessthanthe yieldstress
of the material orthe crane will fail.
Types of Cranes :
Overhead Crane --- Anoverheadcrane,alsoknownasa bridge crane,isa type of crane where the
hook-and-linemechanismrunsalongahorizontal beamthatitself runsalongtwowidelyseparated
rails.Oftenitisina longfactorybuildingandrunsalongrailsalongthe building'stwolongwalls.Itis
similartoa gantry crane.Overheadcranestypicallyconsistof eitherasingle beamora double beam
construction.These canbe builtusingtypical steel beamsoramore complex box girdertype.
Picturedonthe right isa single bridge box girdercrane withthe hoistandsystemoperatedwitha
control pendant.Double girderbridge are more typical whenneedingheaviercapacitysystemsfrom
10 tons andabove.The advantage of the box girdertype configurationresultsinasystemthathas a
lowerdeadweightyetastrongeroverall systemintegrity.Alsoincludedwouldbe ahoistto liftthe
items,the bridge,whichspansthe areacoveredbythe crane,and a trolleytomove alongthe bridge.
The most commonoverheadcrane use isinthe steel industry.Ateverystepof the manufacturing
process,until itleavesafactoryas a finishedproduct,steel ishandledbyanoverheadcrane.Raw
materialsare pouredintoa furnace bycrane, hotsteel isstoredforcoolingbyan overheadcrane,
the finishedcoilsare liftedandloadedontotrucksandtrainsby overheadcrane,andthe fabricator
or stamperusesan overheadcrane tohandle the steel inhisfactory.The automobile industryuses
overheadcranesforhandlingof rawmaterials.Smallerworkstationcraneshandle lighterloadsina
work-area,suchas CNCmill orsaw.
Almostall papermillsuse bridge cranesforregularmaintenance requiringremoval of heavypress
rollsandother equipment.The bridge cranesare usedinthe initial constructionof papermachines

because theyfacilitateinstallationof the heavycastironpaperdryingdrumsand othermassive
equipment,some weighingasmuchas 70 tons.
In manyinstancesthe costof a bridge crane can be largelyoffsetwithsavingsfromnotrenting
mobile cranesinthe constructionof a facilitythatusesa lotof heavyprocessequipment.
MobileCrane --- The most basictype of mobile crane consistsof a trussor telescopicboommounted
on a mobile platform — be itonroad, rail or water.Commonterminologyisconventional and
hydrauliccranesrespectively.
Truck-Mounted Crane : A crane mountedona truck carrier providesthe mobilityforthistype of
crane.This crane has two parts:the carrier,oftenreferredtoasthe Lower,and the lifting
componentwhichincludesthe boom,referredtoasthe Upper. These are matedtogetherthrougha
turntable,allowingthe uppertoswingfromside toside.These modernhydraulictruckcranesare
usuallysingle-enginemachines,withthe same engine poweringthe undercarriage andthe crane.
The upperis usuallypoweredviahydraulicsrunthroughthe turntable fromthe pumpmountedon
the lower.Inoldermodel designsof hydraulictruckcranes,there were twoengines.One inthe
lowerpulledthe crane downthe roadand ran a hydraulicpumpforthe outriggers andjacks.The
one inthe upperran the upperthrougha hydraulicpumpof its own.Many olderoperatorsfavorthe
two-enginesystemdue toleakingsealsinthe turntable of agingnewerdesigncranes.
Generally,thesecranesare able totravel on highways,eliminatingthe needforspecial equipmentto
transportthe crane unlessweightorothersize constrictionsare inplace suchas local laws.If thisis
the case,most large cranesare equippedwitheitherspecial trailerstohelpspreadthe load over
more axlesorare able to disassemble tomeetrequirements.Anexampleiscounterweights.Oftena
crane will be followedbyanothertruckhaulingthe counterweightsthatare removedfortravel.In
additionsome cranesare able to remove the entire upper.

Rough terrain crane :
A crane mountedonan undercarriage withfourrubbertiresthatis designedforpick-and-carry
operationsandforoff-roadand"roughterrain"applications.Outriggersare usedtolevel and
stabilize the crane forhoisting.
These telescopiccranesare single-enginemachines,withthe same engine poweringthe
undercarriage andthe crane,similartoa crawlercrane.In a rough terraincrane,the engine is
usuallymountedinthe undercarriage ratherthaninthe upper,aswithcrawlercrane.Most have 4
wheel drive and4wheel steeringwhichallowsthemtotraverse tighterandslickerterrainthana
standardtruck crane withlesssite prep.Inaddition,there are roughterraincraneswiththe
operatingcabmountedonthe loweras opposedtothe P&H in the above image.
All terrain crane :
A mobile crane withthe necessaryequipmenttotravel atspeedonpublicroads,andon rough
terrainat the job site usingall-wheel andcrabsteering.AT‘scombine the roadabilityof Truck-
mountedCranesandthe manoeuvrabilityof RoughTerrainCranes.
AT’shave 2-9 axlesandare designedforliftingloadsupto1,200 tonnes.
Fixed Crane ---
Exchangingmobilityforthe abilitytocarry greaterloadsandreach greaterheightsdue toincreased
stability,thesetypesof cranesare characterizedbythe fact that theirmainstructure doesnotmove
duringthe periodof use.However,manycanstill be assembledanddisassembled. The structure
basicallyare fixedinone place.

