REPORT ON
INDUSTRIAL TRAINING
AT
HMT MACHINE TOOLS LTD, KALAMASSERY
Submitted by
VEDANT PRUSTY
Reg. No.: 120929210
DEPT.OF MECHATRONICS ENGINEERING
MANIPAL INSTITUTE OF TECHNOLOGY (A constituent institution of Manipal University)
January 2015
Report on Industrial Training at HMT Machine Tools, Kalamassery January 2015
2 Vedant Prusty Dept. of Mechatronics Engineering, MIT Manipal
Report on Industrial Training at HMT Machine Tools, Kalamassery January 2015
3 Vedant Prusty Dept. of Mechatronics Engineering, MIT Manipal
CONTENTS
Chapter Page No.
________________________________________________________________________
i. Training Certificate…………………………………………………………02
ii. Contents……………………………………………………………………. 03
iii. Acknowledgement..…………………………………………………………04
1. Introduction…………………………………………………………………05
2. Objectives…………………………………………………………………...13
3. Plant Services Department………………………………………………….14
4. Foundry and Pattern Shop…………………………………………………..17
5. Planning Department………………………………………………………..22
6. NH Assembly……………………………………………………………….27
7. CNC Assembly……………………………………………………………...30
8. Quality Control……………………………………………………………...33
9. Heat Treatment………………………………………………...…………....37
10. High Technology Center………………………………………………...….41
11. Printing Machines Division…………………………………………………44
12. Heavy Parts………………………………………………………………….46
13. Conclusion ……………...…………………………………………………...49
iv. References………………….………………………………………………..51
Industrial Training Schedule………………………………………………...52
______________________________________________________
Report on Industrial Training at HMT Machine Tools, Kalamassery January 2015
4 Vedant Prusty Dept. of Mechatronics Engineering, MIT Manipal
ACKNOWLEDGEMENT
"...the beauty of the destination is half veiled and the fragrance of success half dull until
the traces of all those enlightening the path are left to fly with the wind, spreading word of
thankfulness..."
I am grateful to my guide, Mr. K. Ramachandran Nair, Deputy Chief Engineer (TS) for
leading the path and encouraging me to widen my horizons. Thank You Sir for letting me
dig deep into and exploring the concepts and practices of machine tool manufacturing, and
production planning.
My gratitude to Mr. Gopi Mohan of the Training Center at HMT MTK for helping me
identify, select and decide over the subject and scope of this training. Despite his busy
schedule, he took out time to patiently guide and nurture us, making sure we had the best
all-round exposure to the industrial practices.
Without the companionship of Mr. Sarthak Prakash and Ms. Sruthy J. Kunnel, HMT and
Kalamassery would not have happened!
Thanks to Sarthak, we made it!
Thanks to Sruthy, we tried to make the fullest of our time here!
I run out of words while expressing my heartfelt gratitude and salutations to the kind couple,
Mr. and Mrs. T.G. Job of Peruva, Kottayam District. Their foster parenthood, care and love
added to the joy of learning and experiencing through this month.
This project would not have seen the light of day without the constant support of my family
– my parents and my sister.
Special thanks to Mr. B. Sarkar at HVF, Dr. Chandrasekhar Bhat and everyone at the Dept.
of Mechatronics Engineering, MIT Manipal for their help and support in realizing this
training.
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1. INTRODUCTION
The machine tool industry constitutes the backbone of the industrial sector and is vital for
the growth of the Indian Economy. Even though the Indian machine tool industry is a small
segment of the engineering industry, it plays a very important role in the development and
technology upgradation of the engineering industry. The quality and cost of engineering
products depends on the quality of mother machine tools and their automation level. The
development of the machine tool industry is therefore of paramount importance for a
competitive and self-reliant industrial structure. This report discusses the 1 month Industrial
Training at HMT’s Machine Tool Division at Kalamassery, Kerala. The training was
completed in December-January 2015.
1.1 Company Profile
By end of the Second World War, the government of India confronted by a big problem of
disposing the colossal war waste. Ultimately, a committee was constituted to inquire into
the possibilities. The committee report of 1948 proposed the establishment of a government
owned machine tool industry. This was expected to fulfill two aspects. The first was being
utilization of the Rs.4000 million worth of metallic waste. The second was the
incorporation of a state owned infrastructure – manufacturing facility. The result was the
birth of THE HINDUSTAN MACHINE TOOLS LIMITED, which diversified in due
course of time to the present stature of the multi core, multi-location, and multi-unit, multi-
product industrial giant HMT Ltd.
The HMT Ltd was started as a single factory to produce Tool Room Lathe at Bangalore in
collaboration with M/s Oerlikon of Switzerland in 1953, with capacity to manufacture
around 400 machines per year. Since then different collaborations, continued in house
R&D and tremendous marketing efforts brought HMT, to present status.
The growth of HMT Ltd. was characterized by the forward and backward integration of
technology and product diversification. Thus the company that started with manufacturing
and selling lathes expanded its machine tools products range to evolve as the ultimate
solution in metal cutting. The product diversification efforts took the company to the
business of watches in 1962, tractor in 1971, die-casting on plastic machinery in 1971,
printing machinery in 1972, presses in 1972, lamps & lamp making machinery in 1976,
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food processing machinery in 1980, CNC systems in 1986, ball screws in 1986 and
reconditioning in 1990.
The multi product activities made HMT Ltd. change its identity as Hindustan Machine
Tools Limited. Today HMT Ltd has 16 manufacturing units with 22 products divisions
spread through the length and breadth of India. A subsidiary viz., HMT (international) Ltd
undertakes the exports of the company. They are also export agents for general other Indian
companies.
