industrial training report in rane madras mysore

8/13/2019 industrial training report in rane madras mysore

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Industrial Training At M/s Rane (Madras) Limited, Mysore.

Dept of Mechanical engineering, PESCE, Mandya 1

CHAPTER 1

INTRODUCTION

1.1 Objective of Industrial Training:

The main objective of the Industrial Training is to experience and understand real life

situations in industrial organizations and their related environments and accelerating the learning

process of how students knowledge could be used in a realistic way. In addition to that, industrial

training also makes one understand the formal and informal relationships in an industrial

organization so as to promote favorable human relations and teamwork.Industrial training also

provides a systematic introduction to the ways of industry and developing talent and attitudes, so thatone can understand how Human Resource Development works.

Moreover, students can gain hands-on experience that is related to the students majoring so

that the student can relate to and widen the skills that have been learnt while being in university.

Industrial training also exposes the students to the real career world and accustoms them to an

organizational structure, business operation and administrative functions.

In conclusion, there is strong evidence that industrial training is highly beneficial to students

development, and it is highly valued. The students are well equipped to manage the period of

industrial training successfully and undoubtedly gain useful experience of applying their specialist

and technical skills, as well as developing their personal and communications skills. This internship

also help student to prepare for the work environment and also teach the ergonomics of organizations

in the real world. In brief:

To understand the organization structure of an industry. To understand Management skills. To understand the functions and responsibilities of different departments.

1.2 Methods of Industrial Training

There are many methods used to assist me in gathering sufficient information for my report.

The main source of information was gathered through interviews with particular employees and

managers. They were very approachable and assisted me in providing information and knowledge.

Next, I also used discussion method to gather information. I discussed with the staffs on

certain task that I was not sure and they helped me by explanation briefly about their job description

and also about the organization.


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Apart from that, I also used observation method to gather information for my project. I

observed how the operations are carried out, how the employees interact among themselves, how the

working culture is practiced, how the relationship between the manager and the sub ordinates is and

the how the working environment is.

1.3 Scope of Industrial Training:

Industrial Training is very important for student learning process in order to

understand the theory that already learned and relate it with practical which have been done

in practical work at sites, labs, workshops and much more. Therefore, the trainee should be

able:

To train at real working situation at industries before applied the real job. T o e xpose to a new technology and applications in engineering. T o respect and follow the companys rules. To involve in the real working environment. To improve students confidence and develop responsibility. To know how to solve a problem that occurs in a real work. To increase the creativity and innovative during the work. To improve working skill.


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CHAPTER 2

COMPANY PROFILE

2.1 Company profile:

Fig. 2.1 Rane (Madras) Ltd., Front View

RANE (MADRAS) LIMITEDPLANT II

79/84, HOOTAGALLI INDUSTRIAL AREA,

MYSORE570018.

Rane (Madras) Ltd is one of the top auto ancillary company and is a part of the Rs. 2709

crore Rane group, engaged in the manufacture and distribution of steering and suspension

systems.


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2.2 RANES MISSION :

Provide superior products and services to their customers and to maintain market leadership. Evolve as an institution that serves the best interests of all stakeholders. Pursue excellence through total quality management. Ensure the highest standards of ethics and integrity in all their actions.

2.3 RANESVISION :

Rane has been an integral part of the Indian Automotive Industry since 1929. Founded by Mr.

T.R.Ganapathy Iyer, Rane started as a Trading House for automobiles and parts. The history of Rane

is growing from this reputed Trading House into a major manufacturer of vital components for the

Automotive Industry.Seeking world-class technology and adapting it perfectly to Indian conditions,

RANE has been a key support system in the growth of the automotive industry.

Today, the Rane group, under the leadership of Mr. L Ganesh, Chairman, has in its fold

manpower strength of 4500 people and a sales turnover in excess of Rs.2709 crores. And the RHL

vision is tomaintain market leadership, to establish global presence and to achieve sales of Rs. 4,300

crores.

Ranes major customers in India are Ashok Leyland, Hyundai, Fiat, Hindustan Motors,

Mahindra and Mahindra, Hero Honda, Maruti Suzuki India Ltd., VOLVO-EICHER Ltd., TATA

Motors, Eicher, TAFE, Escorts, New Holland Tractors (India) Ltd., John Deere Equipments Pvt.

