Successfully reported this slideshow.
We use your LinkedIn profile and activity data to personalize ads and to show you more relevant ads. You can change your ad preferences anytime.

INDUSTRIAL TRAINING REPORT

1,177 views

Published on

  • Be the first to comment

INDUSTRIAL TRAINING REPORT

  1. 1. INDUSTRIAL TRAINING REPORT (15’June-15’July 2o16) LUMAX MANNOH ALLIED TECHNOLOGIES Submitted by:- Suyash Trivedi (B.tech 3rd year) Central Institute of Plastics Engineering & Technology (C.I.P.E.T.) Lucknow
  2. 2. TABLE OF CONTENT CERTIFICATE ACKNOWLEDGEMENT PREFACE COMPANY PROFILE CUSTOMERS THE GEAR SHIFTER R &D APQP INTRODUCTION Benefits Of Using Advanced Product Quality Planning APQP MAJOR ELEMENTS APQP- PHASES AND ACTIVITIES PROCESS OUTPUTS FFMEA POTENTIAL FAILURE MODES FAILURE MODE EFFECTS POSSIBLE CAUSES OF FAILURE EFFECTS ANALYSIS INSPECTION INTRODUCTION
  3. 3. INSTRUMENTS USED DURING INSPECTION DIGITAL HEIGHT GAUGE DIGITAL VERNIER CALIPER DIGITAL MICROMETER PROFILE PROJECTOR RADIUS GAUGE WORK ALLOTED TO ME EXPLODED VIEW BOM MAIN PART OF HONDA 2SJ LIVER ROD LIVER CHANGE LIVER CHANGE AXLE PIVIOT BALL BUSH BRACKET (Shifer Box) COVER SEAT CUSHION SEAT BELL CRANK SPRING FIXATION SHIFT WASHER
  4. 4. SILENT BLOCK COLLAR LIST OF GAUGE REQUIRED Pic Of Spacer Assy. Fixture And Its Sub Assembly PIC OF BUSH, CONNECTING ROD & THEIR ASSEMBLY PIC OF BELL CRANK FIXTURE SENSOR SOME OTHER COMPONTENT AND THEIR ASSEMBLY PIC OF ASSEMBLY FIXTURE PIC OF FINAL ASSY. GAUGE HONDA 2SJ CONCLUSION
  5. 5. ACKNOWLEDGEMENT First of all, I would like to thank Mrs. Preeti Hooda (Manager HRD) for granting me permission to undergo training in this company. Mr. Siddharth Shrivastav (Dr. Manager, R&D) & Mr. Hari Shankar singh (Sr. Engineer, R&D) for guiding and imparting me knowledge under his supervision and helping me throughout my training schedule. Moreover, I would like to pay sincere thanks to Er. Rahul Yadav, Er. Mehak and all the employees for asserting and helping me in clearing my doubts. I sincerely think this training schedule will help me in understanding my engineering branch in the years to come in a much better way. Date: (Siddharth Shrivastava) (Manager R&D)
  6. 6. PREFACE Indian industries are waking up to the challenges thrown in by market economy. To survive in this highly competitive world, industries make efforts to improve quality, enhance productivity, cut down waste and eliminate inefficiency. These attributes are learnt by the undergraduate students through industrial training. It is an integral part of engineering education development. It aims at providing the technical knowledge and skills required for industrial operations. Industry-Academic interaction is necessary for the development of students. It gives an opportunity for interaction between technical institutions, industry and academics. Now a day, purely academic consideration in a system of professional education isn’t the criteria in determining about the suitability of personnel for technical employment. With the purpose of getting exposure to the real working environment and acquaintance with the organization structure, business operations and administrative functions, which is a part of B-Tech. course, I am undergoing ONE month training at LUMAX MANNOH ALLIED TECHNOLOGIES LTD. The following pages contain a report on the practical training undergoing by me in LUMAX MANNOH ALLIED TECHNOLOGIES LTD.
  7. 7. COMPANY PROFILE Formed in the year 1997, LUMAX DK is an integral part of the D.K. Jain Group of companies. It forms 55:45 joint venture with Japan's Mannoh Industrial Co Ltd to design and manufacture complete gear shift lever systems for manual, automatic, AMT & CVT transmissions in India LUMAX Mannoh specializes in design, manufacturing and supply of Gear Shifters, Parking Brakes, Precision Components and Plastic injection trim parts. These are complimented by a range of two wheeler lighting parts. These are manufactured to the highest standards and stringent quality control procedures. LUMAX Mannoh - an ISO 9001:2000 and ISO/TS 16949:2002 certified company, endeavour to provide our customers with quality automotive parts at a competitive price. TECHNOLOGY:- Technology support from Mannoh, Japan especially for Gear Shifters.  Precision Engineering - CAD systems with AutoCAD Inventor & Unigraphics NX3, CATIA, and Tool room with all required machines and fixtures for Tool development and prototyping.  Robust Manufacturing - 3-AXIS Tube Bending and Copping, Hydraulic Pressing, Robotic MIG Welding Stations, Plastic Injection Moulding, Robot Writing for Gear Shifter Knob, and Cellular Assembly Lines  Stringent Testing setup - Endurance Testing for Parking Brake, Tensile Testing, Weld Penetration Check, Hardness Testing, Profile Checking, and Strength Testing.
