This document provides a summary of a seminar report on the implementation of Industry 4.0 at Tega Industries in Dahej, Gujarat, India. Tega Industries established in 1976 and is a global leader in wear resistant products for mining and materials handling. The report outlines Tega's production process, including fabrication, blasting and painting, rubber mixing in the banburry, blank production, and pressing. It identifies key performance indicators to monitor in Phase 1 of implementing Industry 4.0. This includes implementing barcode and digital systems to track production and ensure quality. The report also analyzes utilization of blasting machines and safety issues to address, such as in the banburry and boiler areas.
This document provides information about Sai Engineering, a partnership firm established in 2004 that manufactures and supplies storage tanks, heat exchangers, reactors, and other fabricated components using quality materials. The company has a vast infrastructure with latest machines and tools run by experts to ensure streamlined production. Emphasis is placed on quality testing to assure clients. Information is also provided about their clients, machinery, shop floor, and sample manufactured jobs.
PAL Engineering Corporation is an Indian company established in 1974 that specializes in prefabricating high pressure and high temperature piping systems and related components. The document provides information on PAL's location in Haryana, India, contact details, facilities, capabilities, and projects. It details PAL's experience in fabricating piping for power plants, various certifications, and plans for expanding facilities and capabilities at a new plant under construction.
This document provides an overview of Metso Corporation, including its history, leadership, product offerings, and manufacturing process for slurry pumps. Some key points:
- Metso was formed in 1991 and focuses on mining, aggregates, oil/gas, pulp/paper, and other industries.
- It offers a comprehensive line of horizontal and vertical slurry pumps for transporting abrasive slurries.
- The manufacturing process involves raw material storage, quality checks, assembly of components, testing, and dispatch of completed pumps.
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Product catalogue displaying an overview of the Technologies which Dr. Fritsch has to offer:
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1) Parameters like draft, spreading, roll speed, slip factor, and roll force can impact quality if not properly set initially.
2) Quality can also be affected by improper roll gap, excess temperature, roll force changes, roll deflection, internal stresses, billet dimensions, roll convexity, and non-homogeneous material flow.
3) Optimizing parameters like these can improve productivity by reducing defects and increasing output.
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Tariq Jamil completed a 6-month internship at Sigma Refrigeration Pvt Ltd where he gained experience in various departments including machine shop, shearing, mechanical press shop, hydraulic press shop, molding, paint shop, jig and fixture, tool and die shop, and assembly line. He learned skills in operating machines like lathes, drilling machines, and injection molding machines. Tariq also improved his technical skills and learned about industrial management, quality control, safety practices, and teamwork through hands-on training and guidance from supervisors. Overall, the internship provided valuable practical experience that supplemented his academic studies.
uflex summer internship , all about the machine used and all the process a material goes through during the whole process till the it reaches assembly . all the other equipment's used to in quality check etc. cnc used and its features.
This document provides information about Sai Engineering, a partnership firm established in 2004 that manufactures and supplies storage tanks, heat exchangers, reactors, and other fabricated components using quality materials. The company has a vast infrastructure with latest machines and tools run by experts to ensure streamlined production. Emphasis is placed on quality testing to assure clients. Information is also provided about their clients, machinery, shop floor, and sample manufactured jobs.
PAL Engineering Corporation is an Indian company established in 1974 that specializes in prefabricating high pressure and high temperature piping systems and related components. The document provides information on PAL's location in Haryana, India, contact details, facilities, capabilities, and projects. It details PAL's experience in fabricating piping for power plants, various certifications, and plans for expanding facilities and capabilities at a new plant under construction.
This document provides an overview of Metso Corporation, including its history, leadership, product offerings, and manufacturing process for slurry pumps. Some key points:
- Metso was formed in 1991 and focuses on mining, aggregates, oil/gas, pulp/paper, and other industries.
- It offers a comprehensive line of horizontal and vertical slurry pumps for transporting abrasive slurries.
- The manufacturing process involves raw material storage, quality checks, assembly of components, testing, and dispatch of completed pumps.
Dr. Fritsch Powder Shaping Technologies English CatalogueJens Huber
Product catalogue displaying an overview of the Technologies which Dr. Fritsch has to offer:
FAST Direct Hot-Pressing, Granulation, Mixing.
Main focus is on the manufacturing of friction materials, sputter targets, heat sinks and machines for R&D ( universities, etc.).
