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INPLANT TRAINING REPORT
ATraining Report
Submitted to The HR &Technical Engineers
Of
MESSER CUTTING SYSTEMS INDIA PVT LTD
By
------------------------------------------------
P. RAGHUL
-------------------------------------------------
OF
SRI ESHWAR COLLEGE OF ENGINEERING, COIMBATORE-641 202
TRAINING PERIOD: 20-06-2016 to 25-06-2016.

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INDEX
Page no
Acknowledgement------------------------------------------------------------- 4
Introduction---------------------------------------------------------------------5
Vision & Mission--------------------------------------------------------------6
Our Experience in Messer---------------------------------------------------- 8
Our Interaction with GM----------------------------------------------------- 9
Understanding about Metal Cutting---------------------------------------- 10
Different types of cutting
-Oxyfuel cutting-----------------------------------------------------------11
-Plasma cutting------------------------------------------------------------13
-Laser Cutting-------------------------------------------------------------16
Hand Torch--------------------------------------------------------------------18
An overview about cutting machines
-Omnimat------------------------------------------------------------------19
-Multitherm----------------------------------------------------------------21
Observations in shop floor--------------------------------------------------25
Procurement Department----------------------------------------------------26
QED Department-------------------------------------------------------------27
Maintenance and Service Department------------------------------------28

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Finance Department------------------------------------------------------30
Store--------------------------------------------------------------------------30
Gas Regulators-------------------------------------------------------------31
*************************************

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ACKNOWLEDGEMENT
We heart fully thank Mr. Mani N, Managing Director of Messer Cutting
Systems India Pvt Ltd for granting us permission to undergo Inplant training. We
also thank Mr. Hariharan V, General Manager for his guidance during the
internship training.
We would also like to thank all Managers, Human Resources [HR], Engineers
and Workmen who helped us and guided us during the internship training. We
also had a great learning experience and able to understand about the roles of
Management, Process involved in manufacturing & Technologies used during the
Internship training. It’s been a great experience that we had in the company having
experiencing many new technology aspects.
We would also like to thank our Chairman, Director, Principal, Dean and HOD
of Mechanicaland Electrical Engineering Department of Sri Eshwar College
of Engineering, Coimbatore-641 202. And our special thanks to Assistant
Professor Mr. Rajan Babu, senior Professor of Electrical Engineering
Department for his Support to undergo inplant training.

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INTRODUCTION
Messer Cutting Systems is a global supplier of cutting edge technology. We
provide services for the metal working industry setting standards worldwide. As
the industry pioneer we offer complete solutions and focus strategically on our
customer and on customer driven innovation. We in active in more than50
countries and about 800 employees in 5 main locations with production sites.
Our products range include oxyfuel, plasma and laser cutting systems, from hand-
guided machines right up to special machines for shipbuilding as well as plant and
equipment for oxyfuel welding, cutting, brazing and heating. Spare parts, repairs
and modernization services round off the program as well as environmental
equipment for the systems. Our software solutions optimize production and
business processes. We focus on intensive dialogue with our customers –our
modern training and applications facilities reinforce this claim.
We are the Cutting Systems Partner of choice and are consultants for our
customers.
Messer Cutting Systems partner of choice and are a consultant for the customers.
Messer Cutting systems, products and service for the metalworking industry stand
for cutting edge technology worldwide for more than 115 years.

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VISION & MISSION
VISION:
“WE ARE A WORLD COMPANY”
MISSION:
 To use the unlimited opportunities we have.
 To create value for the benefit of our customers.
 To open up, to think multidimensional.
With this in mind we are able to build bridges for our customer’s future.
For Messer Cutting Systems being a World Company is a fact and a vision at the
same time. In the past our worldwide growth has led us to success, market
leadership and multicultural diversity.
We believe in the future potential we have as a World Company. Across all
countries and regions we want to make the most out of our joint capabilities to
guarantee the long-term partnership with our customers.
“Excellence” is a result of our values and our key success factor.

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Messer Cutting System is Global supplier of cutting edge technology. We provide
services for the metal-working industry, setting standards worldwide. As the
industry pioneer we offer complete solutions and focus strategically on our
customer and on customer-driven innovation. The company is active in more than
50 countries, with more than 800 employees in 5 main locations with production
sites.
Our product range include oxyfuel, plasma and laser cutting systems, from
hand-guided machines right up to special machines for shipbuilding, as well as
plant and equipment for oxyfuel welding, cutting, brazing and heating. Spare
parts, repairs and modernization services round off the program as well as
environmental equipment for the systems. Our software solutions optimize
production and business processes. We focus on intensive dialogue with our
customer-our modern training and applications facilities reinforce this claim.
We are the Cutting Systems Partner of choice and are consultants for our
customers.

