chandra prakash meena

7/27/2019 chandra prakash meena

1/43

E.C.B POLYTECHNIC COLLEGE,BIKANER

TRAINING REPORT

ON

INDUSTRIAL TRAINING

NATIONAL ENGINEERING

INDUSTRIES LTD.JAIPUR

SUBMITTED TO: SUBMITTED BY:

PROF. R.S.SEN

CHANDRA PRAKASH


2/43

POLYTECHNIC(MECH.)

PREFACE

The study of engineering diploma course in recognized technica

institution makes up perfect in technical knowledge. An engineering

diploma should have actually theoretical as well as practically knowledge.

Training creates awareness of industrial approach and work culture we

were exposed to the real working condition. Industrial training enables a

student to open his own small-scale industry after the completion of

engineering diploma.

I had undergone my FIRST industrial training at NATIONAL

ENGINEERING INDUSTRIES LTD., JAIPUR.


3/43

ACKNOWLEDGEMENT

I am very grateful to Mrs. Monika Joshi (DY. HR MANAGER ,NEI

Jaipur) for allotting me training in NATIONAL ENGINEERING

INDUSTRIES LTD, JAIPUR.

Engineers & consultants. I wish to express my per found thanks to ProfR.S.SEN for their suggestion, assistance and encouragement during the

training period.

I would like to give my thanks to all those who help and

guided my directly or indirectly during the course of training.

CHANDRA PRAKASH


4/43

COMPANYS MILESTONES

1946 Company established as National Bearing Company (NBC) under Technical

Collaboration with Hoffman, U.K.

1950 Ball Bearing Production started

1951 Railway Bearing Production started

1957 Company name changed to National Engineering Industries Ltd., (retaining NBC as

Trade Mark)

1967 Tapered Roller Bearing production started

1981 Separate Factory for Ball Bearing at Gunsi (Newai)

1982 Cartridge Tapered Roller Bearing in Technical Collaboration with Brenco

Incorporated

of U.S.A.

1985 Technical Collaboration with NTN Corporation of Japan for Ball,Cylindrical &

Spherical

Roller Bearing

1995 ISO - 9001 Quality Management System Certification

1996 Technical collaboration with Izumi Kinzoku Kogyo Co. Ltd., Japan for Machine

Retrofitting

1997 Technical Collaboration with NTN Corporation of Japan for Tapered Roller Bearing

and

Hub Bearing

1999 Implemented - SAP , Solutions for ERP


5/43

2000 ISO-14001 Environment Management System Certification

2000 QS-9000 Quality System Certification by

AWARDS AND PRIZES

NEI has been awarded with many Biz-awards in its tenure till date. Some ofrecent

awards won by the company are :

1. Winner of DEMING PRIZE 2010.

2. Grand Award for Cost in 2009-10 from Honda Motorcycle & Scooter

India Pvt. Ltd.

3. Award for TPM Excellence Category-A in 2009.

4. Vendor Performance Award in 2008-09 for Overall Commendation.

5. Certificate of Appreciation in 2008 from Maruti Suzuki India ltd.

6. Award for Challenge India Support (Engine Group) in 2003-04 from

7. Excellence Award in 2003 from IES.

8. The 4India Pro User Award 2002

9. Award for Excellence in 2001-02 from MICO Bosch Group.

10. Excellence in Performance in 2001-02 from Motors industries

Co. ltd.

11. The 3India Pro User Award 2001.

12. Indian Pro User Award 1999.


6/43

13. Winner of Certificate of Excellence in Industrial Equipment

Category

from PTC.

The company is now preparing for the INDIAN MANUFACTURING

EXCELLENCE AWARD 2011(IMEA).

Technical Collaboration

BRENCO Incorporated of U.S.A.

Since 1982 - For Cartridge Tapered Roller Bearings for Railroad

applications.

NTN Corporation of JAPAN

Since 1985 - For Ball Bearings, Cylindrical & Spherical Roller Bearings,

JPU

Bearings, Double Row Angular Contact Bearings, Hub Bearings

Since 1997 - For Tapered Roller Bearings.

Izumi Kinzoku of JAPAN

Since 1996 - For re-manufacturing, retrofitting and overhauling of

Grinding and Super-finishing machines for Bearing races.


7/43

MAIN CUSTOMERS

Rolling Stock: -

DLW

CLW

ICF

RCF

DCW

CIMMCO

BEML

TEXMACO

BURN Standard

Automobiles-Cars/Jeep:-

Hindustan Motors Ltd.