Ltd., Indian Railways etc.

2.4 Down the memory lane

Founded asRane Private Limitedin 1929, started as a trading house, trading in automobilesand parts. Represented General Motors, Renault, American Motors etc

As first diversification from trading, in 1959 Engine Valves Limited was established formanufacturing IC engine valves.

In 1960 Rane (Madras) limited commenced manufacture of Steering Linkages (Tie rod ends). Rane Brake Linings Limited was established in 1964 for manufacturing friction materials. In 1965 Rane Madras Limited discontinued with its trading activities. In 1975 Rane (Madras) Limited started manufacturing of Steering Gears. RML Mysore division was started in the year 1985.


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2.5 Rane Group Companies and Product Range:

Fig. 2.2 Rane Group Companies and Product Range

2.6 About M/s Rane (Madras) Limited:

2.6.1 Background:

Inception of manufacturing facilities in the year 1960 Manufacturer of steering and suspension systems for every segment of automobile industry,

viz Passenger cars, Multi utility vehicles, Light commercial vehicles, Heavy commercial

vehicles and Farm tractors

Branched in Hydraulic products in anticipation of shift in customer requirements Strategic Technical partnerships with M/s TRW Inc, USA for Steering Gear Products and

TRW Ehrenreich GmbH and Co., Germany for Steering Linkage Products

Holds 39% market share in Steering Gear Products (SGP) and 72% market share inSuspension and Steering Linkage Products (SSLP) in India.


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2.6.2 Plant Locations:

Fig.2.3 RML Plant locations

The 5 manufacturing facilities location and the product range following locations

Location Product Costumer Segment

Mysore plantSSLP, SGP, Hydraulic

products

Tractor and Commercial vehicle segments,

and Hydraulic products

Puducherry plant SSLP,SGP Passenger Car segmentUttarakhand (Pantnagar)

plantSSLP,SGP

Tractors and small commercial vehicles

catering to customers in North India

Velachery (Chennai)

plantSSLP

Passenger Car, utility vehicle mainly caters

to exports market

Varanavasi (Chennai)

plantSSLP,SGP

Light Commercial vehicle, Heavy

Commercial vehicle and Utility vehicles

segmentsTable 2.1 Manufacturing facilities location and the product range


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2.6.3 Product range and Customer base:

Fig. 2.4 RML Product range.

Fig. 2.5 RML customer wise product range


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2.6.4 List of customers:

Sl no Customer Products

1 MandM- TD Mumbai 1.Linkage assembly

2.Steering gear assembly2 MandM-AD Mumbai 1.Suspension ball joint 2.AXLE BJA

3 MandM(Swaraj Division) 1.Steering gear assembly

4 TATA MOTORS Ltd. 1.Suspension ball joint assembly

5 Escorts limited farm

Equipment division

1.Linkage assembly

2.Steering gear assembly

6 TAFE Ltd. 1.Linkage assembly


3.Cylinders

7 TMTL 1.Linkage assembly2.Steering gear assembly

8 New Holland Tractors(I) Pvt. Ltd. 1.Linkage assembly


9 JDEPL 1.Linkage assembly


10 Inter National Tractors 1.Steering gear assembly

2.HSU

3.Cylinders

4.Steering columns

11 Force Motors 1.Linkage assembly


3.Lower control arms

12 SIAM Kubota 1.Steering gear assembly

13 Indo Farm 1.Linkage assembly


14 Same Greaves 1.Linkage assembly


15 Maruti Suzuki India Ltd. 1.Lower control arms

16 DANA India Pvt. Ltd. 1.Linkage assembly

17 Piaggio Ltd. 1.Lower control arms

18 Ashok Leyland 1.Gear shift lever BJA

2.Cylinders

19 HMT Ltd. 1.HSU

2.Steering column

3.Reservoir

4.Cylinders

20 AMW 1.Cylinders2.GSL ball joint assembly

Table 2.2: Rane products and customers


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2.6.5 DEMING Prize:

The DEMING PRIZE is a prize instituted by the JUSE {Union of Japanese Scientists and

Engineers} in the 1950s. It is awarded annually to those individuals and companies showing the most

important in Quality control. The prize itself is named after Dr. W. Edward Deming Father of

Quality.

