here's a training report which is important in engg. field

1. 1
INDUSTRIAL TRAINING REPORT
ON
HEAVY FABRICATION &
MACHINING INDUSTRY

2. 2
AN INDUSTRIAL TRAINING REPORT
Done By
Shridhar Kadam & Gaurav kumar Singh
At
Hardrock Attachments Pvt. Ltd.
Belur Industrial Area, DHARWAD, KARNATAKA
Submitted To
Department of MECHANICAL Engineering
DKTE SOCIETY’s
YASHWANTRAO CHAVAN POLYTECHNIC, ICHALKARANJI
Approved by AICTE, New Delhi & Govt. of Maharashtra,
Affiliated to MSBTE, Mumbai
R. S. No. 644, Sangli Road, Near Adinath Society, Ichalkaranji – 416 115
Dist. Kolhapur, Maharashtra

3. 3
REPORT CONTENTS
 Introduction
 Actual Plant layout
 Number of Departments
 Nature of Products & Manufacturing Process
 Type of Machine
 Machine Specification
 Maintenance of Various Machines
 Measuring Instruments
 Name of Component/ Items/ Subcomponents/ Assemblies/ Sub-
assemblies Produced
 Raw Material Used
 Quality systems employed (KAIZEN/ 5S)
 Information about Customers and Competitors
 Conclusion

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INTRODUCTION:
HARDROCK ATTACHMENTS PVT LTD (HAPL)
Hardrock Attachments Pvt Ltd belonging to the Hardrock group was
incorporated in April 2008 by Mr. Dharamveer Singh of Jamshedpur, Jharkhand.
HAPL commencement of commercial production in August 2010, is engaged in
manufacturing of fabricated structures for construction machinery such as
Arms, Buckets for Excavators, Frames, etc. These parts are assembled to make
construction equipments like excavators, backhoe loaders etc, which find
application in mining, soil digging and other infrastructural activities. The
manufacturing facility of HAPL is located in Dharwad, Karnataka which is well
equipped with modern amenities and having ISO 9001:2008 certification.

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PLANT LAY-OUT (HAPL)

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NUMBER OF DEPARTMENTS
1) Human Resources
2) Account & Finance Department
3) Costing Department
4) Design & Development
5) Purchase cum Logistics Department
6) Production Department
7) Quality Department
MANUFACTURING PROCESS (FLOW PROCESS)
1) Cutting Process
2) Deburring Process
3) Chamfering Process
4) Rolling Process
5) Bending Process
6) Grinding Process
7) Assembly Process
8) Welding Process
9) Machining Process
10) Dressing Process
11) Shot Blasting Process
12) Painting Process

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NATURE OF PRODUCTS
Products in Heavy Fabrication & Machining Industry:
Main Products: Excavator, Backhoe or Loader Buck
Other Products: Arm, Lever, rear &front Oscillator Cradle
Hardrock manufactures components for excavators from 0.2 tons to 120 tons
capacity.
Buckets:
We manufacture Buckets for Excavators, Back Hoe Loaders, Wheel Loaders and
all other construction equipment machineries. Size of Buckets manufacture by
us ranges from 0.2 Tons to 120 tons and weight from few kgs to above 8000
kgs.
Attachments:
We manufacture attachments like Linkages, Arms, and Booms etc.for all
construction equipment machineries like Excavators, Back Hoe Loaders, and
Wheel Loaders etc.
Structures:
We manufacture Frames like Main Frame, Revolving Frame, Front Frame, Rear
Frame, Centre Frame etc for Excavators, Back Hoe Loaders, and Wheel Loaders.

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Lift Arm Bucket Center Frame
Boom Link Bucket Bucket
Boom Link Links

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MACHINE MAKE & SPECIFICATION
Sr.
No. Machine Name
Manufactured
By Model & Specification
1
CNC Cutting
Machine
MESSER,
Germany
220-240 Volt, 1 Phase,
50-60 Hz
2
Plasma Cutting
M/c
KJELLBERG,
Germany 220-240 Volt, 130 A
3
CNC Rolling
machine DAVI,Italy 400 Volts, 50 Hz, 15 HP
4
CNC Boring
Machine TAL
450 Volt, AC, 3 Phase,50
Hz
5 Welding Robot IGM, Austria 280-320 Volt
6 GMAW Setup ESAB India Ltd.
280-320 Volt, 28-32 A,
Gas Flow 18-20
7
Grinding
&Sandering
MAKHITA,
BOSCH
220-240 Volt, 50-60 Hz,
2200 W
8 Lathe PATHAK
220-240 Volt, 50 Hz, 1
Phase
9
PUG Cutting /
Chamfering ESAB India Ltd. 220-250 Volt, 0.35 A