HMT Ltd was restructured in 1992 to facilitate better administration of the multi product
business activities. Accordingly, the following business groups were established:
Machine tools business group, to concentrate on metal cutting machines
Industrial machinery business group to deal with printing machines, die-casting and
plastic injection molding machines food processing machines and metal forming
machines
Agricultural business group to concentrate on tractor
Engineering components business group to deal with casting and ball screws
Consumer product business group, to deal with watches and lamps
In addition to these business groups, the
company owns three subsidiaries as follows:
HMT (international) Ltd. which
undertakes overseas project &
exports
PRAGA Tools Ltd. which
manufacturers machine tools
HMT bearing Ltd which
manufacture precision bearing in collaboration with M/S Kozo Japan
As per the revival plan of this public sector industry a turnaround plan has introduced in
early days of this millennium and re-organized as HMT Ltd holding company including
tractor division and presently comprises of the following subsidiaries:
Fig. No. 1: The NH 22 High Speed Precision Lathe
is still the primary product of HMT
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1. HMT Machine Tools Limited.
2. HMT Watches Limited
3. HMT Chinar Watches Limited
4. HMT Bearing Limited
5. HMT International Limited
6. PRAGA Tools Limited
1.1.1 HMT Machine Tools Limited
The HMT Machine Tools Limited is engaged in the manufacture and marketing of general
purpose machine tools, special purpose machine tools, computer numerically controlled
machine tools, precision machinery system, printing machines, metal forming passes, dies
casting and plastic injection molding machines, ferrous and non-ferrous casting.
The product range of HMT Machine Tools:-
BANGALORE:
Heavy duty lathes
Single and multi-spindle automates
Radial drilling machines
Multi spindle drills
Cylindrical & surface grinders
Laser cutting machines
CNC turn mill centers
CNC wire cut EDM
PINJORE:
FMS & FMC
Horizontal machining centers
Vertical machining centers
Milling machines
Broaching machines
KALAMASSERY:
CNC turning center
Turn mill center
Fig. No. 2: ECONO CNC 26 Flat Bed Lathe
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Flexible turning cell
Copying lathes
Center lathes
Offset printing machines
Paper cutting machines
HYDERABAD:
Special purpose machines
Horizontal machining center
FMS
CNC horizontal boring machines
Bed type & floor types boring machines
AJMER:
Grinding machines
SPM grinders
CNC grinders
Facilities available in different machine tool units:
CNC ram type Plano miller
Horizontal machining centers
Vertical machining centers
Vertical machining centers
Horizontal jog boring machines
CNC turning centers
Turn mill centers
Slide way grinders
Cylindrical grinders
Internal grinders
Precision gear shapers
Precision gear hobbers
Gear grinders
Induction hardening machines
3D co-ordinate measuring machines
Fig. No. 3: STALLION 100S series Slat Bed Lathes
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1.1.2. HMT Watches Limited
HMT Watch Limited manufactures and markets watches including hand wound / automatic
& quartz.
1.1.3. HMT Chinar Watches
HMT Chinar Watches limited is also one of the subsidiaries engaged in the manufacture
of chinar model watches located in Srinagar, Kashmir state.
1.1.4. HMT Bearing Limited
HMT Bearing Limited is one of the subsidiaries engaged in the manufacture of different
types of industrial bearing situated in Hyderabad.
1.1.5. HMT International Limited
HMT International is engaged in the export of HMT’s range of product worldwide HMT
(I) also market and backed up by a good sales & services network. It also under takes
Turkey project & technical services for developing countries.
1.1.6. Praga Tools Limited
Praga Tools Ltd is also a subsidiary of HMT Limited engaged in the manufacture of machine tools located in Hyderabad.
1.2 The Kalamassery complex of HMT Limited Kalamassery
The Kalamassery unit, the 4th machine tools unit was established in 1963 and started production in 1964. The unit originally manufactured only two types of center lathes viz.
H & LB, but later added special purpose lathes like copying and turret lathes. Model L. T-
20 was the first product to be indigenously developed by the unit (1968) and the
development of this product was a landmark in the history of the unit. The production of
this was later licensed to M/S Qetcos, Kerala, Matools, Philippines Ceylon Steel
Corporation Sri Lanka. The original center lathes H&LB were then replaced by a new
family of unified series of lathes, which was designed and developed by the unit,
incorporating the concepts of typification, standardization & unification.
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Diversification of Kalamassery Unit and Birth of Printing Machine Division
During the period 1972-73,
Kalamassery unit diversified its
product range to include printing
machinery division (PMK). The
commercial entry of PMK was with
two types of letter presses viz. RTE &
RTAF under collaboration with M/S Nebiolo of Italy. Autoplaten, an
indigenous development came up
subsequently. During the ensuing
years, the printing machinery division came up with offset press viz. OMIR in collaboration
with M/S Nebiolo later indigenous offset press viz. SOM 136 was introduced to the market.
The first two-color machine from HMT was OMIR in collaboration with M/S Korning &
Baver of Germany. The latest development of PMK is the paper-cutting guillotine PG
92D3, in collaboration with M/S Divano Blinders of Italy.
THE CURRENT PRODUCT RANGE
Product Model
Offset printing machines SOM436
SOM425 (four colour)
SOM236
SOM231
SOM225 (double colour)
SOM136
SOM131
SOM125g (single colour)
Paper cutting machine PG-92D3
The Kalamassery units of HMT are famous for development activities. Their product have
always fetched award and prized at different trade fair & competitions. To name a few are
the prizes bagged in different IMTEX fairs by FC-25, SBC & SBCNC machines. The CNC
lathe model STC has won the VASVIK Industrial research award 1987 instituted by the
Fig. No. 4: SB CNC30
Fig. No. 5: VMC 1200M
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Vindhalaxi Audyogik Samsadhan Vikas Kendra, (VASVIK) for outstanding advancement
of science and technology.
The machine tool products of this unit have been certified by RWTUV-(Reinisch West
Falischer Techniseruber Wachungs Verein) an international certification agency of high
repute as confirming to total quality management system. Both the division have been
awarded ISO 9001 certification by IROS. The manufacturing shop at MTK is supported
by various infrastructural facilities like high technology CNC machine centers, testing
facilities, foundry, heat treatment, computer system, CAD systems etc. Around 600 well
experienced personnel form the human resources of the unit keeping in line with the current
corporate trends.
