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This document provides an internship report summarizing Prakhar Awasthi's training experience at Bharat Fritz Werner limited (BFW) in Bangalore, India. It includes acknowledgments, contents, an abstract, and chapters on the company profile, products, and manufacturing division. BFW is a leading machine tool manufacturer established in 1961. The report describes BFW's facilities, products like CNC machining centers and turning machines, organizational structure, and manufacturing process which follows quality standards. The training provided practical experience of BFW's operations and technology.

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1 Internship Report Created By: Prakhar Awasthi
2 Acknowledgement I convey my wholehearted thanks to Mr. Gajendra.A for his help and co-operation with me throughout the internship period and letting me know about various activities in the Manufacturing Department. Also I convey my thank to Mr. Madhav Rao, Mr. Valerian Dsouza, Mr. Chendal Kumar for their help which enhanced my knowledge regarding process plan. I also convey my thanks to Mr. Aditya Anant Kamble and Mr. Basavaraj of HR department, BFW limited for giving me the apportunity ti get trained at BFW. I am very much thankful to our beloved Head of the department, Dr. C.P.S. Prakash for allowing me to undergo training at BFW.
3 Content Chapter Title Page no. 1 Company Profile 5 2 Product Profile 12 3 Manufacturing Division 14 4 Maintenance 34 5 Conclusion 36
4 Abstract Industrial Training is a real life experience that will enable one to behave professionally providing contcts with well experienced professionals along with exposure to the industrial standard. In te training, first of all I came to know about the company, the work done, the products manufactured, projects and the standards followed by them during the design cycle. Training at Bharat Fritz Werner limited, Bangalore has helped me a lot to understand the systematic and organized way the firm functions and has given me the practical experience of the efforts involved in implementing a particular technology. This period of training gave me the complete feel of professional life and also gave me immense opportunity to learn about new technologies and increase my technical skills.
5 Chapter 1 : Company Profile Bharat Fritz Werner limited (BFW) located at peenya, the industrial suburb of Bangalore is a leading Machine tool manufacturer in India.  It was established in the year 1961 in techno commercial collaboration with Fritz Werner AG of Germany.  In 1966, BFW become part of Kothari Group and subsequently in 1977, become an associate company of Bukhardt+Weber, Germany.  In 2003, BFW become a fully owned compant of the Kothari Group.  Recently, Starray Herkert, the 125 year old swiss company established a strategic alliance with BFW to design and manufacture the complex, high end 5-axis machining centre for their global market. BFW houses the latest state of the art manufacturing technology and also supported by dedicated team of qualified engineers constantly engaged in updating technology and developing new products. BFW’s R & D Department, is recognized by the ministery of Science and Technology, Government of India and the company has won several awards from the Government of India.  Awards & Recognition 1. EEPC Silver Shield 2013 : Recipient of Government of India Silver Shield award from Engineering Export Promotion Council for outstanding Export Performance in year 2013. 2.FIE Foundation Award 2013 : Winner of FIE Foundation Award for R&D and Innovation in India Machine Tool section, 2013.
6 3.Kirloskar Ferrous Special Award 2013 : Winner of special Appreciation from Kriloskar Ferrous Limited for supply of production line, 2013. 4.India Design Mark for Dhruva & Agni 2012 : India Design Mark for CNC Vertical Machining Centres, Dhruva & Agni, 2012. 5.AAM India Supplier Recognition Award 2010. 6.Ashok Leyland Appriciation 2010 : Ashol Leyland Appreciation for BFW’s contribution to their Pantnagar plant, 2010. 7.FIE Foundation for best Exhibit Award at IMTEX, 2007. 8.HMSI award for Machinery, 2006-07. 9.Best stall award at IMTEX, 2001.  MILESTONES BFW is one of the few private sector machine tool companiesin India to have completed 50 years of operations. This period has witnessed many significant milestones.
7 17 October 1961 CompanyIncorporated 1970 Supply of first special machine to Mico Beosh 1983 Execution of first bulk order : 25 Machinesto TATA Government Tech Centre Supply of 160 milling machines to the Erstwhile, USSR 1979 1985 Approvalof BFW R&D Facility by Ministry of Science & Technology, Government of India 1987 Supply of 16 horizontalmachining centers To the Erstwhile, USSR 1989 Supply of 135 milling machines to The Erstwhile, USSR 1993 Supply of cylinder block and cylinder head Transfer line to Simpson-Perkin
8 1996 India’slargest automobilecompany, Mruti Udyog, starts using BFW products 1998 Production of high speed machiningcentres 2002 Two wheeler manufacturer HMSI, Start using BFW products Kirloskar ToyotaTextile machinery Starts using BFW products. 2000 2005 Production of Vertical DoubleColumn Machiningcentres 2006 Production of high speed vertical machiningcentres
9 2008 Production of vertical turret lathe 2009 Production of 5-axis vertical & horizontalMachiningcentres 2011 Supply of KB engine cyclinder block Machiningcentres to Maruti Udyog. Production of glass bottle handling system Completionof 50 years . Strategic Alliancewith Spinner GmbH 2010
10  General Management BFW is a powerful organization, which follows the rules and regulation of ISO9001 and also has a particular type of working atmosphere. Broadly the company can be categorized into 7 divisions. Each Division has a head, who acts as the chief executive officer of that division and is independent of taking decisions about matters in his division. He is supported by the strong R&D department, engineers and handles it carefully. Modification in working condition, needs of workers and their problems is looked upon and is discussed in the regular meeting of the core committee. The head has to take care to see that any kind of incompetence to the working management is not been entertained. There is a close bonding between all of the divisions so that they act as member of the same family and work with great zeal for the betterment of the industry. Board of Directors MKTG MCD MMD SMD CMD MFD ACD President & CEO Administration & Finance Strategic Sourcing Department
11 Abbreviations MKTG: Marketing Department MCD: Machining Centre Department MMD: Milling Machines Division SMD: Special Purpose Mchines Division CMD: CNC Milling Machines Division MFD: Manufacturing Division ACD: Auto Component Division MEMBERS OF BOARD OF DIRECTORS Mr. A.K. Kothari Chairman Mrs. P.D. Kothri Director Mr. Shailesh Sheth Director Mr. T. Parabrahman Director Mr. Haigreve Khaitan Director Mr. Ajit Khandelwal Director MEMBERS OF MANAGEMENT TEAM Mr. Ravi Raghavan Chief Executive Officer Mr. K.S. Kasturirangan Senior Vice President of Finance & Amnistration Mr. Sujoy Das Gupta Chief Financial Officer Mr. Aditya Anant Kamble General Manager of Human Resources Chapter 2: Product Profile
