SUMMER TRAINING REPORT AT Elin Electronics Ltd. Gzb

SUMMER TRAINING REPORT

14 th June to 5 th July

DEPERTMENT OF MECHANICAL AND AUTOMATION ENGG.MAHARAJA AGRASEN INSTITUTE OF TECHNOLOGY

PSP AREA,SEC-22, ROHINI NEW DELHI -110085

SUBMITTED BY-RAVI KUMAR002148074115M6

TABLE OF CONTENTS

Pages1. Acknowledgement………………………………...…………12. Preface ……………………………………………….……….23. About the Company……………………………….………..3-133.1.The Mission Statement3.2 Vision3.3 Company Introduction3.4 Product Range3.5 Working Condition3.6 Safty Concern 3.7 A Graphical Overview3.8 Awards & Recognitions3.9 Customers

4. I.Q.C……………………………………..……...………...14-164.1 Introduction4.2 Verification of Purchased Product4.3 Sampling Plan

5. MOULDING SHOP………………………………….......17-285.1 Introduction5.2 Types of Plastic5.3 Details of Moulding Machines5.4 Measuring Instruments Details5.5 Process Setting Parameters5.6 Customer Complaint5.7 Preventive Maintaince Of Moulds5.8 Photo Gallery of Moulding Shop

6. PRESS SHOP……………………………..……………...29-396.1 Introduction6.2 Theory of Cutting6.3 Various Cutting Operations6.4 Theory of Bending and Forming6.5 Material Used6.6 Process Flow Chart6.7 Photo Gallery

7. TOOL ROOM………………………….………………...43-517.1 Introduction7.2 Process Flow Chart7.3 Machine Detail7.4 EDM and Wire Cut EDM7.5 Material Colour Code7.6 Measuring Instruments

ACKNOWLEDGEMENT

With profound respect and gratitude, I take the opportunity to convey my thanks to

complete the training here.

I do extend my heartfelt thanks to Mr. R.S Yadav(Sr.Mgr. HR & IR) for

providing me this opportunity to be a part of this esteemed organization.

I am extremely grateful to all the technical staff of Elin Electronics Ltd. Ghaziabad

(U.P.) for their co-operation and guidance that helped me a lot during the course of

training. I have learnt a lot working under them and I will always be indebted of

them for this value addition in me.

I would also wish to convey my warm regards to Mr. Pawan Kumar for

providing me with the entire knowledge database that I needed for this report. I

would also like to thank Brig. S.K. Kakar (Retd.) Dean & Head - HR &

Corporate Relations, Maharaja Agrasen Institute of Technology, Sector - 22,

Rohini, Delhi for providing me this wonderful opportunity to work with the Elin

Electronics Ltd.

PREFACE

This six weeks training is a part of our 4-year degree course. Practical industrial

training mainly aims at making one aware of industrial environment, which means

that, gets to know the limitation, constraint and freedom under which an engineer

works. One also gets opportunity to see from close quarters that indicate

management relation. This training mainly involves industrial and complete

knowledge about designing, assembling and manufacturing of equipments.

Excellence is an attitude that the whole of the human race is born with. It is the

environment that makes sure that whether the result of this attitude is visible or

otherwise. A well planned, properly executed and evaluated industrial training

helps a lot in inculcating a professional attitude. It provides a linkage between the

student and industry to develop an awareness of industrial approach to problem

solving, based on a broad understanding of process and mode of operation of

organization.

During this period, the students get the real experience for working in the actual

environment. Most of the theoretical knowledge that has been gained during the

course of their studies is put to test here. Apart from this, the students get an

opportunity to learn the latest technology, which immensely helps them in building

their career.

I had the opportunity to have a real experience on many ventures, which increased

my sphere of knowledge to a great extent. I got a chance to learn many new

technologies and was also interfaced to many new instruments and all the credit

goes to Elin Electronics Ltd. Ghaziabad.

ABOUT THE COMPANY

The Mission Statement

WE COMMIT OURSELVES TO DELIGHT OUR CUSTOMERS

AND MAINTAIN MARKET LEADERSHIP, THROUGH CONTINUAL

IMPROVEMENT OF OUR QUALITY MANAGEMENT SYSTEMS BY :

• INTRODUCTION OF NEW PRODUCTS

• UPGRADATION OF QUALITY LEVELS

• UPGRADATION OF HUMAN RESOURCES

• COST EFFECTIVENESS OF OUR PRODUCTS AND ACTIVITIES

Vision:-

To meet and exceed customer’s expectation by offering high quality

products & services at competitive prices, in time all the time.

To be recognized as the largest & most efficient manufacturer in our

product line in the Nation.

To be a responsible corporate entity which recognizes and insures that its

activities are sustainable and have a positive impact on its employees and

society.

COMPANY INTRODUCTION

Year of Establishment - 1969

Managing Director - Sh M.L Sethia

Chief Executive (Works) - Sh Kishor Sethia

Executive (Works) - Sh Sanjeev Sethia

Sh Vikas Sethia

Dy Chief Executive - Sh.S.K.Tandon

General Manager - Sh N.C.Agarwal

PRODUCT RANGE

Tape Deck Mechanism :-For Stereo Players, High-Speed Recorders, Car Stereos, Portable Personal Stereos etc.

D.C. Micro Motors :For Tape Deck Mechanisms - Single-Speed, Double-Speed, CD /VCD /DVD loading, Portable Personal Stereos etc.

Synchronous Motors & Stepper Motors :For Air-conditioner louvers, Micro-wave tables, Rotary display tables etc.

