The intern thanks various managers and departments at Simpson for providing guidance during their internship. Simpson manufactures diesel engines at two plants in Chennai. The intern spent three weeks touring departments like assembly, machine shop, and quality control to understand the engine manufacturing process. They then spent three weeks on a project for the materials department developing a statistical forecasting model to predict component procurement needs. The model used moving average forecasting on two years of fuel injection pump part data to estimate procurement quantities for the next year.

1. Acknowledgement
The internship opportunity I had with Simpson and Co Limited was a great
chance for learning and professional development. Therefore, I consider myself
as a very lucky individual as I was provided with an opportunity to be a part of
it. I am also grateful for having a chance to meet so many wonderful people and
professionals who led me though this internship period.
I would like to use this opportunity to express my deepest gratitude to Mr.
N.Rangarajan, Chief General Manager, Simpson, who heartily welcomed me
for the internship and guided and encouraged me through the summer training.
I would also like to convey my heartiest thanks to Mr.N.Santhanagopalan,
Deputy General Manager, Material Control Department, who in spite of being
extraordinarily busy with his duties, took time out to hear, guide and keep me
on the correct path and allowed me to carry out my project at their esteemed
organization during the training.
I express my deepest thanks to Mr. Ravi Sarma, Senior Manager Personnel
and Mr. Raja, Deputy Manager Personnel, for taking part in useful decisions
& giving necessary advice and guidance and also for arranging all facilities to
make the training experience easier. I choose this moment to acknowledge their
contribution gratefully.
Last but not the least, I would like to thank all the department heads and the
staff at the manufacturing plant, for their careful and precious guidance which
were extremely valuable for my study both theoretically and practically.

2. About the Company
Simpsons is one of the oldest business establishments in the country, with
origins dating back to 1840. For about 100 years it contributed in the
development of coaches and carriages, ornate railway coaches, motorcars, steam
passenger buses and public service vehicles in India.
Simpsons entered the diesel power sector when it ushered in engine technology
into India. Simpsons was the first Indian company to indigenously manufacture
diesel engines for surface transport vehicles. Today it is India's leading
manufacturer of high performance 2, 3 4 cylinder diesel engines catering to a
wide variety of applications ranging from 15 to 95 BHP having agriculture,
industrial, power generation and marine applications.
It has two factories in Chennai (at Anna Salai and Sembiam) and one at
Kumbakonam (Tamil Nadu). The company’s current capacity of engine
production is around 72000 engines. Every plant has five major sections:
 Engine Assembly and Testing
 Machine Shop
 Quality Control Department
 Material Control Department
 Maintenance Department

3. About the Internship
The internship was a six week long training period. The first three weeks were
spent in the manufacturing plant and next three weeks were used to work on a
project. The HR department asked me to take a detailed orientation of the plant.
There are two diesel engine manufacturing plants in Chennai.One at Anna Salai
and another one at Sembiam. The first two weeks of my internship were spent
in the Sembiam plant.
Simpson produces a variety of engines for various purposes mainly being
associated to the agricultural sector. The different types of engines are:
 S3
 SJ3 and SJ4
 TSJ3 and TSJ4( Turbo Engines)
 1000 Series
 B 3.3(Cummins Engine)
 S440
Engine Manufacture
The departments that were visited are as follows:
1. Engine Assembly
This department is where all the parts of the engine are brought in and the
engine is fabricated. The cylinder head and block are manufactured in-house
and the other parts are bought from other suppliers.
Processes in the Engine Assembly Unit:
The Assembly consists of two sections:The Pre Build sectionand the J-Hook.
In the pre build section, the crankshaft, main bearing, lube oil pump, timing
gears and the rear oil seal pumps are fixed. The J-hook consists of the fitment of
the piston, fuel injection pump( FIP), sump, oil pan, water pump, pulley and
high pressure pipes.

4. Stage 1
 The serial number of the engine is punched on the cylinder block.
 The Block is sent for washing and then drying to remove any rust.
 Dowel pins are fitted which helps in housing fitment.
Stage 2
 A water heater sensor is fitted on the block and the cap bearing is
separated.
Stage 3: Crankshaft and Bearing Fitment.
 The block bearing is placed and the washers are fixed.
 Crankshaft is fitted on the block and the cap bearing is placed to hold it in
place.
 Torque Tightening is done at 133 Nm.
Stage 4: Front Plate, Idler, LOP and CAM fitment.
 The lube oil pump is fixed on the main bearing cap.
 Front plate is fitted for the gear and cover mounting.
 The idler gear is placed on the Lube Oil Pump hub and the idler gear hub
is fitted.
 The Camshaft is fixed on the block and the end floats of the camshaft and
crankshaft are checked for smooth movement.
Stage 5: J-Hook Loading
 The rotation of the crankshaft is checked.
Stage 6: Piston and Connecting Rod fitment.
 The Con rod and cap are separated and conrod is fixed. The oppositeside
of the rod is pulled and aligned with the crankshaft.