Training Centre
The manufacturing shops at MTK are supported by various infrastructure facilities like,
high technology CNC machining center, testing facilities foundry, heat treatment,
computer system CAD system etc. around 800 well experienced personal form the human
resources of the unit keeping in line with the current corporate trends. This unit views HRD
as one of the primary concerns as a measure to increase productivity and enhance social
stranding. The company has a well-established training system by personnel of high
technical and management skills.
Fig. No. 6: PG 29 Guillotine
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1.3 The Marketing Network of HMT Ltd
The machine tools marketing divisions with its headquarters at Bangalore and having wide
network of regional and divisional offices spread throughout India caters to the marketing
needs of this unit at the primary level. To co-ordinate the marketing activities at unit level
and co offer technical support to machine tool marketing, a strong sales and services team
is constituted at unit level. HMT’s major customer includes defense, railways, automobile
and other engineering industries in various sectors.
Fig. No. 7: HMC 1000 series
1.4 Quality policy
HMT MLT is committed to total customer satisfaction by the supply of quality products
and services through:
Continuous improvement of technology of product and processes.
Innovation and creativity.
Effective implementation of quality management system.
Monitoring the effective realization of quality objectives and periodical review of
its suitability.
This report is structured according to various divisions of the factory at HMT MTK. The
functions, scope, and work done at each division is described briefly under these headings.
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2. OBJECTIVES
The Objectives of this training were as follows:
To study the planning, organization and setup of the Machine Tools Industry at
HMT Kalamassery.
To understand in detail the overall production mechanism and products of HMT
MTK.
To specifically study life cycle of products from casting, forging, machining,
assembly to final testing, inspection and shipping.
To spot possible areas of reduced efficiency in the production cycle and identify
their reasons.
To explore manufacturing and working of CNC, VMC and HMC, their electronics,
control and mechanics, along with use of G- Codes.
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3. PLANT SERVICES DEPARTMENT
Plant services department is responsible for maintaining the machines and equipment of
the unit in optimum condition of performance so as to make them available for production.
The plat services department is responsible for the erection and commissioning of the
machines in the plant. The department is also responsible for the electrical power
distribution of the entire factory complex. The department looks after the internal transport
functions and housekeeping activities inside the factory.
3.1 Scope
Erection, commissioning, repair, maintenance, reconditioning, retrofitting and
preventive maintenance of all the machines and equipment used for production in
the MTD and PMD plants and training center.
Maintenance of the cranes, jib cranes, air compressors and a/c units in the MTD and
PMD plants.
Upkeep of R&M stores and spare parts planning.
Housekeeping activities in the shop floors.
Materials movement in the shop floors and maintenance of internal transport
vehicles and equipment.
Maintenance of power supply to the entire factory complex.
Maintenance of 66 kV sub-station, switchgear, power transformers, and the entire
distribution system.
Maintenance of supply distribution in colony, pump house.
Maintenance of internal telephone exchange and the communication system.
To arrange and co-ordinate contract works in connection with any of the above
activities.
3.2 Objectives
To maintain the plant, machines and equipment in optimum conditions of performance
ensuring availability for production. The plant services department sets its measurable
quality objectives for every year. These objectives ensure that the machines and equipment
are well maintained to meet the requirements of the customers. The quality objectives are
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communicated to all the employees in the department by displaying them in the key areas
of the factory.
Chart No. 1: Process for Breakdown Maintenance
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Chart No. 2: Process for Preventive Maintenance
NO
Prepare preventive
maintenance schedule
Intimate schedule to
chief of manufacturing
Get monthly plan for
preventive maintenance
Ensure
availability
of machine
Perform P.M as per
check list
After completion of PM,
Hand over machine to
production
Update P.M Schedule
Review in the fortnightly maintenance meeting for
process improvement and effectiveness
Review and
Reschedule Plan
Record Deviations,
If any
YES
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4. FOUNDRY AND PATTERN SHOP
The foundry & pattern shop attached to the machine tool division, HMT, Kalamassery and
part of engineering components business group is geared to manufacture all cast iron &
spherical graphical iron required for machine tools and printing machinery division and can
also undertake job orders. Established in 1968 with polish design, it is a semi mechanized
foundry producing heavy duty gray & SG iron casting for machine tools and printing
machines using mains frequency induction furnaces for melting and resin bonded sand for
molding and core making.
4.1 Pattern Shop
A pattern is defined as anything used for forming an impression called mould in the sand.
Mould when filled with molten material on solidifying, forms a reproduction of the pattern
and is known as mould. It is slightly larger in size than casting. As the first stage in
preparing the casting, the pattern of the castings is prepared. Pattern of casting is prepared
at pattern shop with either of the materials given below:
Wood: - Wood is the most commonly used pattern material as it is cheap, easily
available and also easy to join and fabricate. But it has a large rate of moisture
absorption and also warping and wearing is high.
Metals: - Metals have the advantage that they do not warp, are very accurate and
have high strength. But shaping is slightly difficult and it is also subjected to rusting
and the costs are also high.
Plastics: - They are mostly thermosetting plastics. They are light in weight, have
very good surface, do not react with water or air and are not subjected to warping,
but cannot withstand high temperatures.
Plasters: - The most common example is gypsum cement. Repairs can’t be easily
done and it does not need skilled labor.
Wax: - Wax has very good surface finish, can be easily altered to any shape and is
very accurate. But it cannot withstand high temperatures.
Wood with metallic coating
Thermocol: single use patterns are made using thermocol
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In the process of casting, a pattern is a replica of the object to be cast, used to prepare the
cavity into which molten material will be poured during the casting process. The pattern
needs to incorporate suitable shrinkage allowances depending on material flow and heat
transfer considerations. Pattern making is a skilled technique that was highly valued in the
different cultures practicing casting through the centuries.