Tower crane :
Towercranes are a modernformof balance crane thatconsistof the same basicparts. Fixedtothe
groundon a concrete slab(and sometimesattachedtothe sidesof structures),tower cranesoften
give the bestcombinationof heightandliftingcapacityandare usedinthe constructionof tall
buildings.The base isthenattachedtothe mast whichgivesthe crane itsheight.Furtherthe mastis
attachedto the slewingunit(gearandmotor) thatallowsthe crane to rotate.On top of the slewing
unitthere are three mainparts whichare: the longhorizontal jib(workingarm),shortercounter-jib,
and the operator'scab.
The long horizontal jibisthe partof the crane that carries the load.The counter-jibcarriesa
counterweight,usuallyof concrete blocks,while the jibsuspendsthe loadtoand fromthe centerof
the crane. The crane operatoreithersitsina cab at the top of the toweror controlsthe crane by
radioremote control from the ground.In the firstcase the operator'scab is mostusuallylocatedat
the top of the towerattachedto the turntable,butcan be mountedonthe jib,or partwaydownthe
tower.The liftinghookisoperatedbythe crane operatorusingelectricmotorstomanipulate wire
rope cablesthrougha systemof sheaves.The hookislocatedonthe longhorizontal armto liftthe
loadwhichalsocontainsitsmotor.
Components
Towercranes are usedextensivelyinconstructionandotherindustrytohoistandmove materials.
There are manytypesof towercranes.Althoughtheyare differentintype,the mainpartsare the
same,as follows:
 Mast: the main supportingtowerof the crane.It ismade of steel trussedsectionsthatare
connectedtogetherduringinstallation.
 Slewingunit:the slewingunitsitsatthe topof the mast.This isthe engine thatenablesthe
crane to rotate.
 Operatingcabin: the operatingcabinsitsjustabove the slewingunit.Itcontainsthe operating
controls.

 Jib: the jib,or operatingarm, extendshorizontallyfromthe crane.A "luffing"jibisable tomove
up and down;a fixedjibhasarollingtrolleythatrunsalongthe underside tomove goods
horizontally.
 Counterjib: holdscounterweights,hoistmotor,hoistdrumandthe electronics.
 Hoist unit: the hoistunithousesthe hoistdrum, hoistcable,gearbox,gearshift,brake,and
supportingcomponents.
 Hook: the hook(orhooks) isusedto connectthe material tothe crane.It hangsat the endof
thicksteel cablesthatrun alongthe jib to the motor.
 Weights:Large concrete counterweightsare mountedtowardthe rearof the mast, to
compensate forthe weightof the goodslifted.
Different parts of a Crane :
Boom
The crane boomis the easiestfeature torecognize andthe mostessential partof a crane truck.This
isthe crane’sarm that liftsand/orlowersheavymaterials.Perthe above,itcanoperate three
differentwayswhichdefinesthe specificsof the crane boomfor eachtype of operation.
Jib
The jibis an extensionof the crane boomthat extendsoutortelescopestogive greaterlengthtothe
boomand allowsforhigherliftingcapability.
Rotex Gear
The rotex gear islocatedunderthe cab or crane cabinand allowsthe cab to rotate or turn the boom
by meansof a hydraulicmotor.
Operator’s Cab (Crane Cabin)
The operator’scab is attachedto the top of the deck,right ontop of the rotex gearthat allowsfor
the cabin to turn.Inside the cabis the operator’schair,electrical equipmentandthe crane’scontrol
panel.Fromthe chair an operatorcontrolsthe crane byuse of joysticksthatcontrol the left-to-right
and forward-to-aftmotionof the boom;andfootpedalsthatcontrol the rotex gearpumppressure
as well asthe telescopingactionof the boom.
Detachable Counterweights
Detachable counterweightsare placedonthe crane’sback and helppreventthe crane frombeing
unbalancedduringthe liftingoperation.There isaspecificformulatohelpdetermine how much
counterweightisneededbaseduponthe boomradius,loadweightand operational boomangle.
Outriggers
The outriggerprovidesthe stabilityandbalance necessarytooperate the crane byprovidingbalance
to preventthe crane fromleaningoroverturning.Anoutriggerhasthree parts:the beamor leg;the
pad or footand sometimesthe float.The beamextends outtothe foot,whichrestson the ground.

Duty Chart of a Crane
1. DIMENSIONSand WEIGHT - The chart showsthe crane dimensions.Itincludesdataforoperation
withthe outriggersextended,transportweight,andsteeringdimensions.Knowledgeof this
informationisespeciallycritical if the crane will be workinginaconfinedspace,asthe lifting
capacityvariesdependingonwhetherthe outriggersare extended.The transportweight(below)
determinesthe trailertobe used,howtoloadthe crane on the trailer,the route to take,andwhat
permitsare requiredtogetit to the jobsite.
Alongthe topaxis,the firstnumberisthe gross vehicle weight.Inthe othertwocolumns,the arrows
indicate the weightloadforeachaxle dependingonwhatadditional accessoriesare loaded.
2. LIFT CAPACITY - Thisis where the magichappens.Inthe legendatthe top of the chart, you can
see these ratingsapplywhenusing6.5tonsof counterweight,withthe outriggersextendedto22 x
22.3 feet.Here,you’dgraphoutthe specificliftthe crane isneededfor.The ‘ft.’indicatoronthe left
axisrepresentsthe radius,the distance fromthe centerpintothe centerof the load.