IRJET- Productivity and Quality Improvement Through Setting Parameters in...IRJET Journal
This document discusses parameters that affect quality in hot rolling mills. It summarizes that:
1) Parameters like draft, spreading, roll speed, slip factor, and roll force can impact quality if not properly set initially.
2) Quality can also be affected by improper roll gap, excess temperature, roll force changes, roll deflection, internal stresses, billet dimensions, roll convexity, and non-homogeneous material flow.
3) Optimizing parameters like these can improve productivity by reducing defects and increasing output.
This document provides details about the summer internship of Parth K. Gandhi from June 16 to July 16, 2014 at L&T MHI Turbine Generators Private Ltd. in Hazira, Surat. It describes the induction and organization of the production shop, which is divided into machine and fabrication shops. It then discusses Parth's project studying the machining processes and times for a steam turbine bearing pedestal component in the T3 machine shop, finding actual times exceeded standards. Suggestions are provided to improve efficiency, such as using chip breakers, regulating coolant use, and reducing leveling and centering times.
Tariq Jamil completed a 6-month internship at Sigma Refrigeration Pvt Ltd where he gained experience in various departments including machine shop, shearing, mechanical press shop, hydraulic press shop, molding, paint shop, jig and fixture, tool and die shop, and assembly line. He learned skills in operating machines like lathes, drilling machines, and injection molding machines. Tariq also improved his technical skills and learned about industrial management, quality control, safety practices, and teamwork through hands-on training and guidance from supervisors. Overall, the internship provided valuable practical experience that supplemented his academic studies.
uflex summer internship , all about the machine used and all the process a material goes through during the whole process till the it reaches assembly . all the other equipment's used to in quality check etc. cnc used and its features.
The document describes the manufacturing capabilities and quality management systems of a factory that produces castings. The factory has a foundry with various melting, casting, and heat treatment equipment. It also has machining, painting, and assembly capabilities. The factory focuses on continuous improvement and can work with customers on design optimization. It maintains quality control through inspection, testing, record keeping and has received external audits. The factory aims to be a one-stop shop for castings and offers quick response to new product development.
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- It now has facilities in Chicago, Batavia, Illinois, and Shanghai China, serving a wide range of industries through machining, fabrication, assembly, and engineering services.
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iMFT
REVOLUTIONARY TECHNOLOGY
With highly innovative iMFTTM technology we are setting new boundaries in manufacturing of conformal cooling components for die-casting industry.
ADVANTAGES Component dimension
• 900 x 600 x 500 mm
Functionality
• mirror polished inner channels
• no geometry limitations
Material used
• premium forged tool steel as required by the process
Efficiency
• short lead time
• high cost efficiency
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1. The document is a vocational training report submitted by two engineering students detailing their training experience at Axtel Industries Limited, a manufacturer of food processing equipment.
2. It provides an overview of Axtel, describing the company history, products manufactured which include various solids handling, storage, size reduction, mixing and specialized equipment.
3. The report focuses on the manufacturing processes for key components of a horizontal screw feeder such as the body, screw, and their individual parts through various machining and welding methods.
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in this u will come to know about various processes involved in manufacturing of gears and also get the experience how to make slide show on training reports.
There has been a long felt need to bring up speed in the field of construction, which remain a core contributor to the growth of economy, but still suffers from low productivity, higher costs and wastages. Unsafe working conditions and resultant pollution are other areas of concern. This calls for modernization of construction and by using pre cut & bent TMT bars many of these issues are addressed
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Company Profile for Paam Engineering Systems R10_011015 (1)Amit Sonawane
PaaM Engineering Systems is an engineering partnership firm located in Pune, India established in 2011. The company has a vision to excel in engineering, design, fabrication, and automation systems. PaaM has a well-equipped 5000 square foot fabrication shop and machine shop. They specialize in designing and manufacturing process equipment for industries such as breweries, pharmaceuticals, food processing, and more. Their equipment is made from materials like stainless steel, titanium, nickel, and copper. Current customers include Alfa Laval India, Bectochem Consultants, and SABMiller India.