In sand casting, the pattern is usually of wood, whereas it may be metal or other materials
in pressure or centrifugal casting. The patternmaker also decides where the sprues and risers
(inlet and outlet for molten material) will be placed with respect to the pattern. Parts of the
object which have holes or depressions are handled by inserting cores defining volumes
that the material will not flow into. Sometimes patterns may also accommodate chills, solid
pieces of the final material, to enable rapid cooling, resulting in martensitic hardening in
the neighborhood of the chill.
4.2 Sand Mould Making Procedure
The procedure of making a typical sand moulding starts by placing a bottom board first
either on the moulding platform or on the floor, making the surface even. The drag
mounding flask is kept upside down on the bottom board along with the drag part of the
pattern at the center of the flask on the board. There should be enough clearance between
the pattern and the walls of the flask Rest of the drag flask is completely filled with the
backup sand and uniformly rammed to compact the sand. The ramming of sand should be
done properly so as not to compact it too hard, which makes the escape of gases difficult,
nor too loose so that mould would not have enough strength. After the ramming is over, the
excess sand in the flask is completely scraped using a flat bar to the level of the flask edge.
The finished drag flask is now rolled over to the bottom board exposing the pattern. Using
a stick, the edges of the sand around the pattern is repaired and cope half of the pattern is
placed over the drag pattern, aligning it with the help of dowel pins. The cope flask on top
of the drag is located aligning again with the help of the pins. The dry parting sand is
sprinkled all over the drag and on the pattern.
A sprue pin for making the sprue passage is located at a small distance of from the pattern.
Also a riser pin if required is kept at an appropriate place and freshly prepared moulding
sand similar to that of the drag along with the backing sand is sprinkled. The sand is
thoroughly rammed, excess sand scraped and vent holes are made all over in the cope as in
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the drag. The sprue pin and the riser pin are carefully withdrawn from the flask. Later the
pouring basin is cut near the top of the sprue. The cope is separated from the drag and any
loose sand one the cope and drag interface of the drag is blown off with the help of bellows.
Now the cope and the drag pattern halves are withdrawn by using the draw spikes and
rapping the pattern all around to slightly enlarge the mould cavity so that the mould wall
are not spoiled by the withdrawing pattern. The runner and the gates are cut in the mould
carefully without spoiling the mould. Any excess or loose sand found in the runners and
mould cavity is blown any using bellows. Now the facing sand in the form of a paste is
applied all over the mould cavity and the runners which would give the finishing casting a
good surface finish. A dry sand core is prepared using a core box. After suitable baking, it
is placed in the mould cavity. The cope is replaced on the drag taking care of the alignment
of the two by means of pins. The mould is now ready to pouring.
4.3 Moulding Procedure
The pig iron, MS scrap, Carbon, manganese and other constituent materials are melted in
the electric furnace. The molten metal is drawn into a ladder and transported using an
overhead crane. The molten metal is poured to the mould trough the cavity designed for the
same.
4.4 Forging
Forging is the operation where the metal is heated and then a force is applied to manipulate
the metal in such a way that the required final shape is obtained. This is the oldest of the
metal working processes known to mankind since the copper age. Forging is generally a
hot working operation through cold forging is used sometimes.
4.5 Fettling
The complete process of the cleaning of casting, called fettling, involves the removal of the
cores, gates and risers, cleaning of the casting surface and chipping of any of the
unnecessary projections on the surface. The dry sand cores can be removed simply by
knocking off with an iron bar, by means of a core vibrator, or by means of hydro blasting.
The method depends on the size, complexity and the core material used. The gates and
risers can be removed by hammering, chipping, hack sawing, abrasive cutoff or by flame
or cutting. Removal of gates and risers can be simplified by providing a reduced metal
sections at the casting joint, for brittle materials such as grey cast iron, the gates cab easily
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be broken by hitting with a hammer. For steel and other similar materials sawing with any
metal cutting saw like hack saw or band saw would be more convenient. For large size
gates and risers we use flame or arc cutting to remove them. Similarly, abrasive cut off may
also be used for removal of gates. Most of the abrasive cut off can be carried out by portable
grinding machines with an angled grinding head.
For cleaning the sand particles sticking to the casting surface, sand blasting is normally
used. The casting is kept in a closed box and a jet of compressed air with a blast of sand
grains or steel grits is directed against the casting surface, which thoroughly cleans the
casting surface. T The shots used are either chilled cast iron grit or steel grit. Chilled iron
is less expensive but is likely to be lost quickly by fragmentation. In the operation, the
operator should be properly protected.
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Chart No. 3: Foundry Process
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5. PLANNING DEPARTMENT
The Production planning department is the most vital link between product design and
production department. This department provide necessary facilities and technical
knowhow for the manufacture of the product. Production requires optimum utilization of
natural resources, men, money, material and machines. But before starting the work of
actual production, Production planning has to be done in order to anticipate possible
difficulties and decide in advance how the production should be carried out in the best and
economic way. The principle of Production planning lies in the statement “First plan your
work, and then work for your plan”.
5.1 Objectives
In any business organization, production activities must be related to market demands as
indicated by the continuous stream of the customer’s orders. For maximum effectiveness
this must be done in such a way that customer’s demand is satisfied. But at the same time,
production should be carried out in an economic manner. The process of developing this
kind of relationship between market demand and production capability is the function of
production planning and control.
