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Internship Report (MEchanical Engg) by kalpesh pawar


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Internship Report of 15days Internship at Esmech Equipments Pvt. Ltd. Wada

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Internship Report (MEchanical Engg) by kalpesh pawar

  1. 1. 1 ESMECH EQUIPMENT PVT. LTD. Engineering Excellence... INTERNSHIP REPORT NAME OF STUDENT: Kalpesh Gurunath Pawar NAME OF COLLEGE: Bharat College Of Engineering B.E. (Mechanical Engineering) NAME OF GUIDE: Mr. Harish Sharma DGM- Esmech Equipment Pvt. Ltd.
  2. 2. 2 ACKNOWLEDGMENT I am highly indebted to Mr. Harish Sharma Sir, DGM-Assembly department for their guidance and constant supervision as well as for providing necessary information regarding the internship and also for their support in completing the internship. I would like to express my gratitude towards member of organization for their kind co-operation and encouragement with help me in completion of this internship.
  3. 3. 3 CERTIFICATE This is to certify that Mr. KALPESH G. PAWAR have satisfactorily completed this summer training in the FAB, MACHINE & ASSEMBLY workshop at “ESMECH EQUIPMENT PRIVATE LIMITED. WADA” during period from 20th June to 7th July, 2015 Mr. Harish Sharma Mr. Mukesh Kapoor DGM VP Esmech Equipments Pvt.Ltd. Esmech Equipments Pvt.Ltd.
  4. 4. 4 Table of Contents 1 Company Overview 5 2 Introduction About Project 6 3 Planning Dept. 7-9 4 Fabrication Shop 10-11 5 Machine Shop 12-15 6 Assembly Shop 16 7 Reflection of Internship 17 8 Conclusion 18
  5. 5. 5 COMPANY OVERVIEW Esmech Equipment is a Joint Venture between SMS Siemag AG (Germany) and HB Esmech Pvt. Ltd (India), and is the leading manufacturer of World Class Cold Rolling Mills and Strip Metal Process Line equipment. Esmech Equipment is a subsidiary of SMS Siemag AG, and is therefore a proud member of the SMS Group. Esmech Equipment’s mission is to combine SMS’s World Class Technology with Esmech’s low cost manufacturing ability to give its customers an unbeatable advantage ! Esmech Equipment is headquartered in Thane, India (adjacent to Mumbai). Esmech has its manufacturing facility in two locations Thane and Wada. Esmech Equipment has a very long reputation of quality supplies and has a Reference List of over 275 Lines. Esmech’s product Range Includes: ● Cold Rolling Mills (Single stand and Twin Stand-compact Mill) ● Skin Pass Mill ● Galvanizing Lines ● Color Coating Lines ● Pickling Lines ● Cut-To-Length Lines ● Recoil Lines ● Electrolyte Cleaning Lines ● Slitting Lines ● Tension Leveling Lines ● Blanking Lines ● Rewinding (Recoiling) and Trimming Lines
  6. 6. 6 INTRODUCTION OF PROJECT In this project, we can understand the Manufacturing Process of various parts of design structures/flat products in Fabrication shop. In Machining department, various M/C processes done on fabricated parts. At last the fabricated & machined parts of M/C assembled in assembly shop. In Planning Dept. the planning of Project Manufacturing Process takes place. In Fabrication Dept. with the help of M/C such as cutter, driller, CNC, Grinder, Welding M/C components are to be fabricated. Various checking parameters & inspection done with respect to Quality purpose & then structures/flat products are passed to Machine shop. In Machine Dept. of an Industry; carries out various kinds of processes to finalize the assembly of a structure. In Assembly Dept.; Assembly modeling, technology, and methods used by computer aided design & product visualization software.