This document provides an overview of ZX factory facilities, products, certifications, and sales footprint. It discusses the size and capacity of ZX and DP manufacturing factories. It also describes ZX and DP's engineering abilities, quality control processes, and system management departments. The document highlights ZX's history and introduces their product lines including adjustable shocks and struts, electronic remote control systems, gas-filled shock absorbers, steering dampers, twin tube shocks, strut modules, cartridges, and adjustable suspension shock absorbers. It also lists the certificates ZX has obtained and their sales footprint in over 35 countries.
This document provides a curriculum vitae for Gajanan N Sawant, who has 21 years of experience in manufacturing. It details his work history including his current role as Plant Head at Oriental Foundry Pvt Ltd since 2015, where he successfully completed a greenfield steel casting project. It also outlines his previous role as Manufacturing Head at Ashok Iron Works Pvt Ltd, where he increased production levels and reduced costs. The CV provides extensive details on the equipment and processes handled during his career in areas like moulding, melting, core making, and more. It positions him as an experienced professional conversant in quality systems and improvement techniques.
Southern Manufacturing Technologies is an aerospace and defense manufacturing company located in Tampa, FL with 90 employees. They have capabilities for machining metals like aluminum, titanium, and stainless steel. They have recently invested in new CNC machines and a waterjet deburring system to improve efficiency. Customers praise their quality, short lead times, and commitment to continuous improvement.
Southern Manufacturing Technologies is an aerospace and defense manufacturing company located in Tampa, FL with 90 employees. They have capabilities for machining metals like aluminum, titanium, and stainless steel. They also have certifications like AS9100 and ISO9001. The document provides details on their manufacturing processes, customers, capabilities, and awards.
Southern Manufacturing Technologies is an aerospace and defense manufacturing company located in Tampa, FL with 90 employees. They have capabilities for machining metals like aluminum, titanium, and stainless steel. They also have certifications like AS9100 and ISO9001. The document provides details on their manufacturing processes, customers, capabilities, and awards.
- Prince Industries pursues excellence in developing its global team and providing exceptional value for customers and ownership. It was founded in 1959 and has expanded its operations and capabilities over the decades.
- It now has facilities in Chicago, Batavia, Illinois, and Shanghai China, serving a wide range of industries through machining, fabrication, assembly, and engineering services.
- Prince Industries aims to be the premier domestic integrator of globally supplied products, employing advanced manufacturing technologies and a commitment to continuous improvement.
The document provides details about Tayo Rolls Ltd, including its production planning process. It discusses [1] the company's various departments involved in production planning, [2] factors that affect machine shop production planning such as product mix and cycle times, and [3] the objectives and key elements of an effective production planning and control system.
This document provides information about Surendra Elastomers Pvt Ltd, a leading manufacturer of rubber compounds located in Mysore, India. It includes details about the company's mixing plant layout, machinery used in production, product offerings, and custom compound development capabilities. The company specializes in producing synthetic and natural rubber compounds for applications like automotive, industrial, medical and other sectors.
iMFT
REVOLUTIONARY TECHNOLOGY
With highly innovative iMFTTM technology we are setting new boundaries in manufacturing of conformal cooling components for die-casting industry.
ADVANTAGES Component dimension
• 900 x 600 x 500 mm
Functionality
• mirror polished inner channels
• no geometry limitations
Material used
• premium forged tool steel as required by the process
Efficiency
• short lead time
• high cost efficiency
MAKE IN INDIA @ KONZERT_ATD_PTD_04_AUG_2015RAJIV SESHADRI
Konzert is an ISO 9001-2008 certified manufacturer of tooling and dies located in Pune, India. Over the past 15 years, it has expanded its facilities and capabilities. It now has the ability to design, engineer and manufacture a variety of tooling products including progressive, transfer, and tandem dies as well as molds, fixtures and other precision tooling. Konzert prides itself on timely delivery, quality workmanship and serving customers in automotive and other industries.
1. The document is a vocational training report submitted by two engineering students detailing their training experience at Axtel Industries Limited, a manufacturer of food processing equipment.
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in this u will come to know about various processes involved in manufacturing of gears and also get the experience how to make slide show on training reports.
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mid sem report.pptx
1. Seminar report
Implementation of
Industry 4.0
at
Tega industries Dahej(Gujarat)
Submitted to
Dr Arun maity
Instructor in charge-
Department of Mechanical engineering
Bits pilani
Submitted by
Shubham pareta
ID no-2018H1410159P
ME –Design engineering
Bits pilani (Rajasthan)
2. Tega industries established in 1976. It is a global leader in the
design and production of consumables for the mineral
beneficiation, mining, bulk solid handling industry. Headquartered
in Kolkata, India. Tega offers a range of abrasion and wear resistant
products and services required for mining and mineral processing,
grinding, material handling industry.
