FOR THE FULFILLMENT OF B-TECH COURSE

IN

HEMA ENGINEERING INDUSTRIES LTD.1/3 KM,KHANDSA ROAD,GURGAON,

HARYANA.122001.

SUBMITTED TO:- SUBMITTED BY:- Er. AJAY SINGH RANA ANUJ MALIK HOD: MECHANICAL ENGG. 7th SEM.,B-TECH. LUDHIANA COLLEGE OF MECHANICAL ENGG. ENGG. AND TECH. REG.NO.- 309119339

UNITS OF HEMA GROUP

1.Hema Engg industry ltd. a.)Unit-I Gurgaon b.)Unit-II Hosur c.)Unit-III Manesar

2.Kay-Jay Auto Ltd.,Dharuhera.3.Tobu India Ltd.4.Flash Hema Energy Devices Ltd.

Among all of these units Hema Engineering Industries Ltd.,1/3 km, Khandsa Road Gurgaon, is the major company of HEMA Group of industries. It is the major ancillary unit of HERO HONDA MOTORS LTD.Due to hard work, dedication and the able guidance of Mr .K.K. Jajoo (Chairman, Hema Group) it has grown up as a major ancillary unit for Hero Honda Motor Ltd. The unit is dedicated to its quality policy. It is TS 16949-2002 and ISO14001 certified company.

COMPONENTS MANUFACTURING IN HEIL

1.CHSSIS PARTS FOR HEROHONDA MOTORS LTD.2.REAR FORK (TWO WHEELER) FOR HHML.,TVS MOTOR COMPANY LTD.,MAJESTIC AUTO LTD.3. FRONT & REAR PANEL (TWO WHELLER) PARTS FOR HHML.4. MUFFLER PARTS FOR HHML.5. SEAT PARTS FOR HHML.6. FRONT/RR WHEEL PARTS FOR HHML/ HERO MOTORS LTD./ YAMAHA MOTORS LTD.7. SHOCKER PARTS FOR MUNJAL SHOWA LTD., GABRIEL INDIA LTD., YAMAHA MOTORS LTD., HYDRAULICS LTD.8. STRUT PARTS (FOUR WHEELER) FOR MARUTI LTD. (ACT AS A SUB VENDER.9. RR WHEEL (TWO WHEELER) SUPPORTING PARTS FOR HHML. TVS MOTORS LTD., MAJESTIC AUTO LTD.10. POWDER COATING J/W FOR HONDA SIEL LTD.

CUSTOMERS OF HEIL

1. HERO HONDA MOTORS LTD.,DHARUHERA2. HERO HONDA MOTORS LTD.,GURGAON3. TVS MOTORS LTD.,HOSUR4. TVS MOTORS LTD.,MYSORE5. MAJESTIC AUTO LTD.,GAZIABAD6. GABRIEL INDIA LTD.,HOSUR7. GABRIEL INDIA LTD.,GURGAON8. HYDRAULICS LTD9. INDIA METER LTD.,HOSUR10. GUJRAT CYCLES LTD.,VARODARA11. RENOWED AUTO PRODUCTS.12. STALLION SHOX LTD.,NOIDA13. AUTO FIT LTD.,DHARUHERA14. EUROTHERM,GERMANY15. ESCORTS LTD.,FARIDABAD16. MUNJAL SHOWA LTD.,GURGAON17. AUTOMAX LTD.,GURGAON18. DELPHI AUTOMOTIVES NOIDA19. SANDHAR INDUSTRIES,GURGAON20. HONDA SIEL MOTORS LTD.,NOIDA21. MINDA INDUSTRIES LTD.,MANESAR

THE DEPARTMENTS IN HEIL

1. PERSONNAL & ADMINISTRATION2. DOCUMENTATION CENTRE3. COSTING4. PURCHASE5. QUALITY ASSURANCE6. DESIGN/TOOL ROOM7. MIG WELDING SHOP

8. STURT SHOP9. PRESS SHOP 10 STANDARD ROOM11 SPOKE,NIPPLE AND PLATING SHOP12 EFFLUENT PLANT13 PAINT AND POWDER COATING14 CHEMICAL TESTING LABORATORY15 MAINTENANCE SHOP16 Q.A (ASSEMBLY AND FINAL)

PERSONNEL AND ADMINISTRATION

The Personnel and Administration Department of HEIL deal with various aspects of manpower employed in the plant.

The work of this department starts with the recruitment of the manpower for the plant whether it is skilled,. Semi skilled or unskilled.After the recruitment of the manpower they take care of proper training of every person according to the need so that each and every person can be an asset to HEIL and can help in increasing the productivity and profit of the company. For this purpose various type of training is arranged by the personnel department . For this purpose the department has to keep a close eye on every employee that where a person is lagging behind and needs training in the specified field so that one can give better results.