  7. 7. 7 PROJECT PLANNING DEPARTMENT The Planning Dept. plays the role of Brain for the industry body. Every Project in company starts from Project Manufacturing Process Planning in Planning Dept. Each Project has a Unique Identification NO.(UIN) given by the planning Dept. A single project contains a no. of sub-assemblies (for Ex. For a single slitting line has 49 Assemblies.) In Design Dept. there is a folder contains particular assembly drawing, drawing no., Assembly part list, part code, Such detail of assembly which den transfer to Planning for further process. In the Dept; Manufacturing Process Planning starts from raw material. Requirement of Raw material is given by planning Dept. RAW Material: Bill of Material (BOM) Part List by Assembly Drawing Drawing Reading. Req. Raw material by Quantity The list then transfer to Fabrication OR Machine shop according to the operation. M/c Shop: Hacksaw Cutting- pins, shafts/drum shafts, spacer. Fabrication: Cutting List Drawing, FAB Drawing STORE: Hardware, Baring, Hex-bolt, Hex-nut. Cutting parts after Fabrication Process send for the process in M/C shop. Inspection is done by the Quality Control Dept. And components go for Assembling. Planning Dept. maintain the schedule as per target date of the dispatch of Project Assembly. System ACR- All Component Readiness; to check whether component ready within target date or not. Dispatch of Project Assembly is then done according to Project Order. IMP steps in Planning: Drawing Reading: Process Sequence (depends on requirement of product.): Cutting Finishing/Grinding Fabrication Turning Milling
  8. 8. 8 ERP PROCEDURE Enterprise Resource Planning (ERP) Raw Material ISSUE :  Master data management—transaction--project assembly--UIN no--- copy.(drawing no--product no)  Procurement management—transactions--RM Issue--new-paste  Save-lines--new--product--key--paste--search--double click-  Storage bin--wip--enter--save & new-product--key--fab key  Paste--with store--select—ok--moment quantity--save --header  RM Issue completed --Document no INTERNAL CHALLAN :  Internal challan--new--business pa--Wada –-save--lines--new  Product--paste--with stock--search-moment quantity--storage bin--enter--wip select--new storage bin--IBP –enter--save  Challan line activity--new--sequence--ex--fabrications--save  Header-- challan send to approve--ok
  9. 9. 9 GOOD RECIEPT :  New --is internal challan --business partner--name--% esm %--All--search-- 4no Wada select-save--creates line from--order--warehouse position--7 no Wada -–save-ok—line--supplier challan –quantity--weight--save--header-- complete—ok PRODUCTION MANAGEMENT :  Batch planning--planning--search record--product--key paste--search--select-- ok.--Po & Wo & Iwo--Good receipt--select sequence--fabrications--save--good r. process--ok REQUISITIONS :  Productions management--transactions-- req--non--project item--new--save-- lines--new—product--key--name—search—description--quantity--save-- header--completed--ok--print.
  10. 10. 10 FABRICATION SHOP Raw Materials: Max length 6m.  Plates: As per thickness MS/C45/S355  I-Beam  C-Channels L-Angle: As per angle 35/50/65/75/80/100 upto 250 Equal Angle (h=w) Unequal Angle (h=/w)  Box(Square Tube): As per Length and Width Equal Box(Square box) Unequal Box(Rectangular box)  Bar(Round Bar): As per Diameter D25/50 Metal Cutting:  Hand Cutter: Directly cut over marking on structure.  Profile Cutting M/C: Gas Cutter(consist Nozzle) contains LPG+O2  CNC Cutting M/C: Cuts only Plates. Capacity thickness max. 75mm.  PUG Cutting M/C: Moves on Rails Straight Cut Angular Cut Metal Grinding/Finishing:  Handle Grinder/Angle Grinder: Uses Grinding Wheel  Shot Blasting: M/C in which small metal balls hits surface of structure.
  11. 11. 11 Welding:  A union of material produce by heat & pressure.  A welding procedure is a systematic method. Heat is used to repeatedly produce sound welds.  There is over 100 recognized welding or thermal joining processes.  ARC (MMA) welding: Uses Rectifier, sometimes transformer. Dia of Rod 2.5/3.15/4/5/6  GMAW(MIG/MAG) Welding: Wire spool Filler Wire 0.8/1/1.2/1.6 Fabrication:  With the help of fabrication Drawing structures are Fabricated after Metal Cutting, Welding & Grinding.