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CNC OXY CUTTING MACHINE
CNC ROLLING MACHINE

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CNC BORING MACHINE
MIG WELDING MACHINE

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CNC PRESS BRAKE MACHINE
ROBOTIC WELDING MACHINE

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MAINTENANCE OF VARIOUS MACHINES
MAINTENANCE of CNC CUTTING MACHINE
Check and clean the guiding and carrying wheels
Check and clean the guiding and running wheels
Check the Racks and clean it
Check the tracks, racks and steel belt on the transverse beam
Check the functions of limit switches for transfers movement
Check the height adjusting equipment, rack and pinion
check all side guides clean & adjust if necessary
Check all hose & hose connections & Tighten it
Check all the valves and the connections
Check sliding surface of lifting shafts and greasing
Check engaging surface of transverse rack and gear
Check transverse rail lubricating oil
Check bearing of band drive system greasing
Check longitudinal rail lubricating oil
Check bearing for longitudinal drive greasing
MAINTENACE OF PUG CUTTING MACHINE
Check the electrical connections for there for there any loose connection
Check the stability of m/c on AL rail
Check the gas hoses for there any leakages and arrestit
Check and clean the nozzle

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MAINTENANCE OF CNC BORING MACHINE
Pneumatic
Check and cleaned pneumatic filters
Pump Unit
Operation status of fan cooler
Is there any abnormal heat
Spindle-R & L
Measure the clearance between front cap and spindle (0.06-0.13) mm
Check the spindle cap
Oil/Air lubrication unit
Check and clean the filter elements
Check and refill the all lubricants
Eletrical
Check and Retighten the power cables
Check the limits Switches and Proximity Switches
Axis
Check the axis X, Y & Z square Guide
Check the axis X, Y & Z Ball Screw, is there any chips presence
Coolant Unit
Check and clean the coolant filter
Check is there any coolant leakage

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MAINTENANCE OF WELDING ROBOT
Robot
Check the axis zero position (pinning position)
Check the torch safety function
Check the liners ,rollers & house package
Check and lubricate the Axis (if required -500hrs)
External axis
Check and lubricate the rail and sliding
Check the axis zero position
Inspect the axis movement ,is there any abnormal noise
Manipulator
Check and lubricate the moving part
Check and lubricate the negative brushes
Check the axis zero position
Electrical
Check and clean the KUKA &RCI panels
Check and clean the coolers filters
Check the earthing
connection, check the 'V' between N-E (if required)
Check the stabilizer I/P & O/P voltage
Power source
Check and clean the water unit
Check and clean the linear and roller

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MAINTENANCE & INSPECTION OF MIG WELDING
The maintenance and inspection should be carried out only after the switches in
the switch box are certain turn off
Try to maintain and inspect the set regularly as per the following guide line
regular Inspection.
Inspection portion Inspection point Maintenance method
Fuse box
Fastening & looseness at the
connection, confirmation of
proper fuse
Refer to the
equipment capacity
Input and output
terminals
Fastening & looseness at the
connection, confirmation of
insulation
Fasten first and tape
Electro-magnetic
contractor
Confirmation of abrasion at
contact points
Replace with new
ones
Interior of welding
power source
sedimentation of dust trace
of overheat
Blow off dust with
compressed air

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Measuring Instruments & their Applications
1) Vernier Calliper: Small length, thickness & O.D. as well as I.D.
2) Micrometer/ Setting ring: Especially for internal dia.
3) Fillet Gauge: For welding inspection, leg length &throat length inspection.
4) Measuring Tapes: To measure length.
5) Feeler Gauge: Measuring gap between two gaps.
6) Bore Dial Gauge: To check/ inspect the ovality.
7) Height Gauge: To take vertical height of point from ground level.
8) Air Plug Gauge: To explore uniform readings.
9) D.F.T. : To measure paint thickness.
10)SRR (Digital): To measure Surface Roughness.