Along with the recruitment this department keeps the full detailed record of each employee of HEIL so that in case of any need it can be used..The various norms regarding the environmental safety are to be taken care by this department only. Various problems of the employees like regarding working conditions , pay scale and health are dealt by this department only.As this department has to deal with the manpower so the work of this department is a typical one and for it the concerning staff has to work hard.

MIG WELD SHOP

It is the first production shop of the unit. As its name states that MIG (Metal inert gas welding) welding shop, MIG welding is used to manufactured the components. A gas is used to prevent the oxidation of weld. CO2 is used as shielded gas over the work when welding is done. The components produced in this shop are swing arm for the various models of Hero Honda Motor Ltd., TVS Motor Company Ltd.

Machine Used Special Purpose M/CConsumable Electrode Steel Wire With Copper coating Shielded Gas Used Carbon Dioxide

Main Models Produced By HEIL :-Model Customer Name Customer Model NameP-11 HHML CD-100P-17 HHML SPLENDERP-21 HHML PASSIONP-40 HHML CBZP-60 HHML AMBITIONP-70 HHML KARIZMACDN HHML DAWNP-90 HHML SPLENDER SUPERKTNA HHML ACHIVERKTRA HHML GLAMOUR

PROCESSES THAT ARE PERFORMED ON SWING ARM

1.Collar WeldingPipe + Collar

Pipe Supplier Vankatsawra EngineeringCollar suppleir Emkay Engg.,Ggn.,Magna auto ltd.,Sheel Auto Ltd,Ggn.Main dimensions. (LH , P-60) :- (All dimension in mm.)Total length of pipe 454.5 -1 Dia of pipe 31.8 Bending height 19.5 Length of elliptical section 35Main dimensions of collar:- (All dimensions are in mm.) Total length of collar 46External dia. 31Internal dia. 25.2

2.End Piece Welding:- The end piece is welded on the other end of pipe. The end of pipe is already in the shape to sit in end piece easily.

End piece supplier Vankateshwar Auto Co.Ltd.Main dimension :- ( All dimensions are in mm.)Total length of endpiece 192Length of centre slot 48.5Width of centre slot 19.5Width of pipe seat 31.6Dia. Of hole for bolt 10.2Dis. from hole centre to pipe seat 4Width of elliptical sectoin of seat 36Dis.from slotto seat end 13

3.Plate A Tacking:- At this step first plate is tacked on the the pipe . The plate A is tacked for fitting of chain case.

Plate A supplier Sheel IndustriesBut in P-60 Plate A is eliminated.

4.Arm Welding: - Now weld is completed for the whole length of the plate.

5.Cross plate, stopper arm, plate B tacking: - At this step the stopper and plate B are tacked on the cross plate of the swing arm.

Cross plate supplier Aditraj Auto (P) Ltd. Stopper Arm Supplier Sheet Components Pvt. Ltd.Plate B Supplier Sheel Industries

Main dimension of Cross member :- (All dimensions in mm.)Thickness 2.6Gap between walls 30Length 118Width 72Other dimensions are 13,14Due to design plate B is eliminated in P-60.

6.Cross Plate welding: - In this step cross plate is welded on the pipe.

7.Top Edge Welding-Top edge is welded on the swing arm.

8.Collar Alignment: - At this step 1st inspection is held for the alignment of collar. If there is any misalignment occurs in swing arm, then corrective action is taken.

9.Stay A Chain Case Tacking: - A Stay for chain case is tacked on swing arm.

Stay A Ch. Case Supplier Aditraj Auto(P) Ltd

Main dimension :- (All dimension in mm.)Thickness 2Nut Thread M6*1.0Other Dimension are 14.5,20,22.5,12.

10.Stay A Chain welding: -Stay is welded completely on the LH pipe of swing arm.In P-60 model we have another stay called as stay B.Supplier of this component is also Aditraj Auto.

Main dimension are:- (All dimension are in mm.)Bending height 15.9Slot size 15*25Slot ends radius 15.9 Length 60Width 45

11.Chipping: -At this step the spatters are removed from the welded area with the help of chipping hammer.

12.Collar Boring: -Collar boring is done on the collar after welding. Boring of collar is done to get the required dimensions after welding.

M/C used for Collar boring XLO Boring MachineThe size before boring for P-60 is 25.2 and size after boring is 25.95. In every case the boring depth is .325mm.. 13.Alignment of end piece of swing arm: -The alignment of end piece on swing arm is done with the help of right angle.

14.Slot alignment: -Alignment of slot is done in this step.

15.Visual inspection: -The swing arm is inspected visually at this step. Minor defects are removed in this step also. If any major fault/defects found in the component, then it is sent back on the line according to the defects.

16.Thread rolling: -Die is rolling on the thread.

17.Gauging: -Stays alignment are done at this step

Thus the weld shop of our concern forms the major workshop requiring the major part of the work force of HEIL . The weld shop is running all 24 hrs in 3 shifts to match the requirement of our customers.