12 BFW initially started with the manufacturing of Knee type milling machines in various sizes. Subsequently BFW entered into the CNC field and also int area of special purpose machines. Today BFW offers a wide varieties of general purpose machines, special purpose machines, CNC machining centers etc. to meet the demands of the customers. Every single product is supported by best engineering inputs which naturally lead to high quality machine tools to meet today’s user standards and they have found ready acceptance world wide.  Product range includes: 1.) CNC Vertical Machining : i. Chandra + ii. Dhruva iii. Gaurav iv. Agni+ v. Agni++ vi. Vayu vii. Chakra viii. Sooraj ix. Astra x. Vajra xi. Virat xii. Pentaxes xiii. DMC xiv. Matec 30 HV xv. Matec 40 P 2.) CNC Horizontal Machining : i. Maxpro E series ii. Maxpro series iii. Vega iv. Tej v. Shaksham vi. Airavat 3.) Special Purpose Machines :
13 i. Front axle beam Machines ii. Crank Pin Milling Machines iii. Facing Centering Machines iv. Duplex Milling Machines v. Gantry type Machines vi. Pipe Chamfering Machines vii. Crank Shaft Oil Hole Drilling Machines 4.) CNC Turning Machines : i. Sudarshan BVL550H & 700H ii. Sudarshan BVL800H iii. Sudarshan BVL800ML iv. Sudarshan BVL1200 R/RL v. Sppiner TC vi. Spinner PD vii. Spinner U 5.) Non CNC milling Machines i. Knee Type Milling Machines 6.) Automation Chapter 3 : Manufacturing Division (MFD) INTRODUTION
14 This is the main division and probably can be called as heart of the company. This Caters to the needs of all other divisions. In other words, it satisfies the needs of the internal customers by supplying the individual jobs which then be assembled in the respective division. CLASSIFICATION In order to identify and to carry out the operations depending on the difficulties involved in handling etc., MFD is Classified into three cells. CELL 1: This is also know as heavy part cell. Some of the machines coming under this cell are: Waldrich Siegen, Waldrich Coburg, TMC 800, TMC 1250, Noble and Lund, HMT Radial Drilling machine, etc. CELL 2: This is also known as medium part cell. Some of the machines Under this are TMC 500, SIP, Nissin, VMC 500, etc. CELL 3: This is also known as small part section. Some of the machines coming under this cells are: Lathe, Milling machines, Grinding machines, etc. HOW DOES MANUFACTURING DIVISION WORK? As manufacturing division follows ISP rules, there is a proper sequence in which it works and can be given as below: i. Engineering Method ii. Material Planning iii. Manufacturing
15 iv. Quality Assurance 1.Engineering Method: When MFD takes up an assignment from the internal customer, it has to be given a component manufacturing order number (CMO no.) in addition to the work order number which is already entitled by the concerned division and this work order number indicates the external customer to whom the job belongs. The main purpose of giving CMO no. is to identify the division to division from which order is taken. It also indicates the demand for that particular job. The CMO no. for the following division are: For MCD - ‘2’ for regular items For SMD – ‘3’ for regular items For CMD – ‘5’ for regular items Each Component which is used for the manufacturing of the part is given a communication part number. Example : A simple communication part no. would look like – ‘32002422’ The order also contains the quality required, time to be taken for manufacture and the cell to be used to manufacture. Concept of Process Sheet: Process sheet is the written format of the component drawing are really a complicated one for the operations to understand, so a written format of the actual drawing helps the operator to perform the operation in a particular manner without any spoilage of the work.
16 The contents present in the process are as follows: I. Raw material: There is a particular coding for each raw material and they are indicated in the process sheet, so that operator can get the same material as mentioned by engineer in the form of coding on the process sheet. Examples: Low carbon steel has a coding as C2, High carbon steel has a coding as C1, Tool steel has a coding as T1, Nitriding steel has a coding as N1. SEQUENCE OF PROCESS The manufacturing of a component involves various operation such as turning, drilling, tapper turning, taper boring, boring, milling, grinding etc., these operations are called as machining processes. The particular sequence of process must be followed in order to get the component as given by the drawing. The operation. This sequence of processes is mentioned in the process sheet as shown below; a.) Serial no. – it is the increasing order starting from initial operation till the final operation. b.) Machine no. – the particular machine, which has to be used to carry out the process. c.) Description of operation – this involves the way in which the operation has to be done and even the type of surface finish required is also defined. Duration of operation, the approximate time which could be utilized for the particular operation is also mentioned in the process sheet. Usually duration of operation involves only two parts, setup time and operation time. Sometimes it may be needed to use special tool to obtain complicated shapes as indicated in the drawing and this has to be mentioned in the process sheet, so that operator will not be in dilemma about the way to obtain the particular shape.
17 Engineering Support flow chart: CMO & Drawing from respective division Deciding the unclassified items ( as OM/SCF) with respective Informing the division regarding ‘H’ items
18 Checking the availability of process layout for accepted items Preparing/updating process layout for the items Checking for special tool requriment Checking for special material requriment Requesting tool engineer for procurement of special tool Providing the required special tool Classifying new items into ‘D’ NO YES InformingMPfor the release of casting/raw material NO Resting MP for the procurementof special material YES YES
19 Manufacturing Service Flow Chart: 2.Material Planning: Drawing from the customer Preparing the quotation Customer Preparing the Q.A. Customer Recieve the material Prepare job card & drawing to Product component Carry out Manufacturing Inspection Deliver to Customer after commercial clearance
20 The proper planning of material storage and even handling is very important in any organization. The material handling engineer has to take care of the materials and even has to analyze the requirement of materials before purchase. After engineering analysis, the order is placed at material management section of MFD. The engineer has to decide about the procurement of the material such as bar stocks, casting, weldaments and other components as per the specification in the process sheet. If there is any shortage of material, it is needed to be informed and proper step must be taken to replace it. The raw material for the bed, Knee, column, spindle etc., is castings which are done in the company’s foundry, if its weight is less than 1 ton otherwise order is given to outside sub-contactor. For storing of standards parts used in manufacturing, there is a separate store room, where the components are kept in a systematic manner based on communication part number. This is done according to the specification of ISO 9001, which says that the right things at right place is the key of successful implementation of ISO 9001. Material Planning Flow Chart: Raw Material