Universal Motors & Eco Motors :For food processors, Mixer & Grinder.

Free Power Generators : For Transistors for Philips

Audio Systems :Complete Audio System as Tape Recorder, Two in One, Walkman and Radio for Philips at Elin, Goa

Home Appliances :Electric light weight Irons, Toasters, Mixer/Juicer/Grinders for Philips at Elin, Baddi.

Electrical Light Fittings : Electrical Luminaires for Philips.

CD Mechanism :For Audio/Video Systems

Terminal Blocks : For Refrigeration

Speakers :For TVs, Audio Systems

Fan Blower Motor :Fan Blower Motor :

For Frost Free RefrigeratorsFor Frost Free Refrigerators

Submersible Pump:Submersible Pump:

For Air CoolersFor Air Coolers

ISO IMPLEMENTATIONISO IMPLEMENTATION :-:-

• ISO 9001 : 2000 - For Quality since 1996

• ISO 14001:2004 - For Environment since 2002

• ISO TS 16949.2002 - For specific requirement of

Automobile Industries since 2005

CERTIFIED BY - DNV (DET NORKSE VERITAS)

WORKING CONDITION

• Canteen Lunch Timings - 11:30 to 2:00 PM. Coupens for lunch

Provided in Canteen.

• Shift Timings - General/ A,B,C.

• Punctuality - 100%. 3 times late coming (10 min. ) are

allowed in a month after 3 late coming

half day will be marked

• Attendance marking - Punching card has to be punched in

Recording machines which are maintained at main gate and second gate

for all the times for maintaining incoming and out going time of

persons.

• Gate Pass System ( Employees)- Official / Personal

• Security System - Workmen are Searched by Security and

staff as and when required.

• Bus Arrangement - Only for Female Employees for which

approx. Rs. 350.00 will be deducted.

• Compensatory Payment - Jr. Staff upto Senior Engineers and

officers are entitled to compensatory payment if they are continuously

staying on duty for more than 6 hrs. After 8 hrs. of working. They will be

entitled for one day’s salary payment. Requisition for compensation to be

submitted to HRD department after sanctioned from HOD and approval of

Management.

• Performance Appraisal - Annually in April, for new person

quarterly.

• Salary / Wages Payments - Before 7 th of every month. Workers

are paid by cash and Staff through Bank.

• Tea Facilities - (Staff) - Tea is provided free 2

times in a day. (Workmen) - Workmen have to pay subsidized cost for

tea.

• Traveling Expenses - Paid by the accounts deptt by

recommendation of HOD and approval of GM / Dy. C.E., as per rules

available at Accounts deptt.

• Out door duty - Authorization slip has to be submitted

in Personnel deptt. before or after finishing of assignment.

• Leaves Facility - 7 Causal Leave (CL), 7 Medical Leave

(ML,only for the persons out of ESI coverage ) Earned Leave - EL (1 day

after 20 days working) EL can be accumulated upto maximum 45 days.

• Leave Available system - Leave application is to be

submitted to Personnel deptt after Getting approval of HOD.

• Grievances Handling - In case of Grievance , following

procedure has to be followed :-

1. HOD 2. Personnel 3. G.M / Dy. C.E.

4. C.E

• Loans and Advance Payment - Loan may be granted once

in two years to permanent employees . Max. 2 months salary which

should be deducted within that year. Eligible person can put forward

loan application to Personnel department after recommendation of HOD

for approval from the management. Advance can be availed once in

3 months between 20th and 22nd of every month.

• Manpower Requirement - Through Authorization slip

required by HOD, and approved by the GM. The slip has to be

submitted to Personnel Deptt for arrangement of manpower.

• Selection of Manpower - Selection committee will

take the interview of the candidate and if found suitable the

application will be forwarded for approval to the Management for final

interview and selection.

SAFETY IS OUR CONCERN

It is advised to use Personal Protective Equipment’s (PPE) for safe working in the factoryFollowing PPE is being used in the departments.1. Aprons - Use for Painting work2. Shoes - Compulsory in Chemical working area3. Goggles - For machining jobs, welding jobs.

4. Dress - For girls, jacket and cap.5. Helmet - Use while working on height or working on

crane / lifter.6. Safety Ropes/ Safety belt - Use during construction work , paints of

Shad.7. Mask - Where fumes and gasses are used.

8. Rubber hand globes - Use where chemical is being used.9. Thick Cotton hand globes - Use where cut injury chances are there i.e. While unloading of CRCA sheet

SCHEME IMPLEMENTED IN COMPANY

Suggestion Scheme :-We value suggestion given by our employees and expect that every employee will give atleast 2 suggestion in a year. To encourage new ideas for improvement a suggestion scheme is running in the organization .The forms for giving suggestions are available in Personnel as well as with the department’s head.After filling the forms it has to be put in the suggestion box outside the Personnel deptt. Persons whose suggestion are selected Rs. 300/- cash as award given and if the suggestion is fully implemented and has resulted in cost saving an amount equivalent to 10% of saving or Rs. 5000 whichever is lower is given to the employees on 1st of January (Annual day)

A Graphical overview

Group Turnover

TURNOVER OF LUMINAIRE BUSINESS

2009 2010 2011

Turnover 32.79 39.11 68.12

5

15

25

35

45

55

65

75

Turnover(Crores)

Valu

e (C

r.)