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Name of Major Components Produced in Industry
CATERPILLAR 2021 BUCKET ASSY. - 1.53RK
CATERPILLAR 2021 BUCKET ASSY.- 1.7GP
CATERPILLAR 2021 BUCKET ASSY. - 1.7RK
CATERPILLAR 2021 BUCKET ASSY. -2.5GP
CATERPILLAR 2021 BUCKET ASSY. 3.0GP
CATERPILLAR 2021 ARMASSY
CATERPILLAR 2021 FRAME ASSY.WELDED
CATERPILLAR 2021 FRAME ASSY.FRONT
CATERPILLAR 2021 OSCILLATION MTG.
CATERPILLAR 2021 LEVER ASSY.FAB.
CATERPILLAR 2021 LINKASSY.FAB
CATERPILLAR 2021 PLATE
TELCON EX200 BUCKET GP
TELCON EX200 BUCKET HD(0.8 CUM)
TELCON EX110 WIDER BUCKET
TELCON TATA 315V LOADER BUCKET
TELCON EX110 BUCKET HD
TELCON Z-AXIS 120 BUCKET GP(0.7CUM)
TELCON Z-AXIS 120 BUCKET HD(0.6CUM)
TELCON 76 HP 0.25 CUM BACKHOE BUCKET
TELCON 86 HP 0.25 CUM BACKHOE BUCKET
JCB 1.5 CUM 1.5 CUM. GP BUCKET
JCB 1.7 CUM W.A.SHOVEL 1.7 M.Z-BAR
JCB 1.7 CUM W.A.SHOVEL 1.7 M.Z-BAR
JCB 1.7 CUM 1.7 CUM Z-BARBUCKET
JCB 1.7 CUM 1.7 CUM Z-BARBUCKET
JCB 1.9CUM 1.9 CUM G.P. BUCKET (WELDED TEETH)
JCB 2.5 CUM W.A.SHOVEL 2.5 CUM M-ZBAR-P107
JCB 3.0 CUM 3.0 cum SHOVEL BUCKET

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RAW MATERIAL USED
1. M.S.-(mild steel)
2. Sailma-350HI
3. Sailma-450HI
4. Hardox-400
5. Weldox-700
6. Welten-80
7. Welten-60

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Inventory Control
Inventory Control is the supervision of supply, storage and accessibility of items
in order to ensure an adequate supply without excessive oversupply.
It can also be referred as internal control - an accounting procedure or system
designed to promote efficiency or assure the implementation of a policy or
safeguard assets or avoid fraud and error etc.
Inventory control may refer to:
 In economics, the inventory control problem, which aims to reduce overhead
cost without hurting sales
 In the field of loss prevention, systems designed to introduce technical
barriers to shoplifting
Applications
An inventory control system may be used to automate an order fulfillment
process. Such a system contains a list of orders to be received, and then
prompts workers to pick the necessary items, and provides them with
packaging and shipping.
An inventory system also manages in and outwards material of hardware.
Real-time inventory control systems may use wired, mobile terminals to record
inventory transactions at the moment they occur. A wired LAN transmits the
transaction information to a mobile network.
Physical inventory counting and cycle counting are features of many inventory
control systems which can enhance the organization.
Business inventory
Reasons for keeping stock
There are four basic reasons for keeping an inventory

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1. Time - The time lags present in the supply chain, from supplier to user at
every stage, requires that you maintain certain amounts of inventory to
use in this lead time. However, in practice, inventory is to be maintained
for consumption during 'variations in lead time'. Lead time itself can be
addressed by ordering that many days in advance.
2. Uncertainty - Inventories are maintained as buffers to meet uncertainties
in demand, supply and movements of goods.
3. Economies of scale - Ideal condition of "one unit at a time at a place where
a user needs it, when he needs it" principle tends to incur lots of costs in
terms of logistics. So bulk buying, movement and storing brings
in economies of scale, thus inventory.
4. Appreciation in Value - In some situations, some stock gains the required
value when it is kept for some time to allow it reach the desired standard
for consumption, or for production. For example; beer in the brewing
industry
All these stock reasons can apply to any owner or product
Purpose:
Inventory proportionality is the goal of demand-driven inventory management.
The primary optimal outcome is to have the same number of days' (or hours',
etc.) worth of inventory on hand across all products so that the time of runout
of all products would be simultaneous. In such a case, there is no "excess
inventory," that is, inventory that would be left over of another product when
the first product runs out. Excess inventory is sub-optimal because the money
spent to obtain it could have been utilized better elsewhere, i.e. to the product
that just ran out.
The secondary goal of inventory proportionality is inventory minimization. By
integrating accurate demand forecasting with inventory management, rather
than only looking at past averages, a much more accurate and optimal outcome
is expected.
Integrating demand forecasting into inventory management in this way also
allows for the prediction of the "can fit" point when inventory storage is limited
on a per-product basis.