Tega offers a range of rubber, polyurethane, abrasion resistant
steel and ceramic based lining products which have been
incubated in our R&D centers. The company offers value added
consultancy services and solution in areas of mineral beneficiation
and material handling industries.
Tega industries at glance
3. How a product is made in Tega industries
• Fabrication shop- Basic raw material hardox ,mild steel, cast iron ,aluminum is process by cutting ,
welding, grinding. Material is send to blasting shop.
• Blasting & painting shop-High velocity steel grit of suitable hardness make impact on metal
surface to improve surface finish of metal. Blasting is done to remove impurities and improve
bond quality between metal and rubber. It is a surface finishing operation. Metal is send for paint
shop to obtain high quality surface.
• Banburry shop- In the banburry mixing of natural rubber with suitable chemicals such as carbon
black took place at suitable pressure and temperature in spiral mixer called banburry to make
rubber ply .
• Blank shop-In the blank shop rubber ply output from banburry works as a input to make rubber
blank of suitable shape, size and dimensions. Machine used is cold feed extruder.
• Press shop-The output of blasting shop i.e. reinforcement and output of blank shop i.e. blank is
input to press shop . In the press shop blank and reinforcement at placed carefully in heated
mould at suitable temperature. After curing time is over product is ready for quality test and
dispatch.
4. RAW MATERIAL 1
INSPECTION
REJECTED
ACCEPTED
FABRICATION
INSPECTION
REJECTED
BLASTING
INSPECTION
REBLAST
PRIMARY COAT
FINAL COAT
INSPECTION
REBLAST
REPAINT
RAW MATERIAL 2
INSPECTION
BANBURRY
BASE STOCK
READY STOCK
BLANK SHOP
BLANK
PREPARATION
INSPECTION
ELASTIC PROPERTY
VISCOSITY
RHEOMETRE
ABRASION
DENSITY
COLD FEED EXTRUDER
MIXING MILL
BLANK CORE TEMP
BLANK WEIGHT
CHARGING TIME
PRESS SHOP
LABELING
REINFORCEMENT
FINAL PRODUCT
INSPECTION
REJECT
ACCEPT
REWORK
PACKING &DISPATCH
HARDNESS
UT
CUTTING
WELDING
GRINDING
HARDNESS
UT
BOILER
STEAM
7.5KG/CM^
2
PRV
HANDLINING
AUTOCLAVE
FINISHED
PRODUCT
PACKING
DISPATCH
SIMPLE
SHAPE
INSPECTION
STEEL GRIT
SIEVE TEST
3 ROLL
CALENDER
DFT
DFT
COMPLETE
FLOW CHART
6. Long-term vision by implementing industry
4.0
• It would be big milestone in era of Smart factories.
• The overall operational efficiency will increase.
• Better Control on performance measurement system.
• Better control over SOP (Systematic operating procedure).
• Per product cost will be less.
• Better control over quality of product
7. List of activities performed
• Study the plant and process from end to end carefully.
• Detailed study of each process –press shop ,banburry , blank shop, blasting shop.
• Collect the critical parameters from each process and find the way to capture
them by sensors and electronic devices.
• Design the blank ordering system as apart of industry 4.0.
• Design the reinforcement ordering system as part of industry 4.0.
• Time study of blasting machine to improve its utilisation.
• Study safety issues in Tega industries and suggest preventive actions.
• Design a disaster management system for comman hazard.
• Review paper writing on industry 4.0
• Post covid 19 lockdown strategy in Indian manufacturing sector.
9. Phase 1 Industry 4.0 Objectives
1) The blank should be charged within 30 minutes of making else press should not charge the blank.
2) We should ensure blank is going to charge on right press so bar code system should be implemented on blank.
3) Reinforcement should also be charged with in 30 min of placing it in cavity.
4) Reinforcement should arrive at right press so some barcode system requires.
5) Complete digital form of job card which is issued at each press for new order.
6) Mould temp should be 150 degree for SOP CP 21 and 170 degree for SOP CP 09.