Rane (Madras) Ltd received the JapaneseDeming Grand Prize in 2012. The company also

won the Deming Application Prize in 2007. Rane (Madras) Ltd. is the only steering and suspension

manufacturing company globally to win the Deming Prize and Deming Grand Prize.

2.6.6 The Key initiatives for the future are:

Expanding Rack and Pinion business through new customer acquisition. Establishing stronger position in suspension ball joints. Expanding export business through current and new customers in different geographies. Enhancing the Companys position significantly in hydraulic products. Expanding scope and reach in after market segment Company plans Capex of Rs. 160 crore, achieve CAGR of 21% in Sales and ROCE of 30%

by 2015-16
http://en.wikipedia.org/wiki/Deming_Prizehttp://en.wikipedia.org/wiki/Deming_Prize


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CHAPTER 3

AREA OF TRAINING

3.1 Imparts/Insights obtained:

Industrial training is an exposure to the industry at the right time. It helps in learning the

details of company such as the organization structure, functions and responsibilities of different

departments, management skills, technology, the product and services, maintenance procedure,

various tools used etc. Through the training one will know the hierarchy of departments and also

it helps to closely watch the happenings in an industry. Through the industrial training program

one can prepare himself for the further project work and will provide a strong base for his career.

The industrial training helped me to get a deep insight about the structure of the

organization, and various departments. It also helped me to gain the knowledge of how

departments perform individually and co-ordinate with each other to service the customer needs.

3.2 ORGANIZATION STRUCTURE:

Chart below shows the organization chart with different levels of hierarchy.

Fig 3.1 Organization structures - RML, Mysore


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3.3 Plant Maintenance Engineering Department (PLE):

Fig 3.2: Organization structurePLE - RML, Mysore

3.3.1 Purpose:

The purpose is to sustain and enhance availability of plant and machinery to it's maximumlevel and to improve quality and maintainability of equipments.

3.3.2 Role:

Upgrade equipment availability Control maintenance cost Reduce power cost

3.3.3 Functions:

Plant consists of around 320 production machines, H.T furnaces, utilities and facilities

including buildings. Caters to the technical service requirement of manufacturing and calibration

requirement of testing and measuring instruments. It takes care of company statutory and legal

requirements.


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3.4 Manufacturing Engineering Department (MED) :

Fig 3.3: Organization structureMED - RML, Mysore

3.4.1 Purpose:

The purpose is to support the manufacturing function through optimizing the process through

modern and innovative tooling, Reduction in cycle time and setup time, Establishmanufacturing process for New Product, to meet market demand and quality

3.4.2 Role:

Improve manufacturing Processes Productivity Improvement Projects Special initiative on Tool Cost Saving Projects

3.4.3 Functions:

Manufacturing cost competitiveness. Manufacturing system inability to meet fluctuating demand Lead time of New product productionization Process Quality improvement Inadequate use of Statistical tools


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3.5 Quality Assurance (Q.A.):

Fig 3.4: Organization structureQ.A. - RML, Mysore

3.5.1 Purpose:

To achieve quality to meet customer expectation.

3.5.2 Role:

Improve incoming material quality Improve in-process quality Improve out going product quality

3.5.2 Functions:

Customer Quality Assurance (CQA) - To improve out going product quality. In process Quality Assurance (IQA) - To support in-process material quality to meet internal

customer requirements.

Supplier Quality Assurance (SQA) - To improve incoming material quality to meet internalcustomer requirement.


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CHAPTER 4

MY OBSERVATIONS AND TASK

As a CIM student I studied the plant layout, cell layout and the process flow of a product of a

particular variety (Customer Company)

Fig 4.1 Layout of SSLP (Not to scale)

4.1 CASE STUDY (ISHIKAWA PRODUCT MODULE):

In this cell the final part obtained is the drag link for cars like MARUTI 800 and OMNI. This

final part is obtained by assembling ball pin and socket which are manufactured in this cell and then

finally assembling them.