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Quality System Employed in Industry: KAIZEN
What is Kaizen?
Kaizen is the practice of continuous improvement. Kaizen was originally
introduced to the West by Masaaki Imai in his book Kaizen: The Key to Japan’s
Competitive Success in 1986. Today kaizen is recognized worldwide as an
important pillar of an organization’s long-term competitive strategy. Kaizen
is continuous improvement that is based on certain guiding principles:
 Good processes bring good results
 Go see for yourself to grasp the current situation
 Speak with data, manage by facts
 Take action to contain and correct root causes of problems
 Work as a team
 Kaizen is everybody’s business
 And much more!
KAI = CHANGE
ZEN = GOOD
Kaizen = Continuous Improvement...By Everybody! Everyday! Everywhere!
Why Kaizen?
 To remain competitive we need to change for better.
 We may become worse by not using our ability
to think.
 Make our job simpler, safer and faster.
 Improves customer service and makes them
happier.
 Improves productivity and quality.
 Helps achieve growth of the organization.
 To get satisfaction by seeing our idea being
implemented.
 Work smarter, not harder.

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5S METHODOLOGY
Tools drawer at a 5S working place
5S is the name of a workplace organization method that uses a list of
five Japanesewords: seiri, seiton, seiso, seiketsu, and shitsuke. Transliterated or
translated into English, they all start with the letter "S".
The list describes how to organize a work space for efficiency and effectiveness
by identifying and storing the items used, maintaining the area and items, and
sustaining the new order.[2]
The decision-making process usually comes from a
dialogue about standardization, which builds understanding among employees
of how they should do the work.
The 5 S's
o 1. Seiri (sort)
o 2. Seiton (straighten or streamline)
o 3. Seiso (shine)
o 4. Seiketsu (standardize)
o 5. Shitsuke (sustain)
Additional S's
o 2.1 Safety
o 2.2 Security
The Origins of 5S

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The 5 S’s: There are five primary 5S phases: They can be translated from the
Japanese as Sort, Systematize, Shine, Standardize and Self-Discipline. Other
translations are possible.
1. Seiri (sort)
Remove unnecessary items and dispose of them properly
 Make work easier by eliminating obstacles
 Reduce chance of being disturbed with unnecessary items
 Prevent accumulation of unnecessary items
 Evaluate necessary items with regard to dept/cost/other factors.
2. Seiton (straighten or streamline)
Arrange all necessary items in order so they can be easily picked for use
 Prevent loss and waste of time
 Make it easy to find and pick up necessary items
 Ensure first-come-first-serve basis
 Make work flow smooth and easy
 Can also be translated as "set in order"
3. Seiso (shine)
 Clean your workplace completely
 Use cleaning as inspection
 Prevent machinery and equipment deterioration
 Keep workplace safe and easy to work
 Can also be translated as "sweep"
4. Seiketsu (standardize)
 Maintain high standards of housekeeping and workplace organization at all
times
 Maintain cleanliness and orderliness
 Maintain everything in order and according to its standard.
5. Shitsuke (sustain)
 To keep in working order
 Also translates to "Self-Discipline" meaning to do without being told