GSRS RATING

Avg 2

010-

11

Avg 2

011-

12

0102030405060708090

63.751

78.22

GSRS Rating for Elin

YEAR

Awards & Recognitions

69.5 77.0 72.0 79.0 77.0 81.5 79.0 86.575.5 84.0 79.5

0.0020.0040.0060.0080.00

100.00

Sc

ori

ng

Months

SRS Rating of Philips For ELF

SRS Rating

1982 ELCINA award for Excellence In Exports1991-92 1991-92 Philips (C.E.) the Best Co-maker award.

Elin R & D Recognised by Deptt. of Science & Technology, Govt. of India.1993 Two Star Industries award from Directorate of Industries1994 Import Substitution award from All India Radio and Electronic Association1994 Excellence in Electronics award from Govt. of India.1996 ISO 9001 certification by DNV (Netherlands)

ELCINA award for Indigenous Development of Capital Goods1997-98 ESC award for Excellence in Export.

ELCINA award for Export Growth.1997-98 ELCINA award for Excellence in Quality.

National award for Excellence in Electronic Components from Deptt. of Electronics (Govt. of India)

1999-00 ELCINA award for Indigenisation of Capital Goods for Manufacture of Electronic Products.ELCINA award for Research & Development Work in the field of electronic components.

2001-02 2001-02 ELCINA award of Excellence for Environment ManagementELCINA award for Quality

2002-03 Quality Excellence Award from Institute of Trade & Industrial Development2003-04 Certificate of Green Partner from Sony – Japan (ROHS Compliance)2006 -07 Best Delivery Performance Award from Denso2007-08 MSME – National Award -2008 Ministry of Micro, Small & Medium Enterprises, Govt. of India for

outstanding efforts in Entrepreneurship2008-09 FICCI-SEDF Corporate Social Responsibility Award 2009.

“Jury Commendation Award” Category: Small & Medium Enterprises (SMEs)2008-09 Award for Best Performance in Outstanding support from Denso2009-10 Award For Best Performance in Cost from Denso2009-10 HR Excellence Award for The Year 2009-102009-10 Gold Award for Innovation In RETENTION STRATEGY.

CUSTOMERS

INCOMING QUALITY CONTROL(I.Q.C) DEPTT.

It is the job of the IQC to conduct inspections and handle quality problem before the manufacturing process starts.

Specific tasks of IQC include:

To perform approved list check To evaluate supplier quality records To perform sampling of incoming material based on the IS-2500 Part-1

1991 ISO2589-1:1989 Verifying accuracy through calibration Assess dimension, visual & functional inspection of significant

deviations. Continually Enhance the IQC process Evaluation of online rejection Co-ordination with suppliers for quality problem To short quality related problem in shop floor. Evaluation of new parts & report generation. To recover salvageable class component from broken / damaged To carry out aging test of components. To conduct supplier’s end audit for factory evaluation and to made 4M

agreement.

VERIFICATION OF PURCHASED PRODUCT

SAMPLING PLAN

LOT SIZE CODE LATTER

SAMPLE SIZE

ACCEPTED REJECTED

2-8 A 2 0 19-15 B 3 0 116-25 C 5 0 126-50 D 8 0 151-90 E 13 0 191-150 F 20 0 1151-280 G 32 0 1281-500 H 50 0 1501-1200 J 80 0 11201-3200 K 125 1 23201-10000 L 200 2 310001-35000 M 315 3 4

35001-150000

N 500 5 6

150001-500000

P 800 7 8

500000OVER Q 1250 10 11MOULDING SHOP

Mould: - is the common term used to describe the production tooling used to produce plastic parts in injection Moulding machines.

Mould Design: - Mould is separated into two halves :- 1) Core 2) Cavity

Main Parts of Moulds:-

S.No. Parts S.No. Parts S.No. Parts

1 Mould Base 6 Riser (Spacer) 11 Limit Bolts2 Location Ring 7 Slider 12 Spring3 Sprue Bush, 8 Feeding Bush 13 Cooling Channerls4 Core & Cavity insert 9 Core Pin 14 Nylon Bush5 Ejector pins 10 Guide pin 15 Guide Bush

Type of Injection Moulds:-

S.No. Types

1Two plate moulds (Standard moulds)

2Three plate moulds (stripper plate moulds)

3 Split cavity moulds

4 Hot runner moulds

Type of Mould Maintenance:-

a) Preventive Maintenance :- Each time the mould is removed from the injection moulding m/c preventive maintenance is done.

b) Rectification Maintenance :- When any part of mould has broken, damage, bend and wear out then damage parts are repaired or replaced by new .

PLASTIC

• Plastics are Macromolecular structured Polymer. • Polymer is made up of many repeating simple chemical units, known as Monomer.• All Plastics are Polymers- But All Polymers are not Plastics, they may be Fibers , Elastomers (Rubbers) or adhesives.In simple words plastic is one of the family members of polymers.

TYPE OF PLASTIC

1. THERMOPLASTICS: -Thermoplastics are materials that can be repeatedly heated, melted and converted into a product.

2. THERMOSETS :-Thermosets undergo a chemical reaction during conversion into a product.The product cannot be re-melted and converted into another product again.

CLASSIFICATION OF THERMOPLASTICS :- 1. Commodity Plastics – The Plastics which are used in Non critical

applications.

2. Engineering Plastics – The Plastics which are used in Engineering applications.

ADVANTAGES OF USING PLASTIC

Light in weight

•Higher strength to weight ratio

•Wider design freedom

•Easy Processability

•Low Energy Required for Manufacturing

•Minimum post finishing required

•Corrosion Resistant.

