The document provides an overview of Akshay Jangid's summer training experience working in the maintenance department of JBM Auto Ltd. It includes: 1) An introduction to JBM Auto Ltd and its various production areas including press shops, weld shops, tool shop, and quality department. 2) A description of Akshay's work experience assisting the maintenance team, including repairing breakdowns of machinery like a 400-ton press. 3) Topics covered in awareness training like TPM, 5S, and the whistleblower policy. 4) Akshay's conclusion that the summer training increased his technical knowledge of plant operations and maintenance work.

1. By,
Akshay jangid
Department:- Maintenance

2. Company profile
Different learning areas in JBM.
My area of interest.
My work experience with maintenance team.
Awareness training material.
Conclusion.
Appreciation.

3. JBM Auto Ltd. was originally set up in the year 1990, mainly to manufacture Tools,
Dies and Moulds at Faridabad. In the year 1993, the Company established a
Press Shop for manufacturing Sheet Metal Components and Welded Sub-
assemblies to meet the growing stringent quality requirements of automobile
industry. The company went for its first public issue in March 1994.
Plant Particulars
•Faridabad Plant -Press shops suitable for manufacturing components for car,
tractor and truck industry. Current product range includes BIW parts and sub-
assemblies for cars, skin panels and axles for tractors & body components,
bumpers, axles and suspension components for trucks. Components are being
also exported to various truck manufacturers in Europe.
The Company’s philosophy of corporate governance is based on integrity, respect
for the laws & compliance thereof and transparency & accountability in all facets
of its operation. The Company believes that good governance brings sustained
corporate growth and enhances returns to all its stakeholders viz. customers,
suppliers, shareholders, employees and government agencies including society
of which the Company is an integral part.

4. FARIDABAD JBM AUTO LIMITED, PLANT-I
GLOBAL PARTNERS
OF JBM GROUP :-

5. CUSTOMERS;- PRODUCTS:-
•Air tank
•BIW parts and assemblies
•Buses
•Chassis and suspension parts
•Cross car/truck beam
•Cross members
•Engineering
•Fabrication
•Fuel filter
•Fuel tanks
•LPG/CNG cylinders
•Oil sump
•Shaped blanks
•Steel fasteners
•Tailor welded blanks
•Skin panels
•Tools,jigs and fixtures
•Wheel assembly
•Tubes and tubular
manipulations

7. .
•Heavy Press Shop:
Components for which heavy tonnage is required for most of their processes are
worked upon in this shop. These processes include blanking, flattening, draw
operation, forming, flanging, trimming, piercing, bending etc.
•Light Press Shop
Components for which heavy tonnage is not required for most of their processes are
worked upon in this shop. These processes include flanging, trimming, piercing, bending
etc.
•Weld Shop 1:
Spot welding and MIG welding on various components are carried out in this shop
.
•Weld Shop 2:
After being worked upon in weld Shop 1, the components are sent to Weld Shop 2 for
denting, deburring, grinding, buffing, sanding etc. Besides these processes MIG
welding, Arc Welding, Spot Welding etc. are also carried out on components for some
customers, in this shop.

8. Tool shop is the area in which tools, dies ,jigs and fixtures. are prepared upto
finish using a series of operations. Design section is the main part in tool shop
.The process starts with the design making of which pattern is made ,this
pattern is inspected and send out for casting .After casting is brought ,it is
machined under 2d and 3d operations on CNC machines .Additional manual
operations are performed for further inspection and finishing including
grinding,drilling etc.Dies are inspected under spotting press for colour test and
pieces are made. If fine, dies are declared ready for use.
Quality department is the area where product’s quality is checked,whether
the produt has achieved its required dimensions and other physical
properties. Process of quality check is divided in to three steps namely –
•Incoming quality control
•In process quality control
•Finished product quality control
Inspite of these three, customer complaint handling is also done.