21 Input from methods/Dispatch programme/Information from respective division Estimate Annual requriment of steel from MRP Check w.r.t. stock Prepare Demand note Check & Clarify demand note & send for cutting. After the material is cut, receive back copy of demand note. Prepare Batch Release Send for H item demand notes & Batch release notes to respective division subcontractor Foe D & I items, release batch, release notes route card, job card, process sheet & drawing to MFD. 1b. for C.W.B.B. (refer to next flow chart Special Material Request. Raise Purchase Order Receipt of Material & Issue Q.A Methods 1.a If material isnot available H items D & I items If material isavailable 1.b Casting, Weldments, Brass, & Bronze
22 Material Planning flow Chart: Purchase Check availability of the material Prepare the purchase order as per CMO Scrutinise & approve Purchase Order Send Purchase order, Drawing & Process sheets to vendor Supplymaterial/parts to stores with Q.C. & P.O. reference Receipt Prepare Demand note & Batch Release notes for D, I & H items Send Demand notes & Batch Release notes of H items to respective division sub- contractor Send Demand notes to Fettling & priming for D & I items Receive Demand note after fettling & Priming Release batch note, Route card, Processes sheets & Drawing to MFD. Q.A Finance H items D & I items If Not available If available PURCHASE ORDER VENDOR APPROVAL
23 3.MANUFACTURING Receive request for material Select Vendor from approved vendor list If repeat Order Enquiry Place repeat order Scrutinize Quotation & select vendor Place Purchase Order Send Purchase Order, Drawing & process sheets to vendors Supply parts to shores with Q.C. & PO reference Reciept Q.A Requirement/ request for vendor registration Evaluate Vendor Check Evaluation Score Refuse Registration Enquiry Place Trial Order Receive & Check material Include in Approved Vendor List FINANCE FINANCE YES NO LESS THAN 65 IF SCORE65 OR MORE APPROVED RE JE CT
24 The material planning is then followed by the manufacturing process. The process sheet along with the procured materials is then passed to the machining cell where process on the materials are carried out as explained in the process sheet. The inspection of the job in between the processes may even be carried out as mentioned in the process sheet. The manufacturing division has a ‘tool crib’ from where the various tools are issued as required for the operation. The tools are arranged in a particular format and bins are provided for smaller tools and larger tools are placed in convenient places. The ‘tool crib’ follows ISO9001 rules strictly and if there is any tool spoilage then it has to be taken in writing from the operator who has been working on with that tool. There is a store for issuing smaller parts like screws, nuts, bolts, gears, etc., that is of minimum use in case of manufacturing division, since no assembly work is carried out in this division. The final product after passing through the mentioned machines, performing various operations on it, is then given for panting.  MARKING OUT: Marking out or layout is the process of transferring a design or pattern to a work piece according to given drawing, as the first step in manufacturing process. Marking out consist of transferring the dimension from the drawing to the work piece in preparation for the next setup, machining or manufacture. Typical tools include;  Surface plate or Marking out table: Provides a true horizontal flat surface on which work piece can be supported.
25  Angle Plates: Assists in holding the work piece perpendicular to the table.  Scriber: It is equivalent of a pen or pencil, it literally scratches the metal surface leaving behind a fine, bright line.  Height Gauge or Scriber block: Allows lines to be scribed at a preset distance from the work table surface.  Surface Gage: An ungraduated comparison measuring tool that performs much the same function as the vernier height gage. It is often used in conjunction with a dial indicator and a precision height gage.  MACHINING: Machining is any of various processes in which a piece of raw material is cut into a desired final shape and sized by a controlled material-removal process. The many processes that have this common theme, controlled material removal, are today collectively known as subtractive manufacturing, in distinction from processes of controlled material addition, which are known as additive manufacturing. Exactly what the “controlled” part of the definition implies can vary, but it almost implies the use of machine tools (in addition to just power tools and hand tools).  Types of Machining Operation: There are many kind of machining operations, each of which is capable of generating a certain part geometry and surfaces texture. In turning, a cutting tool with a single edge is used to remove material from a rotating work piece to generate a cylindrical shape. The speed motion is provided by rotating the work piece and the feed motion is achieved by moving the cutting tool slowly in a direction parallel to the axis of rotation if the work piece and depth of cut is given my moving cutting tool in direction perpendicular to the axis of rotation of the work piece.
26 Drilling is used to create a round hole. It is accomplished by a rotating tool that typically has two or four helical cutting edges. The tool is fed in a direction parallel to the axis of rotation of tool into the work piece to form the round hole. In boring, a tool with a single bent pointed tip advanced into a roughly made hole in a spinning work piece to slightly enlarge the hole and improve its accuracy, It is a fine finishing operation used in the final stages of product manufacture. In milling, a rotating tool with multiple cutting edges is moved slowly relative to the material to generate a plane or straight surface. The direction of the feed motion is perpendicular to the tool’s axis of rotation. The speed motion is provided by the rotating milling cutter. The two forms of milling are: I. Peripheral Milling II. Face Milling Other conventional machining operation include shaping, planning, broaching and sawing. Also, grinding and similar abrasive operation are often included within the category of machining.  HEAT TREATMENT: Heat treatment is the process of heating and cooling metals to achieve desired physical and mechanical properties through modification of their crystalline structure. The temperature, length of time, and rate of cooling after heat treatment will all impact properties dramatically. The most common reason to heat treatment include increasing strength or hardness, increasing toughness, improving ductility and maximizing corrosion resistance.
27  INDUTION HARDENING: Scope: Applicable to heat treatment of parts/components manufactured from raw materials. Procedure: i. Choose the suitable inductor coil that has an inside diameter 4-6 mm more than outside diameter of the part to be heat treated. ii. Make sure that the axial length of the indicator is equal to the length of the portion to be heat treated or the coil can be moved to the required length of hardening. iii. Set the voltage, power rating and time suitable for the choose inductor coil. Also set the feed rate of the coil, water flow for quenching in case of moving coil. iv. Place a setting piece inside the coil and switch on. v. At the end of the cycle allow the part to fall into water bath for quenching. vi. Check the setting piece for establishing the process parameters. vii. Place the parts to be heat treated in the inductor coil and follow the above steps. viii. Check hardness. ix. Note down the process parameters set for the above process for that material.