5.  Torque tightening is done and end float is verified.
Stage 7 and 8: FIP and Front Cover Fitment
 The spill timing gauge to the FIP is fixed.
 The FIP gear and the FIP shaft are aligned with the Idler Gear timing
mark on the gears.
 The piston travel requirement is then checked by rotating the engine in
the anti-clockwise direction.
 Gear Lock tool is fixed to remove any backlash movement.
Stage 9: Rear Housing and Seal Fitment.
 The rear end oil seal is placed and plugged on the crankshaft flange.
Stage 10 and 11: Cylinder Head and Sump Fitment
 The cylinder head is fixed on the top face of the Block.
 The oil pan and the Suction pipe are fixed on the head.
 The rocker shaft is fitted on the head.
Stage 12: Tappet Setting
Stage 13: Valve door cover, Water Pump, Injector Fitment.
 The pulley is fixed for the rotation of crankshaft and water pump.
 The water pump is fitted and injector is placed.
Stage 14: HP Pipes, Leak Off Pipe Fitment.
Stage 15
 The turbo chargers are fixed on the engine.
 The oil drain tube and exhaust pipes are fitted.
2. Testing

6. In the testing area, there are two types of tests: Cold Test and Hot Test.
 Cold Testing
This is used to check for blow holes, porosity and other such material defects in
the components by applying high pressure air to the engine. The leak points in
the engine namely: injector pipes, water outlet, high pressure pipes are also
checked.
 Hot Testing
This test is executed with the help of a dynamometer. The engine is checked
for: Brake Horse Power (BHP), Fuel Consumption, Leaks, Noise and Smoke
Value.
If the engine passes through the Cold and Hot Tests, it is sent to the Engine
Finishing Department (EFD). At the EFD the flywheel housing, the rear
housing and the tightening of nuts and bolts is checked and further sent to the
Paint shop.
3. Machine Shop
The machine shop consists of two lines of production, one for the cylinder block
and one for the cylinder head.
The cylinder block casting is acquired from a supplier and all the finishing
operations are performed in the shop.
The operations performed on the cylinder head are as follows:
 Rough and Finish Milling of Top and Joint face.
 Drill and hole mill dowel holes.
 Drill steam vent holes.
 Finish Mill joint, read, exhaust and induction face.
 Banjo hole Drilling and Tapping.
 Drill and Spot Face of top and joint face.
 CNC- two way Drilling.

7.  Tap holes on induction and exhaust manifold sides.
 Drill and Ream injector bore.
 Tap rocker shaft fixing holes.
 Hand Grind inlet port.
 Gun Ream Tappet holes.
Operations performed on Cylinder Block:
The block consists of six faces namely:
1. Front, 2. Rear, 3. Cam opposite, 4. Cam face, 5. Top, 6. Bottom.
 Milling and Drilling of top face.
 Two side Milling.
 Finish Milling.
 Boring.
 Threading and Tapping.
 Honing of Piston cylinder bores.
 Angular Drilling.
 Cam Bush pressing machine.
4. Quality Assurance
There are various types of quality checks for the engine manufactured.
 In house quality in Engine Assembly Unit and the Machine Shop.
 Supplier Quality or Receiving Quality
 Customer group quality.

8. The first step in quality check is that the engine components be tested in the
Standards Room.
Standards Room
For the calibration of gauges micrometers, Vernier calliper and slip gauges are
used and further these gauges that are calibrated help to check the engine
components.
The calibrating devices:
 Gauge Block comparator for calibration of gauge blocks.
 Universal Horizontal Metroscope for external, internal and thread
measurements.
 Sigma External Comparator for calibrating gauge blocks.
 Electronic Diesel Calibration Test for calibrating plunger type dial gauge
and bore dials.
 Bench Center.
 Screw Diameter measuring machine.
 Hommet Etamic T 8000 to measure roughness parameters and contour.
Responsibility of the Standards Room
 Monitoring and updating gauge control system and select the proper
MMD.
 Repair and calibrate MMDs.
Receiving Inspection
The quality and material department receives three types of parts:
i. Preparatory Items: These are the parts which have supplier’s own
design and have no inspection report.
ii. Self-Certified Items: These are the engine parts that are designed in
Simpson itself and all the visual defects are checked.