  8. 8. THE GEAR SHIFTER For those of you who don’t know, it’s that rod like thing with a knob on top you must have seen sticking out from the floor of your car. And you use it to shift gears while driving. Nomenclature for Basic Cable Type Gear Shifter
  9. 9. R & D  Research and Development department has to actually “create” the product as per the requirements of the customer, as stated in the LOI.  ADVPR o Analysis/Development/Validation Plan and Report (ADVPR): A timeline with different steps from LOI to final product is made with respective target times.  DESIGN  DesignDrawing o Design team prepares the 3-D drawing of model as per requirements using software CATIA or UG. o FEA (Finite Element Analysis) is done at different load conditions, and any changes, if required are made. o Build of Material (BOM) sheet is prepared. 1. Shows part picture, material, weight and quantity. 2. BOM is forwarded to the Purchase department for costing.  Costing o Design Costing is done to project the estimated cost of the product for the buyer. o It includes the cost of material, cost of molding; machining etc. Whatever is required to make it, packaging and a profit? Adding all of these gives the cost price.  DEVELOPMENT o After the designing is done and design approved, product development begins. Different child parts for the shifter are procured and prototype is made for trial. If it is approved then go ahead is given for tooling. o Further testing is done on the parts and if OK, process is developed. Product and process validation is then done by customer.
  10. 10. Introduction Advanced Product Quality Planning (APQP) enables product quality to improve and ensure that customer needs and wants are satisfied. APQP includes a number of procedures structured in such a manner that it satisfies customers. Here is a closer look at the basics of APQP and how it works to benefits our business. APQP is uses extensively in a number of industries including automotive and manufacturing industries as a means to improve product quality. The end goal is to ensure that the quality of the final product is top – notch by using a number of tools and techniques.
  11. 11. Benefits of using Advanced Product Quality Planning:-  To direct resources to satisfy customer  To promote early identification of required changes  To avoid late changes  To promote a quality product on time at the lowest price  Identify ways to improve.  Means for tracking and checking.  Continual improvements.  Reduction in time cycle by upfront planning.  Better communication.  On time output.  Do it right, first time and every time.
  12. 12. APQP Major Elements  Understand customer need. This is done using voice of the customer techniques to determine customer needs and using quality function deployment to organize those needs and translate them into product characteristics/requirements.  Proactive feedback & corrective action. The advance quality planning process provides feedback from other similar projects with the objective of developing counter-measures on the current project. Other mechanisms with verification and validation, designreviews, analysis of customer feedback and warranty data also satisfy this objective.  Designwithin process capabilities. This objective assumes that the company has brought processes under statistical control, has determinedits process capability and has communicated it process capability to its development personnel. Once this is done, development personnel need to formally determine that critical or special characteristics are within the enterprise's process capability or initiate action to improve the process or acquire more capable equipment.  failure modes and effects analysis or anticipatory failure determination
  13. 13. APQP- PHASES AND ACTIVITIES The Advanced Product Quality planning process consists of four phases and five major activities along with ongoing feedback assessment and corrective action.
  14. 14. Process Outputs
  15. 15. FFMEA FFMEA - FAST Failure Modes and Effects Analysis .  This approach to problem solving and product/process improvement uses FAST Modeling as a beginning point to identify functions to be analyzed using the FMEA approach.  FMEA & FAST: Describe the product/process and its function. An understanding of the product or process under consideration is important to have clearly articulated.  Create a Block Diagram of the product or process. A block diagram [FAST Model] of the product/process should be developed. This diagram shows major components or process steps [Functions] as blocks connected together by lines that indicate how the components or steps are related.  Identify Failure Modes. A failure mode is defined as the manner in which a component, subsystem, system, process, etc. could potentially fail [or has failed] to meet the design intent.  A failure mode in one component can serve as the cause of a failure mode in another component. [This is a basic premise of FAST]  Failure modes should be listed for functions of each component or process step. At this point the failure mode should be identified whether or not the failure is likely to occur.