•Low creep

•Better aesthetics

DETAILS ON PLASTIC

TYPE OF PLASTICS

TYPE OF THERMOPLASTICS

MECHANICAL PROPERTIES PROPERTIES APPLICATIONS

Very Low Density (0.890-0.905 g/cm3) Shrinkage :- 1.5 %

Melting range - (1600C-1650C) Processing temp :- 250-270C

Good surface hardness and scratch resistance Mould temp. :- 50-75 C Good dimensional stability Dry temp. :- 40-90 C

Dry time :- 2-3 Hrs Transparent, ( light transmission up to 89% ) Shrinkage :- 0.60 % •High-gloss ; good mould surface reproduction Processing temp :- 170-280C •High Rigidity Mould temp. :- 10-80C

•Good chemical resistance Dry temp. :- 60-80C

•Heat deflection temperature >90 °C Dry time :- 2-4 Hrs

•High dimensional accuracy and stability

•Good Electrical insulation

•Transparent, ( light transmission up to 89 % ) Shrinkage :- 0.50 %

•High-gloss ; good mould surface reproduction Processing temp :- 180-270C

•High Rigidity Mould temp. :- 50-80C

•Good chemical resistance Dry temp. :- 70-85C

•Heat deflection temperature >90 °C Dry time :- 2-4 Hrs

•High dimensional accuracy and stability Dehydrification

•Good Electrical insulation

• Highly Transparent Shrinkage :- 0.1-0.4% • Hard,Rigid,Strong ,Stiff Processing temp :- 210-240C • Good Impect strength Mould temp. :- 50-70C • Good Chemical Resistancc Dry temp. :- 70-80C

Dry time :- 3-5 Hrs Dehydrification

•Poly Propylene (PP)

Clamp Seal,Top Housing,

Protector Wiper

TRD KNOBS•Poly Styrene (GPPS, HIPS)

JAR•Styrene

Acrylonitrile (SAN)

•Poly Methyl Methacrylate

(PMMA)LENSE

CO

MM

OD

ITY

PL

AS

TIC

S

TYPE OF PLASTICS



Good rigidity and hardness Shrinkage :- 1.20%-1.5%

•Good dynamic fatigue resistance Processing temp :- 240-290C

•High impact strength, even at low temperatures

Mould temp. :- 70-120C

•Toughness improved by water absorption

Dry temp. :- 75-80C

•High heat resistance Dry time :- 4-6 Hrs Dehydrifica

•Excellent electrical properties •Virtually no stress cracking (stress relaxation•Glossy surface finish Shrinkage :- 0.50% •Low dust attraction / • Rigid Processing temp :- 210-270C •Good shock and fracture resistance Mould temp. :- 50-90C •Good Chemical resistance Dry temp. :- 80-90C •Heat resistance up to 105 °C Dry time :- 2-3 Hrs •High Dimensional accuracy and stability•Good Electrical insulation•Good flowability / •Readily electroHigh tensile, impact, and stiffness Shrinkage :- 2.0%

•Outstanding fatigue endurance Processing temp :- 200-210C

•Excellent resistance chemicals Mould temp. :- 40-100C

•Excellent dimensional stability Dry temp. :- 90-100C •Good electrical insulating characteristics

Dry time :- 2-3 Hrs

•Good resilience and resistance to creep•Good abrasion resistance

ELF TOP and BOTTOM,Deck parts, Eveready

parts,Submersable

comp.Mindarika parts

Many type Gear of Deck

machanism, U.V Moror Fan Knob

Wiper

Poly Amide (Nylon 6, 66,12)

EN

GIN

EE

RIN

G P

LA

ST

ICS

CDS,EN-97,EN-77,EN-303,EN-57,EN-36, TRD,

DC Motor,Sync.Motor,Mindarika parts

•Poly Oxy Methylenes

(POM)Poly Acetal

•Acrylonitrile Butadiene

Styrene (ABS)

TYPE OF PLASTICS



• Excellent transparency Shrinkage :-

•High strength and toughness up to 140oC Processing temp :- 280-320C

•Very High Impact and break resistant Mould temp. :- 80-100C

•Very good heat resistance Dry temp. :- 110-120C

•High Weathering Resistance Dry time :- 2-3 Hrs

•Good processing characteristics

PBT :- High strength & rigidity Shrinkage :- 1.75%

•High impact resistance Processing temp :- 240-260C

•High heat resistance Mould temp. :- 60-80C

•Excellent dimensional stability Dry temp. :- 120-140C

•Excellent flame resistance Dry time :- 3-4 Hrs

•Good electrical insulation

•Good abrasion resistance

•High gloss, good moulded surf

•Resistant to fuels, lubricants

PP Dana Processing temp :- 220-280 c

PP Dynapurge

MASTER BATCH

Master batch used for colour change 2 -4 %

Knob wiper,Sync.Motor,Sub.pump,TRD Knob,DC Motor

PIGMENT Pigment used for colour change 0.10% Wings,45914,Jar

•Thermoplastic Polyesters (PET,PBT)

EN

GIN

EE

RIN

G P

LAS

TIC

SP

urgi

ng

Mat

eria

l

6352 (DC MOTOR) 37511,6877,6858, (SYNC .MOTOR)

•Poly Carbonate (PC)

Terminal parts of LG

Details of Moulding Machines

S.NO.

