ipt report naseem new.docx

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An In-plant training Report on

AAVIN NILGIRIS &TNSTC Cbe., OOTY

Submitted by

MOHAMMED NASEEM.S.D

(12RBEMEO80)

In partial fulfilment for the award of the degree of

BACHELOR OF ENGINEERING

in

MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICALENGINEERING

FACULTY OF ENGINEERING

KARPAGAM UNIVERSITY: COIMBATORE 641 021

OCTOBER 2014


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KARPAGAM UNIVERSITY

Coimbatore-641 021

FACULTY OF ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

BONAFIDE CERTIFICATE

This is to certify that the Summer In-plant training report submitted by MOHAMMED

NASEEM.S.D, (12RBEME080) to Karpagam University, Coimbatore in partial fulfilment

of the requirement for the award of the degree of Bachelor of Engineering in Mechanical

Engineering is a record of bona fide Summer In-plant training undertaken by him under

my supervision. The training fulfils the requirements as per the regulations of this

University and in my opinion meets the necessary standards for submission. The contents

of this report have not been submitted and will not be submitted, either in part or in full,

for the award of any other degree or diploma in this institute or any other institute or

university.

Prof. E.BABURAJ Mr.G.VIGNESH

PROFESSOR & HEAD SUPERVISOR

MECHANICAL DEPARTMENT LECTURER

FACULTY OF ENGINEERING MECHANICAL DEPARTMENT

KARPAGAM UNIVERSITY FACULTY OF ENGINEERING

KARPAGAM UNIVERSITY

Submitted for the boardpractical examination held on .

Internal Examiner External Examiner

Date: Date:


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ACKNOWLEDGEMENT

I express my sincere thanks to Karpagam University providing me the life necessary facility to

bring out our In-plant training report successfully. It gives me pleasure to express my most profound

regards and sense of great indebtedness and sincere gratitude to Chancellor Dr.R.VASANTHAKUMAR

B.E. (Hons.)., D.Sc.,

I would like express my special thanks to our Dean Dr.C.R.HEMA Ph.D., Faculty of

Engineering, for giving this opportunity to do this In-plant training during third year of my graduation

course.

I would like to express our first foremost gratitude to Prof. E.BABURAJ M.E., (Ph.D)Head of

Mechanical Engineering Department for his valuable guidance, persistent, encouragement and keep

involvement throughout this training which was of immense pleasure and helping successfully to

complete the training

I wish to express my heartfelt thanks and sincere acknowledgement to our faculty advisor

Mr.G.VIGNESH B.E., (ME).,Lecturer Mechanical Engineering Department for his concern about the

training and his timely help to direct me for every move in the training.

It is always a pleasure to remind the fine people in the AAVIN Nilgiris, and TNSTC Ooty, for

their sincere guidance I received to uphold my practical as well as theoretical skills in engineering.

I would like to thank Mr. RAJA SHARBUDHEEN, AM, AAVIN Nilgirisfor convincing me the

fact Whatever a mancan imagine, that can be achieved, treating me as a son of his own and guiding me

to taste the real flavour of engineering.

I would like to thank Mr. SHANKAR, BM, TNSTC Ootyfor the positive attitude he showed for

my work, always allowing me to question him and giving prompt replies for my uncertainties in all the

fields including educational, social and managerial to labour work. And I always great him for his aspects

of crew resource management who always said, I may be wrong.

The Workshop Engineer Mr. RAJENDIRAN, Workshop Superintendents and all other workmen

are also greeted. I thank all the AAVIN and TNSTC trainees who underwent training with me for themutual support I received from them.

Finally I apologise all other unnamed who helped me in various ways to have a good training.

Knowledge is power and unity is strength.