A drag link converts rotary motion from a crank to a second crank or link in a different plane

or axis. The term is commonly used in automotive technology for the link in a four

bar steering linkage that converts rotation of a steering arm to a center link and eventually to tie


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rod links which pivot the wheels to be steered. A drag link is used when the steering arm operates in

a plane above the other links. The drag link converts the sweeping arc of the steering arm to linear

motion in the plane of the other steering links. Typically, one end of the drag link is connected via

the Pitman arm and steering gearbox to the steering wheel (providing the connection between the

driver and the steering system); the other end is attached to the vehicle frame by the idler arm.

Fig 4.2 Drag link assembly

Ishikawa product module(Integrated cell) is as shown in the figure

Fig 4.3 Process Flow of Integrated Cell


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Process Flow in Integrated cell:

1. Raw materials from supplier to stores2. Raw materials (Forged part) to the Integrated cell3. Machining Process

I. Machining of Ball pina. Turning

b. Pin hole drillingc. Pin hole chamferingd. Turning and Burnishinge. Thread rolling

II. Machining of Socketa. Piercing

b. Bore machiningc. Garter groovingd. Stem centeringe. Stem turningf. Thread rolling

4. Heat Treatment5. Inspectionmagnetic inspection for crack detection and other faults6. Assembly Line

a. Pre assemblyb. Roller peeningc. Boot greasingd.

Boot assembly

e. Boot clip assemblyf. 90 deg correction and Packing


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4.2 Machining process:

4.2.1 Machining of Ball pin:

1 Turning:

Fig 4.4 Ball pin turning

Mount the ball pin between the tail stock center and the face drive and clamp the component.

Switch on the machine, after completion check visually and if found ok proceed to first off

inspection check with appropriate gauges and continue.

Machine Used: C.N.C. TURNING MACHINE

Process parameters:

PARAMETER SPECIFICATIONS CHECK METHOD

Speed 3150-2000 rpm Visual

Feed 0.28-0.22 mm/rev Visual

Tail stock pr. 16-20 Kg/cm Visual pressure gage

Cutting medium Soluble oil Visual

Tooling details:

TOOL NO DESCRIPTION TOOL LIFE

Per Edge No of Edges Total

MTJNL 2020 Holder

TNMG 150608 Insert 200 6 1200


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2 Pin hole drilling:

Fig 4.5 Ball pin hole drilling

Mount the ball pin in the guide bush and lock the Pneumatic cylinder. Switch on the cycle.

After completion visually check and if found ok proceed to first off inspection and check with

appropriate gauges and continue.

Machine Used:DRILLING MACHINE (AURAM)

Process parameters:



Feed Auto Visual


Tooling details:



RJF 0314 Fixture

MJF 0151 Drill jig 3.2 s.s drill 100 10 1000

3 Pin hole chamfering:

Fig 4.6 Ball pin hole chamfering

Hold the component in the vice and switch on the cycle. After completion check & if found

ok continue.

Machine Used: DRILLING MACHINE (AURAM)


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Process parameters:



Feed Manual Visual

Cutting medium Dry Visual

4 Turning and Burnishing:

Fig 4.7 Ball pin head turning & burnishing

Mount the ball pin in the spindle, and switch on the cycle .After completion of the process

visually check and if found ok proceed to first off inspection check with appropriate gauges and

continue.

Machine Used:BALL PIN TURNING & BURNISHING MACHINE

Process parameters:


Speed Fixed Visual

Feed Hydraulic Visual


Hydraulic Pr. 30-40 Kg/cm Visual

Tooling details:


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Per Edge No of

Edges

Total

ZZ 473 Parent collet

ZZ 363 Burnishing roller 1 in 2 month

DSDNN 25 25 Holder

SNMG Seco make 250 8 2000

5 Thread rolling:

Fig 4.8 Ball pin thread rolling

Place the ball pin on the ball head rest (Nylon), and stem on the rolling blade, switch on the

cycle. After completion visually check and if found ok proceed to first off inspection and also check

for any flat threads and also any over ride of the thread.