NAME OF M/CNO. OF M/C

CLAMPING FORCE

MIN. MOULD HT.(MM)

OPENING STOCK

MAX. DAYLIGHT

SPACE BETWEEN TIE BAR H*V

SHOT WT.(PS)

1 TOSIBA IS 130 1 130 TON 265 560MM 750MM 460*460 MM 83GMS

2 TOSIBA IS 80 1 80 TON 220 400 MM 620MM 390*390 MM 72 GMS

3 TOSIBA IS 170 1 168 TON 295 720 MM 950 MM 560*510 MM 150 GMS

4 DEMAGE 50 2 50 TON 210 370MM 610 MM 355*355 MM 55 GMS

5 DEMAGE 150 1 150 TON 240 500 MM 950 MM 490*490 MM 280 GMS

6SUPPER MASTER 90 (TOGGLE)

2 90 TON 125 270 MM 620 MM 360*360 MM 156 GMS

7SUPPER MASTER 90 (HYDRAULIC)

2 90 TON 200 500 MM 670 MM 360*360 MM 132 GMS

8 SUPPER MASTER 50 2 50 TON 100 220 MM 540 MM 310*310 MM 55 GMS

9 SUPPER MASTER 220 1 220 TON 250 760 MM 1000 MM 510*510 MM 424 GMS

10 JSW 15 1 15 TON 145 200 MM 350 MM 225*225 MM 14 GMS

11 JSW 70 1 70 TON 278 195 MM 295 MM 320*320 MM 72 GMS

12 MULTIPLAST 1 50 TON 200 195 MM 295 MM 320*320 MM 55 GMS

13 SUMITOMO 1 7 TON 145 150 MM 210 MM 140*140 MM 6 GMS

14 CN 50 1 50 TON 200 410 MM 580 MM 320*320 MM 55 GMS

15 CN 75 1 75 TON 250 450 MM 610 MM 340*340 MM 60 GMS

16 FEROMATIC 350 1 350 TON 300 675 MM 1475 MM 722*722 MM 200 GMS

ALL MACHINE ARE PROGRAMABLE LOGIC CONTROL MACHINE

Measuring Instruments Details

1 Dial/DIGI. CALIPER 0.01 mm 0-150 mm Length,Width,Thickness 6 Month

2 Micrometer 0.001mm 0-25mm O.D.Thickness 6 Month

3 DIGI. HT. GAUGE 0.001 mm 0-50 mm Depth,Height 6 Month

4 Height Gauge 0.01mm 0-10 mm Depth,Height 6 Month

5 Pappy Dial 0.01 mm 0-0.80 mm FRO 6 Month

6 Profile Projector 0.001 mm - FRO,RRO,Radius,Angle 6 Month

7 Std.Pin Gauge 0.01mm 1.50-7.00 mm I.D 6 Month

8 Std Slip Gauge 0.01 Slot 6 Month

CharactersticSl.Calibration Frequency

Least Count

Instruments Range

Flow Diagram of Production

Loading of Tools & take the Set up samples

Not O.K.Corrective Action

Monthly Production Plan from PPC

Receipt of Raw material from Store

Capacity Assessment

Receipt of Work Order from PPC

ShortMake the alternate Arrangement

Check the availability & condition of tools Corrective Action

Not O.K.

Preparation of Daily M/c Loading Plan

Provide drgs., specs., process inspn. Sheets, Work Instructions etc.

Set up sample Inspection

O.K.

OK

Not O.K.

Scrap

Component Deposit in Stores/Excise

Process Inspection

Yes

No

Rework

Send to Scrap Yard

Component Production

Deposit to StoreParts Scrap

Final Inspection

If reusable

Unloading of Tools & send to Tool

O.K.

Process Setting Parameters

LESS MORE

1 Ejector Comp.not eject proper Ejector mark &mould not closed

2 Temperature Filling problem&screw broken problem Material burn

3 Material Shrinkage&short moulding Flash

4 Injection pressure Short moulding& weld line Flash

5 Injection speed Weld line Burn mark

6 Injection time Comp. Not fill properly Catching problem

7 Holding pressure Dim. Varying &Warpage Flash &catching problem

8 Holding time Warpage & ejector mark Catching problem

9 Cooling time Warpage Production loss

10 Back pressure Silver mark Nozzle choke

11 Screw rotation No effect Flash

EFECTSProcess ParameterS.NO.

Customer Complaint

S.NO DATE CUSTOMERPART NAME

PHOTO PROBLEM CAUSE ACTION

1 12/2/2007 MINDARIKAKNOB WIPER

Flash observed on Locking Rib Area

Angular ejector worn out .Hardness of angular ejector was less Hardness 32-33 HR)

New angular ejector has made (Hardness 45-46 HR) and new design is under development for flash free lock area and new OGS made for checking criticality of Lock

2 21/02/07 DENSODENSO PLATE

Arm Short Moulding

Due to power failure

After power failure operator will kept 5 shots separately and one more stage added for100% visual inspection in PFD and this point add to Quality check sheet


Blow hole observed inside Knob Wiper

Design problem, component not fill properly inside neck area

Component run on best parameter condition and material increased in component and weight 28 gm fixed

4 15/03/07 MINDARIKABODY 21028, 21029

Short Moulding Start up rejection mix100% Inspection to be done at packing stage before despatch and start up pcs will be kept in red bin

CUSTOMER COMPLAINTS RECORD FOR OEMS PART FROM JAN ~ SEPT. 2007

5 15/05/07 MINDARIKASTATOR VOLUME

Component Dia found oversize

Process not stableProcess parameter established as per dim. Requirement

S.NO DATE CUSTOMERPART NAME

PHOTO PROBLEM CAUSE ACTION

11 24/10/07 MINDARIKAKNOB

UPPER RH

Insert change to opposite direction

Moving slider interchanged during mould cleaning as both sliders are symmetrical &same size . There is no identification on sliders

Mark will be embossed on slider & housing as 1,1 &2,2.so every time during assembly marking to be matched .Check point added in OGS

