This document provides a summary of a training project completed by Devilal Sharma at JBM Industries. It includes an acknowledgement, introduction to JBM Industries, details of the training received in the fabrication division, and a project aimed at reducing rework parts per million (PPM) in the outer leg formation process. The project identified undercuts in thread bosses and reinforcement plates as the main defects, and an action plan was implemented including operator training and standard operating procedure displays which reduced the PPM from 2,352 to 113.

1. UNDER THE GUIDANCE-
NAME-SC NARULA
SUBMITTED BY:-
NAME-DEVILAL SHARMA
ROLL.NO.- 10/FET/AU(S)/2009

2. CONTENTS
1) Acknowledgement
2) Introduction
3) Training detail
4) Project detail

3. ACKNOWLEDGEMENT
I take this opportunity to express my profound gratitude to express
my profound gratitude & deep regards to my guide Mr.S.C Narula for
his exemplary guidance ,monitoring & constant encouragement
throughout this training period.The blessing ,help & guidance given
by him time to time shall carry me a long way in the journey of life on
which I am about to embark.
I also take this opportunity to express a deep sense of gratitude to
Mr.N.K saxena (sr.manager production,Fabrication,JBMI) for his
cordial support,valuable information & guidance,which helped me in
completing this task through various stages.
I am obliged to staff members of JBMI company for the valuable
information provided by them in their respective fields.I am greatful
for their cooperation during the period of my assignment.

4. INTRODUCTION
About JBM INDUSTRIES
•JBM group has its global presence in automotive,education,engineering
services & renewable energy sectors,
•Today the company has 33 manufacturing plants,5 engineering & design
centres across 19 locations globally.
•It has a turnover of USD 1.2 billion.
•JBM Group caters to clients in Automobile OEMS like Ashok
Leyland,bajaj,Fiat,GM,Hero,Honda,JCB,Mahindra,Maruti suzuki,Renault-
Nissan,TATA,Toyota,TVS,VECV,VolksWagon,volvo & many more.
•Products-Body Assembly,Body in white,Chasis and suspension system,Die
casting,Engineering services,Exhaust systems,Fabrication,LPG &CNG
Cylinders,Steel fastener,Skin panels,Steel processing,Tailored Welded
Blanks,Tools,Jigs & Fixtures,Tubes & Tubular Manipulations,Welded
Assemblies Systems.Wheel assembly.

5. TRAINING DETAIL
FABRICATION DIVISION
LINE:-
1. H/T welding
2. D/T welding
3. H/T Assembly
4. D/T Assembly
5. Inner leg
6. Outer leg
7. S.S Foot
8. Cross box
9. Torsion tube
10. Boom
11. 2DX line
12. Engine mount
13. Axle yoke
14. Export engine mount.
:- Cylinder formation.
:- studied about MIG and TIG
welding
:- Studied about spm machines.
:- Railway doors formation & its Fuel
tank formation
:- Type of welding done in railway
doors.
JCB SECTION

6. Project NameProject Name:- Reduce In-house
Rework PPM-Outer leg

7. Outer leg formation
Parts
• U-channel plate
• Closing plate
• Saddle bracket
• Backing plate
• Thread bush
• Big bush
• Reinforcing plate
• Small bush
• washer
Dimension
1) U-channel
Thickness=8mm
Length=1233mm
Breadth=153mm
2) Closing plate
Thickness=8mm
Length=1233mm
Breadth=153mm
3) Thread Bush
Internal dia=65mm

8. FLOW CHART
Raw material Raw material
shearingPlasma cutting
Bending Drilling
U-channel plate
formed
Chamfering
Both closing plate & u channel
plate welded together

9. Tagging
Welding(line
welding on SPM)
2nd layer welding(23*3
Boss,small boss,big
boss,washer welding)
Saddle bracket welded
RNC plate
welded
Final welding
Grinding
Buffing
Punching Dispatch

10. Part wise contribution in overall PPM
Product Wise Rework PPM (AUG-2013)
Part Name
Hydraulic
tank
Outer leg Diesel tank
Torsion
tube
Cross Box S.S foot Inner leg
Total
Produce/R
ework Qty.
Produce
Qty.
792 480 784 300 300 1415 1030 5101
Rework
Qty.
27 29 21 8 9 7 0 101
PPM 34091 60417 26786 26667 30000 4947 0 19800
Part Name Defects Qty. Contribution in overall PPM
Hydraulic tank 27 5293
Outer leg 29 5685
Diesel tank 21 4117
Torsion tube 8 1568
Cross Box 9 1764
S.S foot 7 1372
Inner leg 0 0

11. Defects Wise Contribution in Overall PPM
PPM
Defects Name
Defect Qty. PPM
Undercut 12 2352
Overwelding 6 1176
Blow hole 5 980
Welding miss 2 392
Dent 2 392
Uneven welding bead 2 392
2352
1176
980
392 392 392
0
500
1000
1500
2000
2500
Undercut Overwelding Blow hole Welding miss Dent Uneven
welding bead

12. Concentration Diagram

13. Concentration Diagram
Day 1 Day 2
Day 5 Day 6
Day 3
Day 4

14. Concentration Diagram
Day 7 Day8 Day 9
Day 10

15. S. No Area
Defects
Welding
undercut
Welding
miss
Bow
holes
Dent
Over
welding
Uneven
welding
bead
Spatters Total
1 A 2 2
2 B 1 1
3 C 2 2
4 D 4 2 1 7
5 E 12 4 16
6 F
7 G
8 H 2 2
9 I 2 1 3
10 J
11 K
12 L 1 1
Total 16 3 4 2 7 1 1 34
Compilation of Data

16. Pareto - Zone wise
16
7
3
2 2 2
1 1
0 0 0 0
47
68
76
82
88
94
97
100 100 100 100 100
0
10
20
30
40
50
60
70
80
90
100
0
5
10
15
20
25
30
E D I A C H B L F G J K

17. Pareto - Operator wise
9
8
3
1 1
41
77
91
95
100
0
10
20
30
40
50
60
70
80
90
100
0
5
10
15
20
Nirmal Roshan Sunil Rajender Ranjeet

18. Area Identified On The Basis Of Pareto
Undercut In Area E& D (Thread Boss &Reinforcement plate)

19. Action Plan For Problem
S. No Cause Activity Responsibility Status
1
Welding voltage too high.
Training to be impart to
operator through one
point lesson.
Trainer Completed
S.O.P to be display. Trainer Completed

20. Improvement To Control Undercut In Thread
Boss.
One point lesson not displayed. Now training given to operator through one
point lesson.
Before After

21. S.O.P not displayed. Now training given to operator through S.O.P.
Before After
Improvement To Control Undercut In Thread
Boss.

22. 0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
14.02.13 15.02.13 16.02.13 18.02.13 19.02.13 20.02.13
Result Monitoring

23. 679
566 566
340
226 226
113
0
500
1000
1500
2000
25002352
1176
980
392 392 392
0
500
1000
1500
2000
2500
Before After
Result