Maruti Udyog Ltd.

Mahindra & Mahindra

Automobiles-LCV: -

Ashok Leyland


8/43

Force Motors

Eicher Motors

TATA Motors

Automobiles-Two/ Three Wheelers:-

Bajaj Auto Ltd.

Hero Honda Motors Ltd.

Honda Motorcycle & Scooters India Ltd.

Suzuki Motorcycle India

Majestic Auto

Piaggio India Ltd.

Royal Enfield Ltd.

Yamaha Motors India Pvt. Ltd.

TVS

Tractors: -

Eicher

Escorts

HMT

International Tractor

Mahindra & Mahindra

Punjab Tractors

TAFE

VST Tillers


9/43

Electric Motors & Pumps:-

Crompton Greaves

G.E. Motors

Kirloskar Electric

NGEF

MICO

Fans: -

Bajaj Electricals

Crompton Greaves

Khaitan

Orient

Polar

Large Dia Bearing Customers: -

Cement Plants

Earth Moving Equipment

Steel Plants

Thermal Power Plants


10/43

NEIS PRODUCT RANGE


11/43

BALL BEARINGS: -

Radial Ball Bearing

Angular Contact Bearing

Self Aligning Two Row Ball Bearing

Belt Tensioner

TAPERED ROLLER BEARING: -

Single Row & Double Row Tapered Roller Bearing

LARGE DIA SPECIAL BEARING: -

Single Row

Double Row Ball, Cylindrical and

Four Row Tapered Roller Bearing

Thrust Bearing

SPHERICAL ROLLER BEARING: -

RAILWAY BEARING

DEPARTMENT OF N.E.I.


12/43

Railway bearing Deptt.

Ball bearing Deptt.

Taper Roller Deptt.

Machine building Deptt.

Ball department.

Large diameter bearing Deptt.

Research & Development Deptt.

Forging Deptt.

INFORMATION ABOUT THE PRODUCT


13/43

PARTS OF BEARING:

Basically every anti-friction bearing consists of four basic parts

1. Outer ring : Outer ring for NBC spherical roller bearings are manufactured

from forged and rolled rings from bearing quality steel. It is through hardened and

precision ground all over. The track or roller surface of bearing outer ring is

spherical in shape for self-aligning.

2. Inner ring : Inner ring for NBC spherical roller bearing are also made from

bearing quality steel which is forged and rolled. Inner rings are also precision

machined heat-treated and precision ground. Inner ring have two rolling surface

which are ground together with high accuracy.

3. Balls or cylinders (Rolling Element) : These are either forged or machined

from bearing quality steel bars & then through hardened and ground to high degree of

accuracies. The rolling element on bearings can be balls, cylindrical rollers or taper rollers.

4. Cage : The cage keeps the rolling elements properly spaced out between two

rings. Cage may be of steel, brass or bronzed etc. depending upon the type &

application of the bearings. NBC spherical roller bearings are fitted with machined brass

cages. These cages are made from brass centrifugal castings and then precision machined.

Brass cages have advantage of assuring positive lubrication and cooler running of the

bearing therefore are best recommended for railway applications.

DIMENSIONS OF BEARING:

Among the various dimensions of the ball & roller bearings the most important

dimension is:


14/43

Bore :-Use for suitability of shafts

Outer Diameter :-For Housing Suitability

Width or Thickness .

These dimensions are established by the industry under the IOS dimensions scheme.

TYPES OF BEARINGS

A BROAD RANGE BORN OF PRECISION

From a few mms to thousands of mms, from a few grams to a few tons, the NBC

range is hard at work in some of the most critical areas of Indian industry. There

are many types of bearings, each used for different purposes. These include ball

bearings, roller bearings, ball thrust bearings, roller thrust bearings and tapered

roller thrust bearings.

Ball bearings, as shown below, are probably the most common type of bearing.

These bearings can handle both radial and thrust loads, and are usually found in

applications where the load is relatively small.

In a ball bearing, the load is transmitted from the outer race to the ball, and form

the ball to the inner race. Since the ball is a sphere, it only contacts the inner and

outer race at a very small point, which helps it spin very smoothly. But it also

means that there is not very much contact area holding that, so if the bearing is

overloaded, the balls can deform or squish, running the bearing.