CUSTOMER COMPLAINTS RECORD FOR OEMS PART FROM JAN ~ SEPT. 2007


Cover fitment NG with Knob Wiper

Dim. 5.73 +/-0.05 observed 6.10 over size

Tool rectified

7 11/6/2007 MINDARIKABODY 21007

Short filled pcs Due to power failureMake new OGS for operator, After power failure operator will checked 5 shots and verify by process inspector

8 20/07/07 MINDARIKABODY 21007

Flash observed Flash observed due to not proper matching at slot area

Cutting gauge made to cut feeding point precisely and Mould matching at slot area corrected for flash

9 23/08/07 LIFE LONGCLAMP SEAL

Lag bend problem

Handling/ packing problem Packing standard changed

10 12/9/2007 MINDARIKAKNOB

UPPER RH

Parting line height observed more

Mould problem Mould rectified

PROCESS FLOW CHART FOR PREVENTIVE MAINTENANCE OF MOULDS

Receipt of Tool with History Card after Production

Condition of Tool & Quantity

Produced

Only Cleaning and Lubrication required

Complete Preventive Maintenance Required

Cleaning, Lubrication and Preservation

( Shrink Film Wrapping)

Handing over to Tooling

Storage and Updating Tool Storage register

Updating Tool History Card

Performing Preventive Maintenance as per checklist and other Problem noticed

Updating Tool History Card

History Card to Comp. file

Sent to M/s Maint. Dept.

OK NG

PHOTO GALLERY OF MOULDING SHOP:-

CNC MOULDING MACHINE

MOULDING SHOP

PART MANUFACTURED IN MOULDING SHOP

PRESS SHOP

Elin Electronics is a world class manufacturer and exporter of sheet metal

components, precision engineering components, and Deep Drawn Components in

India with our clients spread all across India and overseas. The unit is equipped

with all necessary production machinery and various equipments for quality

control. Presses available also include high speed presses up to 600 spm.

Secondary operations like projections welding, liquid painting and powder coating

are also available in house that adds value to our supply portfolio. More than 60

stamping machines from 10 tons to 300 tons give us flexibility to serve vast range

of customers having varied requirements. Our specialization in offering

customized solutions as per clients’ specifications also helps us to add value to our

customers’ product portfolio.

THEORY OF CUTTING

When cutting sheet metal in a die the forces applied to the sheet by the punch and

die are basically shear forces, that is, equal and opposite forces spaced at a small

distance apart on the metal and produce the cutting.

The cutting or separation of the sheet metal is effected through the following stages

of shearing

• Roll over

• Penetration

• Fracture

http://www.elinindia.com/press_shop.html

http://www.elinindia.com/press_shop.html

From both punch side and Die side simultaneously the spacing or the small

distance of the two shearing planes is called clearance. It will be generally about 8

- 10% of metal thickness for MS Sheets.

THEORY OF BENDING AND SPRING BACK

• BENDING Bending is the process of folding a sheet about a straight line axis which lies in the neutral plane. Bends are made in sheet metal to gain rigidity, to produce a part of desired shape & perform a particular function etc. The cross section of the bend inward from neutral axis is in compression, outward from neutral axis is in tension as shown in the fig.

• SPRING BACK During bending the metal nearer to the neutral axis is stressed to the values below the elastic limit. This phenomenon creates a narrow elastic band on both sides of the neutral axis. The metal further away from the neutral axis is stressed beyond the yield strength and is plastically deformed and permanently set. When the bending force on the metal is released the elastic band tries to return to the original flat condition but cannot return fully due to the restrictions of the plastically deformed zones. Some slight return does occur as the elastic and plastic zones come to equilibrium and this return is known as spring back.• The amount of spring back mainly depends on the ratio of bending radius to stock thickness.• Spring back can be reduced by over bending, Bottoming or stretch bending.

THEORY OF FORMING

• Forming is the process in which the shape of the punch and die is directly

reproduced in the metal with little or no metal flow.

• Forming, Bending or drawing actions may be combined in a die and is classified

as Form die or Draw die depending on the dominant action of

Process

• The decision to use a form die instead of a Draw die will depend largely on

the complexity of the shape & geometrical criteria.

• The use of draw die may be indicated, if the form die would cause the metal to

tear because of excessive tensile strain (stretch) or form objectionable wrinkles

because of excess crowding

of metal etc defects.

VARIOUS TYPES OF FORMING OPERATIONS

THEORY OF DRAWING

• Drawing is a process in which the punch causes a flat , precut metal blank in to

the die cavity to

assume the shape of seamless hollow vessel without excessive wrinkling, thinning,

or fracturing.

• METAL FLOW IN DRAWING PROCESS

when the punch of draw die forces a portion of metal blank through the bore of

draw ring, different forces such as radial tension, circumferential compression and

bending & frictional forces come in to action as shown in the fig.These forces

cause a complicated plastic flow of the material in the blank.

The volume and the thickness of the component remain constant and the final

shape of the cup will be similar to contour of the punch. The progressive stages of

cupping are schematically shown in fig. After a small stroke of the punch,

Cupping stage A, the metal elements 2, 3, 4, & 5 of the blank move radially toward

the center of the blank. The flow of these elements goes on till the final stage C of

the cup is reached. Thus by the end of the draw of the cup area 1 is unchanged in

shape and size in the bottom of the cup. The areas 2, 3 & 4 change from the shape

of angular segments to longer parallel-sided shapes and area 5 also changed in it’s

size and shape. Due to this metal flow phenomenon in drawing operation, Blank

holding pressure is to be applied on the blank in such a way that the metal flow

will be a controlled one so as to avoid wrinkling, tearing, thinning etc.

