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INDUSTRIAL TRAINING PRESENTATION
By
RAHUL BANERJEE
(MECHANICAL ENGINEERING)
BEEKAY ENGINEERING
CORPORATION
1
CONTENTS
INTRODUCTION
History
Manufacturing Infrastructure
PRODUCTS MANUFACTURED
DEPARTMENT/SHOPS AND THEIR PROCESSES
CAST IRON FOUNDRY SHOP
Estimation of Cost of Castings
FABRICATION SHOP
MACHINE SHOP
TESTING
LEARNING OUTCOMES
CONCLUSION
INTRODUCTION
HISTORY
Year of Established:1949
Managing Director (S. D. Shibulal)
Established for Manufacture of equipment and spares for Bhilai Steel Plant
It soon began catering to the requirements of other Steel plant at Rourkela,
Durgapur & Bokaro.
Beekay entered the field of turnkey projects in 1987 .
Beekay has also successfully completed the construction of 600 m3 BF for Nacast,
Notable achievements recently was supply of BF & HS shells for POSCO's 4000M3 BF
project at SAIL ISP.
Beekay is accredited with ISO 9001, ISO 14001, ISO 18001, API, ASME U Stamp and
CCE approvals.
Beekay is using cutting edge technology for the manufacturing of their products.
They also have some technologies from different countries like China, Italy, etc
MANUFACTURING
INFRASTRUCTURE
PRODUCTS
MANUFACTURED
Iron Making Equipments
Blast furnace
SPONGE IRON PLANTS
Dewatering drumHot metal car
TYRE SHELL FOR 300 TPD
Steel Making Equipments
Steel making equipments
Caster equipments
RH Vacuum Degassing Vessel Twin Pot Slag Thimble Car
Addle turret Segment for slab caster
ROLLING MILL EQUIPMENTS
Pinch Roll Merchant Mill Rolling mill
COKE OVEN EQUIPMENTS
Coke quenching car waste gas valve
PRESSURE VESSELS
Vapour collecting unit Nitrogen tank
RAILWAYS
140 T Jib crane boom Engine floor frame
An Industry comprises of different types of departments and shops for the proper working
and completion of a job in a required time period with efficiency.
The different departments can be classified as :-
Marketing department.
Finance department
Planning department
Machine shop
Fabrication shop
Foundry shop
Assembly shop
Testing department
Other
DEPARTMENT/SHOPS AND
THEIR PROCESSES
The product undergoes by sequential process are :-
Enquiry done by the customer about the product to know about it and related queries.
Quotation is made to show all the specification and expected cost for a particular
product which is asked by the customer.
It involves the extra cost like excise duty ,sales tax, e-tax, etc.
A sample diagram is sent by the customer to the industry.
Finance department estimate the basic cost of the materials and other resources used.
Standards of the material are followed and if standards do not match an alternate
standard is confirmed by the customer.
Original manufacturing drawing is sent with actual specification of the size and shape.
Planning department plan a efficient way to achieve the target of the product to be made.
Manufacturing involving the different shops the product is formed.
Product is tested by the NDT department.
Delivery of the product is done.
CAST IRON
FOUNDRY SHOP
TO PRODUCE THE METAL CASTING DIFFERENT OPERATIONS ARE DONE
ARE:-
Drying of sand
Separation of sand in different size
Mixing of the Mold Mixture
Melting of cast iron
Collection of molten metal
Mold and riser making
Chipping of the waste material after removal of the casting
Stress relief provided to the casting
Estimation of Cost of Castings
The total cost of manufacturing a component consists of following elements :
 Material cost.
 Labour cost.
 Direct other expenses.
 Overhead expenses.
Material Cost
From the component drawing, calculate
the volume of material required for casting.
This volume multiplied by density of
material gives the net weight of the casting.
Add the weight of process scrap i.e.
weight of runners, gates and risers and other
material consumed as a part of process in
getting the casting.
Add the allowance for metal loss in
oxidation in furnace, in cutting the gates and
runners and over runs etc.