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Additional S's
Other phases are sometimes included e.g. safety, security, and satisfaction.
These however do not form a traditional set of "phases" as the additions of
these extra steps are simply to clarify the benefits of 5S and not a different or
more inclusive methodology.
Safety
The phase, "Safety", is sometimes added. There is debate over whether
including this sixth "S" promotes safety by stating this value explicitly, or if a
comprehensive safety program is undermined when it is relegated to a single
item in an efficiency-focused business methodology.
Security
The phase, "Security", can also be added. To leverage security as an investment
rather than an expense, the seventh "S" identifies and addresses risks to key
business categories including fixed assets (PP&E), material, human capital,
brand equity, intellectual property, information technology, assets-in-transit
and the extended supply chain. Techniques adapted from those detailed
in Total security management (TSM) or the business practice of developing and
implementing comprehensive risk management and security practices for a
firm’s entire value chain.
The Origins of 5S
5S was developed in Japan and was identified as one of the techniques that
enabled Just in Time manufacturing.
Two major frameworks for understanding and applying 5S to business
environments have arisen, one proposed by Osada, the other by Hirano. Hirano
provided a structure for improvement programs with a series of identifiable
steps, each building on its predecessor. As noted by John Bicheno, Toyota's
adoption of the Hirano approach, was '4S', with Seiton and Seiso combined.
However, Toyota now uses the 5S as a standard.
Although the origins of the 5S methodology are in manufacturing, it can also be
applied to knowledge-economy work, with information, software, or media in
the place of physical product.

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Information about CUSTOMER & COMPETITOR
Customer
1. TATA HITACHI CONSTRUCTIONEQUIPMENT LTD
2. CATER PILLARLTD
3. JCB INDIA LTD
Competitor
1. APEX AUTO LTD
2. RSB LTD
3. ASHWA ENERGY PVT LTD
4. FERRUM EXTREME ENGINEERING PVT LTD
Tata Hitachi Construction Machinery Company is an India based joint
venture between Tata Motors and HCM, Japan. It was previously known as
Telco Construction Equipment Co. Ltd.
It has more than half of the market share in the excavator segment.[2]
The
company has its corporate office at Bangalore and three manufacturing bases
in Jamshedpur, Dharwad and Kharagpur. It also has two subsidiaries Serviplem
S.A. and Lebrero in Spain. The annual turnover of the company is 2300 Crores.
Caterpillar Inc., is an American corporation which designs, manufactures,
markets and sells machinery and engines and sells financial products and
insurance to customers via a worldwide dealer network. Caterpillar is the
world's leading manufacturer of construction and mining equipment, diesel and
natural gas engines, industrial gas turbines and diesel-electric locomotives. With
more than US$89 billion in assets, Caterpillar was ranked number one in its
industry and number 44 overall in the 2009 Fortune 500.

27. 27
Caterpillar stock is a component of the Dow Jones Industrial Average. Caterpillar
Inc. traces its origins to the 1925 merger of the Holt Manufacturing
Company and the C. L. Best Tractor Company, creating a new entity, the
California based Caterpillar Tractor Company. In 1986, the company re-
organized itself as a Delaware corporation under the current name, Caterpillar
Inc. Caterpillar's headquarters are located in Peoria, Illinois, United States.
Caterpillar machinery is recognizable by its trademark "Caterpillar Yellow"
liveryand the "CAT" logo.
J.C. Bamford Excavators Limited, universally known as JCB, is a British
multinational corporation, with headquarters in Rocester, Staffordshire,
manufacturing equipment for construction, demolition and agriculture. It is the
world's third-largest construction equipment manufacturer. It produces over
300 types of machines, including diggers (backhoes), excavators, tractors and
diesel engines. It has 22 factories across Asia, Europe, North America, and South
America; its products are sold in over 150 countries.
JCB was founded in 1945 by Joseph Cyril Bamford, after whom it is named; it
continues to be owned by the Bamford family. In the UK 'JCB' is often
usedcolloquially as a generic description for mechanical diggers and excavators
and now appears in the Oxford English Dictionary, although it is still held as a
trademark.

