CONTENTSSubject Page

1. Acknowledgement 3

2. Student Declaration 4

3. Preface 5

4. Certificate 6

Chapter 1: Introduction to Organization

1.1 Introduction 7

1.2 Location 8

1.3 Organization Structure 9

1.4 Plant Structure 10

1.5 Achievements 11

1.6 Objectives 12

1.7 Departments: 13

1.7.1Machining and Assembly Department 13

1.7.2 Design Department 13

1.7.3 Quality Section 14

Chapter 2: Training Given 15

Chapter 3: Result & Discussion 30

Chapter 4: Conclusion 32

ACKNOWLEDGEMENT

 I Antriksh pal student of Mechanical Engineering in Punjab College of Engineering & Technology. Would first of all like to pay my special regards and thanks to Mr. Raj Kumar and who has given me the opportunity to work as a summer trainer in G Max Auto Ltd. Bawal, Haryana.

I wish to pay special thanks to Mr.Vikash choudary and Mr. Ravi Pal for providing me their valuable guidance and Co-operation.

Last but not the least, I would like to thank all the Workers and Executives of “G MAX” who had Co-operated with me in completing my training and project report successfully.

It is a matter of proud and honor for me that I had got the chance to undergo my summer training in an Esteemed Company; G MAX where I got the support from each and every corner of the company.

Place:- Antrksh Pal

Date:-

 

 

PREFACE

Working in an industry provides us a practical approach to our theoretical basis of knowledge acquired in our classroom. It has been a great pleasure, training atG MaxLtd. Bawal, basically a sheet metal industry which helped me boost up my practical skills correlating the theories of book into actual work environment.

The following implant training report presents all my observations, analysis made during my training period of 6 (six) month. The report concerns mainly with the Tool Room and quality department where I have been deputed in the training.

The information data furnished in the context are on the basis of my information collected through interaction with the Engineers, Technocrats, Technicians, and Workers working in the firm. I have tried to include a few typical readings for some sections as an example to give a basic idea of the operation.

Despite taking every effort to produce an error free report, I apologize for any mistakes evident in the context on my part.

CHAPTER-1

INTRODUCTION TO ORGANIZATION

1.1 INTRODUCTION

G Max isa premier industry setup inBawal, Haryana dedicated for the production and designing of various moulds associated with automobiles. It has been a vendor Hero Moto Corp. It is a multi-disciplinary and multi-dimensional organization dedicated for the production of number of components

It is one of the sister company out of group of companies. It is serving several of its clients. Large number of components ranging from simple to highly sophisticated ones, have been designed and developed by the company and their know-how’s have been passed on to the various of its clients.

Over a period of time, G Maxhas acquired state-of-art expertise in designing components for different applications associated with automobile industry. Keeping pace with emerging trendsG Max has developed various components using state of the art technologies.

It’s an ISOCertified company. It performs all of its operations under the norms as laid by the International Standardization Organization, keeping in view the well being of its employees and workers at every level.

It is spread over an area total of 14000 SQM and the covering area is being 10500 SQM.

1.2 LOCATION

It is located inBawal, the industrial city of Haryana state. Plot no. 33, sec.5, Phase.2, Industrial Growth Centre Bawal, Rewari (Haryana) INDIA One of the great advantages for the location is being that it is situated very near to the Gurgaon.An Overview of G MAX AUTO LTD:-

1.3 ORGANISATION STRUCTURE

G MAX AUTO LIMITED

Plot no. 33,sec.-5,Industrial Growth Centre, Bawal, Rewari (Haryana) INDIA

* ORGANISATION STRUCTURE

G MAX AUTO LIMITEDPlot no. 33, sec.-5, Industrial Growth Centre, Bawal, Distt. Rewari (Haryana) INDIA

1.4 PLANT STRUCTURE

i. Total Area :- 14000 SQMii. Covered Area: - 10500 SQM.

Power Back-Up Facility

i. Gen Set :- 325 KVAii. Gen Set :- 180 KVA

In the plant there is good power back up facility. It is work automatically during the connection cut from outer electricity.

1.5 ACHIEVEMENTS

Maintaining ZERO DEFECT Products for HERO, HONDA, MAHENDRA since Last 1.5 Years

Delivering Products ON TIME – EVERY TIME for all Customers.

1.6 OBJECTIVE

Aims at producing professionals endowed with technical competence andLeadership qualities.

To infuse thorough knowledge and impart industry -oriented practical training to make the students a breed apart.

To inculcate a sense of discipline and responsibility coupled with logical thinking, so that they are an asset for their employers.

To instill a high level of self-confidence to make them successful in all walks of life including entrepreneurship.

To emphasize their all round development, by ensuring participation in cultural activities, group discussions, social get-togethers, sports, etc.

To imbibe a quality that makes them better citizens.

To create professional competence.

1.7 DEPARTMENTS

(i) Machining and Assembly

(ii)Design

(iii) Quality section

(i) Machining and Assembly

INTRODUCTION

1. Generally in machining we machined the raw material as we required with the help of CNC machines.

2. After machining the parts of mould come in assembly for assemble after few operation it assemble properly and mould should ready for trial.

(ii) Design

G Max has a great power of designer which are capable to make any type design of mould.

The first work to make the mould is to make the design of their reliable structure in the design department.

In design department designer make the design of electrode which are used in mould to remove the extra material from critical areas.

(iii) QUALITY CONTROL SECTION

As the name suggests this section houses all sorts of tools and measuring instruments like venire calipers, venire height gauge, slip gauges, surface plates, radius gauges, inside/outside micrometers, depth gauges and hardness testing machines, torque wrench testing machine etc. for checking the components purchased from the vendors from outside the firm before being stored into the store lying adjacent to this section.