MATRIAL USED

Material Thickness Used for Problem

CRCA- Cold Rolled Comtrolled Annealed

0.5-2 mm

UV Motor

E.L.F(Electro

Light Fitting)

Thickness

variation

EGCC-Electrical Gr. Carbon

content

0.4-2 mm Deck Port

Auto Part

Width

Variation

Rust Problem

GPSP-Galvanized plated Skin

Pass

1.5-3 mm Auto Part Deep Scratches

Aluminum 0.4-1 mm Steam Cover Dent

Phosphorous Bronze

0.2 mm Leaf Switch Blackish Shed

http://www.ahmedabadstrips.com/Cold_Rolled_Closed_Annealed.html

http://www.ahmedabadstrips.com/Cold_Rolled_Closed_Annealed.html

Product Gallery

Varios Part Mfg. in Press Shop

Part Manufactured By Progressive Press

Varios Part Mfg. in Press Shop

Hydraulic Press

Press Shop Overview

TOOL ROOM

With more than three decades of experience in tool design and tool manufacturing.

Elin is known to its customers as manufacturer of critical tools. Tool room

infrastructure includes CNC machining center (3 no), 3 CNC wire cut, 2 CNC

EDM, high precision surface grinder and host of conventional machines. Standard

room is equipped with CMM, Smartscope from Mitutoyo along with other

standard equipment for making accurate inspection reports. Elin tool room has

capacity to deliver more than 200 critical tools in a year and also has tie-up with

oversees tool maker which doubles its capacity.

PROCESS FLOW CHART

MACHINE DETAIL

1.CNC EDM DIE SINKING:- 2.CNC Milling M/c:-

Accuracy-0.005 mm Accuracy-0.005 mm

Axis Trevel-350*250*250 Bed size-600*350*400

Max.Weight-200kg R.P.M-8000

Max. Electrode Weigth-50kg Axis Trevel-500*350*450

Max. Weight of Job-400kg

3.CNC WIRE EDM:- 4.EDM CNC

ELECTRONICA


Bed size-400*250*400 Axis Trevel-300*200*250

Axis Trevel-375*240*350 Max. Weight of Job-300kg

Max.Weight-500kg Max. Electrode Weigth-30kg

5.CNC WIRE CUT 6.CNC EDM DIE SINKING

7.CYLINDERICAL GRINDER 8. SURFACE GRINDER


9. CNC MILLING WITH AUTOMATIC TOOL CHANGER

EDM & WIRE CUT EDM

What is EDM?EDM is a machining method primarily used for hard metals or those that would be

impossible to machine with traditional techniques. One critical

Limitation, however, is that EDM only works with materials that are electrically

conductive. EDM or Electrical Discharge Machining is especially

well-suited for cutting intricate contours or delicate cavities that would be difficult

to produce with a grinder, an end mill or other cutting tools.

Metals that can be machined with EDM include hast alloy, hardened tool-steel,

titanium, carbide, Inconel and kovar.

EDM is sometimes called "spark machining" because it removes metal by

producing a rapid series of repetitive electrical discharges. These

electrical discharges are passed between an electrode and the piece of metal being

machined. The small amount of material that is removed from

the workpiece is flushed away with a continuously flowing fluid. The repetitive

discharges create a set of successively deeper craters in the work

piece until the final shape is produced.

Wire Cut EDMIn wire EDM a very thin wire serves as the electrode. Special brass wires are

typically used; the wire is slowly fed through the material and the

electrical discharges actually cut the workpiece. Wire EDM is usually performed in

a bath of water.

If someone was to observe the wire EDM process under a microscope, he would

discover that the wire itself does not actually touch the metal to

be cut; the electrical discharges actually remove small amounts of material and

allow the wire to be moved through the workpiece. The path of the

wire is typically controlled by a computer, which allows extremely complex shapes

to be produced.

Diagram:

MAJOR COMPONENTS

A Wire EDM system is comprised of four major components.

(1) Computerized Numerical Control (CNC)

Think of this as “The Brains.”

(2) Power Supply

Provides energy to the spark.

Think of this as “The Muscle.”

(3) Mechanical Section

Worktable, work stand, taper unit, and wire drive mechanism.

(This is the actual machine tool.)

Think of this as “The Body.”

(4) Dielectric System

The water reservoir where filtration, condition of the water

(resistivity/conductivity)

and temperature of the water is provided and maintained.

Think of this as “The Nourishment.”

PRINCIPLE OF WIRE ELECTRICAL DISCHARGE MACHINING

The Spark Theory on a wire EDM is basically the same as that of the vertical EDM

process. In wire EDM, the conductive materials are machined with a series of

electrical discharges (sparks) that are produced between an accurately positioned

moving wire (the electrode) and the workpiece. High frequency pulses of

alternating or direct current is discharged from the wire to the workpiece with a

very small spark gap through an insulated dielectric fluid (water).

Many sparks can be observed at one time. This is because actual discharges can

occur more than one hundred thousand times per second, with discharge sparks

lasting in the range of 1/1,000,000 of a second or less. The volume of metal

removed during this short period of spark discharge depends on the desired cutting

speed and the surface finish required.

The heat of each electrical spark, estimated at around 15,000° to 21,000°

Fahrenheit, erodes away a tiny bit of material that is vaporized and melted from the

workpiece. (Some of the wire material is also eroded away) These particles (chips)

are flushed away from the cut with a stream of de-ionized water through the top

and bottom flushing nozzles. The water also prevents heat build-up in the

workpiece. Without this cooling, thermal expansion of the part would affect size

and

positional accuracy. Keep in mind that it is the ON and OFF time of the spark that

is repeated over and over that removes material, not just the flow of electric

current.