28  GAS CARBURISING & ANNEALING: Scope: Applicable to heat treatment of case hardened parts/ components manufactured out of raw material having C2M, C2R codes. Procedure: i. Load the parts in the gas carburizing furnace. ii. Raise the temperature to the preheat limit of 550 ºC, gradually at 4 to 5ºC per hour and ensure that the gas shield is maintained in the furnace. iii. After the pre heat temperature is stabilized, raise the temperature to 915 ºC and gradually at 90ºC per hour. iv. Soak it at this temperature for the required hours based on the required case depth (refer chart 1 given below). v. At the end of the period, allow to defuse for and required hours based on the case depth(refer given chart 2 below). vi. Allow the part to cool down in the furnace by switching off the furnace. General guidelines for achieving the required case depth during Carburizing (Temp: 915 +/- 5ºC) Case depth ( in mm) Activation Time (in hours) Diffusion Time (In hours) Total Time (in hours) 0.6 – 0.8 2.5 1.5 4 1.0-1.2 3.5 2.5 6 1.3-1.5 4.0 3.0 7 1.6-1.8 6.0 4.0 10
29 Values of case depth calculated by Harris relation from heat treaters guide Time (in hours) Case Depth in mm after Carburizing at 870ºC 900ºC 950ºC 2 0.635 0.762 0.889 4 0.889 1.070 1.270 8 1.270 1.520 1.800 12 1.550 1.850 2.210  Flame Hardening: Scope: Applicable to heat treatment of parts/components manufactured from raw material codes C1, C3R, EN9. Procedure: i. Fix the part to be flame hardened on a suitable fixture suitable for traversing the portion to be flame hardened below the torch. The torch (burner) shall have holes for inlet/outlet of water for quenching. ii. Set the gap between the portion to be hardened and the burner to 8-10 mm. iii. Set the pressure for oxygen at 5 kg/sq.cm. and that for acetylene at 3 kg/sq.cm. iv. Set the feed rate at 0.8 mm/sec. v. The flame is moved at the above rate over the component and water jet which follows the flame quench the item. vi. Check the hardness at random and make sure that it is within the specified limits.
30 vii. If the material has not responded, redo the flame hardening cycle.  Stress Relieving: Scope: This is applicable to both welded and casting structure. Procedure: i. Suitable structure is taken for stress relieving. ii. The residual stresses are measured before stress relieving from sample structure and the value is noted. iii. Stress relieving treatment as per standard n. B7600/B7601 (as applicable to casting/welments) is imparted on this structure. iv. After stress relieving, the sample structure is taken for residual stress measurement. The value of the residual stresses should be in the order or 80-90% for qualifying the stress relieving process. v. The structure is machined and one particular dimension is identified for measurement over a period of 90 days at an interval of 30 days. If the dimension are within the tolerance given in the drawing of the sample structure for the identified dimension, the procedure for qualifying the stress relieving is accepted.
31 4. PAINTING: Painting is common for all the departments. It is placed with in the MFD but at a suitable location to which the transportation of job from various departments may not be in a problem. Painting of the job as per customer specification is done and then passed on to the processes. In painting section, spray- painting technique is used. During spray painting, the tiny particles of paint in the form of jet is ejected from the gun which impacts on the job which has to be painted. There is a high possibility of these tiny particles spilling out to the atmosphere, which is hazardous to worker in this section. In order to avoid this, the updraft and lower draft is provided through which the continuous water circulation is maintained and this absorb the paint particles from the atmosphere, thereby providing a safe working condition.
32 5.QUALITY ASSURANCE: Since BFW limited is an ISO 9001 company, prime importance is given to quality assurance. The division has a high tech dimension checking room and standards room. These two rooms are maintained at particular temperature so that measurement can be made accurately and calibration can also be done to maximum perfection. The common instruments used by QA department of MFD are: i. Sine bar: They are used to measure angle and tapers. The slip gauges are made use of in this process and accuracy obtained in this method is 0.001µ. ii. Dial Indicator: the plunger type dial indicators are used and accuracy up to 10µ can be obtained. iii. Trimos Calibration: This is used to check the squareness, coaxiality of bores and bore sizes. It is also used to measure vertical heights. The accuracy of measurement is up to 5µ. iv. Internal Micrometer: The range is 70-80 mm and least count of the micrometer is 0.005 mm. v. Comparators: These are used for checking the components at a faster rate in mass production. The accuracy of the comparator is 1 µm.
33 PROCEDURE ADOPTED FOR CHECKING DIMENSION ACCURATELY: Purpose: To establish a procedure of in process items at final stage. Scope: Covers items processed in house Procedure: i. Take the item offered from process as per the relevant route card for inspection. ii. With appropriate instruments and gauges carry out the inspection as per relevant quality plan, drawing and operation layout. iii. Reward the results of inspection in route card as follows :  Record the confirming quality in the quantity accepted column and sign.  Record the details of non confermence if any in the remark column indicating the quality. iv. Identify the following with serial no. a) Heavy parts b) Spindle Components(Small Parts) v. Record the inspection results guide lines as below in respective register against specified serial no. for items identified with serial no. vi. Record the inspection results in the check list wherever specified. vii. Only final entry need to be made for these items in their route card. viii. Identify the inspection status of items with tags as follows:  Green : For accepted items  Pink : For rework items  Red : For rejected/ scrapped items  White : Items released without inspection  Blue : Concessionally accepted items  Brown : Item under non conformance.
34 6. MAINTENANCE Some of the maintenance schedules followed by BFW for their machines used in the auto components division are as follows:  DAILY MAINTENANCE: i. Clean chips on the pallet changer and index table cover. ii. Clean operator window from inside and outside. iii. Clean spindle taper bore with lint free cloth iv. Check coolant level in the coolant tank. v. Check oil level in the air lubricator, hydraulic powder pack, ATC and index table. vi. Check hydraulic pressure vii. Check air pressure viii. Check through tool coolant pump pressure. ix. Check index table air curtain pressure. x. Check hydraulic oil temperature. xi. Check for oil foaming or heating.  WEEKLY MAINTENANCE: i. Check axes drives for quiet run and smooth movement. ii. Clean and visually check tool holder for damage or loosening of pull studs. iii. Clean filter mesh provided in coolant tank chip conveyor if provided. iv. Clean and replace air filter v. Clean hydraulic return line filter cartridge. vi. Check cooling fans provided in the CNC system for proper functioning. vii. Check air filter regulator for water accumulation. viii. Check for cleanliness of tool magazine and proper tool holding. ix. Check for free movement of tool holding rod and locking pin of tool changer arm.
35  ANNUAL MAINTENANCE: i. Check machine level with level gauge and adjust if required. ii. Check for backlash in axes drives and adjust if required . iii. Check for current drawn in all drives. iv. Check for any damages to the electrical cables. v. Replace dry batteries in electrical cabinet.
36 Conclusion  Bharat Fritz Werner Limited, an ISO9001 company is one of the frontiers in the manufacturing segment related to the production of highly sophisticated CNC machines and Special Purpose Machines. The company works by having well planned mission and vision principles as well as certain environment policies with the customer satisfaction as their main moto.  The company has a very large manufacturing department in which the work is done so as to cater the needs of its own products. The working of different departments gives a clear idea of how a Computer Integrated Manufacturing system works. Various departments such as the Fixture Design, stores, Manufacturing, Design are all completely networked and a trator made ERP system is been used so as to control and perform various activities in the company.  The company always believes in upgrading its resources both technologically as well as the knowledge of its human resources by constant training programs and seminars.  The machines manufactured by them have international repute as well as great national demand because of usage of sophisticated software which are common platforms for CNC machines throughout the world.
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Internship2

  • 1.
  • 2.