Tool Room/Design

This department make the drawings of house production component & the brought out components. We use the software for the drawing are Auto cad & Pro-e. This department makes the tool & dies also.

Machines in Tool RoomConventional Machine :Machine Name Machine Make 1. Milling Machine HMT Ltd.2. Lathe DH-M/c Tools3. Lathe Kirloskar M/c ltd.4. Lathe HMT Ltd5. Drilling Machine Ghalley ltd.6. Drilling Machine Machliss ltd.7. Drilling Machine Machliss ltd.8. Cylinderical Grinding Machines RRM/c tools Gaziabad9. Surface Grinder Praga M/c Tools Ltd.10.Surface Grinder GuruArjun M/cTools 11.Shaper Machine Sagar Engg.Works ltd.12.Shaper Machine Copper Engg.Industries 13.Power Hack Saw Sagar Engg.Works ltd.

Non Conventional Machines :Machine Name Machine Make1.Vertical Machining Centre(CNC) BFW2.EDM Wire Cut Electra DL-25 3.EDM Wire Cut Sodic Wire Cut M/c4.Zig Boring (INC) Precicut M/cvTools

Quality Assurance

The major parts of the QA department are initial or bought out inspection and final inspection. In bought out inspection, we inspect the quality of the bought out components which we are using as the raw material in our plant like the pipe of P-90,P-70 etc based on the standards set by the various parties and the international and the and national standards which our plant is following. After proper inspection of the material the material is kept as the inventory in the plant and used according to the need .

The inventory material in the plant is totally managed by the store department in the plant .

The various operations are to be done on the components and after completing all the operations on the components they are send to the final assembly so that the final product can be carved out of the raw material .

After all the assembling operations are done on the components , they are to be finally checked by the Final Inspection Department. After qualifying all the standards from the final inspection then only the material is dispatched to the concerning party. The customer satisfaction standard is to be maintained by the final inspection department only as the department has to deal with the customer directly to solve the problems which the customer is facing if any.

DOCUMENTATION CENTRE

Documentation Center of HEIL is head by Management Representative.

The function of documentation center is to keep all the records related to company and to represent the company in the market at various stages.

The department keeps all the documents regarding the various polices followed by the company , various Indian and international standards followed by the company and regarding all the dealing by the company.

The department head has the various responsibilities like to get the feed back from the customers regarding quality and timely delivery and other if any.Other then this the head has to keep a close look on all the employees of the company that whether all the standards are properly followed by all or not.

The head also cross check the activities of the heads of all the departments that whether all the norms imposed are being properly followed or not and if there is any leg behind then he looks what are the corrective measures .

COSTING

This Department deals with the cost relating matters of the company like what shall be cost of any component if the company manufactures it or buys from outside .

The decision of any component to be manufactured or to be bought from outside is to be taken on the assumption of the costing department only.So the head of this department should be well versed in all the operations to be done on any component and what shall be the cost of every operation.

PURCHASE

All the matters of purchase of any thing weather it is consumable or any raw material to be used in the company is undertaken by this department only.

This department takes the information from all the departments in the companyand get the details of all the items required in the various departments and forwards it to the various vendors of the company so that they can fulfil all the requirements on time .

STRUT SHOP

Struts are manufactured in this shop. The struts manufactured in this shop are for Gabriel Auto Ltd., Hydraulics India Ltd.

Machine SPM Welding Machine

Type of Welding Mig Welding

Shielded Gas used Carbon dioxide

Components of Strut

1. Pipe2. Seal3. Knuckle Bracket4. Spring Guide

Processes Performed In Strut Strut Shop

1. Name Rolling:-This process is performed on rolling machine with some pressure. The name of the company is engraved on the punch.

2. Reducing Bore:-

In this operation the dia of the pipe is reduced on the press machine.Machine Make MilapSize reduced 5 mm.Length Reduced on pipe 19-20 mm.Boring size i.e. done on reduced dia 2 mm.Facing done on pipe 1 mm.

3. Facing & Boring:-

This process is performed on ordinary lathe which has a single point tool.

4. Sealing Cap Welding:-

The sealing cap is welding on pipe on special purpose welding machine

5.Leakage Testing (I) :-

Leakage test is done to check the leakage in welding.Air Pressure 60-90 psiTime for leakage Testing 30 seconds

6.Spring Guide Welding:-

Gas Flow 10-12 lpmWire Speed 4-6 m/min.Table speed 90-110 rpm.

7. Knuckle bracket pressing:-Machine used Hydraulic press M/cCapacity of Press 2 Ton

8.Knuckle bracket Welding:-

Gas Flow 15-20 lpmWire Speed 6-8 m/min.Table Speed 60-75 rpm

9.Leakage Test (II):-

Air Pressure Durimg Test 60-90 psiTime for leakage testing 30 seconds

10.Code Punching:-

The code of product which is produced in the shop is punched in this step.