5.2 Role of Planning Department
The role of Production planning department comprises of:
Production Pre Planning (PPP) and Planning Estimation (PPE)
Production Planning Ordering (PPO) & Finished Part Section (FPS)
5.3 Functions and Responsibilities
1. PRODUCTION PRE PLANNING
Processing design documents
Identification of house manufacturing item, outside manufacturing item and
brought out parts
Preparation of preparation layouts
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Identifying and intending actions for all special tooling
Implementation of design alterations
Manufacturing special tool data
Attending shop problems
Coordinating activities related to alteration requests
Preparation of documents related to assembly of products
All data entry in computer related to PPP
Verification and approval of materials warrant
Maintain all data and records related to the products
Arranging and ensuring all quality formats
2. PRODUCTION PLANNING ESTIMATION
Estimation of standard time for manufacturing and assembly operations
Preparation and implementation of alterations
Data entry of activities related to PPE function in the computer
Attending shop complaints regarding standard time
Authorization of special time in job cars
Arranging time study
3. PERFORMANCE MONITORING WING
Analyze the organization requirement
Design the structure report
Create appropriate database
Develop software for report
Prepare making list and dispatch of statements
4. COSTING SECTION
Arranging the data related standard labour, material and assembly cost
Assessment of rectification or rework expenses
Coordination of activities related to annual product costing
5. TIME RECORD
Monitoring and ensuring the regular flow of job card
Entering ticket numbers and actual hours on each job
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Calculating the total standard hours for a job
Obtaining signature on job cards and idle cards
Acting as a link between PPD and shop floor.
Table No. 1: Process Model of Production Planning
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Chart No. 4: Planning Process Flow Chart
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Chart No. 5: Planning Process Flow Chart contd.
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6. NH ASSEMBLY
The machine tool assembly department at Kalamassery assembles various components of
conventional lathe and CNC lathes. For convenience, the assembly department is
subdivided into NH assembly and CNC assembly. (NH Lathe stands for New Heavy Lathe).
NH assembly section assembles conventional lathe and CNC assembly section assembles
computer numerically controlled lathes. The most of the electrical components are ‘brought
out’ items and is assembled by electrical assembly section.
Procedure followed in NH Assembly
Scrapping - High points are removed for better contact. Blue paint is rubbed over
parts to find uneven surfaces. Scrapping is done for good quality contact in saddle,
keepers, cross slide, Legs, Apron- Split nut, Tail Stock Base, Compound Slide,
Accessories.
Saddle Assembly-This section includes the grooving for oil passage, installation of
distributor assembly and oil assembly and cross feed assembly.
Feed Base Assembly- Six shaft preassembles with gear core first taken here. This
is followed by friction cone assembly and shifter block assembly.
The machine is run for up to 3 hours to check for noise/friction defects. Assembly
of gears is oiled using a cam mechanism in running lathe.
Apron assembly -this include the pre assembly, the group assembly, the split nut
lead screw engagement, the reciprocating pump and lubrication. Also transmission
of feed drive to cross slide and the longitudinal movement on thread are
implemented there.
Hydraulics - lathe uses hydraulics to engage certain gears and also for braking and
gear shifting lapping and pump assembly, pipe bending, value body assembly,
distributor assembly and piping to machines.
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Trail stock assembly- this includes sleeve clamping, roller assembly, top and bottom
clamping, hand wheel assembly, tail stock group assembly. Needle bearing is used
in roller assembly. The ABPO-464 balancing machine is used to check uniform
weight.
Swivel is assembled next
Headstock assembly- this involves head stock pre assembly , spindle balancing and
pulley balancing, brake assembly, clutch assembly and hydraulic checking ,
lubrication distributor piping and assembly, dial assembly, head stock control
assemblies and headstock group assembly.
Headstock inspection+ noise level is checked. Main spindle run out and headstock
lubrication are also checked as per ISO quality standards. Machines may be returned
to replace component if needed.
Final assembly- this takes 65 hours for complete assembly. It can be divided into
front work and top work.
Front work on bed includes saddle assembly, feed box assembly, lead screw,
bearing assembly, support assembly and rack assembly.
Top work involves head stock assembly, tail stock assembly and centre-
reading of cross slide assembly and swivel assembly.
Quadrant box assembly- Gears with different gear ratios are fitted at quadrant for
feeds as per requirement, AI key is used to shear if high loads occur.
Motor mounting- Depending on requirement pulley A -type, B type for A2-6 and
L/S AL-8 is used.
Machines- For maintaining accuracy of product as per quality standard.
Surface grinder, taper grinding, turning lathe and milling machine.
- Variants include
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Bed length wise
Gap bed /Straight bed
Hardness
Centre height (NH-22, 26, 32)
Headstock
Motor speed
Protection assembly - this includes installing front covers, name plates, chip tray,
splash guard, wipers, side cover and hydraulic tank assembly.
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7. CNC ASSEMBLY
The increasing demands the need for high accuracy, scrap reduction etc. have pulled for
development in the field of machining and manufacture. All these have led to the invention
and improvement of CNC machines which can undoubtedly be termed as one of milestones
of century.
HMT is famous for its world class CNC turning centres. It was in late 80's that HMT
Kalamassery started the production of CNC turning centres. The earlier models of machines
used Sinumerik and Hinumerik control systems and MCU whereas new generation CNC
idea Fanuc/Siemens control systems.
Assembly can be divided into:-
Group assembly
Pre final assembly
Final assembly
Group assembly
Place where assembly of headstock, tailstock, turret indexing unit, power rack, turcite
fixing etc. Is done. After the assembly of each part they are set to an extensive test and it is
passed on to pre final assembly only after inspection department certifies it. Units includes
STC-15, STC-20, STC -25/SBCNC-30, SBCNC-40/60/80, SHELL TURN, STALL 10
AND ECOCNC.
Pre-final assembly
It is the section where the assemblies of various components of CNC lathes like headstock
take place to the lathe bed. It is here that the alignment of ball screw is done. The assemblies
of saddle, cross slide etc. to the bed also take place here. Once the various parts are put
together, lathe is taken to final assembly.
Final assembly
As the lathe is brought from the pre assembly, the various electrical components required
are installed.
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Bed- most of CNC turning centres are of slant bed type.