15/43

Roller bearings like the one illustrated below are used in applications like conveyer

belt rollers, where they must hold heavy radial loads. In these bearings, the roller is a

cylinder, so the contact between the inner and outer race is not a point but a line.

This spreads the load out over a larger area, allowing the bearing to handle much greater

loads than a ball bearing. However, this type of bearing is not designed to handle much

thrust loading.

A variation of this type of bearing, called a needle bearing, uses cylinders with a very small

diameter. This allows the bearing to fit into tight places.


16/43

Roller Thrust

Roller thrust bearings can support large thrust loads.

They are often found in gear sets like car transmissions between gears, and

between the housing and the rotating shafts.

Tapered Roller Bearings

Tapered roller bearings can support large radial and large thrust loads.

Tapered roller bearings are used in car hubs, where they are usually mounted in

pairs facing opposite directions so that they can handle thrust in both directions.

BEARING MATERIAL:

Bearing contains varying amount of carbon, iron, chromium, manganese,

phosphorus, sulphur, silicon etc. chromium and carbon allows deep hardening. The

combination of chromium carbon & iron helps to minimize failure. As they

increase the surface resistance to abrasion and wear increase.


17/43

ELEMENT AMOUNT

Manganese -0.25 to 0.35

Silicon -0.025 to 0.35

Sulphur -0.025 max

Phosphorous -0.025 max

Nickel -0.025 max

Copper -0.35 max

Molybdenum -0.10 max

RAW MATERIAL:

A variety of steel and brasses are used for different components for bearing

depending upon the properties required in the final product.

Balls -Ni-Cr steel wire

Rollers -High carbon chrome steel rods

Cage -Brass and mild steel


18/43

HEAT TREATMENT PROCESS

FLOW CHART OF CHUGAI-RO FURNACE

JOB

/

PRE WASHING(60C)

/

HARDENING BY ENDO (AIR+LPG+CATALYST)

/

ZONE 1ST (840C)

/

ZONE 2ND (850C)

/

ZONE 3RD (850C)

/

ZONE 4TH

(850C)/

QUENCHING IN OIL TANK AT 120C, MIXING IS DONE BY AN AGITATOR

/

AIR COOLING

/

COOLING FROM WATER AND AIR

/

TEMPERING IN A FURNACE AT 170C (90 MINUTES)

/

AIR COOLING


19/43

DEPARTMENT ALLOTED IN NBC:-

BALL BEARING DIVISION- LPE DEPTT.

Grinding processes in Bearing

manufacturing

Face Grinding

Centreless Grinding

External Grinding

Track grinding (I/R)

Internal Grinding

Bore Grinding (I/R)

Track Grinding (O/R)


20/43

BALL BEARING GRINDING

STEP BY STEP PROCEDURE FOLLOWED IN GRINDING

Grinding can be defined as the process of the removal of excess material

from the surface of the job. Grinding is done after the heat treatment

process. Heat treatment is done separately in a work shop.

The operational steps in the grinding are:-

1) Facing

2) OD Grinding

3) OR Track Grinding

4) OR Track Honing

5) IR Track Grinding.

6) Bore grinding.

7) IR Track Honing.

8) Washing

1) FACE GRINDING PROCESS:-The face grinding machine is employed to

face the outer and inner races of bearing material by the application of two

grind wheels. The collant which is used for this process is water soluble

chemical coolant.

2) OD GRINDING PROCESS:-The center less grinding machine is used for this

process (MICRON MACHINE). It uses a grinding wheel whose maximum

speed is 2700 rpm and wheel size is 405 mm. This machine removes the

material from the outer diameter of both the inner and outer races with the

action of grind wheel.


21/43

3) OR TRACK GRINDING PROCESS:- The process removes the material from

the track of the outer race. A grinding wheel is used in this process.

4) OR TRACK HONING PROCESS:- This process is accomplished with the help

of a special grinding machine where the surface of outer race is super

finished with the help of specific stones

5)IR TRACK GRINDING PROCESS:-This process is accomplished with the help

of grinding machine. Here the track of inner races is grinded so as to

achieve the required finish. Oil is used as a coolant.

6)BORE GRINDING PROCESS:-The bearing is now subjected to the bore

grinding machine where the material is removed from the bore of the

bearing job.

The coolant is water soluble chemical.

7)IR TRACK HONNING PROCESS:-This process is accomplished with the help

of a special grinding machine where the surface of inner and outer races of

bearing job are polished from both surfaces and oil is used as a coolant.