7) Blasting shop operator should have clear picture of real time inventory of reinforcement on press machine via
computerised work order. If any press is falling short of reinforcement alarm should be generated until press is
supplied with required reinforcement.
8) Alarm should be generated if parameters cross limit.
9) Energy meters where necessary.
10) Plan vs actual - real time report
11) Integration of data with SAP.
12) Traceability of product .
10. PRESS LOADING CHART
DAILY PRODUCTION
SCHEDULE
PRESS SHOP
JOB CARD
PRESS MACHINE
MOULD
SHOP
BLASTING SHOP
HEATED MOULD
TEMP <140
DEGREE CELSIUS
CURING &FINISHED PRODUCT FPIR QUALITY
PACKIN
G
&DISPA
TCH
BREAK DOWN
BLANK
SHOP
1-BLANK CORE TEMP
T=95 DEGREE
2-BLANK WEIGHT
AS PER BLANK JOB CARD
3-SOP-CP-09
CHARGING TIME<60 MIN
SOP-CP-21
CHARGING TIME<40 MIN
BLANK JOB
CARD
1-TIME<3 DAYS HARDOX
2-TIME<7 DAYS MS & AL
3-TEMP <65 DEGREE
OR CHARGING TIME
LESS THAN 30 MIN
MOULD INSPECTION REPORT
REINFORCEMENT
1-STEAM PRESSURE
2-PLATEN TEMPERATURE
3-HYDRAULIC PRESSURE
4-OIL TEMPERATURE
5-CURING TIME
6-STEAM FLOR RATE
MCC
PANEL
REBLASTING
FABRICATION
PRESS SHOP MAPPING
11. JOB CARD
RECEIVE AT
PRESS SHOP
INFORMATION
INPUT
PRODUCT TYPE
SO. NO
PRODUCT CODE
AT PRESS SHOP
INFORMATION PASS
TO BLANK SHOP
DIGITALLY
REQUIREMENT GENERATED BY
PRESS OPERATOR REGARDING
BLANK WEIGHT,CAVITY AND
BLANK DRAWING
IF AT SAME TIME ANOTHER
PRESS REQUIRED BLANK THEN
ORDER WILL BE PLACED AFTER
PREVIOUS ORDER.
BLANK OPERATOR
SELECT FOR WHICH
PRESS BLANK NEED
TO BE FORMED AS
PER EMERGENCY
REQUIREMENT
TIME START
FROM ZERO
WHEN FIRST
BLANK FORM TO
COUNT 30 MIN.
BAR CODE
GENERATE
IF BLANK TAKES
MORE THAN 30
MIN THEN PRESS
WILL NOT CHARGE
THE BLANK
BAR CODE ON
EACH BLANK –
BLANK WILL GO
TO RIGHT PRESS
BAR CODE
SCANNING
IF BLANK GO TO
WRONG PRESS THEN
QR CODE UNABLE TO
SCAN
BLANK SHOP ORDERING SYSTEM
12. R1 R2 R5 R6 R7 R8 R9 R10 R11 R12 R13
R3 R4
Blasting & painting
shop
Fabrication shop
Just in time
KANBAN
DISPATCH TO PRESS SHOP
REINFORCEMENT ORDERING
SYSTEM
R1-REINFORCEMENT FOR PRESS 1
13. Blasting machine utilization (working in progress)
• The blasting machine utilization is less than 50% in tega dahej plant.
• It is a surface finishing operation in which high velocity metallic grit of high hardness
make impact on metal surface to improve surface quality.
• It becomes a bottleneck operation in tega dahej.
• We need to increase the effective utilization of blasting machine by time study and
motion study.
• During blasting of aluminum utilization is poor but casting and hardox utilization is better.
• Fatigue of operator is also a kind of reason for under utilization of blasting machine.
• Utilization also depends on complexity of part and material.
• Most of ideal time of machine goes in loading and unloading of reinforcement so
automatic conveyor based loading system could be used as apart of industry 4.0
15. Safety study in Tega industries ,Dahej
• Safety study of complete plant with main focus on banburry and
blasting shop.
• High accident prone area in tega industries are mixing mill, material
handling, boiler ,press machine.
• Most hazardous area in plant to work with is banburry because of
high carbon emission which is a health hazard.
• Boiler area is also accident prone area either due to fire, high
pressure etc.
• The safety rules are highly violated in banburry and paint shop.