QUALITY POLICY

We are (HEIL) committed to delight our customer by involving state of the art manufacturing techniques and on time delivery with consistent quality by :- Continual upgradation of technologies, process and

system.

Development of employees by training, involvement and motivation.

Strategic relationship with supplier of on going performance enhancement.

WHY CUSTOMERS QUIT

1% DIE

3% MOVE AWAY

5% FORM OTHER

9% FOR COMPETITIVE REASONS

14% BECAUSE OF PRODUCT DISSATISFACION

68% QUIT BECAUSE OF ATTITUDE OF INDIFFERNCE TOWARDS CUSTOMER BY SOME EMPLOYEE OF DEALER

CHOOSE A JOB YOU LOVE AND YOU WILL NEVER HAVE TO WORK A DAY IN YOUR LIFE !

STANDARD ROOM

As Quality is the heart of the company, Standard Room is the heart beat of the company. In standard room we have done the inspections of samples of the components and gauges.

INSTRUMENTS USED

1. Rockwell hardness tester2. Profile projector3. Micrometers4. Height gauge5. Varnier caliper6. Dial indicator7. Slip gauges8. Filler gauges9. Bore gauges10. Angle protector11. Co-ordinate measuring machine

Co-ordinate Measuring Machine :- It is an automatic (cnc) machine used for measuring the dimensions of the components. It is a three dimensional measuring machine.

Construction and Working :- It has an arm whose position can be adjusted in x, y and z directions. It has a remote which controls the motion of the arm. There is also a temperature sensing element which should be touched with component or v-block while measuring dimensions. Tip is the touch sensing device of the arm. First of all make the profile(all dimensions) of the component in computer memory which u want to measure. Now place the component on the surface plate of the machine. Surface plate has some threading holes used for holding the purposes. Now move the arm with remote control to come in required position. Touch the sensing knob on the component which dimension u want to measure. The dimensions and line diagram automatically measured and drawn on the computer screen. We can measure all the dimensions on this machine. e.g hole dia., depth, height, thickness etc.

CALIBRATION LAB.

In this lab. We have done the inspections and calibrations of gauges and instruments used in the company.

INSTRUMENTS USED :-

*SURFACE FINISH TESTER

*DIAL CALIBRATION TESTER

*PRESSURE GAUGE TESTER

*MECHANICAL COMPARATORS

WORK INSTRUCTIONSMINI POWDER COATING

1. Baking oven switch on and set temperature as per component requirement.

2. Pretreated component inspection.3. If pretreated component phosphating ok or not.4. If not ok send back for re-phosphating.5. If ok start next process.6. Component hang on hangers.7. Apply masking whenever required.8. Check baking oven temperature.9. Switch on electrostatic gun check gun ok.10. Start conveyor and apply powder on component through

electrostatic gun.11. Powder baking in baking oven.12. Check quality of first out component.13. If any problem re-check process again.14. If component satisfactory.15. Unload on trolleys.16. Send for assembly.

Vertical Machining Center Machine :- It is the cnc machine used for drilling, boring, surface finishing etc.

MACHINE SPECIFICATION :-

1. Table working area : 710mm*400mm2. Table longitudinal travel x-axis : 510mm3. Table cross travel y-axis : 410mm4. Spindle head vertical travel z-axis : 460mm5. Positioning rapid travel x-axis and y-axis : 24000mm/min6. Spindle taper : BT-407. Spindle speed range : 60-6000rpm8. Magazine capacity : 20 tools9. Pocket type : BT-40taper10.Tool to tool time : 2.5sec.11.Max. tool dia. (With adjacent pocket occupied) : 80mm12.Max. tool dia. (with adjacent pocket empty) : 125mm13.Max. tool length : 250mm14.Max. tool weight : 6 kg15.Net weight : 3500 kg16.Overall machine height : 3000mm

PAINT AND POWDER COATING

HEIL has a largest paint and powder coating plant in India. In paint shop Paint is done on the outermost parts of the automobiles which needs better look and prevent the parts from corrosion. paint is done with an electrostatic gun.

Powder coating is the process of making a layer over the components. which prevents the component from corrosion. It is done on the innermost or bottom parts. It has more life than paint coating. In powder coating process powder is sprayed on the components with an electrostatic gun. After spraying, powder melts on the surface of the component by heating process and makes a layer on the surface.

Water used at back side of the paint process where the extra paint mixed with water after dropping from gun has been changed after one year. Hot water generators are used for heating the water and produces steam to maintain the temperature of the room heaters.50,000 ltrs. approx. de-mineralised water is used per day at a cost of 1.50 Rs/ltr. in the paint shop.