8) WASHING:- After the grinding process the inner and outer races are

washed before sending them for the assembly.


22/43

BALL BEARING ASSEMBLY

PROCEDURE FOLLOWED IN ASSEMBLY:

1. Transportation from Grinding shop by automation.2. Demagnetizer:-The bearing so obtained is passed through a

Demagnetizer which reduces

the magnetic effects of the job.

3. Washing.

4. Size checking

Bore checking for INNER.

O.D. checking for OUTER.

5. Auto ring pairing:-The outer and inner parts of bearing are matched

properly and inner is placed inside the outer part of the bearing.

6. Automatically filling of balls:-The balls are filled in between the inner and

outer part of bearings by a ball filling machine.

7. KN-705 auto caging and caulking

Checks number of balls.

Separate balls.

Provides equal spacing between balls.

8. 1st Washing.

9. Visual Inspection:-The bearing is now checked for Defaults like black face,

bad riveting, double stamping, pin missing Etc.

10. RADIAL CLEARENCE testing.

11. ID/OD testing.

12. 2nd washing.13. DRYER (removal of kerosene from the surface of ball bearings).

14. Noise testing.

15. Laser marking machine.

16. Grease filling and seal fitting (R.S. and D.S.).

17. Anti-rust oil coating machine.

18. Packing:-Finally the bearing is packed with some poly material.


23/43

Dresser for Grinding wheel dressing

Type of Dresser :

1. Single point type : Diamond point is mounting on a shank . Shank is

clamped to a holder and arm (shaft). Diamond dresses the wheel in a

Arc or Straight line.

2. Diamond roll dresser : In rotary dresser a diamond roll of the same

shape as the work is required to be ground is used . The shape is justmirror image of the track being ground

SINGLE POINT DRESSER

ROLL DRESSER


24/43

TOTAL PRODUCTIVE MAINTENANCE(T.P.M.)

THE T.P.M. POLICY:

Enhancing the profitability of the company, customer satisfaction andcreatingfavorable working environment for all employees by eliminating accidents,defectsand breakdowns.

T.P.M 8 PILLARS:1. Individual Improvement.2. Autonomous Maintenance.3. Planned Maintenance.4. Quality Maintenance.5. Education and Training6. Initial Flow Control (development management).7. Safety and Healthy Environment.8. Office T.P.M


25/43

JAPANI- WORD

5 S

The company follows the 5 S principle of JAPAN:-

The 5-S are the virtues of tidiness orderliness and cleanliness at all timesand atevery place. These account for the clinically clean shop floors and also in

theirpersonal habits. It is the practice of good housekeeping.

The term 5S represents 5 Japanese words

SEIRI

Means - Sort out items and discard the unnecessary

5 QUESTIONS ABOUT SEIRI


26/43

1. Do you find items scattered in your workplace?

2. Are there boxes, papers & other items left in a disorganized manner?

3. Are there equipment and tools placed on the floors?

4. Are all items sorted out and placed in designated spots?

5. Are tools and stationery properly sorted and stored?

SEITON

Means Arrange - A place for everything, Everything in its place

5 Questions about SEITON

1. Are passage ways and storage places clearly indicated?

2. Are commonly used tools and stationery separated from those seldom

used?

3. Are containers and boxes stacked up properly ?

4. Are fire extinguishers and hydrants readily accessible?

5. Are there grooves, cracks or bumps on the floor which hinder work or

safety?

SEISO

Means - Clean your workplace thoroughly

5 Questions about SEISO

1. Are the floor surfaces dirty?

2. Are machines and equipment dirty?

3. Are wires and pipes dirty or stained?

4. Are machine nozzles dirtied by lubricants and ink?

5. Are shades, light bulbs and light reflectors dirty?

SEIKETSU

Means Maintain a standard


27/43

5 Questions about SEIKETSU.

1. Is anyones informs dirty or untidy?

2. Are there sufficient lights?

3. Is the noise or heat at your workplace causing discomfort?

4. Is the roof leaking?

5. Do people eat at designated places only?

SHITSUKE

Means - Train people to be disciplined.

5 Questions about SHITSUKE.

1 Are regular 5S checks conducted?

2 Do people clean up without reminders?

3 Do people follow rules and instructions?

4 Do people wear their uniform and safety gear properly?

5 Do people assemble on time?

5S Benefits

Happier employees with high morale.