Headstock- CNC do not have shift gear incorporated. Main spindle is mounted on
angular contact bearings which could take both axial and radial loads.
Drives - It contain 3 servo motors- one for main spindle, one for saddle traverse
over the bed and the third one for cross slide/turret movement across the saddle.
Saddle- saddle is the portion which carries the turret and slides over the load. The
saddle is actually fixed to a ball nut.
Turret is that part which holds various tools and would position the required tool to
perform the cutting.
Sequence is as follows-
Unclamping- the turret make part unclamped from the curvic coupling. This
is actuated by piston cylinder arrangement enclosed with turret housing.
Rotation- It is actuated by means of a direction control valve- Solenoid
valve. This rotation is fed back to the controller by another encoder.
Creep - As the turret reaches desired angle, an opposite flow is given to
motor so as to reduce the speed.
Clamping- once the desired pain is attained the turret clamps back in to the
coupling and is ready for machining. For operations such as drilling, milling
a special C- axis motor is required and is fitted on consumer request.
Tailstock- Instead of a rotating, a rotation center is used to reduce heat generation.
Hydraulic systems- Many of the critical operations include full proof set ups are
hydraulic systems (owing to their flexibility and controllability)
Headstock- workpiece is clamped by means of piston cylinder arrangement.
Turret- turret clamping, indexing, creeping are controlled hydraulically.
Tailstock- it is controlled by Solenoid controlled valve. The plunger is
hydraulically controlled.
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Gear box- It is actuated by hydraulic systems. Levels are shifted when piston
inside a cylinder pushes them.
Lubrication- ensuring sufficient lubrication to maintain smooth running for the
machine as well as to reduce vibrations, heat generation and errors. Other systems
include
Chip conveyor
Cabinet cooling
Oil refrigeration
Power supply
Axis alignment- it is done by giving the tool pre-defined test feed and then
comparing with actual position.
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8. QUALITY CONTROL
Quality control in its simplest term refers to control of quality during the manufacture. Both
quality control and inspection are envisaged to assure the quality in entire area of
production process. Inspection is a function of determining the quality. When quality
becomes effective, the need for inspection decreases. Hence, the quality control determines
the cause of variation in the characteristics of products and gives solutions by which these
variations can be controlled. It is economical in its purpose, objective in its procedure,
dynamic in its operation and helpful in its treatment.
8.1 SCOPE
Objectives
The total quality management department sets its measurable quality objectives for every
year. These objectives ensure that requirements of the products are not only identified and
met with, but also constantly reviewed and improved.
The quality objectives are communicated to all the employees in the department by
displaying it in the key areas. The measurable objectives are set taking into consideration
of the following:
Reduce internal losses due to scrap rejection and rework.
Reduce external losses due to service cost.
Maximize the customer satisfaction
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Purpose
To ensure the conformance of the incoming items or raw materials being used for
the production with the specified standards.
To ensure that the casting produced in the foundry department meet the design
standards.
To ensure documentation of the quality of the components and assembled units by
inspecting or testing.
To ensure the testing of end products for its conformation with the specification.
This is carried out by inspecting the performance of the end machine in a systematic
manner as specified in the working instruction manual.
To ensure the documentation of all inspection report.
To ensure the procurement of modern testing instruments and periodic calibration
of the existing testing facilities.
To ensure the quality of the manufacturing process of the major components in the
unit.
To ensure the systematic analysis of the feed backs on performance and reliability
reports of the products from inspection.
To ensure the systematic analysis of customer complaints for continual
improvement of the product quality
To ensure total customer satisfaction.
8.2 Measurement of Total Quality Management Effectiveness
Inspection
The effectiveness of the inspection process is measured through four parameters taken from
internal and customer feedback.
An average expected value per annum will be fixed by evaluating previous year’s records
and strategic measures will be planned to bring down it to a lower value than the expected.
The measurement parameters are:-
No. of NCR in assembly due to the manufacturing components
No of NCR in assembly due to brought out parts
Warranty cost due to failure of BOP items during the month in Rupees
Warranty cost due to failure of manufacturing items during the month in Rupees
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Quality Control
The effectiveness of the quality control is measured with five parameters. The average
expected value per annum will be fixed by evaluating previous year’s record and strategic
measures will be planned to bring down it to a lower value than expected.
These parameters will be analyzed monthly in UQC meeting for necessary correction and
preventive measures are taken to ensure its effectiveness.
The measuring parameters are:-
Percentage loss of standard hours
Loss in rupees
Percentage loss in foundry product
Average warranty cost per machine
Average breakdown days per machine
8.3 Quality Policy
HMT MTL is committed to:
Maintain QUALITY LEADERSHIP in all products and services.
TOTAL CUSTOMER SATISFACTION through quality goods and services.
Commitment of management of CONTINUALLY IMPROVE the quality system.
To create a CULTURE among all employees towards TOTAL QUALITY
CONCEPT.
Total quality through PERFORMANCE LEADERSHIP.
Quality Objectives
The objectives of the quality management at HMT MTL at Kalamassery are:-
Total production for the year 2010-11 - 78 cores
Total sales for the year 2010-11 - 78 cores
Operational profit (PBDIT) - 250 lakhs
Internal losses (% of standard hours) - 0.6%
Total foundry rejection - 2.4%
Average warranty cost per month - Rs.900/-
8.4 ISO 9001 Accreditation
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The HMT Ltd is accredited with ISO 9001 certification in 2001. Quality assurance offers
more scope for reducing costs, rework. Extra handling, rejections etc. and enhancing
competitiveness and profitability than other management techniques there by considerably
reducing warranty claims and premium pricing. Effective quality management system in a
company will help the company to acquire and maintain desired quality and optimum costs
through planned and efficient utilization of the technological and material resources
available to the company.
Chart No. 6: Quality Department Structure
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9. HEAT TREATMENT
Heat Treatment is the controlled heating and cooling of metals to alter their physical and
mechanical properties without changing the product shape. Heat treatment is sometimes
done inadvertently due to manufacturing processes that either heat or cool the metal such
as welding or forming.