    2 Acknowledgement I convey mywholehearted thanks to Mr. Gajendra.A for his help and co-operation with me throughout the internship period and letting me know about various activities in the Manufacturing Department. Also I convey my thank to Mr. Madhav Rao, Mr. Valerian Dsouza, Mr. Chendal Kumar for their help which enhanced my knowledge regarding process plan. I also convey my thanks to Mr. Aditya Anant Kamble and Mr. Basavaraj of HR department, BFW limited for giving me the apportunity ti get trained at BFW. I am very much thankful to our beloved Head of the department, Dr. C.P.S. Prakash for allowing me to undergo training at BFW.
  • 3.
    3 Content Chapter Title Page no. 1Company Profile 5 2 Product Profile 12 3 Manufacturing Division 14 4 Maintenance 34 5 Conclusion 36
  • 4.
    4 Abstract Industrial Training isa real life experience that will enable one to behave professionally providing contcts with well experienced professionals along with exposure to the industrial standard. In te training, first of all I came to know about the company, the work done, the products manufactured, projects and the standards followed by them during the design cycle. Training at Bharat Fritz Werner limited, Bangalore has helped me a lot to understand the systematic and organized way the firm functions and has given me the practical experience of the efforts involved in implementing a particular technology. This period of training gave me the complete feel of professional life and also gave me immense opportunity to learn about new technologies and increase my technical skills.
  • 5.
    5 Chapter 1 :Company Profile Bharat Fritz Werner limited (BFW) located at peenya, the industrial suburb of Bangalore is a leading Machine tool manufacturer in India.  It was established in the year 1961 in techno commercial collaboration with Fritz Werner AG of Germany.  In 1966, BFW become part of Kothari Group and subsequently in 1977, become an associate company of Bukhardt+Weber, Germany.  In 2003, BFW become a fully owned compant of the Kothari Group.  Recently, Starray Herkert, the 125 year old swiss company established a strategic alliance with BFW to design and manufacture the complex, high end 5-axis machining centre for their global market. BFW houses the latest state of the art manufacturing technology and also supported by dedicated team of qualified engineers constantly engaged in updating technology and developing new products. BFW’s R & D Department, is recognized by the ministery of Science and Technology, Government of India and the company has won several awards from the Government of India.  Awards & Recognition 1. EEPC Silver Shield 2013 : Recipient of Government of India Silver Shield award from Engineering Export Promotion Council for outstanding Export Performance in year 2013. 2.FIE Foundation Award 2013 : Winner of FIE Foundation Award for R&D and Innovation in India Machine Tool section, 2013.
  • 6.
    6 3.Kirloskar Ferrous SpecialAward 2013 : Winner of special Appreciation from Kriloskar Ferrous Limited for supply of production line, 2013. 4.India Design Mark for Dhruva & Agni 2012 : India Design Mark for CNC Vertical Machining Centres, Dhruva & Agni, 2012. 5.AAM India Supplier Recognition Award 2010. 6.Ashok Leyland Appriciation 2010 : Ashol Leyland Appreciation for BFW’s contribution to their Pantnagar plant, 2010. 7.FIE Foundation for best Exhibit Award at IMTEX, 2007. 8.HMSI award for Machinery, 2006-07. 9.Best stall award at IMTEX, 2001.  MILESTONES BFW is one of the few private sector machine tool companiesin India to have completed 50 years of operations. This period has witnessed many significant milestones.
  • 7.
    7 17 October 1961 CompanyIncorporated 1970 Supply of firstspecial machine to Mico Beosh 1983 Execution of first bulk order : 25 Machinesto TATA Government Tech Centre Supply of 160 milling machines to the Erstwhile, USSR 1979 1985 Approvalof BFW R&D Facility by Ministry of Science & Technology, Government of India 1987 Supply of 16 horizontalmachining centers To the Erstwhile, USSR 1989 Supply of 135 milling machines to The Erstwhile, USSR 1993 Supply of cylinder block and cylinder head Transfer line to Simpson-Perkin
  • 8.
    8 1996 India’slargest automobilecompany, Mruti Udyog,starts using BFW products 1998 Production of high speed machiningcentres 2002 Two wheeler manufacturer HMSI, Start using BFW products Kirloskar ToyotaTextile machinery Starts using BFW products. 2000 2005 Production of Vertical DoubleColumn Machiningcentres 2006 Production of high speed vertical machiningcentres
  • 9.
    9 2008 Production of verticalturret lathe 2009 Production of 5-axis vertical & horizontalMachiningcentres 2011 Supply of KB engine cyclinder block Machiningcentres to Maruti Udyog. Production of glass bottle handling system Completionof 50 years . Strategic Alliancewith Spinner GmbH 2010
  • 10.
    10  General Management BFWis a powerful organization, which follows the rules and regulation of ISO9001 and also has a particular type of working atmosphere. Broadly the company can be categorized into 7 divisions. Each Division has a head, who acts as the chief executive officer of that division and is independent of taking decisions about matters in his division. He is supported by the strong R&D department, engineers and handles it carefully. Modification in working condition, needs of workers and their problems is looked upon and is discussed in the regular meeting of the core committee. The head has to take care to see that any kind of incompetence to the working management is not been entertained. There is a close bonding between all of the divisions so that they act as member of the same family and work with great zeal for the betterment of the industry. Board of Directors MKTG MCD MMD SMD CMD MFD ACD President & CEO Administration & Finance Strategic Sourcing Department
  • 11.
    11 Abbreviations MKTG: Marketing Department MCD:Machining Centre Department MMD: Milling Machines Division SMD: Special Purpose Mchines Division CMD: CNC Milling Machines Division MFD: Manufacturing Division ACD: Auto Component Division MEMBERS OF BOARD OF DIRECTORS Mr. A.K. Kothari Chairman Mrs. P.D. Kothri Director Mr. Shailesh Sheth Director Mr. T. Parabrahman Director Mr. Haigreve Khaitan Director Mr. Ajit Khandelwal Director MEMBERS OF MANAGEMENT TEAM Mr. Ravi Raghavan Chief Executive Officer Mr. K.S. Kasturirangan Senior Vice President of Finance & Amnistration Mr. Sujoy Das Gupta Chief Financial Officer Mr. Aditya Anant Kamble General Manager of Human Resources Chapter 2: Product Profile
  • 12.