9. iii. Regular Inspection Items: These parts have to be checked for
dimensions and material.
Responsibilities of the Receiving Inspection Department:
 Monitor all the specifications of the parts.
 If Assembly unit sends a part back due to defects such as cracks and
leaks, a flash report of complaint is filled out. After the check is done,
the part is sent for rework by the inspection department.
 Timing gauge for the gears is checked.
 The colour code for the calibration of the gauges has to be checked at
regular intervals.
Engine Assembly Quality Responsibilities
 Fix housing fitment.
 Fix flywheel housing fitment.
 Check for free rotation of the crankshaft.
 Visual Inspection for missing parts and loose parts.
 Check the load, fuel time, lub oil pressure and temperature and smoke
value for engine at full throttle.
5. Material Control Department(MCD)
Responsibilities of the MCD
i. Planning, Procurement and Monitoring Suppliers.
 For material procurement obtain product and input plan and receive
materials at the store.
 Update the inventory and send for inspection to the Quality Control
Department (QCD).
 Check the Supplier Rating.

10.  Maintain stock on hand and buffer stock.
 Procure all the standard tools according to the production plan.
ii. Supply Chain Management
 Assessing, evaluating and monitoring the performance of the suppliers.
 Process Inputs- Quality issues and Inputs from other departments about
any new product.
iii. Supplier Performance Monitoring
Supplier Re-Evaluation
 If Supplier Rating is less than target for two consecutive occasions, do an
on-site assessment.
 If there is a change in management at the supplier end, do an on-site
assessment.
iv. Record of Premium Freight
Overall
Supplier's
Performance
Data of
Supplier
quality
rating
Data on supplier
delivery
performance
Data on
supplier pricing
Incidents
of freight
Field
failure
due to
supplier
Special
customer
notifications
due to
supplier.

11.  Explains how to inward material with alternate modes of transport.
 The need for alternate modes of transport could be due to:
Urgencies and to overcome supplier failure of on time delivery.
v. Stores
 Involves receipt of materials, stock transfer, material issues, rejection,
handling and preservation.
1. Receipt of Materials Procedure
 Procure materials and prepare a GI.
 Verify received materials.
 Store materials and send for inspection.
 Forward materials to stores.
2. Issue of Material
 Check the production plan.
 Issue materials on daily assembly plan.
 Follow the FIFO technique.
3. Stock Transfer of Material
 Material Requests and convert to sales order.
4. Handling Rejections
 The components rejected due to damage from line are sent to the
quarantine area.
 If defects are from the supplier end, the components are sent back
to the supplier.
vi. Drawing Amendments
 Method of implementation of change in drawing level.

12. vii. Inventory Management
 The components shall be divided into A/B/C category according to unit
cost and consumption.
 Class is considered when planning material requirement.
 Inventory has to be monitored daily.
6. Maintenance Department
Objective of Maintenance
 To achieve zero breakdown with optimum utilization of power, water and
compressed air supply.
 Continuous monitoring of machines and equipments and maintain stock
of spares.
 Train engineers.
Maintenance Department is responsible for:
 Temperature Indicators
 Rpm indicators
 Load/Torque Indicators.
 Fuel Consumption Indicators.
There are three types of Maintenance:
Predictive, Preventive and Break down Maintenance.
1. Work Instruction for Preventive Maintenance.
 For CNC and Printed Circuit Board- Check the PCB for damage,
check correctness of PCB and put anti-static cover on the it.
 For Bearing- Check for tamper proof sealing and check for rusting,
abnormal noise while rotating and abnormal tightness of ball.

13. 2. Work Instruction for Predictive Maintenance.
 Check for accuracy of the machines.
 Vibration and Bearing analysis, Fluid Analysis and Temperature
Analysis is done either externally or in-house.
3. Environmental Management and Control.
 For Air Compressors- Ensure oil levels, check direction of rotation
and the outlet valve.
 For Chimney Maintenance-Check the condition of: Exhaust pipes,
packing, asbestos rope and support clamps. Monitor abnormal
vibrations and air quality.
 Cleaning Washing machine.
 Avoid leakage of hydraulic oil, lube oil, cutting oil and coolant.
Two important values that are calculated by the maintenance department for
better efficiency of the product are:
 MTBF- Mean Time Before Failure ( Should be large)
 MTTR-Mean Time To Repair (Should be small)
Internship Project
The next three weeks of my training period were spent working on a project
with the Material Control Department. The main objective of the project was to
create a Statistical Forecasting Model to predict the amount of components to be
procured.
The MCD provided me with the last two year data for the Fuel Injection Pump
stranger parts .The project uses the Moving Average Forecasting Method that
removes the irregularity and seasonality components in the previous year
procurement data of FIP. For this method, a datasheet using Excel was used to

14. produce results with the prediction of the quantity required to be ordered for the
next year.
The project validity was checked by comparing the forecasted data with the data
provided by the department. The datasheet also shows a graphical
representation of the data using regression.
.