it includes my Project work on process capability in grinding machines which was undertaken by me during the tenure of jan 2017 to june 2017. This work is an authentic work and all rights are reserved. This presentation can be used for further research purpose.

1. INDUSTRIAL TRAINING
PAGE-01

2. VIJENDER SINGH
8th Semester
1/13/FET/BME/2/040 PAGE-02

3. CONTENTS
INTRODUCTION
HISTORY OF COMPANY
OVERVIEW OF MS MANUF. PLANTS
DEPARTMENT
INDUSTRIAL TRAINING WORK UNDERTAKEN
PROJECT
PAGE-03

4. INTRODUCTION
Maruti Suzuki India Limited, formerly known as
Maruti Udyog Limited, is an automobile
manufacturer in India. It is a subsidiary of Japanese
automobile and motorcycle manufacturer Suzuki
Motor Corporation.Maruti Suzuki manufactures and
sells popular cars such as the Boleno, Dezire, Ignis,
Ciaz, Ertiga, Alto, Swift, Celerio, Swift Dzire and
Omni.
PAGE-04

5. HISTORY
It is an Automobile manufacturer in India,Formerly
known as Maruti Udyog Limited. Maruti was established
in February 1981, though the actual production
commenced only in 1983. It started with the Maruti
800. Originally, 74% of the company was owned by
the Indian Government and 26% by Suzuki of Japan. As
of May 2007, the government of India sold its complete
share to Indian financial institutions and no longer has
any stake in Maruti Udyog.
PAGE-05

6. OVERVIEW OF MARUTI SUZUKI
MANUFACTURING PLANTS
Maruti Suzuki have two plants,one is Gurugram
plant and Second is Manesar plant.I am
persuing my training from Manesar plant.The
plant is divided into two parts,one is MPT
means Maruti power train plant where engines
and transmissions of four wheelers are
manufactured and engine parts of two
wheelers are made.And the second part is
Assembly division where all four wheelers are
assembled.
PAGE-06

7. Department Alotted
The department allotted to me is TMHT (SHM).In
this department grinding operation is performed of
two types of shaft on two types of Line.
1) ISG LINE (INPUT SHAFT GRINDING LINE)
2) CSG LINE (COUNTER SHAFT GRINDING LINE)
PAGE-07

8. The MPT plant is further divided in differet
sections.Like;Engine Plant,Transmission
Plant,Maintainance,Forging ETC.
PAGE-08

9. Industrial training work undertaken-
 get knowledge of SHM (Shaft Hard Machining) line
 wheel specification
 Types of coolant used at MPT & Problem occurred
due to bubble formation
PAGE-09

10. SHM – SHAFT HARD MACHINING
on this line finishing operation of shafts takes place.
This line consists of 7 checkpoints from point 1 to 7
PAGE-10

11. WHEEL SPECIFICATION
 Coding of wheel used at MPT is as – 83 A 1001 J 6 V C 500
 83 – Manufacturer’s symbol
 A – aluminium oxide
 100-1 – grain size
 J – grade
 6 – structure
 V – Vitrified
 C500 – Manufacturer’s private marking
PAGE-11

12. COOLANT & TYPE OF COOLANT USED AT
MPT–
 A coolant is a fluid which flows through or around a device to prevent the
device from overheating.
 transferring the heat produced by the device to other devices that either
use or dissipate it.
 An ideal coolant has - high thermal capacity, low viscosity, non-toxic, and
neither causes nor promotes corrosion of the cooling system.
SR.
NO.
TYPE
CONCENTRATION
RANGE
R.I. OPERATION
1 Micro –cut 3-5 1.2 Grinding
2 Yushiro 4-6 1.42 Cutting
3 Blaser oil 5-7 1 Cutting
4 High cut (trial) 3-5 1.6 Grinding
PAGE-12

13. FOAMING -
 Foam can impede the performance of high – pressure, high – volume machine
tools and lead to machine downtime and tool breakage
 Foam does not lubricate & cool very well
 Foam contributes to chemical odor and mist difficulties
What causes Foam?
 Leakage in valve stems from loose packing
 Leakage in piping, rotary unions or other connections.
 Coolant pump running in the wrong direction.
 Sump too shallow or pump set too high so air is sucked into the intake.
 Washing or floor shop contamination.
 Water and how the fluid mixed with it.
PAGE-13

14. PROJECT – Process capability
 PROBLEM – 1 :
 PROBLEM -2 :
OD undersize
due to amplifier
Variation in the
OP1 Tolerance
of CSG02?
PAGE-14

15. MARPOS NG
Component fall
down at
marposs unit
Problem
Dressing
problem
MARPOS GAIGE
DISTURB
COOLANT
FLOW
ABNORMAL
PART HIT
PAGE-15

16. Why-Why Analysis-2
WHY 1
WHY 2
WHY 3
WHY 4
Response Time Very Slow
No Knowledge About use
WHY 5
Problem statement – OD UNDERSIZE
Amplifier unit not OK
Amplifier unit Damping Type
OD Undersize
PAGE-16