9. This department deals with the releasing of stock as per
customer’s requirement. As per ppm schedule the dispatch team
distribute targets to different shops . and finally the stock is
packed and dispatched as per packaging standards. Dispatch also
takes care of inventory and customer’s remarks .
Other areas include-
•Marketing(takes care of the social approach and customer’s
relations)
•Store(takes hold of the inventory and incoming vendor stock)
•HR(concerned with training and development matters and
recruitment )
•SAP(red bin analysis and product design)

10. WHAT IS MAINTENANCE:-
WHAT IS THE ROLE OF MAINTENANCE DEPARTMENT IN JBM:-
Their chief role is to achieve continuous sustained condition of the whole plant
whether it is a machine or some fitting work. Team maintenance includes works as
given under :-
•Mechanical job(concerned with internal functioning and fitting work of machines)
•Electrical job(concerned with plant electrical supply including fans ,ac ,compressors
etc. And panel problems related with machines )
•Plumbing work.
•Other maintenance of plant.
Sustaining the achieved result is maintenance.
OR
It is the continuous effort to keep a system in its useful condition.

11. Fault occurs Fault is examined
Corrective
action is
taken
Machine or
system is
brought to
sustained
working
condition .
Fault is rechecked
and assured by
the operator.
Preventive action is taken
So that the fault will not
In future.
PROCESS OF MAINTENANCE:-
573
412
17 6
0
200
400
600
800
main derive shaft
problem
mounting bolt
problem
cushion problem slide adjustment
problem
BREAKDOWN TIME VS CAUSES:-

12. WORKING ON PRESS 400 TON :-
Mechanical press 400 ton is one of the oldest
presses in jbm auto ltd. The press is of “H frame”
and is used for low tonnage operations mostly
hole making ,flanging etc. The machine dumped
suddenly and maintenance team was informed .
after being checked , it was found that the slide
has jammed due to improper working of gear.
The worm gear was damaged(as shown in pics )
and was need to be replaced by a new one. The
slide was opened and the damaged gear was
removed out .Proper cleaning was done . After
the new gear has brought and fixed ,the
machine was reassembled. Required oiling was
done by the fitters for proper lubrication. Up
and down movement of the slide was checked
also whether the piece was made right or not?
After it all operator and supervisor were called
for assurance.
And the machine was ready for production .
MY EXPERIENCE WITH MAINTENANCE TEAM:-

13. MOSTLY OCCURRED BREAKDOWN REASONS FOR PRESSES:-
•Air leakage .
•Over motion provided to the slide .
•Lack of lubrication.
•Clutch gap increment.
•Shaft damage.
•Panel problems.
SHAFT FAILURE

14. TPM
5 S
WHISTLEBLOWER POLICY
•The policy empowers employees to report to the management of any malpractices that are
taking place in any organization .
The person who raises a concern about a wrong doing is known as whistleblower
•Whistleblower’s identity is not revealed and is provided protection.
•The complaint can be made considering:-
Abuse of authority.
Breach of contract
Criminal offense
Manipulation of company data and records.
Wastage of company funds /assets etc.

15. 5 ‘S’ THE BASE OF TOTAL QUALITY CONTROL:-
पहचानें और गैर
आवश्यक
वस्तुओं की
छटाई करना
SEIRI
सुव्यवस्थाSEITON
सफाईSEISO
मानकीकरणSEIKETSU
अनुशासनSHITSUKE
आवश्यक वस्तुओ
को उनके ननर्ााररत
स्थान पर व्यवस्स्थत
करना
काया क्षेत्र को
र्ुल और गंदगी से
मुक्त रखना रखना
ननयममत देखभाल द्वारा
काया क्षेत्र को
सुंदर रखना
ननयमो का
पालन करना
ननयम
2-2
छटाई

16. TOTAL PRODUCTIVE MAINTENANCE:-
•This policy implies effective way of maintenance in order to eliminate
loss and increase productivity.
•Having eight pillars as shown below.

17. Doing this summer training I come to know about many new things which I
haven’t studied in my college .I have gathered the “In field work process” of
a multi national company. Along with maintenance, i have gained
knowledge of other departments also including quality, tool shop, dispatch
etc. I have learned here what is the complete procedure on which a
production plant works. I have also learned about teamwork. And study of
numerous machines which are used in this plant has increased my technical
knowledge a lot.
I t was a great experience working with team maintenance in these
45 days . I am thankful to the company authorities for allowing me
for the training. This summer training has given me experience in my
working zone and also has increased my technical knowledge. I even
wish to work here in future .

18. Signature:-
•HOD (MAINTENANCE)……………..
•HR…………………………
•TRAINEE…………………….
DATE OF SUBMISSION:-