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OUR EXPERIENCE IN MESSER
We experienced a great learning condition in Messer. Our interaction with
Managers and Engineers in Messer was Memorable. We learned so much about
cutting technology and we experienced a vast knowledge about the how the
industry works and we learned what are the duties of the different section in an
company.
The people of Messer shared their experience with Messer and they taught us more
about industry. It was very useful for us to gain a great exposure about a MNC.
We really thank Messer People for giving us guide in our life.
After finishing inplant training in Messer we gained a more technical knowledge
and how to work in industry. The working environment in Messer was very good,
we have not seen in any company with such good working environment. The
People in Messer treated as their home people and the accommodation was
excellent. We really thank Messer for such good environment.

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OUR INTERACTION WITH GM
On the first day of our inplant training in Messer we have a discussion
with,company GM Mr. V. Hariharan, He was such a wonderful person, we have
an interaction with him about half an hour, the time with him was very useful and
we learned about that what the Messer is doing really in the industry market, He
guided our group to learn more about Messer and guided to have vast knowledge
about the industry.
Having such interaction with most experienced person for college students is not
easy to have it. So that we were so lucky and blessed to have such discussion with
him. He had interacted with freely and discussed more about industry and guided
our group to how to do undergo inplant training in general.
He also advised us to how to learn the technical aspects and how to learn technical
things. It was a memorable one.

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Understanding about metal cutting
Before our internship in Messer, we don’t know more about cutting process and
their process. But after completing internship in Messer we came to know about
much more about cutting process and the different types of cutting machines, that
are used for different purposes. Wealso had understood the type of cutting process
should be employees for particular type of process and for a particular metal.
We also understood the, how the cutting of the material is done and how the
cutting process is controlled, and high accuracy is maintained with good finishing
property. We came to known about different types of machines that are produced
by Messer for different cutting process oxy-fuel, plasma and laser. And why the
customers arechoosing the particular machines for their requirement.

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Oxyfuel Cutting
Oxyfuel flame cutting is the most economical process for the cutting of mild
and low alloy steels, even with weld preparations. It is one of the most important
production processes in the metal industry.
Oxyfuel cutting is a combustion process using oxygen and fuel gas flame. The
heating flame brings the material up to its ignition temperature. Then a jet of
oxygen at least 99.5% pure is blown onto the heatedspot. The oxygen jet oxides
the metal. The torch is moved and a narrow cutting kerf is created, removing the
slag from the kerf. The quality of the cut depends on the surface condition of the
material, cut-velocity and thickness.
All low alloy steel with a material thickness up to several decimeters can be cut
with this process. Despite the increasing significance of the other cutting processes
such a plasma and laser cutting, oxyfuel flame cutting is still a very economical
process. For heavy material thickness up to 35ich (900mm) there is no alternative
to flame cutting.
Machine flame cutting ensures reliable hole-piercing, high cutting speeds and
allows the production of components to their finished sizes without the need for the
further processing. For weld seam preparations V, Y and K cuts can be produced.
CHARACTERISTICS:
 Plate thickness: 3mm to 900mm.
 Typical: 10mm to 300mm.
KEY FEATURES:
 Good cut quality
 Smooth, vertical planes of cut

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 Carbonizing and hardening within the area of the heat affected zone
 High heat input
 Limited range of material

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Plasma Cutting
Plasma cutting was originally developed for the thermal cutting of materials
which were unsuitable for flame cutting, suchas high alloy steels or aluminum.
Today, the process is also used for the economical of thin, low alloyed steels.
One common description of plasma is to describe it as the fourth state of matter.
We normally think of the three states of matter as solid, liquid and gas. For a
common element, water, these states are ice, water and steam. The difference
between these states relates to their energy levels. When we add energy in the
form of heat to ice, the ice melts and forms water. When we add more energy, the
water vaporize into hydrogen and oxygen, in the form of steam. By adding more
energy to steam these gases become ionize. This ionization conductive, ionized
gas is called a plasma.
The plasma cutting process, as used in the cutting of electrically conductive
metals, utilizes this electrically conductive gas to transfer energy froman electrical
power source through a plasma cutting torch to the material being cut.
The basic plasma are cutting system consists of a power supply, an arc starting
circuit and a torch. These system components provide the electrical energy,
ionization capability and process control that is necessary to produce high quality,
highly productive cuts on a variety of different materials.
The power supply is a constant current DC power source. The open circuit
voltage is typically in the ranger of 240 to 400 VDC. The output current
(amperage) of the power supply determines the speed and cut thickness capability
of the system. The main function of the power supply is to provide the correct
energy to maintain the plasma arc after ionization.
The arc starting circuit is a high frequency generator circuit that produce an AC
voltage of 5,000 to 10,000 volts at approximately 2MH. This voltage is used to