3. LIFT RANGE - Justas importantas liftcapacityisliftrange.Forthat, a range diagramisusually
includedineverychartwhichillustrateshow muchboomlengthisneededtopickupand lifta load
bothat a distance andat height.
EXAMPLE: You needtopickup a loadat 25 feetandliftitto the topof a five-story,65-footbuilding.
Consultingthe range diagram,69 feetof boomisrequiredtomake the lift.
4. LIFT ANGLE - Thischart illustratesthe maximumliftif aluffingorfixedjibisused.Liftswithjib
lengthsof 32 and49 feet(inadditiontoboomextensionof 105 feet) are illustrated.Withhigher
anglesof lift,the maximumloadcapacitydecreases.Withaluffingjib,the angle canbe
automaticallyadjustedfromthe operatorscab.Witha fixedjib,of course,the angle isfixed.
5. CRANE IN MOTION - This illustratesthe lift capacityfora pickand carry. Here,the chart illustrates
the total weightable tobe pickedupat a 360-degree angle while stationaryonwheels,the total
weightbeingable tobe supportedbothwhileslowlyrollingwiththe loadata zerodegree angle
(creep),andthe total weightable tobe supportedwhilemovingat2.5 milesperhour.The columnto
the leftagainindicatesthe radiusof the lift,the one tothe far right,the maximumboomlengtheach
weightcanbe carriedat.

MANUFACTURING DEPARTMENT :
The processof convertingrawmaterials,components,orpartsintofinishedgoodsthatmeeta
customer'sexpectationsorspecifications.Manufacturingcommonlyemploysaman-machine setup
withdivisionof laborinalarge scale production.
Research and Development:These are the engineeringtypeswhoare typicallyhiredfortheir
technical skills. Theylove tomake stuff,theylikechallenges,andare fondof solutionsthatdon't
justwork,but workelegantly(meaningthey're cleverandefficient). Some companiessplitpure
Research(findingasolutiontoa technical problem) fromDevelopment(makingthe Research
solutionsintobuildable,sellableproducts). A goodR&D departmentneedsinputfromcustomers
(eitherdirectlyorthroughMarketing) tounderstandwhatthe real problemsare. A bad R&D
departmentelegantlysolvesreallytoughtechnical problemsthatnoone caresabout.
Production (Manufacturing) : The ProductionorManufacturingdeptobviouslymakesthe stuff that
the companysells. Butit hasto work closelywithDevelopmentandResearchtomake sure that
whatcomesout of Developmentissomethingthatcan be built,tested,andmaintainedata profit.
Good productionpeopleare veryprocessoriented;theywanttodo thingsaccordingtothe book
withno deviations,andtheypayattentiontothe details.
Quality Control (Testing) : It's the job of the QC folksto make sure that whatcomesout of
Productionactuallyworks. Incompanythatmanufacturesstuff,theywill devise teststhatevery
product(or a sample froma productionbatch) has to passbefore itisshipped. Ina software
company,QC usuallyworkswiththe developerstofindbugs(althoughmanycompaniesare letting
theircustomerstake onthe QC task).
Shipping: Big companiesandthose thatdeal withbigor delicate orexpensiveorhuge numbersof
itemswill have aseparate deptdevotedtopackagingandshippingthe stuff quicklyandefficiently.
Sometimesfiguringoutthe fastestandcheapestwaytodeliverthe stuff becomesverycomplicated
and iscalledLogistics.
CustomerSupport : Once the product isinthe customer'shotlittle hands,they'llcontactCustomer
Supportif theyhave questionsoranythinggoeswrong. Companieswanttospendaslittle onCS as
possible,sotheyshouldinvestalotof time inbuildingreliable,robustandeasytounderstand
products. But theycan alsocut costsby outsourcingCSand puttinguponline supportforumsso
customerscan helpeachother.
Marketing : It's Marketing'sjobto understandwhatcustomersneedandwill payfor(these are two
differentthings). Thiscanbe a challenge because sometimesthe customersthemselvesdon'tknow.
There are twokindsof Marketers:the Listenersandthe Talkers. The Listeners tryto understand
whatpeople wantbyfiguringoutwhattheirproblemsare andfindingoutwhatsolutionswill work.
The Talkerstell people whattheirproblemsare andshow themhow the companycan solve them.
Both can be successful.
Sales: The Sales deptisthe connectiontothe outside world. The jobof Salesisfindingpeople who
have problemsthatthe company'sproductscan solve at a price theycan afford. In practice,
emotionsandpersonalitiescanplaya large part inSalesandreallygoodsalespeople know whento
use an argumentand whentouse emotion. Goodsalespeopleare special folks:theyare
competitive,compassionate,andeachlostsale makesthemtryharderon the nextone.

Standard Production Cycle
Customer
Marketing
PPC
Prod. Planning
Capacity planning
Mat. Req. Planning
Production
Purchase
Customer
Quality
Quality
New std.item requirement
Feedback
Mat. Req. plan
Engineering
Manufacturing
Engineering
Shop loading and scheduling
Forecast

PRODUCTION PLANNING AND CONTROL DEPARTMENT:
Production Planningand Control departmentisone of the importantdepartmentforthe apparel
manufacturingcompany.Inthe contextof the apparel manufacturingprimaryrolesof the
ProductionPlanningandControl (PPC)departmenthas beenlistedbelow.Eachfunctionshasbeen
explainedbrieflyjustoverview aboutthe task. Toknow detailsaboutthe taskread relatedarticles.
Job or Task Scheduling: Preparationof time andactioncalendarforeach orderfrom orderreceiving
to shipment.The jobschedulecontainslistof tasksto be processedforthe styles.Againsteachtasks
plannermentionswhentostarta taskand what isdeadline forthat task.Name of responsible
person(department)forthe jobisbeinglisted.Forexample,schedulingplannedcutdate (PCD),line
loadingdate etc.
Material Resource Planning(Inventory) : Preparationof Material requirementsheetaccordingto
sample productandbuyerspecificationsheet.Consumptionof material(fabric,thread,button,and
twill tape) iscalculatedandestimatedcostof eachmaterial.
Loading production : Plannerdefineswhichstyle tobe loadedtothe productionline andhow much
quantitytobe loaded.
Processselection& planning : Processesneededtocompleteanordervary style to style.According
to the order (customer) requirementPPCdepartmentselectprocessesforthe orders.Sometime
extraprocessesare eliminatedtoreduce costof production.
Facilitylocation : Where a companyhas multiple factories(facilities) forproductionandfactoriesare
setfor specificproduct,plannerneedtoidentifywhichfacilitywillbe mostsuitable fornew orders.
Sometimesthere maybe acapacityshortage ina factory,inthat case plannerneedtodecide which
facilitywill selected forthatorders.
Estimating quantity and costs of production : Plannerestimate dailyproduction(units) accordingto
the stylesworkcontent.Withthe estimatedproductionfigure,productionrunsandmanpower
involvementplanneralsoestimate productioncostperpieces.