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PART- A

AAVIN

(The Nilgiris District Co-Op Milk Producers Union Ltd.,)

Udhgamandalam


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TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

LIST OF FIGURES 10

1 Introduction 11

1.1 History Of Industry And Products 11

1.1.1 History 11

1.1.2 Dairy Complex 11

1.1.3 Hill Area Development Programme 12

1.2 Plant Layout 13

1.3 Flow Diagrams 14

1.3.1 Engineering Section 14

1.3.2 Milk Processing 15

1.4 Product Information 16

1.4.1 By Products 16

1.5 Capacity Of The Plant 17

2 Manufacturing Processes 18

2.1 Types Of Processes 18

2.2 Raw Materials 18

2.3 Scrap Maintenance 18

3 Maintenance Schedule 19

3.1 Preventive Maintenance 19


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4 Quality Control 20

4.1 Accreditation 20

4.2 Quality Measures 20

5 Administration And Management 21

5.1 Total Employment 21

5.2 Capital Investment 21

6 Conclusion 22


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LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1.1 Plant Layout 13

1.2 Engineering Section Flow Diagram 14

1.3 Milk Processing Flow Diagram 15


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CHAPTER - 1

INTRODUCTION

1.1. HISTORY OF INDUSTRY AND PRODUCTS

1.1.1. HISTORY

On July 14, 1946 Ootacamund Co-operative Milk Supply Society (OCMSS) under

the tutelage of Shri Giriappa Gowder was registered. The OCMSS then had a membershipof 355 members with the share capital of Rs. 10,275/-.

During mid 1940s, milk was collected from its members residing in and around Ooty and

was supplied to customers. The OCMSS expanded its area into two villages during 1960.

Between 1962 and 1964 the pasteurization plant with the capacity of 10,000 litres per day

was installed. Later in mid 1970s the OCMSS accumulated assets worth Rs. 35.00 lacs.

Dairy stalwarts like Dr. N. Basuvaiah and late Shri Pooviah have lent their able support

during this period.

1.1.2. DAIRY COMPLEX

The New Dairy Complex was eatablished in 1985 with milk handling capacity of

50,000 LPD. Infrastructure assistance for establishing Cheese Plant was availed from

National Dairy Development Board. The additional cost of civil works were met out from

Hill Area Development Programme funds.


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1.1.3. HILL AREA DEVELOPMENT PROGRAMME

For the construction of New Dairy Complex, the government Under Hill Area

Development Programme has sanctioned an amount of Rs.347.361 lacs as 50% Share

Capital and 50% loan. The New Dairy Complex was constructed with milk handling

capacity of 50,000 LPD. It is functioning from the year 1985.


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1.2. PLANT LAYOUT

FIG.1.1 PLANT LAYOUT

SERVICE BLOCK

EFFLUENT TREATMENT

PLANT

DAIRY

TRANSPORT

SECTION

STORE

PRODUCTS OUTLET

MARKETING

SECTION

FURN-

ACE

OIL

S

I

L

O

S

T

O

R

A

G

E


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1.3. FLOW DIAGRAMS

1.3.1. ENGINEERING SECTION

FIG 3.1 ENGINEERING SECTION FLOW DIAGRAM

ELECTRIC POWER

160 KVA DIESELPOWERED

GENERATOR

TNEB

CONDENSORCOMPRESSOR

HOTAMMONIAGAS

RECEIVER

EVAPOURATOR

DAIRY

BOILER HOUSE

REFRIGERATION PLANT

COLDAMMONIAGA

S

BOILER 2BOILER 1

FURNACE

OIL

HOTWATER

COLDWATER


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1.4. PRODUCT INFORMATION

Cows milk is collected, processed and sold to the public by the company. Raw milk

would get spoiled within 6 hours after milking. Pasteurisation is the process done to

prevent this, by heating the milk around 80-85C, thus killing all bacteriae. This could

keep the milk edible for 24 hours.

After processing, three types of milk is available to the consumers based on the fat content

and Solid Non Fat (SNF) content in percentage. They are as follows:

Double toned milk : 1.5% fat, 90% SNF

Special toned milk : 4.0% fat, 85% SNF

Premium milk : 3.5% fat, 85% SNF.

Some quantity of Pure processed milk with 3.5% fat, 80% SNF is specially sent to

Kottakal Aarya Vaythyasala for medical purposes.

1.4.1 BY PRODUCTS

Common by products of milk like butter, cheese, curd and ghee are produced as per

demand along with ice creams, flavoured milk shakes, milk govas are produces in the

industry.

Casein: An important raw material used in the manufacturing of clothing buttons is

obtained as a by product of milk. The process is very interesting that when collected milk

gets soured, the solids in it are extracted and heated to form grains of casein.


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1.5. CAPACITY OF THE PLANT

The infrastructure of the plant is designed to handle 50K Litres Per Day. The average

production ranges from 18 to 20K LPD that depends on demand and availability of milk.