  12. 12. 12 MACHINE SHOP/DEPT. Machine Shop of an Industry; carries out various kinds of processes to finalize the assembly of a structure. Raw material/ Rough material from in-house workshop/outside vendor comes at Machine Shop for Processing. Mostly Fabricated/Forged/Casting/Hardened parts are in Raw Materials of Machine Shop. Various Operations/Processes at M/C Shop:  Milling: To cut a shape with Rotating tool/Grind in a mill. Plano Milling M/C Vertical Milling Horizontal Milling There are four types of Milling M/C are used.  Turning: In which cutting tool non-rotary tool bit describes a helical tool path by moving more or less linearly while work piece rotates. Tool axes of movement may be linearly a straight line, may be along some set of curves or angles. Can be used for boring hole or drilling M/C.  Boring: When same essential cutting action as turning‖ when applied to internal surface is called as boring. The phrase ―turning and boring‖ categorized the large family of (essentially similar) processes. The cutting faces on work piece (i.e. surface perpendicular to rotating axes) whether with turning and boring tool called ―Facing‖. Boring can be done manually on lathe or CNC (Computer Numerical Control). Single point boring Multipoint boring  Drilling: It is a cutting process that uses drill bit to cut or enlarge the hole circular cross section in solid material. The drill bit is rotary cutting tool.
  13. 13. 13 MACHINES SPECIFICATIONS BORING MACHINE: Sr. No. Machine Name (Company) Spindle Dia. Table (LxW) Spindle Stroke Remark 1 Boring-Conventional (KARAM) INDIA Ø100 1100x850 400 For Smaller Operations 2 Boring (STIM) ITALY Ø100 1250x1250 1000 Comparatively Large Structure. 3 Boring RUSSIAN Ø160 1800x1600 900 For Smaller Operations. 4 Boring-Conventional (BUCUREST) AFM 150 Ø150 2500x2000 1000 For Large Structures but slower in operations. 5 Boring (C & E) UK Ø130 1800x1600 1000 For Large Structures- comparatively Faster in operations. 6 CNC Milling & Boring (UNION) GERMANY Ø130 1600x1250 1600 Large Structures. Computer Numeric Control-Ease in Operations. 7 CNC PRECITEC Ø150 - - Covers a Large working area. 8 CNC Boring (DOOSAN) KOREA Ø130 2000x1800 700 For Heavy Machining. 9 STARRAG HECKERT - - 875 For Continuous Process of Operations. Pallets to load jobs. PLANO-MILLER & FTB MACHINE: Sr. No. Machine Name (Company) Spindle Dia. Table (LxW) Spindle Stroke Remark 1 Plano-Miller (LIBERTY) USA HORZ-180 2800x5500 800 Ideal For Large Streuctures. 2 Plano-Miller (TITAN) GERMANY Ø180 1000x4210 1000 For small Structures 3 Plano-Miller (TITAN) GERMAN Ø180 1000x4210 1000 For small Structures
  14. 14. 14 HORIZONTAL MILLING MACHINE: Sr. No. Machine Name (Company) SpindleTaper. Table (LxW) Spindle Stroke Remark 1 Milling (FMT 700) ISO 50 2000x600 450 Horizontal Milling Operations. 2 Milling (TOS) KARAM CZECK ISO 50 2000x450 - Horizontal Milling Operations. VERTICAL MILLING MACHINE: Sr. No. Machine Name (Company) SpindleTaper. Table (LxW) Spindle Stroke Remark 1 Milling (WMW) GERMANY ISO 50 1590x400 - Vertical Milling Operations 2 Milling (TIGER) ITALY ISO 50 1600x400 - Vertical Milling Operations 3 Milling (VF3) ISO 50 2130x350 - Vertical Milling Operations 4 CNC Milling (ZYER) ISO 50 5000x1000 - Vertical Milling Operations, Dovetails, Max Capacity. 5 CNC Milling (MTE COMACT) - 1700x750 2Tone Vertical Milling Operations, Dovetails, Less Capacity DRILLING MACHINE: Sr. No. Machine Name (Country) Table (LxW) Remark 1 HMT RM 61 (INDIA) 1200x640 Smaller Operations 2 HMT RM 63 (INDIA) 1600x750 Smaller Operations 3 HMT RM 65 (INDIA) 2200x850 Large Operations
  15. 15. 15 LATHE MACHINE: Sr. No. Machine Name (Country) Chuck Dia. Table Length Centre Height Remark 1 WMV (GERMANY) Ø1500 5300 800 For shafts/Rods of Large Size, Higher Oprat. 2 Punjab Machinery (INDIA) 20 FEET Ø760 6069 500 For shafts/Rods of Medium Size, 20‖, Higher Oprat. 3 GRD (INDIA) Ø910 8950 610 For shafts/Rods of Medium Size Higher Oprat. 4 16 Foot Ø910 3600 600 Larger Chuck 16‖, Various Operations 5 GUJRAT Ø350 2300 250 Small Lathe 6 BULGARIA Ø250 1500 200 Small Lathe 7 KIRLOSKAR (INDIA) Ø350 2750 190 Larger Chuck, Various Operations, Max Capacity VTL MACHINE: Verical Turret Lathe Sr. No. Machine Name (Country) Chuck Dia. Vertical Travel Cross Remark 1 VTL WMV (GERMANY) 2200 1100 2200 Turning,Boring, Grinding