Capacity planning: PPCdepartmentplays amajorrole duringorderbooking.Theydecide (suggest)
howmuch ordertheyshouldacceptaccordingto theirproductioncapacity.Allocatingof total
capacityor decidinghowmuchcapacitytobe usedforan order outof total factory capacity.
Regularly updatingfactoriescurrentcapacity(productioncapacity).Toknow more readthe article -
How to calculate productioncapacityof a factory
Line planning : Preparingdetailedline planningwithdailyproductiontargetforthe productionline.
Most cases line planningismade afterdiscussingwithproductionteamandIndustrialengineers.
Followup and execution: Whateverplanismade isexecutedbyPPCdepartment.PPCdepartment
keepsclose lookwhethereverythingisprogressingaccordingthe plan.Chasingotherdepartment
headson dailybasistokeepplanontrack. Theyupdate orderwise completedtasksonthe Time &
actionCalendar. Whentheyfoundsomethingisgoingtobe late theyexpedite andcreate analarm
aboutthe delay.

PURCHASE DEPARTMENT:
The purchasing management department ensures that all goods, supplies and
inventory needed to operate the business areordered and kept in stock. Itis
also responsiblefor controlling the cost of the goods ordered, controlling
inventory levels and building strong relationships with suppliers.
Objectives of Purchasing Management :
 To purchasethe required material at minimum possibleprice by
following the company policies.
 To keep department expenses low.
 Development of good & new vendors (suppliers).
 Development of good relation with the existing suppliers.
 Training & development of personalemployees in department.
 To maintain proper & up to date records of all transactions.
 Participating in development of new material and products.
 To contribute in product improvement.
 To take Economic "MAKE ORBUY" decisions.
 To avoid Stock- out situations.
 To develop policies & procedure.
Principles of Purchasing Management
Buying Material at Right QUALITY.
In the Right QUANTITY.
Fromthe Right SOURCE.
At the Right PRICE.
Delivered at the Right PLACE in.
At the Right TIME.
With Right mode of TRANSPORT.
With Right CONTRACT.

FABRICATION DEPARTMENT :
Fabrication, when used as an industrial term, applies to the building of machines,
structures and other equipment, by cutting, shaping and assembling components
made from raw materials. Small businesses that specialize in metal are called
fab shops.
Fabrication comprises or overlaps with various metalworking specialties:
Fabrication shops and machine shops have overlapping capabilities, but fabrication
shops generally concentrate on the metal preparation aspects (such as sawing
tubing to length or bending sheet metal or plate), welding, and assembly, whereas
machine shops are more concerned with the machining of parts on machine tools.
Firms that encompass both are also common.
Metal Cutting :
The raw material has to be cut to size. This is done with a variety of tools. The most
common way to cut material is by Shearing (metalworking).Special band saws
designed for cutting metal have hardened blades and a feed mechanism for even
cutting. Abrasive cut-off saws, also known as chop saws, are similar to miter saws
but with a steel cutting abrasive disk. Cutting torches can cut very large sections of
steel with little effort.
In recent years, developments in plasma cutting and laser cutting of metals have
been combined with computer motion control to accomplish the sequential
operations on a single machine. This has the advantage of minimizing the non-
productive loading/unloading/transport time, and can also improve dimensional
accuracy of the fabricated element, due to the use of position sensors and highly
accurate servo motor drives to position the cutting head or "torch" of the machine.
Plasma Cutting :
Plasma cutting is a process that is used to cut steel and other metals of different
thicknesses (or sometimes other materials) using a plasma torch. In this process, an
inert gas (in some units, compressed air) is blown at high speed out of a nozzle; at
the same time an electrical arc is formed through that gas from the nozzle to the
surface being cut, turning some of that gas to plasma. The plasma is sufficiently hot
to melt the metal being cut and moves sufficiently fast to blow molten metal away
from the cut.
Process :
The HF Contact type uses a high-frequency, high-voltage spark to ionise the air
through the torch head and initiate an arc. These require the torch to be in contact
with the job material when starting, and so are not suitable for applications involving
CNC cutting.

The Pilot Arc type uses a two cycle approach to producing plasma,
avoiding the need for initial contact. First, a high-voltage, low current circuit is used
to initialize a very small high-intensity spark within the torch body, thereby generating
a small pocket of plasma gas. This is referred to as the pilot arc. The pilot arc has a
return electrical path built into the torch head. The pilot arc will maintain itself until it
is brought into proximity of the work piece where it ignites the main plasma cutting
arc. Plasma arcs are extremely hot and are in the range of 25000 °C(45000 °F).
Plasma is an effective means of cutting thin and
thick materials alike. Hand-held torches can usually cut up to 2 in (48 mm) thick steel
plate, and stronger computer-controlled torches can cut steel up to 6 inches (150
mm) thick. Since plasma cutters produce a very hot and very localized "cone" to cut
with, they are extremely useful for cutting sheet metal in curved or angled shapes.
Starting methods :
Plasma cutters use a number of methods to start the arc. In some units, the arc is
created by putting the torch in contact with the work piece. Some cutters use a high
voltage, high frequency circuit to start the arc. This method has a number of
disadvantages, including risk of electrocution, difficulty of repair, spark gap
maintenance, and the large amount of radio frequency emissions. Plasma cutters
working near sensitive electronics, such as CNC hardware or computers, start the
pilot arc by other means. The nozzle and electrode are in contact. The nozzle is the
cathode, and the electrode is the anode. When the plasma gas begins to flow, the
nozzle is blown forward. A third, less common method is capacitive discharge into
the primary circuit via a silicon controlled rectifier.
PLASMA CUTTING MACHINE