    12 BFW initially startedwith the manufacturing of Knee type milling machines in various sizes. Subsequently BFW entered into the CNC field and also int area of special purpose machines. Today BFW offers a wide varieties of general purpose machines, special purpose machines, CNC machining centers etc. to meet the demands of the customers. Every single product is supported by best engineering inputs which naturally lead to high quality machine tools to meet today’s user standards and they have found ready acceptance world wide.  Product range includes: 1.) CNC Vertical Machining : i. Chandra + ii. Dhruva iii. Gaurav iv. Agni+ v. Agni++ vi. Vayu vii. Chakra viii. Sooraj ix. Astra x. Vajra xi. Virat xii. Pentaxes xiii. DMC xiv. Matec 30 HV xv. Matec 40 P 2.) CNC Horizontal Machining : i. Maxpro E series ii. Maxpro series iii. Vega iv. Tej v. Shaksham vi. Airavat 3.) Special Purpose Machines :
  • 13.
    13 i. Front axlebeam Machines ii. Crank Pin Milling Machines iii. Facing Centering Machines iv. Duplex Milling Machines v. Gantry type Machines vi. Pipe Chamfering Machines vii. Crank Shaft Oil Hole Drilling Machines 4.) CNC Turning Machines : i. Sudarshan BVL550H & 700H ii. Sudarshan BVL800H iii. Sudarshan BVL800ML iv. Sudarshan BVL1200 R/RL v. Sppiner TC vi. Spinner PD vii. Spinner U 5.) Non CNC milling Machines i. Knee Type Milling Machines 6.) Automation Chapter 3 : Manufacturing Division (MFD) INTRODUTION
  • 14.
    14 This is themain division and probably can be called as heart of the company. This Caters to the needs of all other divisions. In other words, it satisfies the needs of the internal customers by supplying the individual jobs which then be assembled in the respective division. CLASSIFICATION In order to identify and to carry out the operations depending on the difficulties involved in handling etc., MFD is Classified into three cells. CELL 1: This is also know as heavy part cell. Some of the machines coming under this cell are: Waldrich Siegen, Waldrich Coburg, TMC 800, TMC 1250, Noble and Lund, HMT Radial Drilling machine, etc. CELL 2: This is also known as medium part cell. Some of the machines Under this are TMC 500, SIP, Nissin, VMC 500, etc. CELL 3: This is also known as small part section. Some of the machines coming under this cells are: Lathe, Milling machines, Grinding machines, etc. HOW DOES MANUFACTURING DIVISION WORK? As manufacturing division follows ISP rules, there is a proper sequence in which it works and can be given as below: i. Engineering Method ii. Material Planning iii. Manufacturing
  • 15.
    15 iv. Quality Assurance 1.EngineeringMethod: When MFD takes up an assignment from the internal customer, it has to be given a component manufacturing order number (CMO no.) in addition to the work order number which is already entitled by the concerned division and this work order number indicates the external customer to whom the job belongs. The main purpose of giving CMO no. is to identify the division to division from which order is taken. It also indicates the demand for that particular job. The CMO no. for the following division are: For MCD - ‘2’ for regular items For SMD – ‘3’ for regular items For CMD – ‘5’ for regular items Each Component which is used for the manufacturing of the part is given a communication part number. Example : A simple communication part no. would look like – ‘32002422’ The order also contains the quality required, time to be taken for manufacture and the cell to be used to manufacture. Concept of Process Sheet: Process sheet is the written format of the component drawing are really a complicated one for the operations to understand, so a written format of the actual drawing helps the operator to perform the operation in a particular manner without any spoilage of the work.
  • 16.
    16 The contents presentin the process are as follows: I. Raw material: There is a particular coding for each raw material and they are indicated in the process sheet, so that operator can get the same material as mentioned by engineer in the form of coding on the process sheet. Examples: Low carbon steel has a coding as C2, High carbon steel has a coding as C1, Tool steel has a coding as T1, Nitriding steel has a coding as N1. SEQUENCE OF PROCESS The manufacturing of a component involves various operation such as turning, drilling, tapper turning, taper boring, boring, milling, grinding etc., these operations are called as machining processes. The particular sequence of process must be followed in order to get the component as given by the drawing. The operation. This sequence of processes is mentioned in the process sheet as shown below; a.) Serial no. – it is the increasing order starting from initial operation till the final operation. b.) Machine no. – the particular machine, which has to be used to carry out the process. c.) Description of operation – this involves the way in which the operation has to be done and even the type of surface finish required is also defined. Duration of operation, the approximate time which could be utilized for the particular operation is also mentioned in the process sheet. Usually duration of operation involves only two parts, setup time and operation time. Sometimes it may be needed to use special tool to obtain complicated shapes as indicated in the drawing and this has to be mentioned in the process sheet, so that operator will not be in dilemma about the way to obtain the particular shape.
  • 17.
    17 Engineering Support flowchart: CMO & Drawing from respective division Deciding the unclassified items ( as OM/SCF) with respective Informing the division regarding ‘H’ items
  • 18.
    18 Checking the availability of processlayout for accepted items Preparing/updating process layout for the items Checking for special tool requriment Checking for special material requriment Requesting tool engineer for procurement of special tool Providing the required special tool Classifying new items into ‘D’ NO YES InformingMPfor the release of casting/raw material NO Resting MP for the procurementof special material YES YES
  • 19.
    19 Manufacturing Service FlowChart: 2.Material Planning: Drawing from the customer Preparing the quotation Customer Preparing the Q.A. Customer Recieve the material Prepare job card & drawing to Product component Carry out Manufacturing Inspection Deliver to Customer after commercial clearance
  • 20.
    20 The proper planningof material storage and even handling is very important in any organization. The material handling engineer has to take care of the materials and even has to analyze the requirement of materials before purchase. After engineering analysis, the order is placed at material management section of MFD. The engineer has to decide about the procurement of the material such as bar stocks, casting, weldaments and other components as per the specification in the process sheet. If there is any shortage of material, it is needed to be informed and proper step must be taken to replace it. The raw material for the bed, Knee, column, spindle etc., is castings which are done in the company’s foundry, if its weight is less than 1 ton otherwise order is given to outside sub-contactor. For storing of standards parts used in manufacturing, there is a separate store room, where the components are kept in a systematic manner based on communication part number. This is done according to the specification of ISO 9001, which says that the right things at right place is the key of successful implementation of ISO 9001. Material Planning Flow Chart: Raw Material
  • 21.
    21 Input from methods/Dispatch programme/Informationfrom respective division Estimate Annual requriment of steel from MRP Check w.r.t. stock Prepare Demand note Check & Clarify demand note & send for cutting. After the material is cut, receive back copy of demand note. Prepare Batch Release Send for H item demand notes & Batch release notes to respective division subcontractor Foe D & I items, release batch, release notes route card, job card, process sheet & drawing to MFD. 1b. for C.W.B.B. (refer to next flow chart Special Material Request. Raise Purchase Order Receipt of Material & Issue Q.A Methods 1.a If material isnot available H items D & I items If material isavailable 1.b Casting, Weldments, Brass, & Bronze
  • 22.