17. Problem statement – Amplifier unit not OK
WHAT IS
? (Step 3.Problem
Definition)
Damping type amplifier unit suitable for Spline
grinding in which marposs finger measure the spline
diameter and working on (ON/OFF ) method due to
insertion portion area and not suitable for
plain Diameter.
PAGE-17

18. Problem statement – Amplifier unit not
OK
Damping Type
Amplifier Unit
WHAT IS
? DAMPING
TYPE UNIT
Damping Type Amplifier
Unit Suitable For
Spline Diameter And
Not Suitable For Plain
Diameter Having Poor
Response Due To Spline
Insertion Area
PAGE-18

19. Problem statement – Amplifier unit not OK
WHAT IS
?
PLAIN DIAMETER AND
SPLINE DIAMETER
PAGE-19

20. But we have only plain Diameter for
Grinding and this Damping type unit
not suitable for that Diameter
Problem statement – Amplifier unit not
OK
Marposs Unit
Damping Type
Amplifier Unit
Brief Description Of ProblemNow
ok
Problem
Catch
PAGE-20

21. Problem statement – Amplifier unit not
OK
Marposs Unit
Damping Type
Amplifier Unit
Brief Description Of ProblemNow
Not
ok
Giving
Size
Variation
Problem
PAGE-21

22. Problem statement – Amplifier unit not
OK
Marposs Unit
Damping Type
Amplifier Unit
Brief Description Of ProblemNow
Not
ok
Giving
Size
Variation
Problem
PAGE-22

23. Countermeasure
Action
PAGE-23

24. Countermeasure
Model no-
8126148189
Model no-812f19904
Model no-
8125102109 OK
NG
NG Total 16 units
replaced
PAGE-24

25. Effect after Countermeasure
222
112
156
85
150
0
50
100
150
200
250
OD UNDERSIZE HEIGHT
UNDERSIZE
OVALITY TAPER
SIZE VARIATION
REJECTION
REJECTION AFTER
EFFECT AFTER
CHANGING ALL
NG AMPLIFIER
UNIT
PAGE-25

26. PROBLEM 2 – Variation in the
OP1 Tolerance of CSG02?
 There was problem in the chuck of CSG02 OP-2
machine which can be identified by taking several
readings continuously with the help of
micrometer
S.NO. ISG02 ISG03 ISG04 CSG01 CSG02 CSG02' CSG03 CSG04
ɸ30g6 ɸ26g6 ɸ30g6 ɸ30.5g6 ɸ30.5g6 ɸ35g6 ɸ35g6
29.980-29.993 25.980-25.993 29.980-29.993 30.475-30.491 30.475-30.491 34.975-34.991 34.975-34.991
1 29.987 25.982 29.984 30.482 30.482 34.985 34.982
2 29.986 25.985 29.988 30.0483 30.482 34.983 34.981
3 29.988 25.984 29.983 30.482 30.483 34.987 34.979
4 29.988 25.984 29.985 30.483 30.480 34.982 34.977
5 29.989 25.982 29.988 30.480 30.481 34.987 34.980
6 ad ad ad ad ad ad ad
7 29.987 25.981 29.989 30.484 30.480 34.983 34.983
8 29.985 25.985 29.987 30.481 30.482 34.985 34.977
9 29.989 25.982 29.987 30.483 30.479 34.987 34.978
10 29.989 25.985 29.986 30.481 30.482 34.981 34.977
11 29.990 25.987 29.982 30.484 30.480 34.985 34.978
12 29.992 25.985 29.981 30.483 30.481 34.985 34.978
13 29.989 25.984 29.982 30.480 30.482 34.986 34.980
14 29.989 25.986 29.983 30.483 30.481 34.984 34.981
THMHTHARDGRINDING
OP1PROCESSCAPABILITYOFISG&CSG
TOLERANCE= UPPER LIMIT – LOWER LIMIT
PAGE-26

27.  As a result we successfully attained the tolerance reduction to maximize the
accuracy level of the component by changing chuck and thus I gain my
objective to make the process capable.
%ageincreaseinthecapability–0.012-0.005 x100=58%
0.012
TOLERANCE 0F ISG02 -- 29.991 - 29.985=0.006
TOLERANCE 0F ISG04 -- 25.987 - 29.980=0.007
TOLERANCE OF CSG01-- 29.990 - 29.981=0.009
TOLERANCE OF CSG02-- 30.490 - 30.478=0.012
TOLERANCE 0F CSG02'-- 30.484 - 30.479=0.005
TOLERANCE OF CSG03-- 34.989 - 34.980=0.009
TOLERANCE OF CSG04-- 34.984-- 3.977=0.007
PAGE-27

28. Effect after Countermeasure
0
0.002
0.004
0.006
0.008
0.01
0.012
0.014
CSG02 BEFORE CSG02' AFTER
TOLERANCE
TOLERANCE CSG02 BEFORE
TOLERANCE CSG02' AFTER
EFFECT AFTER
CHANGING
CHUCK ON
CSG-02
PAGE-28

29. PAGE-29

30. PAGE-30