There are six shopsunderfabricationdepartmentwhichare asbelow:
Shop-1:- Operation: Boomfabricationisdone here.
Resources :- a) EOT crane- 2 nos.
b) Jib crane- 9 nos.
c) Weldingmachine- 9nos.
d) Automaticoutside boomweldingmachine- 1no.
e) Automaticinside boomweldingmachine –1 no.
f) Manipulator-5 nos.
g) Workmen – 30 nos.
Shop 2 :- Operations:-
I) Plate cutting
II) Cuttingmaterial identification
III) Marking
IV)Bending
V) Drilling
Resources:- a) Hydraulicpressmachine –1 no.
b) CNCcuttingmachine -2 nos.
c) EOT crane -1 no.
d) Jibcrane -2 nos.
e) CNCbendingmachine -1no.
f) Radial drillingmachine –Ø75 capacity 1 no.
g) Workmen – 20 Nos.
Shop 5 :- Operation:-
I)Chassis,superandoutriggerbeamsof GMK
II) Chassis,rearaxle,counterweightof hyster
III) Chassisof RST-45
IV) N-80 defence crane
Resources:- a) EOT crane – 10 T
b) Jibcrane – 5 nos.
c) Manipulator– 2 nos.
d) Weldingmachine –11 nos.
e) Radial drillingmachine–Ø50 capacity1 no.
f) Grindingmachine –5 nos.
g) Workmen – 30 nos.
Shop 6 :- Operation:- All typescomponentmachininglikeboring, drilling,
shaping,turningetc.are done here by differentmachines.
Resources :a) EOT crane -2 nos.
b) Grindingmachine-1no.

c) Shapingmachine- 1no.
d) Millingmachine -2nos.
e) PowerHack Saw -1 no.
f) Horizontal boringandmillingmachine-1no.
g) Lathe machine -3 nos.
h) Workmen – 3 nos
Shop7:- Operation:- All chassis,superandoutriggerbeamsare fabricated here
Resources:- a) EOT crane -2 nos
b) Jibcrane -12 nos
c) Weldingmachine -12nos
d) Grindingmachine – 10 nos
e) Radial drillingmachine–Ø75 capacity3 nos
f) Workmen – 42 nos.
Shop8:- Operation:- A floorboringmachine isinthisshop.Thismachine is
calledJUARISTImachine.All fabricatedstructures
chassis,super,RST –spreadersupport,RSTslew support
are machinedhere
Resources:- a) Juaristi machine -1no
b) EOT crane -1 no
c) Operators – 4 nos.
FACTORY-FABRICATION CYCLE
Machine Shop
Raw Mat shipment
Floor Boring
Machine
To Shot
Blast/Paint
Shop “5”
For
GMK3055
Fabrication
Shop “7”
Chassis/
supper
Fabrication
Yard
(Steel plates)
Shop
“2”
plate
cutting
Shop “1”
Boom
Fabrication

SHOP 1 AND SHOP 2
SHOT BLASTING SHOP:
It isimportantthat all parts of a crane is free fromrustand otherdamagingeffectswhichcan
hamperthe life andservicingconditionsof the crane.Tostop dustand rust fromgatheringonthe
surfacesthe parts are properlycleanedupandshotblasting processisbeingdone toremove the
dustdepositedalreadyonthe surface.Thenpaintingisdone toinhibitthe growthof rustand
depositionsothatcraneshave a goodaestheticappearance.Before dispatchof the crane,the crane
coveringstructural,electrical andmechanical partsshall be thoroughlycleaned of all dirtgrease ,
scale and rust andthengivena single coatof primer.Mechanical andElectrical componentsshall be
givenadditionalfinishcoatof paintcolourof customerchoice.The exposed mechanical partsof the
crane shall be givenone coatof rustprevention.
Oxy-fuel cutting:
Oxy-fuelcuttingare processesthatuse fuel gasesandoxygentocutmetals.Pure oxygen, insteadof
air (20% oxygen/80%nitrogen),isusedtoincrease the flame temperaturetoallow localizedmelting
of the workpiece material (e.g.steel) inaroomenvironment.A commonpropane/airflame burnsat
about2,000°C, a propane/oxygenflame burnsatabout2,500°C, and an acetylene/oxygenflame
burnsat about3,500°C. Since ironmeltsat about1,500°C (highcarbonsteel atabout 1,150°C), air
flamescanachieve meltingonlyinaspecialized insulatedfurnace.Small,high-flow,oxygenflames
provide enoughheatflowtolocallyexceedthe meltingpointina large workpiece (e.g.sheet).
In oxy-fuel cutting,a cuttingtorch isusedto heatmetal to kindlingtemperature.A streamof oxygen
isthentrainedon the metal andmetal burnsin thatoxygenandthenflowsoutof the cut (kerf) asan
oxide slag. A cuttingtorch headis usedtocut materials.Itissimilartoa weldingtorch,butcanbe
HYDRAULIC
BENDING
MARKING
DRILLING
CNC
BENDING
ID
EN
TI
FI
CA
TION
PLASMA
PLATE
CUTTING
OXY-FUEL
PLATE
CUTTING
DRESSING
METAL
PROCESSING
BOOM FAB
BOOM
FAB
BOX FAB
BOOM
FAB