    22 Material Planning flowChart: Purchase Check availability of the material Prepare the purchase order as per CMO Scrutinise & approve Purchase Order Send Purchase order, Drawing & Process sheets to vendor Supplymaterial/parts to stores with Q.C. & P.O. reference Receipt Prepare Demand note & Batch Release notes for D, I & H items Send Demand notes & Batch Release notes of H items to respective division sub- contractor Send Demand notes to Fettling & priming for D & I items Receive Demand note after fettling & Priming Release batch note, Route card, Processes sheets & Drawing to MFD. Q.A Finance H items D & I items If Not available If available PURCHASE ORDER VENDOR APPROVAL
  • 23.
    23 3.MANUFACTURING Receive request formaterial Select Vendor from approved vendor list If repeat Order Enquiry Place repeat order Scrutinize Quotation & select vendor Place Purchase Order Send Purchase Order, Drawing & process sheets to vendors Supply parts to shores with Q.C. & PO reference Reciept Q.A Requirement/ request for vendor registration Evaluate Vendor Check Evaluation Score Refuse Registration Enquiry Place Trial Order Receive & Check material Include in Approved Vendor List FINANCE FINANCE YES NO LESS THAN 65 IF SCORE65 OR MORE APPROVED RE JE CT
  • 24.
    24 The material planningis then followed by the manufacturing process. The process sheet along with the procured materials is then passed to the machining cell where process on the materials are carried out as explained in the process sheet. The inspection of the job in between the processes may even be carried out as mentioned in the process sheet. The manufacturing division has a ‘tool crib’ from where the various tools are issued as required for the operation. The tools are arranged in a particular format and bins are provided for smaller tools and larger tools are placed in convenient places. The ‘tool crib’ follows ISO9001 rules strictly and if there is any tool spoilage then it has to be taken in writing from the operator who has been working on with that tool. There is a store for issuing smaller parts like screws, nuts, bolts, gears, etc., that is of minimum use in case of manufacturing division, since no assembly work is carried out in this division. The final product after passing through the mentioned machines, performing various operations on it, is then given for panting.  MARKING OUT: Marking out or layout is the process of transferring a design or pattern to a work piece according to given drawing, as the first step in manufacturing process. Marking out consist of transferring the dimension from the drawing to the work piece in preparation for the next setup, machining or manufacture. Typical tools include;  Surface plate or Marking out table: Provides a true horizontal flat surface on which work piece can be supported.
  • 25.
    25  Angle Plates:Assists in holding the work piece perpendicular to the table.  Scriber: It is equivalent of a pen or pencil, it literally scratches the metal surface leaving behind a fine, bright line.  Height Gauge or Scriber block: Allows lines to be scribed at a preset distance from the work table surface.  Surface Gage: An ungraduated comparison measuring tool that performs much the same function as the vernier height gage. It is often used in conjunction with a dial indicator and a precision height gage.  MACHINING: Machining is any of various processes in which a piece of raw material is cut into a desired final shape and sized by a controlled material-removal process. The many processes that have this common theme, controlled material removal, are today collectively known as subtractive manufacturing, in distinction from processes of controlled material addition, which are known as additive manufacturing. Exactly what the “controlled” part of the definition implies can vary, but it almost implies the use of machine tools (in addition to just power tools and hand tools).  Types of Machining Operation: There are many kind of machining operations, each of which is capable of generating a certain part geometry and surfaces texture. In turning, a cutting tool with a single edge is used to remove material from a rotating work piece to generate a cylindrical shape. The speed motion is provided by rotating the work piece and the feed motion is achieved by moving the cutting tool slowly in a direction parallel to the axis of rotation if the work piece and depth of cut is given my moving cutting tool in direction perpendicular to the axis of rotation of the work piece.
  • 26.
    26 Drilling is usedto create a round hole. It is accomplished by a rotating tool that typically has two or four helical cutting edges. The tool is fed in a direction parallel to the axis of rotation of tool into the work piece to form the round hole. In boring, a tool with a single bent pointed tip advanced into a roughly made hole in a spinning work piece to slightly enlarge the hole and improve its accuracy, It is a fine finishing operation used in the final stages of product manufacture. In milling, a rotating tool with multiple cutting edges is moved slowly relative to the material to generate a plane or straight surface. The direction of the feed motion is perpendicular to the tool’s axis of rotation. The speed motion is provided by the rotating milling cutter. The two forms of milling are: I. Peripheral Milling II. Face Milling Other conventional machining operation include shaping, planning, broaching and sawing. Also, grinding and similar abrasive operation are often included within the category of machining.  HEAT TREATMENT: Heat treatment is the process of heating and cooling metals to achieve desired physical and mechanical properties through modification of their crystalline structure. The temperature, length of time, and rate of cooling after heat treatment will all impact properties dramatically. The most common reason to heat treatment include increasing strength or hardness, increasing toughness, improving ductility and maximizing corrosion resistance.
  • 27.
    27  INDUTION HARDENING: Scope:Applicable to heat treatment of parts/components manufactured from raw materials. Procedure: i. Choose the suitable inductor coil that has an inside diameter 4-6 mm more than outside diameter of the part to be heat treated. ii. Make sure that the axial length of the indicator is equal to the length of the portion to be heat treated or the coil can be moved to the required length of hardening. iii. Set the voltage, power rating and time suitable for the choose inductor coil. Also set the feed rate of the coil, water flow for quenching in case of moving coil. iv. Place a setting piece inside the coil and switch on. v. At the end of the cycle allow the part to fall into water bath for quenching. vi. Check the setting piece for establishing the process parameters. vii. Place the parts to be heat treated in the inductor coil and follow the above steps. viii. Check hardness. ix. Note down the process parameters set for the above process for that material.
  • 28.
    28  GAS CARBURISING& ANNEALING: Scope: Applicable to heat treatment of case hardened parts/ components manufactured out of raw material having C2M, C2R codes. Procedure: i. Load the parts in the gas carburizing furnace. ii. Raise the temperature to the preheat limit of 550 ºC, gradually at 4 to 5ºC per hour and ensure that the gas shield is maintained in the furnace. iii. After the pre heat temperature is stabilized, raise the temperature to 915 ºC and gradually at 90ºC per hour. iv. Soak it at this temperature for the required hours based on the required case depth (refer chart 1 given below). v. At the end of the period, allow to defuse for and required hours based on the case depth(refer given chart 2 below). vi. Allow the part to cool down in the furnace by switching off the furnace. General guidelines for achieving the required case depth during Carburizing (Temp: 915 +/- 5ºC) Case depth ( in mm) Activation Time (in hours) Diffusion Time (In hours) Total Time (in hours) 0.6 – 0.8 2.5 1.5 4 1.0-1.2 3.5 2.5 6 1.3-1.5 4.0 3.0 7 1.6-1.8 6.0 4.0 10
  • 29.