Greater people involvement.

Low employee turnover

Increase number of suggestions.

Better use of floor space.

Less work in progress and inventories


28/43

Better flow of work

Low machine breakdown rates

Low accident rates

High yield of materials

High product quality.

JOB RESPONSIBILITIES DURING TRAINING

To take process maturity status of bore size on grinding machines three

times a day, daily and to make report file on MS-excel about the variation

of a machine.

To make control chart of the variation observed in the machine and to

take out the value of Process performance & Process capability.


29/43

To obtain Reproducibility and Reproductivity of radial clearance checking

machines in assembly line.

To monitor the status of the Post Process (PP) gauge daily and make a

report file on MS-excel for the same.

PROCESS CAPABILITY

A measure of the capability of a process achieved by assessing the

statistical state of control of the process and comparing the amount ofrandom variation present with the tolerance allowed by the specification.

The Process Capability is a measurable property of a process to the

specification, expressed as a process capability index (e.g., Cpk or Cpm) or as

a process performance index (e.g., Ppk or Ppm). The output of this

measurement is usually illustrated by a histogram and calculations that

predict how many parts will be produced out of specification (OOS).

Steps followed:-

1. Collection : Gather data and plot on a chart.

2. Control :

Calculate trial control limits from process data.
http://en.wikipedia.org/wiki/Process_capability_indexhttp://en.wikipedia.org/wiki/Process_performance_indexhttp://en.wikipedia.org/wiki/Histogramhttp://en.wikipedia.org/wiki/Process_performance_indexhttp://en.wikipedia.org/wiki/Histogramhttp://en.wikipedia.org/wiki/Process_capability_index


30/43

Identify special causes of variation and act upon them.

3. Analysis and Improvement : Quantify common cause variation; take

action to reduce it.

These three phases are repeated for continual process improvement.

FOR VARIABLE DATA

X - R chart (Control chart for mean & Range)

X - S chart (Control chart for mean & Standard Deviation)

Median - R chart (Control chart for Median & Range)

FOR ATTRIBUTE DATA

p - chart (For proportion non-conforming)

np - chart (For number non-conforming)

c - chart (For numbers of non-conformities)

u - chart (For number of non-conformities/unit)


31/43


32/43

PROCESS PERFORMANCE INDEX (Pp)

It is defined as the tolerance width divided by the process performance,

(irrespective of process centering). This is expressed as

Pp= [USL-LSL/(6s)]

n = (x - x)/(n-1)

i=1

Ppk

This is the performance index which accounts for process centering and is

defined as the minimum of (USL-X)/3 sigma or (X-LSL)/3 sigma.

PROCESS CAPABILITY INDEX (Cp)

It is defined as the tolerance width divided by the process capability,(irrespective of process centering). This is expressed as

USL - LSL

Cp = -----------------------6 (R/d2)

R = -----------

Cpk

This is the capability index which accounts for process centering and is

expressed as minimum of (USL-X)/3 sigma or (X-LSL)/3 sigma.


33/43

Note : Cp is calculated from long term study based on measurement

collected over a period of time, in such a way as to include all expected

source of variation. At least 100 sample parts and a minimum of 20

subgroups should be taken for study to be conducted over a period of 2~3

days. Cp is calculated to assess the ability of a process to satisfy customer

requirements over a long period of time.

In addition to reducing waste, SPC can lead to a reduction in the time

required to produce the product or service from end to end. Process cycle

time reductions coupled with improvements in yield have made SPC a

valuable tool from both a cost reduction and a customer satisfaction

standpoint.


34/43

R&R

This is a technique to measure the precision of gages and othermeasurement systems. The name of this technique originated from the

operation of a gage by different operators for measuring a collection of

parts. The precision of the measurements using this gage involves at least

two major components: the systematic difference among operators and the

differences among parts. The Gage R&R analysis is a technique to quantify

each component of the variation so that we will be able to determine whatproportion of variability is due to operators, and what is due to the parts.

A typical gage R&R study is conducted as the following:

A quality characteristic of an object of interest (could be parts, or any well

defined experimental units for the study) is selected for the study. A gage or

a certain instrument is chosen as the measuring device. J operators are

randomly selected. I parts are randomly chosen and prepared for the study.