MAINTENANCE

This department is to take care of all the industry, i.e maintenance of each and every thing including production parts, machines, various plants (like gas, filter etc.)electric works and utility. Its work is to keep a regular check on the working of the system, machines etc. installed in the industry. Studying why the accident/breakdown occurred, what possible preventive measures can be adopted so that in future no such problems occur. They also have to take care of the infrastructure, machine repairs, their life so that work can done smoothly and more efficiently, taking care that company does not go into losses (i.e useless expenditures ). Various data analysis are carried out like kaizen,o/t chart, operational research management(ORM). Do regular preventive maintenance and productive maintenance for reducing accidents/breakdowns. Regular improvement at all plant e.g (department)that called kaizen.

ENVIRONMENTAL POLICY

We are (HEIL) committed to adopt a comprehensive environment management system to continually improve our environment performance. We shall achieve this by :-

Upgrading process and work practices for pollution and elimination of environmental hazard.

Complying with all applicable environment regulation and legislation.

Minimizing waste generation and promoting conservation of resources I.E. oil, water, energy and chemicals.

Developing and implementing programs to promote environmental awareness through communication, involvement and training of our employees and business associates.

OCCUPATION,HEALTH & SAFETY POLICYWe are committed to adopt a comprehensive occupational health and safety management system to continually improve our occupational, health and safety performance by presentation of occupational illness and accidents and elimination of occupational health and safety risks. We shall achieve this by :-

Upgrading equipment processes and work practices.

Complying with all applicable occupational health and safety regulation and legislation.

Developing and implementing programs to promote occupational, health and safety through communication, involvement and training of our employees.

COMPONENTS DETAIL

1. End piece component for swing arm lh/rh.2. Plate A chain case.3. Arm RR brake stopper.4. Stay A chain case.5. Pipe component.6. Stay seat front.7. Stay stopper arm.8. Boss length TVS.9. Plate winker set.10. Guide drive chain case.11. Plate FR engine hanger.12. Patch fuel cock set.13. Handle holder.14. Bkt.outer LML.15. Pipe LH p-60.16. Cross plate.17. Stay top bridge.18. Stay chain case.19. Plate tail cross.20. Collar RR fork.21. Pipe pivot.22. Arm component middle.23. Bkt.cushion.

24. Rubber bush RR fork.25. Bkt.floor board.26. Patch wheel.27. Chain adjuster.28. Tube foot rest TVS.29. Silent bush.30. Plate chain case outer TVS.31. Upper bkt. Fiero.32. Patch seat rear.33. Stay bkt.spring.34. Foot rest component XLN,ECN.35. Chain adjuster LH step thru.36. Foot rest component(pillion).37. Bkt. Inner LML.38. Plate B chain case.39. Patch wheel.40. Plate chain cover mtg. Front.41. Handle holder TVS.42. Bkt.rear shock absorber.43. Bkt. Link mtg.XLN.44. Cross member TVS.45. Stay breather tube.46. Holder pillion foot rest.47. RIG body B.48. Hing assly.case battery.49. Plate rear swing arm joint(TVS).50. Cross plate p-11/p-17

PRESS SHOP

In this department different types of presses are used for shearing, bending, cutting and punching etc. operations on sheets and components. The components or parts of export OVEN are made in this shop. The ovens are mainly exported to FRANCE. Oven made in this shop are mainly used for room heating. Coal burns in this oven and produces heat which helps to heat the room according to the requirement.

MACHINES USED IN PRESS SHOP

1. POWER PRESSES

2. PNEUMATIC PRESSES

3. DRILLING MACHINES

PROCESSES PERFORMED ON THE PARTS OF MERANO OVEN

1. Handle2. Screw M 5*12 (qty-2)3. Handle strip (shearing,crome plating after nut welding).4. Merano furnace.5. Front closing door assly.6. Front closing door (punching,corner cutting,bending).7. Handle locating bolt.8. Rope resting bkt.RH/LH (shearing ,bending).9. Rope resting bkt. Top/bottom (shearing,bending).10. Door spring locating bkt.(shearing,punching).11. Glass support strip.12. Pinfor door mtg.13. Sliding strip assly.14. Sliding strip.15. Guide bkt.(shearing,bending).16. Glass.17. Handle assly.18. Handle lock plate.19. Main body (punching,bending).20. L-plate top window (round cutting,bending).21. Door hinge upper.22. Upr.front plate l-type assly.23. Upr.front plate l-type (bending).

24. Spacer strip (shearing).25. Internal tray assly.26. Internal tray(bending).27. Spacer strip internal tray (shearing).28. Support plate.29. Support plate ring resting assly.(bending).30. Brick locating bkt. (shearing ,bending).31. Main window support bkt.bottom (bending).32. Main window support LH/RH assly.33. Main window support plate (shearing).34. Ring resting plate (punching).35. Door lock pin.36. Brick resting plate (punching,corner cutting,bending).37. Tray resting plate assly.38. Tray resting plate (corner cuting,bending).39. Tray support strip (shearing,bending).40. Support bkt.(shearing).41. Locating sheet (punching).42. U-bkt.(corner cutting,bending)43. Side cover RH/LH (punching,bending).44. Door hinge lower.45. Top cover assly.46. Top cover (punching,rolling,bending).47. Top cover back/front plate (punching).48. Base frame (punching,bending).49. Rear cover (punching).50. Tray assly.