  16. 16. Potential Failure Modes:-  Corrosion Hydrogen embrittlement  Electrical Short or Open  Torque  Fatigue  Deformation  Cracking  Failure Mode Effects:-  Injury to the user  Inoperability of the product or process  Improper appearance of the product or process  Odors  Degraded performance Noise.
  17. 17. Possible Causes of failure:-  Improper torque applied  Improper operating conditions  Contamination  Erroneous algorithms  Improper alignment  Excessive loading  Effects Analysis:-  A numerical weight should be assigned to each cause that indicates how likely that cause is. A common industry standard scale uses 1 to represent not likely and 10 to indicate inevitable.  Identify controls. Testing, analysis, monitoring, and other techniques should be identified that can or have been used on the same or similar products/processes to detect failures.  Each of these controls should be assessed to determine how well it is expected to identify or detect failure modes.
  18. 18. INTRODUCTION The term Inspection has been defined in different ways by different authors: “Inspection is the art of comparing materials, product, or performances with established standards” -KIMBALL “Inspection is the art of applying tests preferable by the aid of measuring appliances to observe whether a given item of product is within the specified limits of variability” -ALFORD AND BEATTY “Inspection is the process of measuring the qualities of a product or services in terms of established standards” -SPIGEL AND LANSBURG In simple words,” Inspection is the act of comparing a product with accepted specification or other recognized standards”. Thus inspection means checking the acceptability of the manufactured product. Inspection measures the qualities of a product or service in terms of predecided standards. Product quality may be specified by the strength, shape, hardness, surface finish, dimensions or by other parameters.
  19. 19. INSTRUMENTS USED DURING INSPECTION: 1) Digital Height Gauge 2) Digital Vernier Caliper 3) Digital Micrometer 4) Profile Projector 5) Radius Gauge 6) Internal Micrometer 7) Depth Vernier 8) Low Force Vernier 9) Bevel Protector 10) Level Meter 11) Thread Ring Gauge 12) Thread Plug Gauge 13) Hardness Tester
  20. 20. DIGITAL HEIGHT GAUGE :- A digital height gauge is a measuring device used either for determining the height of objects, or for marking of items to be worked on. Height gauges may also be used to measure the height of an object by using the underside of the scriber as the datum. The datum may be permanently fixed or the height gauge may have provision to adjust the scale, this is done by sliding the scale vertically along the body of the height gauge by turning a fine feed screw at the top of the gauge; then with the scriber set to the same level as the base, the scale can be matched to it. This adjustment allows different scribers or probes to be used, as well as adjusting for any errors in a damaged or resharpened probe. Digital Height Gauge
  21. 21.  DIGITAL VERNIER CALIPER:- The Digital Calliper (sometimes incorrectly called the Digital Vernier Calliper) is a precision instrument that can be used to measure internal and external distances extremely accurately. The example shown below is a digital calliper as the distances/measurements, are read from a LCD display. The most important parts have been labelled. Earlier versions of this type of measuring instrument had to be read by looking carefully at the imperial or metric scale and there was a need for very good eyesight in order to read the small sliding scale. Manually operated vernier callipers can still be bought and remain popular because they are much cheaper than the digital version. Also, the digital version requires a small battery whereas the manual version does not need any power source. Digital callipers are easier to use as the measurement is clearly displayed and also, by pressing the inch/mm button the distance can be read as metric or imperial. Digital Vernier Calliper
  22. 22.  DIGITAL MICROMETER:- A micrometer sometimes known as a micrometer screw gauge, is a device incorporating a calibrated screw widely used for precise measurement of components in mechanical engineering and machining as well as most mechanical trades, along with other metrological instruments such as dial, vernier, and digital calipers. Micrometers are usually, but not always, in the form of calipers (opposing ends joined by a frame), which is why micrometer caliper is another common name. The spindle is a very accurately machined screw and the object to be measured is placed between the spindle and the anvil. The spindle is moved by turning the ratchet knob or thimble until the object to be measured is lightly touched by both the spindle and the anvil. Basic types:-  Outside micrometer (aka micrometer caliper), typically used to measure wires, spheres, shafts and blocks.  Inside micrometer, used to measure the diameter of holes.  Depth micrometer, measures depths of slots and steps.
