six weeks training report or presentation for b.tech
DESCRIPTION
six week training report or presentation for b.tech mechanical engineering students. can be used as any semester training report or presentation(1 to 8).TRANSCRIPT
SIX WEEKS TRAINING REPORTAT NEW SWAN AUTOCOMP PVT. LTD.
From 11th june To 23rd July.
NAME : Deepinder Singh ROLL NO. : 80101115008COLLEGE : GURU NANAK DEV ENGG. CLG.BRANCH : PRODUCTION
CONTENTS• Introduction• Statistics• Achievements• Manufacturing Processes• Machinery Used• Departments • Future Plans• Improvements Suggested
IntroductionNew Swan Group started manufacturing precision fine blanking parts in its early stage, and later developed metal body part and sub-assemblies manufacturing. This Group provides convenience, comfort and safety to their customers. We certainly accomplish their commitment through ever improvement of production with latest technology.& this therefore puts us in the frontline of quality auto spare part manufacturers in India & global Market. This Group provides latest machinery present in the global world at present.
New Swan AutocompPrivate Limited
Location Ludhiana, India (Pb)Yr. of Establishment 2002Employees 260Total Space 1,17,000 Sq. Ft.Production Area 60,000 Sq. Ft.Sales (2007-08) 5.25 US$ MillionQS Standard TS –16949 : 2002Power / Self Generation 900 KVASpare Capacity 35%Product Range Fine Blanked Components &
Assemblies
Core Competence• Second largest co in India for fine blanking part for automobiles as
well other applications. • Leading group for catering Stamping, Tubular Parts, Welded ,Coated
parts, Cold Forged Parts, Door Latches ,Seat Latches, Hood Hinges, Parking Brake Parts, Gear Shifting Mechanism & Assembly , Seat Recliner to most of Indian Automobile as well global tier 1 cos.
• 100% tooling support from in-house R&D & advance design tool manufacturing centre for world class manufacturing.
• Capacity of timely development of products with highest quality & accuracy.
• Capacity of Stamping, Welding, Assembly ,Heat Treatment & Surface Treatment under one roof.
• In house facility of Testing Lab, Inspection as well all related endurance test for most of item manufactured.
• 25 % Export of total group sales.
Mission Statement
MISSIONNew Swan Group is focusing on providing superior products in automotive market. Our mission is to be locally and globally competitive in quality and value. VALUESWhole standard product to our customers through quality, reliability and technology. PEOPLEWe encourage the involvement and reward the contribution of each employee. QUALITYQuality is important in everything we do. Quality is everyone's responsibility, and is achieved through continuous improvement. LOCALIZATIONWe always look for the local supply of materials in order to reduce disadvantage of import through our own development or the coordination of our reliable suppliers. DESIGN & DEVELOPMENTWe design and develop our product to serve the requirement of our customers with the latest technology
Group Companies
New Swan Components , Gurgaon New Swan Enterprises – II , Ludhiana
New Swan Enterprises , Ludhiana New Swan Autocomp , Ludhiana
Quality
Quality Policy:
New Swan is TS 16949:2002 Company. New Swan is committed to continuous improvement in quality of its
products and services to exceed the customer expectations.
Achievements
Manufacturing Abilities
FINE BLANKING:
TheplantisequippedwithStateofArtTechnologyofFineBlankingPressesrangingfrom80Tto630T.
The following are the ranging :
TONNAGE NO MAKE80T 1 No FEINTOOL160T 4 No FEINTOOL400T 1 No HEINRICH SCHMID630T 1 No FEINTOOL
Fine Blanking Facility
630 ton press ( Fein tool make )
Stamping Facility
Press shop and Production
The Plant is Equippped with latest presses ranging from 20t to 250 t most of them with the automation. Total nearly 250 no. of presses . Presses are maintained in manner for continuous work flow.
Welding Facility
MIG Welding
TIG Welding
Going for up gradation of the facilities with Robotic welding
Testing Lab
Computerized UTMSST ChamberCold Chamber & Hot ChamberSplash Chamber Cupping TestMegna flux Machine (Crack Detection)Endurance Testing Facility
Heat Treatment Lab
SQF – Heat Treatment Plant
Carburising
Carbon – Nitriding
Hardening
Microscope for checking microstructure
Tool Room FacilitiesTool room is equipped with latest machines like : VMC - CNC – Wire Cut Machines - EDM - CNC Pipe Bending, CNC Strip Forming & Other Latest equipment related to most modernized tool room ie : Hi-tech Drills, Lathes, Grinders Etc
Surface Treatment FacilityPlating plant :
- Tri -Valent plating
Bright
- Alkaline
Bright
Yellow
Green
Golden
- Zinc Nickel Plating
Standard Room
Standard room is a place in a company where standard and precious measuring instruments are used for accurate measurements ,for checking dimensions of all components or products very accurately . It has a motto to defect the problem and give actual status. It also requires some environmental conditions : 1. Temperature – 22 + 2 degree celcius 2. Humidity – 50% + 10% (more than 50% ) 3. Pressure should be positive
Imp. Instruments Used• Digital Vernier Calliper (D.V.C)• Digital Micrometer (D.M.M)• Digital Height Gauge• Linear Height Master (L.H.M)• Bevel Protector• Profile Projector (lens of 10x and 20x)• Slip Gauge Box• Torque Wrench• Tripod• Radius Gauges• Roughness Tester
Digital Vernier Calliper
Linear Height Gauge
Digital Micrometer
Linear Height Master
Profile Projector
Roughness Tester
Radius Gauge
Imp. Processes in Std. Room• Caliberation• Sample Inspection• Layout Inspection• S.P.C• M.S.A• Dock Inspection
Caliberation : Caliberation is a process of caliberating and keeping a record
of any changes to a gauge used for checking the components or products by using its tolerances provided . Any changes to a gauge leads to a reissue of a gauge .