identifiedbythe oxygenblowouttriggerorlever.The metal isfirstheatedbythe flame until it is
cherryred. Once thistemperature isattained,oxygenissuppliedtothe heatedpartsbypressingthe
"oxygen-blasttrigger".Thisoxygenreactswiththe metal,formingironoxideandproducingheat.It
isthisheat whichcontinuesthe cuttingprocess. The cuttingtorchonlyheatsthe metal tostart the
process;furtherheatisprovidedbythe burningmetal.The meltingpointof the ironoxide isaround
half of that of the metal;as the metal burns,itimmediatelyturnstoliquidironoxide andflowsaway
fromthe cuttingzone.However,some of the ironoxide remainsonthe workpiece,formingahard
"slag"whichcan be removedbygentle tapping,and/oragrinder.
Bending:
Bendingisa manufacturingprocessthatproducesaV-shape,U-shape,orchannel
shape alonga straightaxisinductile materials,mostcommonlysheetmetal.
Commonlyusedequipmentinclude box andpanbrakes,brake presses,andother
specializedmachine presses.
In pressbrake forming,aworkpiece ispositionedoverthe die block andthe die blockpressesthe
sheettoform a shape.Usuallybendinghastoovercome bothtensile stressesaswell ascompressive
stresses.Whenbendingisdone,the residual stressescause the material to spring back towardsits
original position,sothe sheetmustbe over-benttoachieve the properbendangle.The amountof
springbackisdependentonthe material,andthe type of forming.Whensheetmetal isbent,it
stretchesinlength.The bend deduction isthe amountthe sheetmetal willstretchwhenbentas
measuredfromthe outside edgesof the bend.The bend radius referstothe insideradius.The
formedbendradiusisdependentuponthe diesused,the material properties,andthe material
thickness.
There are three basictypesof bendingona pressbrake,eachisdefinedbythe relationshipof the
endtool positiontothe thicknessof the material.These threeare AirBending,Bottomingand
Coining.The configurationsof the toolsforthese three typesof bendingare nearlyidentical.A die
witha longrail form tool witha radiusedtipthat locatesthe inside profile of the bendiscalleda
punch.Punchesare usuallyattachedtothe ram of the machine byclampsand move to produce the
bendingforce.A die witha longrail form tool that has concave or V shapedlengthwisechannel that
locatesthe outside profile of the formiscalledadie.Diesare usuallystationaryandlocated under
the material onthe bedof the machine.
In TIL there are twobendingmachineswhichare available forbendingpurposes.
Theyare: 1.CNC BendingGauge Machine.
2. HydraulicpressMachine.

Hydraulic pressMachine
Machining:
Machiningisa part of the manufacture of almostall metal products,anditis commonfor other
materials,suchaswoodand plastic,tobe machined.Itisa material removal processessuchas
turning,boring,drilling,milling,broaching,sawing,shaping,planing,reaming,andtapping,or
sometimestogrinding.
Conventionalmachining,one of the mostimportantmaterial removal methods,isacollectionof
material-workingprocessesinwhichpower-drivenmachine tools,suchaslathes,millingmachines,
and drill presses,are usedwithasharpcuttingtool to mechanicallycutthe material toachieve the
desiredgeometry.
The three principal machiningprocessesare classifiedasturning,drillingandmilling.Other
operationsfallingintomiscellaneouscategoriesinclude shaping,planing,boring,broachingand
sawing.
 Turningoperationsare operationsthatrotate the workpiece asthe primarymethodof
movingmetal againstthe cuttingtool.Lathesare the principal machine tool usedinturning.
 Millingoperationsare operationsinwhichthe cuttingtool rotatestobring cuttingedgesto
bearagainstthe workpiece.Millingmachinesare the principal machine tool usedinmilling.
 Drillingoperationsare operationsinwhichholesare producedor refinedbybringinga
rotatingcutterwithcuttingedgesat the lowerextremity intocontactwiththe workpiece.
Drillingoperationsare done primarilyindrill pressesbutsometimesonlathesormills.
 Miscellaneousoperationsare operationsthatstrictlyspeakingmaynotbe machining
operationsinthattheymay notbe swarf producingoperationsbutthese operationsare
performedata typical machine tool.Burnishingisanexample of amiscellaneousoperation.
Burnishingproducesnoswarf butcan be performedata lathe,mill,ordrill press.

Fabrication Shop
Welding:
Weldingisa fabricationorsculptural processthatjoinsmaterials,usuallymetalsorthermoplastics,
by causingcoalescence.Thisisoftendone bymeltingthe workpiecesandaddingafillermaterial to
forma pool of moltenmaterial (the weld pool) thatcoolstobecome a strong joint,withpressure
sometimesusedinconjunctionwithheat,orbyitself,toproduce the weld. Manydifferentenergy
sourcescan be usedfor welding,includingagasflame,anelectricarc, a laser,an electronbeam,
friction,andultrasound.While oftenanindustrialprocess,weldingcanbe done inmanydifferent
environments,includingopenair,underwaterandinouterspace.Regardlessof location,however,
weldingremainsdangerous,andprecautionsare takentoavoidburns, electricshock,eye damage,
poisonousfumes,andoverexposuretoultravioletlight.
Types:
1. Gas metal arc welding(GMAW),sometimesreferredtobyitssubtypes metal inertgas(MIG)
weldingormetal active gas(MAG) welding,isasemi-automaticorautomaticarc
weldingprocessinwhichacontinuousandconsumable wireelectrode andashieldinggasare fed
througha weldinggun.A constantvoltage,directcurrentpowersource ismostcommonlyusedwith
GMAW, but constantcurrent systems,aswell asalternatingcurrent,canbe used.There are four
primarymethodsof metal transferinGMAW, called globular, short-circuiting,spray,andpulsed-
spray,each of whichhas distinctpropertiesandcorrespondingadvantagesandlimitations.