Each of the J operators is asked to measure the characteristic of each of the

I parts for r times (repeatedly measure the same part r times). The

variation among the m replications of the given parts measured by thesame operation is the Repeatability of the gage. The variability among

operators is the Reproducibility.


35/43

Gage repeatability and reproducibility studies determine how much of your

observed process variation is due to measurement system variation. The

overall variation is broken down into three categories: part-to-part,

repeatability, and reproducibility.

The Repeatability is the uncertainty among replications of m measurementsof a given part made by the an operator. Since part and operator are fixed,

the variance component for the repeatability is the random error, s 2. On the

other hand, the reproducibility is the uncertainty among operators for

measuring the same part. Therefore, the variance component for the

reproducibility is

2 2

+

2 2

2 2 2 2 2

2 2 2 2

,

Further more, the overall uncertaity of a mesurement is

NOTE :

T

repeatability reprodicibilty

overall reproducibility repeatability

overall

= = +

= + + = +

= + +

he proportion of uncertainty due to Repeatability and Reproducibility can be obtain.


36/43

GAUGE R&R FOR RADIAL CLEARENCE TESTING

MACHINE ON A-9 ASSEMBLY LINE

Measurement system - Operation :- Radial Clearance

Spec. LimitUSL LSL

22 7

Total Tol. 15

Part No.Trial

1

Tria

l 2Trial 3 Range

Averag

e

1 12.9 12.3 10.9 2 12.03

2 11.7 11.8 12.1 0.4 11.87

3 11.3 12.4 11.7 1.1 11.80

4 11.5 11.5 10.6 0.9 11.20

5 11.7 16.8 17.4 5.7 15.30

6 28.7 23.3 22.9 5.8 24.977 11.1 11.3 10.9 0.4 11.10

8 9.1 10.2 9.8 1.1 9.70

9 8.4 7.8 7 1.4 7.73

10 13.2 9.4 8.5 4.7 10.37

R bar = 2.35

Part

Variatio

n =

17.2

Sigma

R&R =

1.37026

2

Sigma

PV =

5.42090

7

Sigma

TV =

5.59140

8

% GRR with respect to

60% of tolearance= 91.350826


TV=

24.506569

5

ndc = = 5.5781129


37/43

6

RESULT:- ndc = 5.58


MACHINE ON CA-2 ASSEMBLY LINE


Spec. LimitUSL LSL

22 7

Total Tol. 15

Part No.Trial

1

Tria

l 2Trial 3 Range

Averag

e

1 53.8 52.4 54.1 1.7 53.432 52.7 54 53.8 1.3 53.50

3 53.8 54.6 53.6 1 54.00

4 51 52.8 52.3 1.8 52.03

5 54.8 53.7 54.5 1.1 54.33

6 57.2 58.4 57.2 1.2 57.60

7 56.8 56.9 55.9 1 56.53

8 58 56.5 57.7 1.5 57.40

9 53.1 53.5 54.8 1.7 53.80

10 55.6 54.5 56.7 2.2 55.60

R bar = 1.45

Part

Variatio

n =

5.6

Sigma

R&R =

0.84548

1

Sigma

PV =

1.75104

7

Sigma

TV =

1.94448

1


60% of tolearance=

56.365403

3

% GRR with respect

toTV=

43.481075

4

ndc = =2.9202033

4

RESULT : - ndc=2.92


38/43




Spec. LimitUSL LSL

29 15

Total Tol. 14

Part No.Trial

1

Tria

l 2Trial 3 Range Average

1 20 29 28 9 25.67

2 21 24 20 4 21.67

3 27 20 18 9 21.67

4 20 25 22 5 22.33

5 24 21 21 3 22.00

6 27 20 26 7 24.33

7 22 22 28 6 24.00

8 28 20 27 8 25.00

9 21 27 20 7 22.67

10 24 24 25 1 24.33

R bar = 5.9Part

Variation

=

4.0

Sigma

R&R =

3.44023

3

Sigma

PV =

1.25823

8

Sigma

TV =

3.66310

9

% GRR with respect to 60%

of tolearance=

245.73094

5

% GRR with respect toTV =93.915670