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Create a high intensity arc inside the torch to ionize the gas, thereby producing the
plasma.
The Torch serves as the holder for the consumable especially nozzle and
electrode, and provides cooling (either gas or water) to these parts. The nozzle and
electrodeconstrictand maintain the plasma jet.
CHARACTERISTICS:
 Plate thickness: 0.8mm to 150mm.
 Typical: 3mm up to 75mm.
KEY FEATURES:
 Low to high cut quality
 Smooth, edge surface
 Metallurgical perfect surfaces for welding
 Medium Heat input
 Excellent Cutting speed
 Hardening within the area of the HAZ
 Wide range of material

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Plasma Cutting

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Laser Cutting
The laser cutting process uses a strong focused laser beam, produced by a laser
diode. The high energetic laser beam heats the surface of the material and melts
rapidly a capillary responds to the diameter of the used laser, during the cutting
process, an assistant gas is used to eject the molten material from the kerf. As a
result, the cut quality and speed are very high compared with other cutting
technologies.
Flame Oxygen Cutting by contract, is characterized by the fact that the material
is only heated to its ignition temperature. Oxygen is used as cutting gas, so that the
material burns and forms as oxide which melts through the additional energy from
burning. The cutting oxygen then forces the slag out of the cut. Typical material
is, for example, low alloy steel (Mild steel).
For Fusion Cutting, the material is melted directly by the laser beam. As the
sublimation cutting, an inert gas, usually nitrogen, is also used here to force the
molten material out of the cut. This process is typically used for alloyed steels
(stainless Steel).
All processes have in common that, because of the narrow focus of the laser
beam, the width of cut is very small compared to the other thermal cutting
processes. Thus minimum material is melted and the laser energy is used very
efficiently. The heat input into the material is thus relatively low so that even
small geometries can be cut.
In addition, the cut edge is relatively straight which in all gives very high
componentaccuracy from the cutting process.
This means that laser cutting is used in the most diverse areas, especially
wherever high accuracy for the componentgeometry and the cut edge is required.
The preferred range for steel sheets is up tp a material thickness of 20mm under
certain circumstances up 25mm. n For this application mainly the co2 laser and

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Fiber Laser are used. For greater thickness, Laser cutting only makes sense for
special applications, more unusually other cutting processes are used here.
CHARACTERISTICS:
 Plate thickness: 0.1mm to 25 mm.
 Typical: 1.5mm up to 20mm.
KEY FEATURES:
 Laser light can be well focused from 25mm to 0.2mm.
 Laser radiation: coherent, monochromatic, high energy
 Very high power density
 The light melts or partially vaporizes the material and an additional gas
stream blows it away
 High to medium cut quality
 Smooth to rough, vertical planes of cut
 Metallurgical perfect surfaces or metallic blank surfaces
 Low heat input
 High to low cutting speeds
 Hardening within the area of the Heat-affected-Zone
 Dust as well as UV and IR-radiation

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HAND TORCH
For local and for more comfort of Cutting Hand torch
is used for cutting materials. Usually Hand torch
works on oxyfuel only hence it can also cut thickness
of about 300mm also.
Here the oxyfuel mixture, oxygen and fuel gas is
used. Gas regulators are used to adjust the flow of
the Gas in the torches.