GMAW requiresonlythatthe operatorguide the weldinggunwithproperpositionandorientation
alongthe area beingwelded.Keepingaconsistentcontacttip-to-workdistance (the stickout
distance) isimportant,because alongstickoutdistance cancause the electrode tooverheatandwill
alsowaste shieldinggas.Stickoutdistance variesfordifferentGMAWweldprocessesand
applications.Forshort-circuittransfer,the stickoutisgenerally1/4inch to 1/2 inch,for spray
transferthe stickoutisgenerally1/2inch.The positionsof the endof the contact tip to the gas
nozzle are relatedtothe stickoutdistance andalsovary withtransfertype andapplication.The
orientationof the gunisalsoimportant—itshouldbe heldsoasto bisectthe angle betweenthe
workpieces;thatis,at45 degreesfora filletweldand90 degreesforweldingaflatsurface.The
travel angle,orleadangle,isthe angle of the torch withrespectto the directionof travel,andit
shouldgenerallyremainapproximatelyvertical.However,the desirable angle changessomewhat
dependingonthe type of shieldinggasused—withpure inertgases;the bottomof the torchis often
slightlyinfrontof the uppersection,whilethe opposite istrue whenthe weldingatmosphereis
carbon dioxide.
2. Globular:GMAW withglobularmetal transferisoftenconsideredthe mostundesirableof
the four majorGMAW variations,because of itstendencytoproduce highheat,apoor weld
surface,andspatter.
The methodwasoriginallydevelopedasa cost efficientwaytoweld
steel usingGMAW,because thisvariationusescarbondioxide,alessexpensive shieldinggas
than argon.Addingtoits economicadvantage wasitshighdepositionrate,allowingwelding
speedsof upto 110 mm/s(250 in/min).Asthe weldismade,aball of moltenmetal fromthe
electrode tendstobuilduponthe endof the electrode,ofteninirregularshapeswitha
largerdiameterthanthe electrode itself.Whenthe dropletfinallydetacheseither bygravity
or short circuiting,itfallstothe workpiece,leavinganunevensurface andoftencausing
spatter. As a resultof the large moltendroplet,the processisgenerallylimitedtoflatand
horizontal weldingpositions.The highamountof heatgeneratedalsoisadownside,because
it forcesthe weldertouse a largerelectrode wire,increasesthe size of the weldpool,and
causesgreaterresidual stressesanddistortioninthe weldarea.
3. Spray transfer GMAW wasthe firstmetal transfermethod usedinGMAW, andwell-suited
to weldingaluminumandstainlesssteel whileemployinganinertshieldinggas.Inthis
GMAW process,the weldelectrode metal israpidlypassedalongthe stableelectricarcfrom
the electrode tothe workpiece,essentiallyeliminatingspatterand resultinginahigh-quality
weldfinish.
Asthe current and voltage increasesbeyondthe range of shortcircuittransfer
the weldelectrode metaltransfertransitionsfromlargerglobulesthroughsmall dropletsto
a vaporizedstreamatthe highestenergies.Since thisvaporizedspraytransfervariationof
the GMAW weldprocessrequireshighervoltageandcurrentthanshort circuittransfer,and
as a resultof the higherheatinputandlargerweldpool area(for a givenweldelectrode
diameter),itisgenerallyusedonlyonworkpiecesof thicknessesabove about6.4 mm(0.25
in).Also,because of the large weldpool,itisoftenlimitedtoflatandhorizontal welding
positionsandsometimesalso usedforvertical-downwelds.Itisgenerallynotpractical for
root passwelds. Whena smallerelectrode isusedinconjunctionwithlowerheatinput,its
versatilityincreases.The maximumdepositionrate forsprayarc GMAW is relativelyhigh;
about60 mm/s(150 in/min).

4. Pulsed-spray: A more recentlydevelopedmethod,the pulse-spraymetal transfermode isbased
on the principlesof spraytransferbutusesa pulsingcurrenttomeltthe fillerwire andallow one
small moltendroplettofall witheachpulse.The pulsesallow the average currenttobe lower,
decreasingthe overall heatinputandtherebydecreasingthe size of the weldpool andheat-affected
zone while makingitpossible toweldthinworkpieces.The pulseprovidesastable arcand no
spatter,since no short-circuitingtakesplace.Thisalsomakesthe processsuitablefornearlyall
metals,andthickerelectrode wirecanbe usedas well.The smallerweldpool givesthe variation
greaterversatility,makingitpossible toweldinall positions.
In comparisonwithshortarc GMAW, thismethodhas a somewhatslowermaximumspeed(85
mm/sor 200 in/min) andthe processalsorequiresthatthe shieldinggasbe primarilyargonwitha
lowcarbon dioxide.concentration.Additionally,itrequiresaspecial power source capable of
providingcurrentpulseswithafrequencybetween30 and400 pulsespersecond.However,the
methodhasgainedpopularity,sinceitrequireslowerheatinputandcanbe usedto weldthin
workpieces,aswell asnonferrousmaterials.

