1) The document discusses the author's internship project improving productivity of assembling locator assemblies at Larsen & Toubro Limited. 2) The author analyzed problems with inaccurate welding fixtures that led to defects and proposed new 3D designed fixtures. Layout of the assembly shop was also proposed to reduce material handling time and increase productivity. 3) As part of the project, the author developed logical symbols to identify the operation stages of the locator assemblies and reduce time spent determining their process status. The new fixture designs and shop layout were found to help address the identified problems and improve productivity.

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SVKM’S NMIMS UNIVERSITY
Mukesh Patel School of Technology Management &
Engineering
Executive Summary
On
PRODUCTIVITY IMPROVEMENT OF LOCATOR ASSEMBLY
By
HARSH THAKER
MBATech Mechanical [K038]
Nuclear equipment Department,
Larsen & Toubro Ltd

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INDEX
1. ABSTRACT ------------------------------------------------------------------------------------------------------------3
2. INTRODUCTION----------------------------------------------------------------------------------------------------4
3. MY CONTRIBUTION TO THE LOCATOR ASSEMBLY PROJECT-------------------------------------------5
4. CONCLUSION-------------------------------------------------------------------------------------------------------6

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1. ABSTRACT
Larsen & Toubro Limited (L&T) is a technology, engineering, construction and manufacturing
company. It is one of the largest and most respected companies in India's private sector. The
historical background of M/S LARSEN & TOUBRO highlights its gradual establishment. This
report starts with introduction to the company with the company spectrum and later highlights
the different engineering departments of company.
I was placed in the Nuclear Power Plant Equipment SBU, PMG Department of Heavy
Engineering Division (HED). I gained experience and knowledge about the importance of work
culture and planning & execution, which is one of the privileges of working in the PMG – Project
Management Group.
In this department project named LOCATOR ASSEMBLY is going on. LOCATOR ASSEMBLY is the
assembly of different component which is then used in nuclear reactor which is setup in
KAKRAPUR AND RAJASTHAN. Major operation done by L&T in this project is welding of different
component of locator assembly in dust free environment shop.
Following problems were faced during the operation on locator assembly
 Inaccurate fixture design for trial welding which leads to welding defects like (suck back,
excess filler metal etc.)
 Lot of time consumption in handling the assembly within the shop
 No proper ergonomics within the shop leading decrease in productivity
In order to address this problem I have made two fixture design on 3D software, both the
design are proposed to my mentor with their pros and cons. I have also made the layout of the
shop on the basis of the sequence of the process it follows and to reduce the material handling
time in the shop. I have tried to put my sincere efforts to make this report a worthy & honest
declaration of whatever I accomplished at M/S Larsen & Toubro Ltd.

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2. INTRODUCTION:I worked as “junior supervisor” at the DFE (dust free environment) shop,
where the locator assembly were made. I use to take the status of each locator assembly and
make the record of them. I use to give this status to my mentor on daily basis. I was also
responsible for keeping the record of requirements in the shop for near future, which includes
raw material, tools (filler metal, grinding machine, vernier calliper etc.). I also co-ordinate
different department like quality check department, welding engineering department, project
management department by giving them status and informing problem faced by welders during
welding.
I also use to coordinate with store department at time of any dispatch of the assembly
or procurement of the assembly from the vendors or customer by producing request
notice in the system.
Following were my responsibility during my internship:
1. Getting the detail of the work assign to the welder on each day.
2. Keeping the record of the locator assembly in the shop and no. of operation
done on it.
3. Collecting the record of the Radiographic Test from the R.T. department.
4. Intimating the store department if there is some requirement of any raw
material in the store
5. Coordinating with the vendors in order to know the delivery date of the locator
assembly at the shop
6. Keeping the record of the problem found in the locator assembly during the
radiographic test.
7. Keeping the record of the solution decided for those failed assemblies by
welding engineering department.

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3. MY CONTRIBUTION TO THE LOCATOR ASSEMBLY PROJECT.
I have first analysed the problem faced on automatic welding machine
due to fixture. I had then list down the problem face due to the fixtures on the weld joint.
Following were the problems faced due to inaccurate fixture
1. Multiple layer of filler material on the circumference of the pipe
2. Constant variation of the voltage and current in the automatic machine due to
varying distance between the pipe and the Torch.
3. Sensitivity of the machine for voltage and current was difficult to set.
4. Common defect found in radiographic test of the pipe were: SUCK BACK, EXCESS
PENITRATION, VOID AT SIDE OF THE PIPE.
In order to address this problem I have made two fixture design on 3D
software.(unigraphics , solidworks).Both the fixture designs are made such that it can fix
almost all the standard O.D. Pipes which are commonly available at the shop.
Both the designs are analysed by me and I have made pros and cons of each design and
submitted to my mentor.
I have also made the layout of the shop in order to avoid following problem
1. Lot of time consumption in handling the assembly within the shop
2. No proper ergonomics within the shop leading decrease in productivity
3. No define path for walking in the shop especially while inspection.
There were few operation (like: liquid penetration test, radiographic test, dimension
inspection) done on the locator assembly which cannot be identified weather it is done
or not by just looking at it. Hence to avoid such problem I have developed few logical
symbols which are kept on the locator assembly in order to understand its stage on
operation sequence.

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4. CONCLUSION:
During the process of making design of fixture, I realised that 3-D modelling software makes the
process very easy and quick. It helps to analyse the design more efficiently and precisely. After
a brief discussion with my mentor regarding the two design of fixture proposed by me, we
concluded that design 1 and 2 both can serve the objective, but design 1 is expensive to make
and its use in our project will not be as excessive as compare to design 2.
I had also made shop layout, which was partially implemented and many desired
outcome were noticed like reduction in handling time, increase of productivity etc.
Shop layout can be even more modified if the Radiographic Test machine is setup
within the shop. By doing this huge amount of time can be saved during the process.