  16. 16. 16 ASSEMBLY DEPT. Assembly is an act of combining components of Manufacturing. Assembly modeling, technology, and methods used by computer aided design & product visualization software. Assembly Line, a manufacturing process in which parts are added to a product in a sequential manner. In Assembly Dept. no, of Sub-Assemblies of a single project are combined together. Fabricated/Machined parts/readymade parts from outside vendor; store material are combined with the help of Assembly Drawing. For a single line there are no. of subassemblies; in such condition lines are assembled at the working/installation site of line. Sometimes Errors arises during assembly of a project. As much as concern, Dimensional errors are the most occurring errors at the site of Assembly section. These errors are classified by characteristics and solved/Manipulate by Quality control Dept. Fully assembled project then dispatched by Assembly Dept. as per requirement of client.
  17. 17. 17 REFLECTION OF INTERNSHIP In this chapter, regarding my learning goals I shortly discuss my experiences; if I have achieved my goal, whether I experienced difficulties and what I think I have to improve. Learning Goals: ● The functioning and working conditions of a non-governmental organization. At the beginning I didn’t have any experience of working within a NGO. Although I have seen one, I understand better the functioning like the organization structure and setting up projects. ● The use of skills and knowledge gain in university. It is difficult to say what skills and knowledge gained in my study I could put in my internship. ● Organizing Projects Within the internship I did lot a field work, because of this I have seen of what aspects you have to think while organizing a project. Furthermore I have learned how an education program can be set up and what things have to be taken into account. Before the education I didn’t have any experience in environmental education I had no idea if that would work. ● Skills and knowledge that might be improved to work in professional environment Although you learn and develop the necessary skills and knowledge while working in organization, there are several things that I could improve already. I did not have totally clear what activities I could have done to reach my learning goals. Therefore during my stay I had some difficulties to determine tasks what I could carry out. In advance of my internship I talked with the organization about the project I could participate, however clear agreements on my activities were not made. A more assertive attitude from my side could have helped. To prevent uncertainties in future projects I will pay more attention to my clear agreements and back-up plans.
  18. 18. 18 CONCLUSION On the whole, this internship was a useful experience. I have gained new knowledge, skill and met many new people. I achieved several of my learning goals. I got inside into professional practice. I learned different facts of working within a NGO. I experienced that assembling is an important factor that progress of project related to my study. I learned more about the Fabrication, Machining and Assembling. There is still a lot to discover and to improve. The internship is also good to find out what my strength and weakness are. This helped me to what skill and knowledge I have to improve in coming time. It would be better at the knowledge level of the language is sufficient to contribute fully to project. However I could perform certain tasks better if I practice more. It would be better at knowledge level of language is sufficient to contribute fully to project. However I could perform certain tasks better if I practice more. It would also better if I can present and express myself more confidently. At last internship has given me a new rights and motivation to pursue a carrier in industrial background.
  19. 19. 19 SPECIALLY THANKS TO… Planning Dept.: Mr. Rajan Raut Sir (HOD) Mr. Nikhil Pashte Fabrication Dept.: Mr. Deshpande Sir (HOD) Mr. Vijay Abdar (Jr. Engg) Mr. Manjeet Pawar (Welding Inspector) Mr. Deepak Bagul (GET) Mr. Arvind Shingare (CNC & Tracing) Mr. Mahendra Pal (Jr. Engg) Machine Dept.: Mr. Bhatt Sir (HOD) Mr. Akshay Kumbhar (Jr. Engg) Assembly Dept.: Mr. Harish Sharma (HOD) Mr. Navin Rao (Jr. Engg)
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