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CHAPTER - 2

MANUFACTURING PROCESSES

2.1. TYPES OF PROCESSES

Pasteurisation

Butter churning

Curd production

Cheese production

2.2. RAW MATERIAL COST

Milk is collected from cattle rearing society at an average cost of Rs 35/- per litre.

2.3. SCRAP MAINTEINANCE

Scraps of all sections are stored in a common place and auctioned once a year.


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CHAPTER - 3

MAINTEINANCE SCHEDULE

Preventive and Breakdown maintenances are carried out as per scheduled timetable

and whenever required. Since this is a milk processing industry, any fault in the flow lines

could ruin litres of milk. Stringent preventive maintenance schedule is followed after every

cycle.

3.1. PREVENTIVE MAINTEINANCE

Since this is a food industry, cleaning the machines is crucial. Even a drop of milk of the

previous cycle could make the milk of the next cycle useless. Therefore, after every cycle,

all the pipelines, tanks, silos, etc.., are washed thoroughly with pressurized hot water, acid

and soda.

All other machineries have their respective maintenance schedule and log books are

maintained for each and every machine.


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CHAPTER - 4

QUALITY CONTROL

4.1. ACCREDITATION

This industry is ISO 9001:2008 certified.

4.2. QUALITY MEASURES

Milk samples are collected at the receiving stage and various other stages like after

pasteurisation, from the pre-pack tank, and while in the cold room, etc at constant intervals

and are tested in the lab.

The lab results give a perception of the time that the milk can withstand without getting

soured. If the results arent satisfactory, the milk is re-processed.

The quality of all other edible by-products, rely on the quality of the milk used to prepare

them.


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CHAPTER 5

ADMINISTRATION AND MANAGEMENT

5.1. TOTAL EMPLOYMENT

This industry has a total manpower of 132 staff, working on administrative and

technical levels.

Countless numbers of people are indirectly employed in the supply and collection

chain, in milk products outlets, distribution and selling areas.

5.1. CAPITAL INVESTMENT

The capital investment for this industry funded by HADP for the civil works sums

up to a figure of Rs. 158.406/- lacs.

The cost of plant and machineries equals Rs. 157.888/- lacs.


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CHAPTER 6

CONCLUSION

Since this happened to be my first In-Plant Training, I had spell binding

experiences, which couldnt be included in this report. During this training, I got to see

how generally industries function, how people work for it, why would the industry need

me, and many more. It gave me an opportunity to fine tune myself, to make a good

engineer in future.


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PART- B

TAMIL NADU STATE TRANSPORT CORPORATION

(Coimbatore Ltd.,)

OOTY DIVISION

Udhgamandalam


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TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

LIST OF FIGURES 25

1 Introduction 26

1.1 Main Functions 26

1.2 Different Sections 26

1.2.1 Tyre Section 26

1.2.2 Weekly Maintenance Section 27

1.2.3 Monthly Maintenance Section 27

1.2.4 Bi-Monthly Maintenance Section 27

1.2.5 Semester Maintenance Section 28

1.2.6 Store 28

1.3 Site Layout 29

2 Functions 30

2.1 Running Repairs 30

2.2 A Common Problem 30

2.3 Scrap Maintenance 30

2.4 Concept Of Idle Bus 31

3 Conclusion 32


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LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1.1 Plant Layout 27


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CHAPTER - 1

INTRODUCTION

The Tamil Nadu State Transport Corporation provides road transport

facilities in and around Tamil Nadu. It owns custom built busses whose chasses

are bought from Ashok Leyland powered by Hino engines and TATA powered

by Cummins.

The corp. functions across the state and are divided into six major zones

each covering neighbourhood districts. The TNSTC Coimbatore (hereafter

referred to as department/ dept.) has its headquarters based in Coimbatore, and

serves in the districts of The Nilgiris, Coimbatore, Erode and Tirupur. Zonal

offices are located in Ooty, Erode and Cbe.

1.1. MAIN FUNCTIONS

Since busses need regular and stringent maintenance throughout the year,

all needs of the busses are catered by the branches round the clock. A crew of

skilled labour at every maintenance wing strive to keep all busses running allthe time with the limited resources provided by the department itself.