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OmniMat
For large working areas and square or bevel cuts using oxyfuel or plasma, the
OmniMat is the ideal machine. A full spectrum of marking processes is, of course,
also available.
OmniMatis a large size CNC cutting machine with a heavy-duty structure and
multi axis control, suitable for a wide field of applications and complicated cutting
jobs. A number of different torch suspensions with tool holders is available, e.g.
marking tools, punching and drilling devices, strip cutting attachments, triple torch
or rotating triple torch, plasma arc contour bevel unit.
The CNC cutting machine has a sturdy portal design, positive bilateral longitudinal
drives and a precise machine guiding profile, providing you high cutting accuracy
and contouring precision.
Whether you want to cut with oxy-gas, underwater or dry plasma, whether straight
cuts or weld preparations, the OmniMat offers you the ideal solution. The patented
Global Rotator, equipped with advanced 5 axis robotic compound

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Movement control technology, is ideally suited for "V" & "Y" contour bevelling
with only one pass. This greatly reduces fabrication time and milling after the
cutting process is now superfluous.
The system is now widely used in industries such as shipbuilding, heavy industry,
engineering equipment, etc.
Key Features:
 Depending on the machine equipment a working width up to 12000 mm can
be reached
 Stable construction to guide even the heaviest equipment accurately
 Linear guides on the bridge give smooth and precise cuts
 Designed with the most modern CAD tools for optimum dynamic
performance and maximum robustness
 High performance AC drives for speeds up to 35 m/min and high
acceleration
 Increased productive times through highest acceleration and positioning
speeds
 The system is characterized by its high durability

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MultiTherm
The MultiTherm is the workhorse amongst the Messer cutting range for top quality
and productivity.
Whether plasma (straight or bevel), multi-torch gas cutting, marking or a
combination of all is your requirement, the MultiTherm is THE machine for you.
This powerful CNC-controlled machine is suitable for a wide range of
applications. Twin sided longitudinal drives ensure high quality cuts.
A wide choice of marking processes means you can pick the ideal one for your
production. Naturally multiple torch cutting is possible in both oxyfuel and plasma
modes for high productivity.

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Key Features:
 The 35 m/min high power drives give fast positioning and accurate cuts,
even around fine contours
 The ability to park unused heads over the wheel housings maximizes plate
utilization with the heads used
 Working widths up to 4 m
 Cutting Speeds up to 35 m/min
 Working lengths virtually unlimited
 Cutting Processes: Oxy-fuel, Dry Plasma, WIPC, Laser
 Bevel Cutting Units: Skew, triple torch unit N
 Marking Processes: HF Punch, Powder Marking, Plasma Marking, vibrating
stylus type Omni Script, Inkjet
 Wide range of equipment options available
 Very efficient
 Excellent dynamic performance and accuracy
 Light enough for high cutting speeds and accelerations
 Strong enough to take bevel cutting heads for oxyfuel and plasma
 Hoses and cables lie inside the bridge for safety and neatness
 Integrated transverse linear guide and rack for reduced wear and smoother
drive
 Latest cnc control for increased operator comfort and efficiency

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Plasma and Fiber Laser
Combination

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Combination of plasma and laser

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OUR OBSERVATIONS IN SHOP FLOOR
We have spent almost three days of training in shop floor. It was very useful one
we have observed a lot and also gained more knowledge. We got an opportunity to
observe how the cutting machines are assembled and how they are checked.
We also observed how the gas regulators for different gases like oxygen, acetylene,
carbon-dioxide, LPG are made and how they are tested. We have also come
through the assembly line of the gas regulators, and it equipped with modern
features and also seen how the standard of Messer is maintained, the workmen said
actual cutting pressure is very low when compared to the pressure that they are
actually testing on the gas regulators, we have also seen gas boosters for the
purpose of boosting the gas to the required very high pressure.
We have also come through the laser zone, in this zone we have seen two advanced
cutting machines swift blade and fiber blade, and also seen the working. The work
men in the shop floor explained the working of both swift blade and fiber blade, it
was very interesting and we were understood how the laser source if have been
used for cutting purpose.
The cutting speed for swift blade is very high when compared to other models, this
feature was awesome. The workmen operated the sift blade and explained the rest.
We also have seen the assembly were the cutting machines and assembled
checked. The assembly of each and every machine in unique, the models name are
same but there was some difference between each and every machine.
We have also come through how the cutting machines are checked for there the
cutting accuracy like diagonal test which is almost done for more number of times.
The test for rack and pinion (Butter paper test).

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PROCUREMENT DEPARTMENT
For every manufacturing and Mass Production Company the procurement
department is very important one which confirms the smooth running of
production and assembly without any demands. It play a vital role in smooth
running of the company and confirms that required components and materials are
stored in store room for the required demand.
In Messer in procurement department how they select the contractors and how they
order in respective to the project time, it includes the mode of transport also. The
most of the products in Messer are imported from Germany, USA and some other
European countries hence in Messer Procurement department plays a vital role for
the smooth running of the firm.
The people in this department explained how they order the components and
materials respective to the project lead time. The main important thing required
for procurement department in bill of materials and make or buy decision. Which
involves selection of the make and buy material. Procurement department also a
vital role in satisfying customer expectation.