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COMPETITOR:
RSB is a fast growing global engineering organization with business interest
ranging from design to manufacturing of aggregates and systems related to
commercial vehicles, passenger cars, construction and farm equipment and a
wide variety of automotive and off-highway equipment.
The brothers, R. K. Behera and S. K. Behera, from a humble beginning, scripted
the story of the RSB in 1975 at Jamshedpur. Three decades later, headquartered
at Pune, it has grown into a pulsating institution with manufacturing setups at
Jamshedpur, Pune, Dharwad, Chennai, Pantnagar, Cuttack, Homer (USA) and
Belgium (Europe).
RSB comprises of four different companies, namely, RSB Transmissions (I) Ltd.,
RSB Transmissions North America Inc. (Formerly known as Miller Brothers
Manufacturing) , I-Design Engineering Solutions Ltd. and Ivitesse Technologies
Pvt. Ltd.
All RSB manufacturing units are ISO/ TS16949, ISO: 14001 and OHSAS: 18001
certified.
Apex Auto Ltd is the largest domestic manufacturer of finished fabricated
structures to the earth-moving and construction equipment industry in India.
We are presently manufacturing components for top selling excavators, back
hoe loaders, cranes, compactors, transit mixers, underground drilling, crushing
& screening equipments for the domestic and international market. We also
have facilities that can cater to the general engineering requirements of other
sectors like railways, power, shipping and aerospace.

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Apexhave facilities across five plants located in India in Jamshedpur, Dharwad,
Bangalore and Kharagpur.
Ashwa Energy Private Limited is situated in Dharwad industrial growth center,
Belur industrial area in dharwad, Karnataka – India, near Poona Bangalore
national highway. Dharwad is about 430kms by road from Bangalore & Poona
and connected by road & rail. Ashwa energy private limited commenced its
commercial production in the year 2008.
Ashwa Energy Private Limited engaged in the manufacturing of chemical pumps
and industrial valves namely gate, globe. Swing check valves and high
performance butterfly valves in association with M/s. Akay industries, hubli&
for valves tied up with M/s valtek corporation, dharwad.
Ashwa Energy Private Limited has manufacturing facility equipped by modern
equipments suitable for higher size and higher class valves with a area of 18,000
sq.mtrs.
The company caterers to the needs of the needs of major industries like
fertilizer, pulp and paper, thermal, chemical, nuclear and many other process
industries.
Subsequently the board of visionaries decided to bring Shri Rajesh Goel, who is
an MBA as a chief of the Ferrum Extreme Engineering Pvt. Ltd. (FeRRUM) and
he has worked with his vision and with his entry FeRRUM has achieved a

30. 30
position in the market in the field of extreme engineering of structures and
components within a very short period of one year but always with the prime
consideration of utmost time management and not to take excuse on the
pretext of shortage of time with no compromise & relaxation in quality control
and to maintain this it is an ISO-9001 Certified and ISO 14001: 2004 and ISO
Engineering Unit.
FeRRUM is managed by professional stable management comprising visionaries
with vision of utmost balance of skill and business to promote technological
fineness, international standard, hair-line accuracy, need based result.

31. 31
Conclusion
After the completion of industrial training we enhanced competencies &
competitiveness in our respective area of specialization. We tried to relate the
experience in the workplace with knowledge learned in the institute & applied
the knowledge on the job under supervision.
Here, we gained the experience & knowledge that can be used
for suitable job without delay after studies.
We learned to hone soft skills appropriate to the work
environment. Also get improvised in communication skills. We assessed career
ability, knowledge & confidence as well as enhanced our marketability to be
more competitive.
With experience, knowledge & skills acquired during industrial
training we will be better prepared to face working world.

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OPINION ABOUT INPLANT TRAINING
In plant training provides the industrial exposure to the students how to face
the industry once they foot out from the campus. The industrial knowledge is
essential for all students to get success in their job. Once students step into the
industry they should ready to face competitive world with knowledge. The core
competence area extending its boundary daily as technology grows.
Student need to update day to day stuff from various
innovative technologies.
On successful completion of our in plant training students be
skill enough & ready to shine. Job opportunity for students who has certificate
on the in plant training is high compared to the non-trained student, because
company will know that student’s knowledge will be boosted by in plant
training.

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INDUSTRIAL TRAINING REPORT
ON
HEAVY FABRICATIONINDUSTRY
AT
HAPL DHARWAD
DIRECTOR: SUPERVISED BY:
MR. HARBHAJAN SINGH MR. MANISH SINGH (PROCESSING DEPT)
MR. RANVIJAY PRASAD (PROCESSING DEPT)
MR. AMIT KALIA (DEVELOPMENT DEPT)
MR. MRITYUNJAY KAGADAL
(MACHINING DEPT)
MR. PRAKASH B. (QUALITY DEPT)
PARTICIPANTS:
GAURAV KUMAR SINGH
SHRIDHAR KADAM