51. Tray (corner cutting,bending).52. Bricks.53. Baffle.54. Pin for locating sheet.55. Resting bkt. Front.56. Exhaust ring (shearing,bending,sizing).57. Door spring bkt.58. Glass locating clip.59. Knob (crome plating).60. Handle (main tray) (shearing,corner cutting,bending).61. Front bkt. Assly.62. Plate-1 (shearing,punching).63. Plate-2 (shearing).

PROCESSES PERFORMED ON THE PARTS OF OREGON OVEN

1. Perferated bkt.front cover (shearing,blanking).2. Bracket (shearing,bending).3. Internal tray assly.4. Internal tray bkt. (punching,corner cutting,bending).5. Support bkt.(shearing).6. FR.middle window support bkt.top (shearing,corner cutting l-

type,bending).7. FR.middle window support bkt.RH/LH (shearing,corner

cutting,bending).8. FR.middle window support bkt.bottom (shearing,bending).9. Brick support bkt. Front (shearing,bending).10. Ring resting plate (bending).11. L-plate (bending).12. Support plate (shearing).13. Exhaust ring (shearing,sizing).14. Brick resting plate (punching,corner cutting).15. Tray resting plate assly.16. Tray resting plate (punching,corner cutting)17. Bracket-3 for tray resting plate (sh.,c.c/radius cutting,be.).

18. Angle bkt. Ffor tray resting plate (sh.,be.).19. Brick locating bkt. (sh.,be.).

20. Brick support strip(sh.).21. Locating sheet (pu.).22. Base plate.23. Back side cover assly.24. Back side plate (pu.,c.c)25. Brick support strip(sh.).26. Brick locating bkt.(sh.,be.).27. Back side cover bkt. (sh.).28. Rear cover (pu.,be.).29. Front closing door assly.30. Front closing door (c.c,be.).31. Rope resting bkt.LH/RH (sh.,be.).32. Rope resting bkt.(upr/lwr) (sh.,be.).33. Support bkt.for door (sh.).34. Top cover (c.c,be).35. Main bkt. Assly.36. Main tray (c.c l-type).37. Handle (sh.,c.c,be.).38. Baffle resting tray assly.39. Bracket-4 for baffle resting tray (sh.,be.).40. Bracket-2 for baffle resting tray (sh.,be.).41. Bracket-1 for baffle resting tray (sh.).42. Bracket-3 for baffle resting tray (sh.).43. Front bkt.assly.44. Plate-1 (sh.,pu.).

45. Plate-1 (sh.,pu.).46. Side bricks lock (sh.,be.).47. Packing frame assly.48. Bkt-1 (sh.).49. Bkt-2 (be.).50. Bkt-3 (sh.,pu.).51. Bkt-4 (sh.).52. Bkt-5 (sh.).53. Bkt-6

The assembly of the OVEN is made by tacking and then Mig welding is done on all the parts i.e. front cover, l-plate, back cover, rear plate, ring, base plate etc. and then packed in polythenes & wooden boxes for dispatch.

WORKING OF AN OVEN

The main function of this oven is to heat the room. low carbon content coal is burnt in this oven because it is less harmful for human being and environment. Coal is burnt at the internal cast iron tray which is assembled at the bottom part of the oven. Two perforated holes with open/close arrangement are provided upside of the heating chamber and one is at lower side. These holes allow the air to come into the chamber and burning of coal can be done. We can adjust the heating of the oven or burning of the coal by adjusting the opening of inlet air providing holes and heating of the room can be done as per requirement less or more by this hole adjusting method. By completely shutting off the three perforated holes will not provide heating and oven will shut off with no burning of coal. At the front of the coal inserting chamber a glass window is provided. At the front of the top of the oven L-type plate is covered with surrounding plates with holes which allows the heat flow in the room. At the center of the top of the oven Ring is attached which further attaches to the chimney to allow the exhaust gases out to the atmosphere.

SPOKE,NIPPLE AND PLATING SHOP

In this department spokes and nipples are made which are used in the rim of the motorcycle. Spoke and nipples are also plated in this shop. Different types of chemicals are used for plating the spoke and nipple.

SPOKE :- High carbon steel wire is used for making spokes. It is used in rim of the motorcycle.

OPERATIONS MACHINES USED

1. Cutting of wire SPM cutting machine2. Head making spoke SPM machine3. Bending of head ---------do------------4. Threading of spoke tail ---------do-------------

NIPPLE :- Cold drawn steel wire is used for making nipples. It is used in rim of motorcycle with spoke assembly. First of all cutting of the wire is done on header machine for making nipples. Nipple SPM machine has 8 tools ,all other operations are done on this machine as below:-1. Holding and removing of component.2. Chamfering.3. Counter drilling.4. Drilling dia 3.35. Drilling dia 3.46. Burr cleaning to make the complete throughout hole.7. Cutting slot on head.8. Threading.