Multiply the total weight by cost per unit
weight of the material used.
Subtract the value of scarp return from the
amount obtained in previous step ,to get the
direct material cost.
Labour Cost
Labour is involved at various stages in a foundry shop.
Broadly it is divided into two categories :
The cost of labour involved in making the cores, baking of
cores and moulds is based on the time taken for making various
moulds and cores.
The cost of labour involved in firing the furnace, melting and
pouring of the metal.
Cleaning of castings, fettling, painting of castings etc., is
generally calculated on the basis of per kg of cast weight.
Direct Other Expenses
Direct expenses include the expenditure incurred on patterns, core
boxes, cost of using machines and other items which can be directly
identified with a particular product. The cost of patterns, core boxes
etc., is distributed on per item basis.
Overhead Expenses
The overheads consist of the salary and wages of supervisory staff,
pattern shop staff and inspection staff, administrative expenses, water
and electricity charges etc. The overheads are generally expressed as
percentage of labour charges.
The cost of a cast component is calculated by adding the above
constituents.
CUTTING
CNC Profile Cutting
Gas Cutting
BENDING
Bending Roller
PLANNING
Edge planner
WELDING
GMAW(Gas metal arc welding)
Submerged arc welding
Flux cored welding
Grinding
FABRICATION SHOP
MACHINE SHOP
In this shop the machines are conventional and are manual or semi
automated. Here the parts are machined in accordance with the requirement
of the job. In a separate part there are non conventional machines(CNC machines),
Which work faster than the conventional one and more efficient with more finish.
The different kind of operations done here are:-
Boring :- In this there are horizontal and vertical boring machines of different specifications
for example a HB upto spindle dia 210mm,VB upto height 3700mm and spindle dia 7000 mm,
etc.
Milling: - For milling the boring machine can be used by changing the tool form the tool
post.
Shaper: - Some shaper machines are installed upto stroke 600mm.
Planning:- Planomiller are used having ability to do planning and milling operations.
Turning :- Lathe range upto 3m dia and 11m long.
Slotting:- Slot machine are available upto 200mm.
Cutting:- Hacksaw/Bandsaw are installed.
Pressing:-Single action hydraulic press of upto 400 ton capacity.
Drilling:-It can be done on lathe machine or any other boring machine by placing drill bit.
PLANOMILLER
MILLING
LATHE MACHINE
DEEP BORING
SINGLE ACTION
HYDRAULIC PRESS
BENDING /PRESSING
LATHE MACHINE
TURNING
Physical testing
Universal testing machine
Brinell hardness tester
Charpy tester
Chemical testing
TESTING
Sand testing
Compressive and tensile test
Permeability test
NDT(Non destructive testing)
Radiography (X-ray)
Ultrasonic testing
Magnetic particle testing machine
Die penetrant test
Learned about the standards and its necessity. Also learned that the name
of a material denotes something about it for example material like
S335j0Cu641210 which tells that S means material is structure type and 335
gives its tensile strength J0 gives the detail that it is tested in 0’C and Cu
denotes cupper based and last denotes the standard followed by it.
Learned about the different gases used for different material for cutting like
for stainless steel nitrogen and air is used while for mild steel oxygen and LPG
is used.
Learned about the command for manual control over the path movement for
critical path or for interval based check by the command MDI(Manual data
input).
Lubrication is not used for cast iron and the reason behind it is the brittleness
and hardness of cast iron make the chip like dust which can choke the system if
mixed with lubrication forming a muddy mixture.
LEARNING
OUTCOMES
The BEEKAY ENGINEERING CORPORATION is a well know
industry manufacturing equipments of different industries.
The industry is utilizing its waste resources for the development of the
industry and taking care of the safety and environment.
Very high technology is introduced and is a industry for producing a
variety of products. The profit of an organization entirely depends on the
way the top chairs manage the resources the organization has. Whatever
the other aspects may be, it was seen that managing human resource was
extremely difficult. The stability or the sustainability of the organization
mostly depends on this factor.