Machine Used:THREAD ROLLING MACHINE (PRAGA)

Process parameters:


Hydraulic pressure 8-12 Kg/cm2 Visual

Dwell Time 2.0-4.0 sec Timer

Cutting Medium Servo cut 945 Oil Visual

Tooling details:



M12x1.25 RH

Thread Rolls

1 10000 10000

4.2.2 Machining of Socket:


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1 Piercing:

Fig 4.9 Piercing blank

Load the socket in between the Fixture jaws & Tighten the jaws, Switch on the cycle. After

completion of the cycle, Check visually and if found ok move on to first off inspection. Check with

appropriate gauges for the critical dimensions as in check list and continue the operation.

Machine Used: COLUMN DRILLING MACHINE

Process parameters:


Speed 315 rpm Rotary switch

Feed 0.315-0.5 mm/rev Needle


Tooling details:


Per

Edge

No of

Edges

Total

RJF2002 Pneumatic Vice

MJF 141 26.50mm T S 2F drill within

house made step

500

2 Bore machining:


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Fig 4.10 Bore machining of socket

Clamp the socket in the Spindle and switch on the cycle. After completion, check visually

and if found ok move on to first off inspection. Check with appropriate gauges. If found ok continue

the process.

Machine Used:MURATA CNC CENTER

Process parameters:


Speed 2500 rpm Visual

Feed 0.22-0.28 mm/rev visual


Chuck pressure 16-20 kg/cm Pr. gage

Tooling details:


Per Edge No of

Edges

Total

PCLNR 2020 Tool Holder

CNMG 120408 Insert 800 04 3200

S16SCLCR Boring Bar

CCMT09T308 Special boring bar

cutting Insert

500 2+2 2000

Dia 165 mm 3 Jaw Chuck 4months

3 Garter grooving:


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Fig 4.11 Garter grooving of socket

Clamp the socket in the grooving collet and tight the collet with the help of handle. Switch on

the cycle, after completion of the cycle visually check for any damage and if found ok move on to

first off inspection. Check with appropriate gauges and also check manually for any burr fold and

after inspection continue the process.

Machine Used:COLUMN DRILL MACHINE

Process parameters:


Speed 315 rpm Rotary switch

Feed 0.125 mm/rev Needle


Tooling details:


Per

Edge

No of

Edges

Total

RJF 0216 Fixture

MT 0023 In house made garter grooving

tool 8mm x 8mm HSS Sq.bar of

constant length 47.5 mm to be

used

600 2 1200

4Stem centering:


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Fig 4.12 Stem centering of socket handle

Locate the socket in the bunk and clamp pneumatically. Switch on the cycle, after completion

of the cycle visually check and if found ok move on to first off inspection.

Machine Used:DRILLING MACHINE (AURAM )

Process parameters:



Feed Auto feed Timer


Tooling details:

TOOL

NO

DESCRIPTION TOOL LIFE

Per

Edge

No of

Edges

Total

RJF 0148 Centering fixture

3/16 x7/16 CenterDrill

MT2 Taper shank adapter .

1200 2 2400

5 Stem turning:


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Fig 4.13 Stem turning of socket handle

Locate the groove I.D of socket in the plate provided in headstock fixture. Clamp the socket

in between the Spindle & Tail stock center. Switch on the cycle, after completion of the cycle check

visually and move on to first off inspection and check with appropriate gauges and continue.

Machine Used:TAKISAWA

Process parameters:



Feed 0.2-0.3 mm/rev Timer

Cutting medium Coolant Visual

Tooling details:



PDJNN TOOL HOLDER

DNMH12 INSERT 200 4 800

6 Thread rolling:


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Fig 4.14 Thread rolling on the socket handleLoad the dummy component on the work rest blade, Switch on the cycle. After completion

check visually and if found ok move for first off inspection and continue the process with socket.