7

ndc = =0.5156961

1

RESULT: - ndc = 0.52


39/43




Spec. LimitUSL LSL

22 7

Total Tol. 15

Part No.Trial

1

Tria


1 12.5 11.7 13.8 2.1 12.67

2 11.7 13.2 12.2 1.5 12.37

3 13.4 12.7 12.9 0.7 13.00

4 14.3 11.9 13.9 2.4 13.37

5 13.4 12.1 15.3 3.2 13.60

6 14.4 14.6 14.3 0.3 14.43

7 13.2 14.1 14.6 1.4 13.97

8 16 16.5 16.4 0.5 16.30

9 15.7 15.8 15.9 0.2 15.80

10 12.7 13.7 12.7 1 13.03

R bar = 1.33

Part

Variation

=

3.9

Sigma

R&R =0.77551

Sigma

PV =

1.23726

7

Sigma

TV =

1.46022

1


of tolearance=

51.700680

3


1

ndc = =2.2495465

8



40/43




Spec. LimitUSL LSL

22 14

Total Tol. 8

Part No.Trial

1

Tria


1 21.4 18 19.7 3.4 19.70

2 17.3 22.4 22.8 5.5 20.83

3 19.1 16.5 19 2.6 18.20

4 16.8 19.7 23.6 6.8 20.03

5 24 21.8 23.5 2.2 23.10

6 21.1 20.4 17.7 3.4 19.73

7 18.4 24.5 21.4 6.1 21.43

8 23.2 21.3 21.8 1.9 22.10

9 21.4 22.9 20.2 2.7 21.50

10 19.7 19 24.6 5.6 21.10

R bar = 4.02

Part

Variation

=

4.9

Sigma

R&R =

2.34402

3

Sigma

PV =

1.54134

1

Sigma

TV =

2.80538

4


of tolearance=

293.00291

5


4

ndc = = 0.9271626





41/43


Spec. LimitUSL LSL

72.2 15.2

Total Tol. 57

Part No.Trial

1

Tria


1 24.8 25.3 24.4 0.9 24.83

2 24.6 22.3 23.9 2.3 23.60

3 26.2 23.9 24.6 2.3 24.90

4 22.2 25.4 20.5 4.9 22.70

5 22.9 20.7 22.5 2.2 22.03

6 23.4 24.1 24.5 1.1 24.00

7 25.5 24.1 23.2 2.3 24.27

8 24.6 23.6 26.5 2.9 24.90

9 24.7 26 25.2 1.3 25.30

10 22.3 24.2 26.1 3.8 24.20

R bar = 2.4

Part

Variation

=

3.3

Sigma

R&R =

1.39941

7

Sigma

PV =

1.02756

1

Sigma

TV = 1.73615

9


of tolearance=

24.551173

9

% GRR with respect toTV = 80.604184

ndc = =1.0353315

7





42/43


Spec. LimitUSL LSL

99.6 62.9

Total Tol. 36.7

Part No.Trial

1

Tria


1 89.7 88.6 89.3 1.1 89.202 86.7 86 85.8 0.9 86.17

3 82.3 81.4 82.5 1.1 82.07

4 78.2 78.5 80.4 2.2 79.03

5 80.8 80.9 86.9 6.1 82.87

6 87.6 88.2 81.5 6.7 85.77

7 81.2 80.1 81.9 1.8 81.07

8 81.8 80.4 88.7 8.3 83.63

9 84.3 84.9 85.2 0.9 84.80

10 86 86.8 85.8 1 86.20

R bar = 3.01

Part

Variation

=

10.2

Sigma

R&R =

1.75510

2

Sigma

PV =3.19802

Sigma

TV =

3.64797

4


of tolearance=

47.822943

9

% GRR with respect toTV = 48.111687

ndc = =2.5692003

2


SUMMARY


43/43

I completed 4 weeks of my training at NATIONAL ENGINEERING INDUSTRIES

LTD., JAIPUR. During this period I learnt many aspects of practical

applications in industries. I acquired knowledge about the working and

functioning of such a huge factory.

I learnt about various machines , grinding lines, production lines and also

the concepts of management such as PROCESS CONTROL, TOTAL

PRODUCTIVE MAINTENANCE(TPM), TOTAL QUALITY MANAGEMENT(TQM),

STATISTICAL PROCESS CONTROL(SPC), PROCESS CAPABILITY and

REPRODUCTIBILTY & REPRODUCIBILITY(R&R).

I also worked upon some machines to understand them better and to gain

some practical knowledge.

Working at the NEI was a very good experience and I gained a lot from the

engineers, foremen and workers of the company.

I am heartily thankful to all the NEI family for providing me an opportunity

to work here.

Documents

chandra prakash meena