Application:

Prototype production

The EDM process is most widely used by the mold-making tool and die industries,

but is becoming a common method of making prototype and

production parts,[25] especially in the aerospace, automobile and electronics

industries in which production quantities are relatively low. In Sinker

EDM, a graphite, copper tungsten or pure copper electrode is machined into the

desired (negative) shape and fed into the workpiece on the end of

a vertical ram.

Coinage die making

For the creation of dies for producing jewelry and badges by the coinage

(stamping) process, the positive master may be made from sterling silver,

since (with appropriate machine settings) the master is significantly eroded and is

used only once. The resultant negative die is then hardened and

used in a drop hammer to produce stamped flats from cutout sheet blanks of

bronze, silver, or low proof gold alloy. For badges these flats may be

further shaped to a curved surface by another die. This type of EDM is usually

performed submerged in an oil-based dielectric. The finished object

may be further refined by hard (glass) or soft (paint) enameling and/or

electroplated with pure gold or nickel. Softer materials such as silver may be

hand engraved as a refinement.

Small hole drilling

On wire-cut EDM machines, small hole drilling EDM is used to make a through

hole in a workpiece in through which to thread the wire for the wirecut

EDM operation. A separate EDM head specifically for small hole drilling is

mounted on a wire-cut machine and allows large hardened

plates to have finished parts eroded from them as needed and without pre-drilling.

Metal disintegration machining

Several manufacturers produce EDM machines for the specific purpose of

removing broken tools (drill bits or taps) from work pieces. In this

application, the process is termed "metal disintegration machining".

Advantages:

1) Complex shapes that would otherwise be difficult to produce with conventional

cutting tools

2) Extremely hard material to very close tolerances

3) Very small work pieces where conventional cutting tools may damage the part

from excess cutting tool pressure.

4) There is no direct contact between tool and work piece. Therefore delicate

sections and weak materials can be machined without any distortion.

5) A good surface finish can be obtained.

6) Very fine holes can be easily drilled.

Disadvantages:

1) The slow rate of material removal.

2) The additional time and cost used for creating electrodes for ram/sinker EDM.

3) Reproducing sharp corners on the workpiece is difficult due to electrode wear.

4) Specific power consumption is very high.

5) Power consumption is high.

6) "Overcut" is formed.

7) Excessive tool wear occurs during machining.

8) Electrically non-conductive materials can be machined only with specific set-up

of the process.

MATERIAL COLOUR CODE

SR.NO MATERIAL COLOUR CODE

1. HIGH CARBON HIGH CHROMIUM

STEEL(HCHCK)

YELLOW

2. OIL HARDNING NON SHRINKAGE

STEEL(OHNS)

DARK GREEN

3. KE-355 EN-24 MOULD STEEL VOILET

4. SILVER STEEL NATURAL

5. EN-8,EN-19 HIGH TENSILE STEEL WHITE

6. HIGH CARBON SPRING STEEL RED

7. HIGH SPEED STEEL YALLOW/DARK

GREEN

8. HOT DIE STEEL RED/YALLOW

9. MILD STEEL BLACK

MEASURING INSTRUMENTS

SR.NO INSTRUMENT NAME QUANTITY MANUFACTURER LEAST

COUNT

1. CMM(Beyond-A504) 1 Mitutuyo 0.001

2. CMM(600/9205) 1 Metrology 0.001

3. PROFILE PROJECTOR

(10*120*100)

1 Mitutuyo 0.05

4. CONCENTRICITY

GAUGE

1 Universal Punch 0.05

5. HIGHT GAUGE(0-

310mm)

1 Accurate 0.001

6. MICROMETER(0-25mm) 1 Mitutuyo 0.001

7. MICRIMETER

POINTED(0-25mm)

1 Mitutuyo 0.01



10. MICROMETER(75-

100mm)

1 Mitutuyo 0.01

11. MICROMETER

FLANGE(0-25mm)

1 Mitutuyo 0.01

12. DIAL CALLIPER(0-

150mm)

1 Mitutuyo 0.01

13. DIAL CALLIPER(0-

200mm)

1 Mitutuyo 0.01

14. VERNIER CALLIPER(0-

350mm)

1 Mitutuyo 0.02

15. DIAL GAUGE(0-10mm) 1 Mitutuyo 0.01

16. DIAL GAUGE(0-1mm) 1 Mitutuyo 0.01

17. DIAL CALLIPER(0- 1 Mitutuyo 0.01

150mm)

18. DIGI MICRO(0-30mm) 1 Mitutuyo 0.01

19. DIAL THICKNESS

GAUGE

1 Nikon 0.01

20. HIGHT GAUGE(0-

300mm)

1 Mitutuyo 0.01

21. SLIP GAUGE(0.5-100mm) 1 Mitutuyo 0.01

22. FILLER GAUGE(0-10mm) 1 Micronix 0.01

23.PIN GAUGE(0-10mm)

1 Mitutuyo 0.01

24. PIN GAUGE(7.05-12mm) 1 Mitutuyo 0.01




28. PIN GAUGE(1.00-

1.49mm)

1 Mitutuyo 0.01

29. PIN GAUGE(0.5-0.99mm) 1 Mitutuyo 0.01



CO-ORDINATE MEASURING MACHINE(CMM)

CNC MILLING MACHINE

MANUFACTURING OF EDM ELECTRODE

Documents

SUMMER TRAINING REPORT AT Elin Electronics Ltd. Gzb