Machine Used:THREAD ROLLING MACHINE (PRAGA)Process parameters:


Hydraulic pressure 25-40 kg/cm Pr. gage

Dwell Time 25-60 sec Timer

Cutting Medium Servo cut 945 oil Visual

Tooling details:


Per

Edge

No of

Edges

Total

RZZ 2111 M12x1.25 6g RH ThreadRolls for(M12)

50000

M14x1.25x90 LH/

RH thread Rolls for (M14)

50000

4.3 Drag link assembly line:

1 Pre assembly:


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Fig 4.15 Pre assembly of Drag link

Press the bottom cup into the socket, apply a thin layer of AP2 INDROL grease on the ball

pin head, then Insert ball pin & top cup on the ball pin head .Press the grease smeared ball pin ,top

cup into the socket by operating the switch. After completion of the operation check visually and if

found ok continue.

Machine Used:PNEUMATIC PRESS

Process parameters:


Pneumatic pr. 4-6 kg/cm Visual

2 Roller peening:


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Fig 4.16 Roller peening machine

Assemble spring, spring seat & end plug into the socket, place them in the fixture & Peen it.

After completion of the cycle check visually& if found ok move to first off inspection & continue.

Machine Used:ROLL PEENING MACHINE

Process parameters:


Roller gap 1.250.1 mm plate gage

Pneumatic pr. 4-6 kg/cm indicator

Dwell time 110-130 sec indicator

3 Boot grease filling:

Fig 4.17 Boot greasing

Set for approximately 5gms AP2 (Yellow colour) & fill uniformly on inside groove of

Laser sensorto ensure

Internals.

Pokayoke

fixture to

detect wrong

ballpin.


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the boot by operating the switch. After completion check visually for proper filling of grease inside

the groove portion & if found ok continue.

Machine Used:GREASE DISPENSING UNIT (CENLUB)

Process parameters:



4 Boot assembly:

Fig 4.18 Boot assembly

Manually fit the larger dia of the grease filled boot on the back opening of the peeened end

through ballpin after completion check visually & if found ok continue. Boot after assembly should

be in free condition & not to be in squeezed condition.

5 Boot clip assembly:

Fig 4.19 Boot clip assembly


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Insert the boot assembled end on the taper cone through the ball pin end. Place the clip on the

clip seat & position the taper cone, operate the air valve. After completion of the cycle check visually

100%.

Machine Used:BOOT CLIPPING MACHINE

Process parameters:



6 90 deg correction and Packing:

Fig 4.20 90deg correction and packing of drag link assembly

Insert 3mm pin into the ball pin hole & turn such a way that the ball pin hole axis is

approximately90deg (15deg ) to the axis of the socket stem center.

1. Apply rust off oil.2. Fix the protective cap to the ball pin.3. Place the assembly into the cartoon box (16 Nos. in each box).4. Check for the presence of batch code.


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CHAPTER 5

CONCLUSION

As a postgraduate student I would like to say that a training program like an industrial

training is an excellent opportunity for me to get to the ground level and experience the things that

we would have never gained through going straight into a job. I am grateful to my college PESCE

and Dept of Mechanical Engineering, for including training like this in the curriculum. The industrial

exposure and learning is the best way to get the knowledge about the manufacturing world. It gives

clear picture of the organization.

The main objective of the industrial training is to provide an opportunity to postgraduates to

identify, observe and practice how engineering is applicable in the real industry. It is not only to get

experience on technical practices but also to observe management practices and to interact with

fellow workers.

During my stay at RML, I got hat experience and the feeling of responsibility. It was a great

experience. Engineering personnel of the RML are people that have a lot of experience. All of them

were willing to help in my training. They have a vast knowledge about the fields they are work with.

So it was easy to learn from them.The 2 months training that I received at Rane (Madras) Ltd., was great experience for me not

only on technical terms but also in terms of interaction with other workers. I learnt a great deal on

applying the knowledge I have gained at the college. Learning something from books and lectures is

nothing like having firsthand experience. At Rane I got to apply my knowledge. The company gives

the full freedom for the trainee. The trainees are allowed to ask and do anything relevant to the

training. Engineers are always very enthusiastic on giving us the best training experience.


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CHAPTER 6

BIBLIOGRAPHY

Bibliography:

Information from departments. RML library. Company Literature. Annual reports. Internet

www.rane.co.in http://en.wikipedia.org/wiki/Rane_(Madras)_Ltd

Documents

industrial training report in rane madras mysore