This section monitors whether the components supplied by the allied vendor party covers the quality specifications of the company or not and according takes corrective action as and when required. It also keeps a track record of the stock of components inside the store.

Being an ISO certified company; the firm is deeply concerned with managing of quality of the purchased components which ultimately affect the quality of its final product.

The Quality Policy of the company can be quoted as:

Producing world class tractors in quality and reliability Total customer satisfaction through services Creating a culture among all employed toward total quality

concepts Constant up gradation of technology and human excellence

After so many accomplishments, the company is still striving hard to expand its capabilities and setting up new establishments and manufacturing units in different parts of the country. Some of the manufacturing units are under construction and soon will be ready to work. It has signed with several international firms to match up with the latest trends in the automobile industry, the fastest growing industry of its kind in the current scenario.

CHAPTER-2

TRAINING GIVEN

2.1MANUFACTURING OF PARTS

For the manufacturing of the parts first of all the Overview

Of The plant is given. Different operations are performed

during the manufacturing of the different parts. The

operations performed during the manufacturing of different

parts the following processes are involved

(1) CNC

(2) Assembly

(3) Quality Section

2.1.1 CNC:

1. VF-3 YT(VMC) 4.Takumi (H16)2. VF-2 YT (VMC) 5.Takumi (H16)3. VF-1YT(VMC) 6. BC 2112

These are the machine in Tool Room of G MAX.

VF-1 is specially dedicated to the electrode.

VF-2 is specially dedicated to the child parts.

VF-3 is specially dedicated to the small moulds core and cavity.

Takumi (H16) and (BC 2112) for all type of moulds (core ,cavity).

CNC (Computer Numeric Control) is used in tool room for

machining of raw material.

Some over view of few machines:

Takumi Machine used in G Max Auto LTD

This machine is Takumi BC 2112

2.1.2Assembly section:

In assembly section we can do many little operation on mould before assemble the mould.

1. Chamfering in core,cavity, ejector plate, top plate, bottom plate etc.

2. Drilling on RDM machine (for cooling channels and for eye bolts)

3. Tapping in eye bolts holes for put the eye bolt.

4. Child parts grind on surface grinder as properly butt in mould.

5. Few operation on lathe and milling machine as we required.

6. After all small operation we go for bedding on disporting Machine.

7. After that we assemble it and paint it and sent it to go for trial.

2.1.3Quality Section:

In the quality section the part manufactured can be checked out completely. In quality section these things can be checked out in the part:

(i) Overlapping(ii) Wrinkle(iii) Deformation(iv) Crack(v) Dent(vi) Material Strength

These are different facts that can be checked out in quality section which are necessary to be checked out for the strength and accuracy of the part.

CHAPTER-3

RESULTS & DISCUSSION

3.1RESULTS:

3.1.1 Successful Development:In the final we getting the result of the company it is a very reliable and peace full company. It provides the mould to the vendor company as per their demand with high quality and provide on time to time. It is a growing company. It is ready to get his Objective in upcoming years. I hope it will be a MNC in upcoming years.

3.1.2 Get the Chance to Gain The Knowledge: After watching the complete phenomenon of manufacturing of part we are able to getting the knowledge about the different mould operation such as drawing, Machining, Bedding Etc. The different part of the Mould works in a manner and these are automatically done so after watching these operations we are able to get the knowledge of different press operations.

3.2 DISCUSSIONS:

3.2.1 Defects Produced:During discussion we discuss about the problem facing during the manufacturing process of the different parts. Basically the main problem can be faced is of different defects produced during the manufacturing phenomenon. The different defects produced are:

(i) Wrinkle(ii) Crack(iii) Deformation

These are the main problems that are faced during the manufacturing process of part. These defects can be discussed during the training.

3.2.2 Problem Produce duringthe working of Mould:There are different problem that produce during the working condition of Mould and these defects can be studied or discussed during training. The different defects produced in the presses are:

(i) Cooling Problem

(ii) Pressure Problem

(iii) Stick the plastic part inside the mould.

(iv) Wrinkle problem in plastic part.

These are the problems that are produced during the working condition of the mould. So these defects can be discussed or solved out during training.

CHAPTER-4

CONCLUSION

In conclusion we are discussed to solve the problems produced during the working condition of the mould and manufacturing of the parts. To solve the defects produced on the surface of the plastic part during operations different processes can be used if the damage is small and it can easily be repaired then it can be machined and repaired it but if the defect is not be able to correct then the plastic part can be thrown into the scrap. If the problems are small and it can easily be repaired then different operations such as hammering, machining can be used. After applying these processes the defects can be removed from the surface of plastic part because without removing these defects it can’t be possible to use these parts. A defected piece can’t be used in the manufacturing of the car so it is necessary to remove theses defects. In conclusion we discussed the process used for the removal of the defects.

There are certain defects produced during the working of mould. The different defects produced during the mould operation are cooling problem, less pressure produced in the mould. It is necessary to solve these problems because without solving these problems the mouldcan’t work properly. If any operation of the mould stops working then mould stops working so it is necessary to solve these problems. Sometimes the pump of cooling stop working and the mould stops working. So this effect can be checked out and clear it so that the mould should work properly. Sometimes the nozzle cannot produce proper pressure for the stroke of the mouldso it is necessary to solve this problem that the mould should work properly.

So these are the basic conclusions that are made to solve the problems produced during the different operations.