    29 Values of casedepth calculated by Harris relation from heat treaters guide Time (in hours) Case Depth in mm after Carburizing at 870ºC 900ºC 950ºC 2 0.635 0.762 0.889 4 0.889 1.070 1.270 8 1.270 1.520 1.800 12 1.550 1.850 2.210  Flame Hardening: Scope: Applicable to heat treatment of parts/components manufactured from raw material codes C1, C3R, EN9. Procedure: i. Fix the part to be flame hardened on a suitable fixture suitable for traversing the portion to be flame hardened below the torch. The torch (burner) shall have holes for inlet/outlet of water for quenching. ii. Set the gap between the portion to be hardened and the burner to 8-10 mm. iii. Set the pressure for oxygen at 5 kg/sq.cm. and that for acetylene at 3 kg/sq.cm. iv. Set the feed rate at 0.8 mm/sec. v. The flame is moved at the above rate over the component and water jet which follows the flame quench the item. vi. Check the hardness at random and make sure that it is within the specified limits.
  • 30.
    30 vii. If thematerial has not responded, redo the flame hardening cycle.  Stress Relieving: Scope: This is applicable to both welded and casting structure. Procedure: i. Suitable structure is taken for stress relieving. ii. The residual stresses are measured before stress relieving from sample structure and the value is noted. iii. Stress relieving treatment as per standard n. B7600/B7601 (as applicable to casting/welments) is imparted on this structure. iv. After stress relieving, the sample structure is taken for residual stress measurement. The value of the residual stresses should be in the order or 80-90% for qualifying the stress relieving process. v. The structure is machined and one particular dimension is identified for measurement over a period of 90 days at an interval of 30 days. If the dimension are within the tolerance given in the drawing of the sample structure for the identified dimension, the procedure for qualifying the stress relieving is accepted.
  • 31.
    31 4. PAINTING: Painting iscommon for all the departments. It is placed with in the MFD but at a suitable location to which the transportation of job from various departments may not be in a problem. Painting of the job as per customer specification is done and then passed on to the processes. In painting section, spray- painting technique is used. During spray painting, the tiny particles of paint in the form of jet is ejected from the gun which impacts on the job which has to be painted. There is a high possibility of these tiny particles spilling out to the atmosphere, which is hazardous to worker in this section. In order to avoid this, the updraft and lower draft is provided through which the continuous water circulation is maintained and this absorb the paint particles from the atmosphere, thereby providing a safe working condition.
  • 32.
    32 5.QUALITY ASSURANCE: Since BFWlimited is an ISO 9001 company, prime importance is given to quality assurance. The division has a high tech dimension checking room and standards room. These two rooms are maintained at particular temperature so that measurement can be made accurately and calibration can also be done to maximum perfection. The common instruments used by QA department of MFD are: i. Sine bar: They are used to measure angle and tapers. The slip gauges are made use of in this process and accuracy obtained in this method is 0.001µ. ii. Dial Indicator: the plunger type dial indicators are used and accuracy up to 10µ can be obtained. iii. Trimos Calibration: This is used to check the squareness, coaxiality of bores and bore sizes. It is also used to measure vertical heights. The accuracy of measurement is up to 5µ. iv. Internal Micrometer: The range is 70-80 mm and least count of the micrometer is 0.005 mm. v. Comparators: These are used for checking the components at a faster rate in mass production. The accuracy of the comparator is 1 µm.
  • 33.
    33 PROCEDURE ADOPTED FORCHECKING DIMENSION ACCURATELY: Purpose: To establish a procedure of in process items at final stage. Scope: Covers items processed in house Procedure: i. Take the item offered from process as per the relevant route card for inspection. ii. With appropriate instruments and gauges carry out the inspection as per relevant quality plan, drawing and operation layout. iii. Reward the results of inspection in route card as follows :  Record the confirming quality in the quantity accepted column and sign.  Record the details of non confermence if any in the remark column indicating the quality. iv. Identify the following with serial no. a) Heavy parts b) Spindle Components(Small Parts) v. Record the inspection results guide lines as below in respective register against specified serial no. for items identified with serial no. vi. Record the inspection results in the check list wherever specified. vii. Only final entry need to be made for these items in their route card. viii. Identify the inspection status of items with tags as follows:  Green : For accepted items  Pink : For rework items  Red : For rejected/ scrapped items  White : Items released without inspection  Blue : Concessionally accepted items  Brown : Item under non conformance.
  • 34.
    34 6. MAINTENANCE Some ofthe maintenance schedules followed by BFW for their machines used in the auto components division are as follows:  DAILY MAINTENANCE: i. Clean chips on the pallet changer and index table cover. ii. Clean operator window from inside and outside. iii. Clean spindle taper bore with lint free cloth iv. Check coolant level in the coolant tank. v. Check oil level in the air lubricator, hydraulic powder pack, ATC and index table. vi. Check hydraulic pressure vii. Check air pressure viii. Check through tool coolant pump pressure. ix. Check index table air curtain pressure. x. Check hydraulic oil temperature. xi. Check for oil foaming or heating.  WEEKLY MAINTENANCE: i. Check axes drives for quiet run and smooth movement. ii. Clean and visually check tool holder for damage or loosening of pull studs. iii. Clean filter mesh provided in coolant tank chip conveyor if provided. iv. Clean and replace air filter v. Clean hydraulic return line filter cartridge. vi. Check cooling fans provided in the CNC system for proper functioning. vii. Check air filter regulator for water accumulation. viii. Check for cleanliness of tool magazine and proper tool holding. ix. Check for free movement of tool holding rod and locking pin of tool changer arm.
  • 35.
    35  ANNUAL MAINTENANCE: i.Check machine level with level gauge and adjust if required. ii. Check for backlash in axes drives and adjust if required . iii. Check for current drawn in all drives. iv. Check for any damages to the electrical cables. v. Replace dry batteries in electrical cabinet.
  • 36.
    36 Conclusion  Bharat FritzWerner Limited, an ISO9001 company is one of the frontiers in the manufacturing segment related to the production of highly sophisticated CNC machines and Special Purpose Machines. The company works by having well planned mission and vision principles as well as certain environment policies with the customer satisfaction as their main moto.  The company has a very large manufacturing department in which the work is done so as to cater the needs of its own products. The working of different departments gives a clear idea of how a Computer Integrated Manufacturing system works. Various departments such as the Fixture Design, stores, Manufacturing, Design are all completely networked and a trator made ERP system is been used so as to control and perform various activities in the company.  The company always believes in upgrading its resources both technologically as well as the knowledge of its human resources by constant training programs and seminars.  The machines manufactured by them have international repute as well as great national demand because of usage of sophisticated software which are common platforms for CNC machines throughout the world.
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