In most cases it could be seen that there exists easier or better ways to do
something.
Adopting new methods provide efficient use of resources and can enhance
the effectiveness of the work.
CONCLUSION
Industrial training presentation (mechanical engineering)

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Industrial training presentation (mechanical engineering)

  • 1. INDUSTRIAL TRAINING PRESENTATION By RAHUL BANERJEE (MECHANICAL ENGINEERING) BEEKAY ENGINEERING CORPORATION
  • 2. 1 CONTENTS INTRODUCTION History Manufacturing Infrastructure PRODUCTS MANUFACTURED DEPARTMENT/SHOPS AND THEIR PROCESSES CAST IRON FOUNDRY SHOP Estimation of Cost of Castings FABRICATION SHOP MACHINE SHOP TESTING LEARNING OUTCOMES CONCLUSION
  • 3. INTRODUCTION HISTORY Year of Established:1949 Managing Director (S. D. Shibulal) Established for Manufacture of equipment and spares for Bhilai Steel Plant It soon began catering to the requirements of other Steel plant at Rourkela, Durgapur & Bokaro. Beekay entered the field of turnkey projects in 1987 . Beekay has also successfully completed the construction of 600 m3 BF for Nacast, Notable achievements recently was supply of BF & HS shells for POSCO's 4000M3 BF project at SAIL ISP. Beekay is accredited with ISO 9001, ISO 14001, ISO 18001, API, ASME U Stamp and CCE approvals. Beekay is using cutting edge technology for the manufacturing of their products. They also have some technologies from different countries like China, Italy, etc
  • 5. PRODUCTS MANUFACTURED Iron Making Equipments Blast furnace SPONGE IRON PLANTS Dewatering drumHot metal car TYRE SHELL FOR 300 TPD Steel Making Equipments Steel making equipments Caster equipments RH Vacuum Degassing Vessel Twin Pot Slag Thimble Car Addle turret Segment for slab caster
  • 6. ROLLING MILL EQUIPMENTS Pinch Roll Merchant Mill Rolling mill COKE OVEN EQUIPMENTS Coke quenching car waste gas valve PRESSURE VESSELS Vapour collecting unit Nitrogen tank RAILWAYS 140 T Jib crane boom Engine floor frame
  • 7. An Industry comprises of different types of departments and shops for the proper working and completion of a job in a required time period with efficiency. The different departments can be classified as :- Marketing department. Finance department Planning department Machine shop Fabrication shop Foundry shop Assembly shop Testing department Other DEPARTMENT/SHOPS AND THEIR PROCESSES The product undergoes by sequential process are :- Enquiry done by the customer about the product to know about it and related queries. Quotation is made to show all the specification and expected cost for a particular product which is asked by the customer. It involves the extra cost like excise duty ,sales tax, e-tax, etc. A sample diagram is sent by the customer to the industry. Finance department estimate the basic cost of the materials and other resources used. Standards of the material are followed and if standards do not match an alternate standard is confirmed by the customer. Original manufacturing drawing is sent with actual specification of the size and shape. Planning department plan a efficient way to achieve the target of the product to be made. Manufacturing involving the different shops the product is formed. Product is tested by the NDT department. Delivery of the product is done.