PROCESS SEQUENCE OF NON-CYANIDE ALKALINE ZINC

SPOKE PLATING

PROCESSES TEMP. TIME (C) 1. Loading/unloading2. Soak cleaning 55-65 3'-4'3. Anodic cleaning-1 55-65 2'-3'4. Water swill counter flow 5. Acid pickling-1 2'-3'6. Water swill counter flow7. Anodic cleaning-2 55-65 2'-3'8. Water swill counter flow9. Acid pickling-2 1'-2'10. Water swill11. Neutralizer12. Zinc plating 22-29 30'-32'13. Zinc drag out14. Water swill counter flow15. Nitric acid dip 8"16. Passivation 18"-22"17. Water swill 18. Resin coat 6"-8"19. Oven dry 80-90 40'

PROCESS SEQUENCE FOR ACID ZINC NIPPLE PLATING

PROCESSES TEMP. TIME (C)1. Caustic barrel cleaning 50-60 50'-60'2. Water swill 3. Acid pickling 4'-8'4. Water swill5. Water swill6. Acid zinc plating 35-40 1:30hrs7. Water swill8. Water swill9. Nitric acid dip 3"-5"10. Passivation 12"-30"11. Water swill12. Water swill13. Dry in centrifugal dryer 50-60 1'-2'

PROCESS SEQUENCE OF NON-CYANIDE ALKALINE ZINC RACK PLATING

PROCESSES TEMP. (C) TIME Loading/unloading 1. Soak cleaning-1 60-70 3'-4'2. Soak cleaning-2 60-70 4'-5'3. Anodic cleaning-1 60-70 4'-5'4. Water swill counter flow 5. Acid pickling-1 3'-4'6. Water swill counter flow7. Anodic cleaning -2 60-70 4'-5'8. Water swill counter flow9. Acid pickling-2 3'-4'10. Water swill counter flow11. Neutralizer12. Zinc plating -NCZ 25-32 24'13. Water swill counter flow14. Nitric acid dip 3"-10"15. Passivation bright room 10"-22"16. Passivation yellow 20-50 23"-27"17. Passivation green 20-30 35"-45"18. Passivation black room 12"-30"19. Water swill counter flow20. Air dry21. Dry in oven 50-60 5'-10'

EFFLUENT PLANT

Effluent plant is one of the best plant which reduces water pollution and saves the environment. Lesser amount of water is used due to treatment of that water re-circulate to the plant. In this plant, water coming out from the plating shop is very harmful. This water is treated before disposing outside the industry. If it will not treated before disposing out it will be very harmful for human being and pollute the environment. It is also reused for plating after treatment. Different types of chemicals are used for treating the harmful water to make it pure for reuse or re-circulating. The name of HEIL is one of that industries using treated water for re-circulating or reuse for plating and gardening.

PROCESS FLOW CHART OF EFFLUENT PLANT NAOH 6.5% Bleaching NAOH 6.5% Polyelectrolyte Powder 0.15%

Alkaline effluent Reaction tank Equalization tank Pump from plating no. 1 ph 6-8 ph 9-10

H2SO4 10% Sodium bisulphite sludge with Clarifier 5% water

Acid chrome Reaction tank Air Effluent from No. 2 Plating Ph 3-4 Filter press

Return effluent

To plating overhead Storage tank

Cation tower Activated carbon Pump overflow clear sludge in Filter water storage pit

To gardening Water storage tank

PROCESSES PERFORMED IN EFFLUENT PLANT

Stage1. Two stream of effluent acidic :- cr+6 treatment alkaline :- sodium hydro chloride

Stage 2. Acidic :- ph 2-3 checked sodium meta sulphite

USE - for removal of chromium 6+ (toxic)

Stage 3. Alkaline :- Dosing of sodium hydrochloride Check ph above 10

USE - for removal of cyanide (toxic)

Stage 4. Flash mixer -dosing of caustic and poly-electrolyte lifted to clarifier.

USE - ph for precipitating of other metals

Stage 5. Clarifier solid liquid separation clear water to CWT sludge to filter press

Stage 6. Now water passes through filter to remove TSS (total suspended solids) carbon filter to remove other heavy metals

Stage 7. Sludge to filter press Dry matter separation

IMPORTANT PARAMETERS FOR ETP (PLATING)

1. Ph (1)2. T.S.S (total suspended solids)3. Oil and grease4. Chromium (hexavalent)(2)5. Total chromium6. Cyanide7. COD & other

Q.A (ASSEMBLY AND FINAL)

In this department all the components coming from other departments (welding, press, and paint shop) are assembled with the help of nuts and bolts etc. Nuts and bolts are screwed by nut tightening m/c. Different types of operations are done in this shop e.g boring, tapping and rubber bush pressing etc. Boring and tapping operations are done for removing of extra paint material inside the holes and threading. Oils and greases are also provided over the required parts so that the components can prevent from corrosion and can't be damage easily due to friction etc. final inspection is also done here before packing and dispatch. Rejected components send back to the departments for their maintenance. After assembly the components are packed in polothenes, cartoons and boxes as per requirement and finally dispatched to other companies.