Heat Treatment is often associated with increasing the strength of material, but it can also
be used to alter certain manufacturability objectives such as improve machining, improve
formability, and restore ductility after a cold working operation. Thus it is a very enabling
manufacturing process that can not only help other manufacturing process, but can also
improve product performance by increasing strength or other desirable characteristics.
Fig. No. 8: Heat Treatment
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The various components used for the manufacture of parts for machine tools and printing
machines are shown in Table 2 below.
Table No. 2: Components used for Machine Manufacturing
Sl. No. Material Analysis by ERC weight
1. Cast Iron 70%
2. Steel 20%
3. Non-ferrous alloys 5%
4. Non-metallics (Plastic, rubber, etc.) 5%
____________________________________________________________________
Cast Iron is comparatively low in cost and has the following properties:
Castablility
Machinability
Wear Resistance
Damping Characteristics
Dimensional Stability
Pressure tightness
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Table No. 3: Process of Heat Treatment
BATH/FURNACE APPROX CONTENTS
1. Carburising Bath Sodium Cyanide 8 – 10%
Sodium Chloride, Barium Chloride
Temp 910 degrees C+-20
2. Hardening Bath NaCl, Barium Chloride,
Working Temp 850 degrees C +- 20
3. Annealing Bath Same as hardening bath
Working Temp 650 degrees C +-20
4. Quenching Bath Sodium Nitrite, Sodium Nitrate
Working Temp 180 degrees C +-20
Electroplating Section
BATH/FURNACE APPROX CONTENTS
1. Chromium Plating Bath Chromium acid 200gm/liter,
300gm/liter H2SO4,
Temp 45-50 degrees C
2. Blackening Bath NaOH, Sodium Nitrite,
Sodium Nitrate,
Temp 145 degrees C +- 10
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Prepare Job for Hardening
Pre-heat at 450 degree C +-20
Heat treat at 650 degree C +-20 for 30 mins
Heat at 780/820/850 degree C for 30 mins
Quench in Quenching bath at 180 degree C +-20
Cool at room temp by quenching in water
Is hardness as per requirement? NO
Temper at 180 +-20 degree C in quenching bath
Cool to room temp by quenching in water
YES
Wash and dispatch job
Chart No. 7: Hardening Process
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10. HIGH TECHNOLOGY CENTER
A machine tool is a power driven machine which can be used for the manufacture of
components of other machines. HMT Kalamassery unit is a machine tool factory. In the
High Technology Center there are 5 CNC machines.
VMC
HMC
HM4
VTC
VTC2
All these machines are working with the help of CNC control. Controlling a machine tool
by means of a prepared programme which consists of blocks or series of numbers is known
as Numeric control. It contain machine control unit and machine tool itself.
VMC 400
It can do drilling and milling operation. It can hold 12 tools in the magazine. The work
table movement in X and Y axis are 400 mm and z axis is 420 mm. System 802- Auto tool
change- pneumatic control.
HMC (Horizontal milling machine)
Spindle works horizontally. It table length of X axis 630mm, Y axis 560mm and Z axis
500mm. It can hold 60 tool. It has 4 axis X, Y, Z and B.
HM4 - its table capacity is x axis 1600 y axis 1200 and B axis 360 degrees. It can hold 60
tools in the magazine.
VTC 1 AND 2
Vertical Machining Centre with automatic tool changer. Its capacity is X axis 1150mm, Y
axis is 640mm and z axis is 500 mm. It can hold 30 tools.
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10.1 Applications of CNCs
It includes both for machine tools as well as non-machine tools. CNC is widely used for
lathe, drill press, milling machine grinding unit, laser, sheet metal press, tube bending
machine.
Elements of a CNC
Part program
Machine control unit
Machine tool
Part program is a detailed set of commands
to be followed by the machine tool. Each
command specifies a position in the Cartesian coordinate system. Programmers should be
well versed with machine tools machining process.
Machine Control Unit (MCU) is a microcomputer that store the program and executes the
command into actions by the machine tool.
It consists of two main units the date processing unit (DPU) and control loop unit (CLU).
DPU software includes control system software, calculations algorithm, translation
software that converts path program into usable further, interpolation algorithm to achieve
smooth motion of cutter, editing of part program. CLU consists of the circuits for position
and velocity control loops, deceleration and backlash take up, function controls such as
spindle on/off.
Point to Point systems
That move the tools or the workpiece from one point to another and then the tool programs
the required task.
Continuous path systems
It provides continuous path such that the tool can perform while the tools are moving,
enabling the system to generate angular surfaces, two dimensions or three dimensional
contours. Velocity error is significant in affecting the position of the cutter.
Fig. No. 9: HINUMERIC 2100M CNC Control System
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Interpolator
The input speed of 1in/sec in example 2 is converted into the velocity components by an
interpolator called the linear interpolator whose function is to provide the velocity signals
to X and Y directions.
Incremental and absolute systems
In incremental, sister distance is measured from one point to the next. An absolute system
is one which all the morning commands are referred from a reference point.
Open loop control
There is no feedback and uses motors for driving the lead screw. A motor is a device whose
output shaft rotates through a fixed angle in response to an input pulse.
Closed loop control
There is a force resisting the movement of the tool/work piece. Milling and turning are
typical examples. Servo motors and feedback devices are used to ensure that the desired
position is achieved.
Manual part programming
It first prepares the program manuscript in a standard format .Manuscripts are typed with a
device known as flexo writer. The punch type of prepared on the flexo writer.
Computer aided programming
Complex shaped component require calculation to produce the component done by
programming software contained in the computer. Program communicates through system
language which is based on words. Programming languages are:
APT, ADAPT, AUTOSPOT, COMPAT – 2, CLROMANCE, SPLIT.