ASSEMBLY DEPARTMENT :
The planning of the modern flexible manufacturing systems including the Flexible
Assembly Systems (FAS) is a very complicated and responsible task. It assumed
that the FAS are universal enough to be able to connect a high production capacity
with the small quantities of production lots and short cycle time. It should ensure a
production under the conditions of dynamical and sudden changes of the product
range, the planed fixed dates for order realization and also the possibility of fast
introducing of product design change into production.
ASSEMBLY SHOP
SHOP NO 3
SHOP N0 4
The module assembly means, that the assembly system has a modular structure and each
module realizes a defined function or a limited function range, which are part of a general
assembly process. According to the definition a technological assembly model composes
“an integral set of the main and auxiliary activities of assembling, which are realized in a
defined sequence at one station and uses a defined tool set for connecting of surfaces,
parts, subassemblies, assemblies”. The connection of the elementary technological modules
lies in a proper development and selection of technological modules. Each of them realizes a
proper design module of construction.
ENGINE-
TRANSS/ASSY
S/S CAB
MECH/ELECTRI
CAL ASSY
RST-45
CHASSIS ASSY
MECH
ASSY
CHASSIS
FIRST
OPEN
HYD ASSY
S
T
O
R
E
S
N-50
BOOM
MOUNTING
BOOM
ASSY
ELEC
ASSY
CABIN
MECH/
HYD
ASSY
R
O
L
L
O
U
T

During the planning of the flexible assembly systems with the modular assembly engineering
the following stages can be selected:
 Analysis of the construction of the assembled product and the assembling
technologies.
 Identification and classification of objects into groups and subgroups of the
processed parts and (technological similar) assembly sets. The working out of a
typical flow chart (based on common assembly sequences, similar to the
manipulation activities, duration, etc.).
 Separation of autonomic, integrated assembly activities from the flow charts, then
assembling the separated assembly units into groups depending on equipment with
instrumentation to carry out these operations.
 Planning of structures and functions of the constructional modules.
 Preliminary planning of elementary technological modules.
 Assembling of the elementary modules and selection of proper, possible variants of
the technological and constructional modules.
 Optimization of the technological module structure and the structure of the
constructional module realized.
 Clustering of the elementary technological assembly modules.
 Final planning of the technological assembly modules, the modular technological
complexes and of the corresponding constructional modules.

QUALITY ASSESSMENT AND TESTING DEPARTMENT :
Crane Testing Requirements for Performance Tests---
1. Performance testing:
Performance testing includes both operational performance testing and load
performance testing. The following sequence and limitation shall be complied with
when conducting performance tests:
(a) Test rigging first.
(b) Conduct the operational performance test before the load performance
test.
(c) Test the main hoist before testing the auxiliary or whip hoists.
(d) Test loads shall be raised only to a height sufficient to perform the test.
2. Operational Performance Testing:
(a) Raise the load hook through all controller points stopping below the upper
limit switch (where applicable).
(b) Slowly raise load hook into the upper limit switch to establish that limit
switch is operating properly.
(c) Slowly raise hook through the upper limit switch by using limit switch
bypass (where applicable)
(d) Lower load hook below the upper limit switch using all the lowering control
points.
(e) Slowly lower load hook into the lower limit switch to establish that limit
switch is operating properly.
CRANE PERFORMANCE TESTING REQUIREMENTS AT-LOAD TESTS
(1) All subtests under the test designation are required as applicable.
(2) For variable-rated cranes, perform the applicable variable-rated crane tests in
addition to any other required tests.
(3) Conduct for main, auxiliary, jib, and whip hoists.
(4) Conduct rotation tests through normal design operating arc.
(5) Conduct hoist tests in combinations such that all structural, mechanical and
electrical components are tested in all possible configurations.
(6) Complete tests shall be performed on each hook. Extend the outriggers or
stabilizers as specified by the manufacturer. Level the crane as specified by
the manufacturer’s load chart. Rotate the boom 90° from the longitudinal axis
of the crane carrier and position the boom at the minimum working radius.
(7) Rotate the maximum degrees allowed by the manufacturer. Tests shall be
performed with boom fully retracted and fully extended.

TEST BED AND INSPECTION
Structural Fabrication
 Raw material cutting and processing.
 Load chart creation for various group centers.
 Fabrication plan generation.
 Machine shop planning.
Steps followedinSystemDispatch
 Step-1:- Release Jobs from MRP – Project wise.
 Step-2:- Daily Raw Material Achievement.
 Step-3:- Achieve operations from all components - Project wise.
 Step-4:- Completion of Shop Manufactured Items.
 Step-5:-Loose MO entry in Final Job.
 Step-6:- Shortage cleaning for Final Assy Job.
 Step-7 :- Labor hours booking.
 Step-8:- Issuing items in final job.
 Step-9:- Entry of all remaining items not consumed in final job but in workbench.
 Step-10:- Variance report analysis & Checking Material cost.
 Step-11:- Final dispatch.
ASSYMBLY TEST BED &
INSPECTION
FINISH PAINT DESPATCH

What is OSP?
OSP is outside resource to add value for the material send by us to respective vendor.
What is OSP in TIL?
 OSP always comes from job. If we decide that we want to buy some component from
outside but will provide vendor some free supply items then it is always OSP.
 Items will remain in vendor locator until the OSP component is received in TIL.
 After receipt that job need to be completed & automatically all items which has been
send to vendor as free supply will be consumed & parent item stock will be
developed.
OSP FLOWCHART
Create OSPBOM & Routing
Create OSPJob
Raise OSPJob
Raise PO
Raise Move Order
Transact the Move order
Make 57F4
Checkall 57F4 itemswithmove order
Sendmat. To Vendor
Receive the itemandmake GRN
Inspection
DeliveryinSystem
Complete JobinSystem Daily find jobs in the GRN
delivered
Reserve instore locator

CONCLUSION
During my vocational training at TIL, I came to know about the
different parts of a crane and the manufacturing processes of each of
them in their respective workshops. I also learnt about the various
types of cranes used and the numerous functions and uniqueness of
each of them. TIL gave me an idea about the different departments
of a manufacturing company and their responsibilities. I consider
myself fortunate to have undergone this training course.
...............THANK YOU..............

TIPL

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