  23. 23. Digital Micrometer  PROFILE PROJECTOR:- A profile projector is also referred to as an optical comparator, or even known as a shadowgraph, a profile projector is an optical instrument utilized for measuring. It is a valuable item in a small parts machine shop or manufacturing line for the quality control assessment staff. The projector magnifies the profile of the specimen, and shows this on the built-in projection screen. From this screen there is usually a grid that could be rotated 360 degrees therefore the X-Y axis of the screen could be aligned correctly using a straight edge of the machined part to analyze or measure. This projection screen shows the profile of the sample and is zoomed for better ease of computing linear dimensions. An edge of the sample to analyze could be aligned using the grid on the screen. After that, basic measurements could be obtained for distances along with other points. This is being carried out on a zoomed profile of the specimen. It could be easier and also lessen mistakes by measuring on the magnified projection screen of a profile projector.
  24. 24. Profile Projector  RADIUS GAUGE:- A radius gauge, also known as a fillet gauge, is a tool used to measure the radius of an object. Radius gauges require a bright light behind the object to be measured. The gauge is placed against the edge to be checked and any light leakage between the blade and edge indicates a mismatch that requires correction. A good set of gauges will offer both convex and concave sections, and allow for their application in awkward locations. Every leave has different radius. The material of the leaves is stainless steel. It is of two types: 1. Internal 2. External. It is used to check the radius of inner and outer surfaces.
  25. 25. Radius Gauge THE WORK ALLOTTED TO ME……. I am Working on HONDA 2SJ. Under the guidance of Mr. Rahul Yadav
  26. 26. HONDA 2SJ (Shifter Box)
  27. 27. MAIN PART OF Honda 2SJ (HCIL):-  LEVER ROD  Lever Change  Arm Axle  Piviot Ball  Bush  Bracket/Shifter Box  Cover  Seat  Cushion  Bell Crank  Spring  Fixation Shaft  Washer  Silent Block  Collar  Grease
  28. 28. PART NAME –LEVER ROD
  29. 29. PART NAME – Lever Change Finish Weight (Gram):- 255gm Material:- S35C or equi. PART NAME - Axle Finish Weight (Gram):- 27gm Material:- S35C or equi.
  30. 30. PART NAME – Piviot Ball Finish Weight (Gram):- 12gm Material:- PA66-GF-15. PART NAME – Bush Finish Weight (Gram):- 2.1gm Material:- POM (Natural
  31. 31. PART NAME – BRACKET (SHIFTER BOX) Finish Weight (Gram):- 416gm Material:- PA6-GF-30. PART NAME – COVER Finish Weight (Gram):- 416gm Material:- PA6-GF-30.
  32. 32. PART NAME – SEAT CUSHION Finish Weight (Gram):- 2gm Material:- NBR. PART NAME – SEAT Finish Weight (Gram):- 18gm Material:- POM.
  33. 33. PART NAME – BELL CRANK Finish Weight (Gram):- 32gm Material:- PA6-GF-30. PART NAME – SPRING Finish Weight (Gram):- 10gm Material:- Stainless steel (4454P-1GR3).
  34. 34. PART NAME – FIXATION SHAFT Finish Weight (Gram):- 62gm Material:- S45 or equi. PART NAME – WASHER Finish Weight (Gram):- 2gm Material:- SPS65.
  35. 35. PART NAME – SILENT BLOCK Finish Weight (Gram):- 6gm Material:- EPDM Hs50. PART NAME – COLLAR Finish Weight (Gram):- 11gm Material:- SAE1010 or equi.
  36. 36. LIST OF GAUGE REQUIRED:- 1. SPACER ASSY. FIXTURE 2. BUSH FIXTURE 3. BELL CRANK FIXTURE SENSOR 4. ASSEMBLING FIXTURE 5. FINAL ASSY. GAUGE.
  37. 37. PIC OF SPACER ASSY. FIXTURE AND ITS SUB ASSEMBLY
  38. 38. PIC OF BUSH FIXTURE
  39. 39. PIC OF BELL CRANK FIXTURE SENSOR AND ITS SUB ASSEMBLY
  40. 40. PIC OF ASSEMBLING FIXTURE
  41. 41. PIC OF FINAL ASSEMBLING GAUGE
  42. 42. TOP VIEW HONDA 2SJ
  43. 43. CONCLUSION Lumax Mannoh Allied Technologies was a challenging place for students to do their internship program. By this internship program, I have gained a wide knowledge of technical job scope and also the technical works from my superior, Rahul Yadav Sir and colleagues from other department. The company provides me with the real working environment. Not only learning the general work scope here but the practical students also have got the opportunities to implement the work scope with their own strength and abilities during the internship. It was an advantage for me to be in the R &D Division where I have boosted up my skills and abilities. The conclusion that I can make is that Lumax Mannoh Allied Technologies is the right place for students to do their industrial training.

×