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QED DEPARTMENT
In Messer quality is not checked but it is inbuilt in every process for the
manufacture of the component hence here quality is not checked but it is produced
internally. The Quality Engineering Department is very interesting one and also
very important to ensure the quality of the machines. The main duty of the quality
engineering department is to build quality inside the process and very work that
includes the manufacture of the machine.
Hence the quality is need not to be checked, because the quality is built inside
through every process and work. We have not seen any kind of actions and
process to check the quality in Messer. Because the quality build inside the each
and every manufacturing process.

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MAINTANANCE AND SERVICE DEPARTMENT
In these departments we have come through how the maintenance of the plant is
done and the services of the machines is done. They explained how the
maintenance of this done and how the electrical supply is done to the Messer. And
also about the building area which includes all the blocks.
We have understood in Messer maintenance department is giving more important
to cleanness and good gardening. Which makes the Messer as a Heaven like
working environment it was very good for the company and also for the people
working in this firm and for the development of the company also.
The service department play a major role in getting good reputation from the
customers. They have doing a great job by keep the promises that given to the
customer while the machine is delivered to the customer. The service department
takes the full charge of the machine when machine is delivered to the customer.
They have service engineers to service the machines in cyclic period and to also
undergo any type of service when there is any malfunction in the machine, Which
will affect the manufacturing ability of the company. The role of the service
engineers after the delivery of the machine is very important. By providing very
good service to the customer and replacing of the components which can become
repaired.
Service Department offers a preventive maintenance (PM). Tailored to meet your
needs, the PM may be set up for regularly-scheduled or as-needed visits, or both
options. Your systems are regularly adjusted and calibrated to ensure optimum
performance. Potential problems can be addressed before they become issues that
affect your productivity.
It can also help with budgeting as you will know your yearly maintenance costs in
advance. Our systems are designed for long productive lives. However, this
requires proper maintenance and service.

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Make sure of a high level of production reliability and avoid problems by
inspections and preventative maintenance.
Key Features:
 Systematic inspections
 Tests
 Performance Measurements
 Detection
 Adjustments to retain a functional unit in such a specified state that it can
perform its required functions
 Correction and prevention of incipient failures, before they become actual or
major failures

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Finance Department
In Finance Department we had learned how the financial status of the company
is maintained and how the entire process is done. The Company Secretary and the
staff explained about the entire process.
It is very big challenge for that employees to maintain and to show good
economic status of the company in the world. It a big challenge in this Developing
Nation. They also see the legal activities of the company regarding any problems.
They also have explained how the shareholding process is done and how it is
working regarding the current status of the company. And they also perform
money transform between the company, customer, contractors, etc., and they
esnusre that all the money transfers are legal without any illegal activities. The
Finance Department Play an important role in the smooth running of company
without any economic crises.
Store
In Messer we had gone through store which supplies all the materials required
for manufacturing, assembly and all the department. They explained how the store
functions and how the materials are arranged in the store. They told that if a
workmen shows required papers from the respective department then he/she will
be able to take the required material without any interfere.
And the special feature of the shop is also is it is a open shop. It enables it to
perform on full sing.

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GAS REGULATORS
Messer cutting systems are pioneers in manufacturing Gas regulators. The
regulators manufactured by Messer Cutting Systems totally differ from other
manufactures. They have three safety measures induced in regulators which is not
found in any other manufacturers.
It consists of boosters which is used to convert small pressure into larger pressure
Since Propane and Acetylene are generally considered to be explosives this safety
measures are taken. Mostly industries uses propane instead of acetylene because
cost of propane is minimum when considered to Acetylene .But efficiency of
acetylene is greater than efficiency as propane
One of the safety measure is flash back arrest, this flash back arrest is mostly used
in all Gas regulators.

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Regulator nose in the gas regulator is called as Bull nose. While cutting 150 bar
pressure is compressed in the cylinder. While Oxygen is connected to 10 bar
output. Cylinder pressure is shown in the inlet gauge .In propane gas 0.5-1 bar is
enough to cut a material .Safety valve is used to avoid damage to the workers
.Other measure taken for the purpose of safety is that all gas regulators consists of
micro filters .
Some of the torches manufactured are Essen torch, Star cut torch, and Profile cut
torch, Star cutting attachment.
Acetylene has low density so separate valve is used in the gas regulators.
Material used to make that acetylene valve is EPDM.

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THANK YOU