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11. PRINTING MACHINES DIVISION
The printing machine department of HMT Kalamassery is a leading manufacturer of offset
printing machines in India. PMK department is functioning very similar to that of MTK
manufacturing. The major components are cast with the help of foundry department. The
cast components are manufactured into printing machine components at PMK
manufacturing department.
11.1 Sections in PMK manufacturing
The PMK manufacturing is broadly divided into three sections, namely, small parts, heavy
parts and high technology center.
Small parts
The small parts are again sub-divided into rounds non rounds and CGR (cams, gears and
rollers). The round or symmetrical objects are machined rounds. The irregular parts are
machined in non-rounds cams, Gears and rollers require more accuracy, hence they are
machined in separate special purpose machines (SPM) in CGR.
Heavy Parts
As the name suggests, the
heavy parts deals with
machining of heavy parts
like:
1. Weld metal base – The
base is made by welding
together the beams in the
welding shop.
2. Side frame – Side frames are mechanized, drilled bored.
3. Cylinder Drums are machined, and grinded
Fig. No. 10: SOM 536
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High Technology Center
In this section works which require high accuracy are done in certain special machines.
11.2 Machines Available at PMK Manufacturing
1) NH/CNC Lathes
2) Grinding Machines
3) Milling Machines
4) Drilling Machines
5) Rack cutting machine
6) Cam milling machine
7) Gear hobbing machines
8) Planning machines
9) Boring machine
10) Straight bevel conflux
generator
11) Engraving machines
Each unit is of single colour. A four color machine will have 4 units, one for each color,
ink first comes on to plate roller then transferred to blanket roller and then to impression
roller on which paper is being fed. Thus, the image is formed on the paper. After sheet is
passed through all the units, required image is formed.
Fig. No. 11: SOM 436
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12. HEAVY PARTS
This section is in charge of manufacturing heavy parts like:
Headstock
Tailstock
Bed/Guideways
Marking
It is the first process in which dimensions are marked on the surface of the casted product,
so that machining can be done on it.
Many machining operations are carried out in heavy parts.
Planing Machine
It is used to machine the guideways.
Profile Milling Machine
Cutting tools are made in such a way that it is having the profile which is milled on the jobs
surface. This machine has 8 cutting tips they are carbide and replaceable.
CNC Plano Milling
This is a computer numerically controlled milling machine. It has 6 point Tools. Tool
Movement and changing are controlled by the computer. It has 3 axes, that is x, y, z axes
and a right angle unit that allow tool Movement in the perpendicular direction.
Groove Cutting
Groove is made using an ‘L’ shaped cutting tool which pushes. At first, a circular slot is
made using normal cutting tool. Then ‘L’ shaped tool is inserted and by push action, it is
made to go forward.
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Grinding
Sideway grinding, surface
grinding, and internal grinding
etc. are used in Heavy Parts. The
grinding wheel is made of
aluminum oxide and diamond is
used to shape them.
Grinding is mainly done on
guideways and bed using surface
grinding wheels.
An Autocollimator is used to
check the convexity of the guideway.
Line Boring Machine
In very long holes, ordinary boring is not done and it causes bending and taper. In such
cases, a single point tool supported at many parts is inserted through workpiece.
Induction Hardening Machine
Many parts require hardness only at selected region; so hardening operation are done only
in those parts by principle of induction.
Other Functions
At heavy parts coolants are rarely used as cast Iron is self-lubricating due to presence of
carbon in it. In many machines, bore center, parallelism, etc. are obtained by use of dials.
This is called “dialing”
All objects in this section are carried by cranes.
Fig. No. 12: PSG 200 Surface Grinding Machine
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Chart No. 8: Objective Measurement Chart
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13. CONCLUSION
HMT Machine Tools Kalamassery is one of the last few profit generating facilities in
HMT’s core and original field – heavy machine tool manufacturing. Recently, HMT
Machine Tools at Kalamassery has made a foray into defence manufacturing by producing
directing gears, a ship-borne positioning mechanism, for sonars fitted on warships for
tracking enemy submarines.
HMT Machine Tools completed the project around September 2014 in collaboration with
the Naval Physical and Oceanographic Laboratory (NPOL), a DRDO lab that designs and
develops sonars and underwater surveillance and communication systems for the Indian
Navy, and Bharat Electronics Ltd (BEL), which manufactures the whole system. It has
already received orders for several of these modules. The contract for this was valued at
about Rs.16 crore. HMT MTK has not only re-entered the market, but has revitalized the
heavy machine manufacturing industry in India this decade. While it may not be in its
erstwhile glory days of thousands of employees, the facility is slowly but surely rising
quickly.
Fig. No. 13: The Main Manufacturing Facility at HMT Kalamassery
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Perhaps one point that is a big boost to this company is the tremendous respect it has for
quality of service. From microscale precision right in the convexity of lathe beds, rigorous
testing of all equipment, and secured delivery and training services, HMT MTK is now
generating clientele in the public as well as private sectors.
My experience has been one of thrill as well as intense learning. The on-site exposure to
the traditional methods of manufacturing using lathes, cutting, drilling, milling and slotting
machines, using collimators for measurement, as well as hands on experience with modern
Computer Integrated Manufacturing using VMC and HMC lathes, multi-point cutting tools,
multi tool turret systems, etc. The exposure to areas like Production and Operations
management, Job Shop Scheduling, Aggregate Planning, etc. were a key aspect of the
training period.
At the end of it, I have had quite a bit to take back from this place, and recognize the
contribution it made in my understanding of the industry in engineering.
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REFERENCES
All content in this report are based solely on company reports and documentation at HMT.
All procedures mentioned are HMT customized versions of standards available in open
source. Any images of machines are taken from the website of Hindustan Machine Tools
http://www.hmtmachinetools.com/.
The company profile and product range is readily available for further perusal at
http://www.hmtmachinetools.com/kalamassery-complex.htm.
Fig. No. 14: HMT Kalamassery
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