  • 8. CAST IRON FOUNDRY SHOP TO PRODUCE THE METAL CASTING DIFFERENT OPERATIONS ARE DONE ARE:- Drying of sand Separation of sand in different size Mixing of the Mold Mixture Melting of cast iron Collection of molten metal Mold and riser making Chipping of the waste material after removal of the casting Stress relief provided to the casting
  • 9. Estimation of Cost of Castings The total cost of manufacturing a component consists of following elements :  Material cost.  Labour cost.  Direct other expenses.  Overhead expenses. Material Cost From the component drawing, calculate the volume of material required for casting. This volume multiplied by density of material gives the net weight of the casting. Add the weight of process scrap i.e. weight of runners, gates and risers and other material consumed as a part of process in getting the casting. Add the allowance for metal loss in oxidation in furnace, in cutting the gates and runners and over runs etc. Multiply the total weight by cost per unit weight of the material used. Subtract the value of scarp return from the amount obtained in previous step ,to get the direct material cost. Labour Cost Labour is involved at various stages in a foundry shop. Broadly it is divided into two categories : The cost of labour involved in making the cores, baking of cores and moulds is based on the time taken for making various moulds and cores. The cost of labour involved in firing the furnace, melting and pouring of the metal. Cleaning of castings, fettling, painting of castings etc., is generally calculated on the basis of per kg of cast weight. Direct Other Expenses Direct expenses include the expenditure incurred on patterns, core boxes, cost of using machines and other items which can be directly identified with a particular product. The cost of patterns, core boxes etc., is distributed on per item basis. Overhead Expenses The overheads consist of the salary and wages of supervisory staff, pattern shop staff and inspection staff, administrative expenses, water and electricity charges etc. The overheads are generally expressed as percentage of labour charges. The cost of a cast component is calculated by adding the above constituents.
  • 10. CUTTING CNC Profile Cutting Gas Cutting BENDING Bending Roller PLANNING Edge planner WELDING GMAW(Gas metal arc welding) Submerged arc welding Flux cored welding Grinding FABRICATION SHOP
  • 11. MACHINE SHOP In this shop the machines are conventional and are manual or semi automated. Here the parts are machined in accordance with the requirement of the job. In a separate part there are non conventional machines(CNC machines), Which work faster than the conventional one and more efficient with more finish. The different kind of operations done here are:- Boring :- In this there are horizontal and vertical boring machines of different specifications for example a HB upto spindle dia 210mm,VB upto height 3700mm and spindle dia 7000 mm, etc. Milling: - For milling the boring machine can be used by changing the tool form the tool post. Shaper: - Some shaper machines are installed upto stroke 600mm. Planning:- Planomiller are used having ability to do planning and milling operations. Turning :- Lathe range upto 3m dia and 11m long. Slotting:- Slot machine are available upto 200mm. Cutting:- Hacksaw/Bandsaw are installed. Pressing:-Single action hydraulic press of upto 400 ton capacity. Drilling:-It can be done on lathe machine or any other boring machine by placing drill bit.
  • 12. PLANOMILLER MILLING LATHE MACHINE DEEP BORING SINGLE ACTION HYDRAULIC PRESS BENDING /PRESSING LATHE MACHINE TURNING
  • 13. Physical testing Universal testing machine Brinell hardness tester Charpy tester Chemical testing TESTING Sand testing Compressive and tensile test Permeability test NDT(Non destructive testing) Radiography (X-ray) Ultrasonic testing Magnetic particle testing machine Die penetrant test
  • 14. Learned about the standards and its necessity. Also learned that the name of a material denotes something about it for example material like S335j0Cu641210 which tells that S means material is structure type and 335 gives its tensile strength J0 gives the detail that it is tested in 0’C and Cu denotes cupper based and last denotes the standard followed by it. Learned about the different gases used for different material for cutting like for stainless steel nitrogen and air is used while for mild steel oxygen and LPG is used. Learned about the command for manual control over the path movement for critical path or for interval based check by the command MDI(Manual data input). Lubrication is not used for cast iron and the reason behind it is the brittleness and hardness of cast iron make the chip like dust which can choke the system if mixed with lubrication forming a muddy mixture. LEARNING OUTCOMES
  • 15. The BEEKAY ENGINEERING CORPORATION is a well know industry manufacturing equipments of different industries. The industry is utilizing its waste resources for the development of the industry and taking care of the safety and environment. Very high technology is introduced and is a industry for producing a variety of products. The profit of an organization entirely depends on the way the top chairs manage the resources the organization has. Whatever the other aspects may be, it was seen that managing human resource was extremely difficult. The stability or the sustainability of the organization mostly depends on this factor. In most cases it could be seen that there exists easier or better ways to do something. Adopting new methods provide efficient use of resources and can enhance the effectiveness of the work. CONCLUSION