MACHINES USED

1. Boring machines2. Tapping machines3. Nut tightening machines (hand gun)4. Drilling machines5. Rubber bush pressing machine(SPM)

1. OVERVIEW2. ACKNOWLEDGEMENT3. FUTURE AIMS AND OBJECTIVES4. KEY PERSONNAL ORGANISATION CHART5. POLICIES6. UNITS OF HEIL7. CLIENTS OF HEIL8. RANGE OF PRODUCTS9. PRODUCTON ACTIVITY10.DEPARTMENTS WITH PROCESSES PERFORMED11.PROJECT WORK12.CONCLUSION

CHEMICAL TESTING LABORATORY

The life of the component mainly depends upon the environmental conditions so that the component should be secure in any environmental conditions. It means the component should be prevented from rust, moisture etc. Different tests are performed in laboratory to insure the life of the component as per company requirement. These tests are performed at worst environmental conditions so that the life of the component could be more. Tests performed in lab. are as given below :

1. SALT SPRAY TEST : The component is dipped in Sodium hydroxide and de-mineralize water solution for 120 hrs.(painted) and 240 hrs. (powder coated). If there will be no any rust and yellow pane etc. over the surface of the component in the prescribed hrs. then the component will have long life in any environmental conditions. The component will not damage due to rust etc.

2. HUMIDITY TEST : Water is heated to make the steam and this steam is then send to the humidity chamber. The component is placed at a temperature of 50*c inside the chamber for 240 hrs. (both painted and powder coated). If there is no removing of paint from the surface and no pitting on the component then the component could not damage at high moisture environmental conditions and has more life.

3. HOT WATER CHAMBER TEST : The component is placed in de-mineralize hot water at 40*c for 120 hrs. If there will be no rust, pitting etc. then the component will have long life. It will not damage or rusty for continuously placing in hot water surroundings.

There will be more tests performed in the lab. for checking the paint coating over the surface of the component.

1. ADHESION TEST : Adhesion tape is used for checking the adhesion or sticking of the paint layer over the surface of the component. The layer of paint is first scratched with the help of knife to make the grid over the surface and the tape is stacked and rubbed on that grid surface of the paint layer. Now remove the tape, If there is no removing of paint from the surface then the layer of the paint is properly stacked on the surface and the paint coating is ok.

2. HARDNESS TEST : A hardness pencil is used for checking the hardness of the paint layer over the surface of the component. Mark a line on the painted surface, if there is no removing of paint layer then the hardness of the paint coating is ok.

3. Xylene is rubbed over the painted surface with the help of cloth (malmal) to check the surface coating of paint layer.

4. Paint coated component is dipped in 1 ltr. Petroleum for 30

mins. to check the surface layer of the paint coating is properly stacked or not .

ACKNOWLEDGEMENT

I would like to dedicate my work to Mr. P.L.Sharma (Gen. Manager P&A) who allowed me for six months industrial training in his esteemed organization. I would like to special thanks to Mr. Pankaj Aggarwal (Assist. Manager B.O.P) who helped me in my training with his highly technical work experience and I complete my project work under his seasoned guidance. The process chart displayed on every machine or work station and practical experience of the workers also helped me in making my training report. I am highly obliged to all the experienced staff members of HEIL who helped me in my project work.

CONCLUSION

In the training duration after undertaking inspections of various components according to the technical specifications, I can conclude that the components which HEIL is producing are of high precision and their quality is one of the best in the market according to the standards. The main reason of best quality of HEIL is due to the great efforts of all the experienced staff and workers who work under discipline and best working standards. All the process flow charts and detail of machine work displays on all machines in every department which helps all to work under specified conditions and best environment. This makes all the workers to work in discipline and reducing accidents. I

also observed that best working environment which helped me in making my training report. This best quality of the components are giving a best output and increases HEIL clients day by day. Due to this best quality HEIL is the original equipment manufacturer (OEM) of Hero Honda Motors Ltd. and TVS Motors Ltd.

AIM: - TO IMPROVE THE WELDING FINISH AND REDUCES THE REWORK ON SUB ASSEMBLY OF END PIECE AND PIPE P-90 COMPONENT.TO MEASURE THE DIMENSIONAL ACCURACY OF VARIOUS COMPONENTS ACCORDING TO TECHNICAL SPECIFICATION UNDER THE SEASONED GUIDANCE OF

Mr. Pankaj Aggarwal(Assist. Manager Q.A)