1.2. DIFFERENT SECTIONS

1.2.1. TYRE SECTION

Here, the tyres of all busses are looked after. Tyres of different

sizes are used as per specifications of the manufacturer. Mostly, all tyres are re-


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groovable. Once theyre fully worn, each tyre is re- treaded by the dept. at least

once.

Puncture works, spare tyre maintenance, providing each bus with all tools

sufficient to deal with any tyre malfunction/ failure while en- route, and all sorts

of tyre repair/ maintenance works are taken care by this section.

1.2.2. WEEKLY MAINTENANCE SECTION

Provided with a hydraulic hoist and two ramps, the labours gain

access to every nook and corner of the vehicles under parts with ease.

Here, they look after the part of maintenance that has to be carried out

each week, such as chassis lubrication, evacuation of water from air tank,

adjustment of wearing parts such as brakes and clutches, visual inspection of

almost all the functional parts, etc

1.2.3. MONTHLY MAINTENANCE SECTION

The so called wheel service which includes striping all the

wheels of the busses all the way up to the axle, to inspect the condition of the

wheel bearings, clean the old lubricant, and to apply new lubricants is done in

this section. Air filter clean up is done by looking at the red band indicator.

1.2.4. BI-MONTHLY MAINTENANCE SECTION

Adjustment of the valve clearance of the engine as per the

manufacturers specifications by PCRA labours is carried out in this section.

Their main function is to maintain the vehicles performance always at the

maximum level possible, to achieve top notch fuel efficiency and to keep

emissions under control.


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1.2.5. SEMESTER MAINTENANCE SECTION

A complete re- conditioning of the bus is carried out along with a

thorough paint job and stringent repair works are done so that the bus complies

with the fitness standards of the dept. Thus the bus is issued a fitness certificate

by the dept. which is valid for the next six months.

The fitness certificate by the dept. is accompanied by a certificate given

by the Regional Transport Officer, which is valid for twelve months. Though

every bus comes under this tenure, the dept. maintains its own standards by

having the fitness tested and checked every six months.

1.2.6. STORE

Inventory from where all the new parts for the busses are obtained

and the scraps are stored.


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1.3. SITE LAYOUT

FIG. 1.1 SITE LAYOUT

WORK SHOP

BATTERY ROOM TYRE SECTION TECHNITIANS LEISURE

ROOM

BUSSTAND

STORE

DRIVERS/ TECHNITIANS TRAINING CLASS ROOMS

ADMINISTRATIVE

OFFICE

SECURITY ROOM

FUELSTATION


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CHAPTER2

FUNCTIONS

2.1. RUNNING REPAIRS

The crew of experienced mechanics are well versed in trouble shooting

any faults that arise out of nowhere or by mishandling, wear or any other

external factors. Once the problem is sorted out, the required mechanics gather

up, and will fix it immediately so as not to create any discomfort to the users.

Any kind of repair works can be dealt with at the maintenance wing at each

zone. Parts that could be reconditioned are collected from all zones and

reconditioned at a common place in Pollachi, and supplied to where ever it is

necessary.

2.2. A COMMON PROBLEM

Since this maintenance wing deals with busses operated in hilly terrain,

the most common problem among all busses is that, failure of leaf springs of the

suspension. With an average of ten cases per day, it stands first on the scale.

The complete faulty spring arrangement colloquially called as CUT is

replaced with a new / working set of springs.

The broken springs are reconditioned / recycled at Pollachi, and are

reused.

2.3. SCRAP MAINTENANCE

Scraps are collected and auctioned once a year.


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2.4.CONCEPT OF IDLE BUS

Once a bus has completed its life of 15 to 16 lac kms, it is termed as idle

and is declared as a scrap even if it is in running condition. The labours get all

freedom to utilize all functional parts from the so called idle bus, i.e, if there is a

demand for a spare part, irrespective of availability and cost, it is desirable that

the part is obtained from the idle bus, and the faulty part is installed on the idle

bus.

At a point of time, once the idle bus is devoid of working parts, it is

auctioned a scrap, but in the shape of a bus.


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CHAPTER3

CONCLUSION

An In-Plant Training at TNSTC was not like one in the previous industry.

We received real training with strict supervision and we were asked to perform

tough tasks within some specified time. This training gave me a good exposure

to the basic problems in automobiles and troubleshooting techniques as how

experts do it.

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