It can also be stated as a process in which every single gauge has a particular frequency of time after which the gauge dimensions has to be checked with instruments after particular interval.S.P.C :SPC is a tool, which applies basic statistics to control the process. C.P – Process Capability C.P.K – Process Capability index C.P >= 1.33 and C.P.K >= 1.67 C.P is always greater than CPK.
M.S.A : Measurement system analysis R and RR – Repeatability (Instruments Variation and within Appraiser )R – Reproducibility (Appraiser Variation and Between Appraiser )(a)Up to 10% errors – Measurement system acceptable.
(b) (10-30)% errors – May be acceptable based on importance of acceptance.(c) Over 30% errors – Measurement system needs improvement, make every effort to identify the problem and have them removed. BIASBias = Observed Avg. – Reference Value. ATTRIBUTE STUDYIt is only for rec. gauges study (whether it’s accept the OK pcs. And reject the NG pcs. Or vice versa.) STABILITY STUDYIt verifies the Appraiser, Equipments and Environment. LINEARITY STUDYDock Inspection – It verifies the packing standard of the component and pre-dispatch inspection also for the component only.
Types of Gauges used in Caliberation
• Receiving Gauges • Plug Gauges• Snap Gauges
Each and every gauge has a upper and lower limit in records which can also be called as its GO and NOGO . For plug gauges its upper limit is NOGO and lower limit is GO whereas it is vice versa for snap gauges.
Each and every gauge has its own speciality and its own purpose :
Plug gauges are the one used for only and only checking holes of different sizes
Receiving gauges are the gauges used mainly for checking its length, breadth and height of a product or component
Snap gauges are the one which are used for checking some dimensions for a component .
There are also some other types like fixtures which are used for fitting in a machine .
Sample Inspection
Sample inspection is a kind of procedure in which with the help of a drawing we check all the dimensions of a sample or newly designed component with very limited quantity . After checking the sample the report is made named as sample inspection report in which all the dimensions are measured after checking with the instruments also whether the sample is pass or not is mentioned . Some of the mentioned dimensions in this report are c.d , radius , flatness etc.
Layout Inspection
Layout Inspection is the complete measurement of all part dimensions shown on the design record. A layout inspection is required for some customers for all products annually unless another frequency is established in a customer approved control plan. In this inspection all the minor and major readings of the product are checked completely as shown in the drawing of the component issued by the company whose product is to be made.
Other Specialities
Other Facilities Like Expert Design Department Equiped with Workstations and Softwares like Autocad, Solidworks Etc. Various Type of Coating and Surface Treatments, Powder Coating, Cold Forging, are also done in the works
Details of Press ShopPOWER PRESS
CAPACITY NOS
250T 1
150T 2
100T 6
75T 4
50T 2
30T 23
20T 1
10T 3
5T 2
HYDRULIC PRESS
CAPACITY NOS
80T 1
160T 4
400T 1
630T 1
Detail of hydraulic press
Total capacity 80t
Max shut ht 215
Min shut ht 200
Max cutting force 40t
Total capacity 150t
Max shut ht 265
Min shut ht 230
Max cutting force 100t
Total capacity 400t
Max shut ht 400
Min shut ht 360
Max cutting force 220t
Total capacity 630t
Max shut ht 400
Min shut ht 320
Details of Machine ShopTYPE NOS
Lathe 6
CNC lathe (8 tools) 1
Bench grinder 2
Grinder 6
Edm 1
Wirecut 1
Drill machines 20
Special purpose lathe 3
Broaching 1
Sletion 1
Centre less grinding 1
Special purpose lathe 1
Buffing 1
Boring 1
Details of Welding shop
MIG WELDING 18 SETS
PROJECTION WELDING 3 SETS
Raw Materials Used
Carbon Steel -- CRCA, C45,C55, C60, C80, SK5,CS4,
Alloy Steel -- 16MnCr5, SCM 415, SCM 435
Stainless Steel -- 304, 409, 304L,439
Special Steel -- 11SMn30
Components or Products
• Sheet metal assemblies ,door latches,parking brakes
Fine blanked and other components
Future Plans
•To Strengthen the Product line for 4 – Wheeler Automobile Segment
•To Upgrade the manufacturing Facility with Latest Technologies
•Setting up new manufacturing plants in various places closer to customers.