1. Praful G Khandalkar
Department:Turned Cage
Designation: Graduate Apprentice-Production Engineer

2.  I am using this opportunity to express my gratitude to
everyone who supported me throughout my one year
apprenticeship.
 I express my warm thanks to Mr. M. Patra, Mr. Ankit
Agrawal, Mr. Girish Ghatnadrekar, Mr. Sajjad Shaikh
and Mr. Arjun Shinde for their support and guidance in
NRB Bearings Ltd.
 I would also like to thank Dept Head A A Mapari and all
the people who provided me with the facilities being
required and conductive conditions for my Training.

3.  Shift Handling
 Material Movement
 Maintain WIP
 Safety precaution of operator and Casuals
 Quality assurance
 Follow-up with maintenance department for
breakdowns
 Use of ERP for OSP material movement

4.  Process Documentation
Updating Production sheet-MS-Excel
Maintain Log book
 Audit Related Documents
Control Plan
PFMEA
Process Flow
Revise Control plans for KB60306TM, KB60188TM
(Customer : Mahindra and Mahindra)
New Control Plans for NPD-KB60361TM, KB60362TM
(Customer : Avtec)
Periodic review of all other CP and documents

5. 1. KB60100TMC Broach life Improvement
2. HMT Bush life Improvement
3. LEM Punch Lapping Elimination
4. Benchmarking in coolant concentration level to
reduce the rust problem in cage to Zero
5. Grinding wheel life improvement

6.  Problem Detected:
• Broach tools were continuously breaking.
 Activity:
• Punch length increases in punching from
13.80±0.05mm to 13.90±0.05mm.
• Less material for broaching
 Achievement:
• Broach life increased to 10000 Nos so the Broach
Cost ( Rs.6930) and Broach Changing time(Loss
time).

7.  Problems Detected:
• Bush wear out
• Face Damage
 Activity:
• Material of bush changed to Carbide by taking help
from GG(Tool room)
• Groove increased in OD of Carrier to improve
holding capacity of bush in carrier.
 Achievement:
• Bush Trial is ongoing and so the frequency to be
determine.

8. BEFORE AFTER
Small groove and early
wear of HSS bush
Carbide bush
with groove in
OD
Groove increased

9.  Problem Detected:
• Lapping of punch (Loss time)
• Burr problem
• Affects life of Punch
• Chances of overlapping so the pocket width undersize
 Activity:
• Punch Width (Middle) dimension changes from 2.41mm to 2.39mm for
Size KB60035TMC
 Achievement:
• Trial taken on 24th
Aug 2014
• Successful Punching of 3500 Nos of Cages with out burr in dimensions.
• Cages to be sent for plating on 28th
Aug to Shree Vyankatesh Engg.
• Controlling and skew test to be taken and drawing to be finalized.
• Horizontal Deployment: KB60092TMS, KB60175TM

10.  Maintaining Coolant concentration
 Prevention of Rust after Deburring
Rusty Problem-
2013
Rusty Problem-
2014
2000 Nos Zero

11.  Problems Detected:
• More No. of set-ups
 Activity:
• Wheel grade change A80 O5PVP6
 Achievement:
• No. of set ups reduced from 24 to 18 per year
• GW consumption reduced from 48 nos to 36 nos
• Cost saved in grinding wheels= Rs. 74652
• No. of hours saved in changing the wheels for one
year=6x8=48 Hours

12.  WIP
 Automation of Face grinding machine
 Rib variation of Sutantra , Godrej and Barrenburg
 Main Cause: Play in indexing, Brake to Clutch modification
 To eliminate problems to minimum