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INDUSTRIAL TRAINING REPORT ON HEAVY FABRICATION & MACHINING INDUSTRY 1

INDUSTRIAL TRAINING REPORT BY ShRiDhAR KaDaM

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Page 1: INDUSTRIAL TRAINING REPORT BY ShRiDhAR KaDaM

INDUSTRIAL TRAINING REPORT

ON

HEAVY FABRICATION & MACHINING INDUSTRY

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Page 2: INDUSTRIAL TRAINING REPORT BY ShRiDhAR KaDaM

AN INDUSTRIAL TRAINING REPORT

Done By

Shridhar Kadam & Gaurav kumar Singh

At

Hardrock Attachments Pvt. Ltd.

Belur Industrial Area, DHARWAD, KARNATAKA

Submitted To

Department of MECHANICAL Engineering

DKTE SOCIETY’s

YASHWANTRAO CHAVAN POLYTECHNIC, ICHALKARANJI

Approved by AICTE, New Delhi & Govt. of Maharashtra,

Affiliated to MSBTE, Mumbai

R. S. No. 644, Sangli Road, Near Adinath Society, Ichalkaranji – 416 115

Dist. Kolhapur, Maharashtra

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Page 3: INDUSTRIAL TRAINING REPORT BY ShRiDhAR KaDaM

REPORT CONTENTS

Introduction

Actual Plant layout

Number of Departments

Nature of Products & Manufacturing Process

Type of Machine

Machine Specification

Maintenance of Various Machines

Measuring Instruments

Name of Component/ Items/ Subcomponents/ Assemblies/ Sub-

assemblies Produced

Raw Material Used

Quality systems employed (KAIZEN/ 5S)

Information about Customers and Competitors

Conclusion

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Page 4: INDUSTRIAL TRAINING REPORT BY ShRiDhAR KaDaM

INTRODUCTION:

HARDROCK ATTACHMENTS PVT LTD (HAPL)

Hardrock Attachments Pvt Ltd belonging to the Hardrock group was incorporated in April 2008 by Mr. Dharamveer Singh of Jamshedpur, Jharkhand. HAPL commencement of commercial production in August 2010, is engaged in manufacturing of fabricated structures for construction machinery such as Arms, Buckets for Excavators, Frames, etc. These parts are assembled to make construction equipments like excavators, backhoe loaders etc, which find application in mining, soil digging and other infrastructural activities. The manufacturing facility of HAPL is located in Dharwad, Karnataka which is well equipped with modern amenities and having ISO 9001:2008 certification.

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PLANT LAY-OUT (HAPL)

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NUMBER OF DEPARTMENTS

1) Human Resources

2) Account & Finance Department

3) Costing Department

4) Design & Development

5) Purchase cum Logistics Department

6) Production Department

7) Quality Department

MANUFACTURING PROCESS (FLOW PROCESS)

1) Cutting Process 2) Deburring Process3) Chamfering Process4) Rolling Process5) Bending Process6) Grinding Process7) Assembly Process8) Welding Process9) Machining Process

10) Dressing Process11) Shot Blasting Process12) Painting Process

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NATURE OF PRODUCTS

Products in Heavy Fabrication & Machining Industry:

Main Products: Excavator, Backhoe or Loader Buck

Other Products: Arm, Lever, rear &front Oscillator Cradle

Hardrock manufactures components for excavators from 0.2 tons to 120 tons capacity.

Buckets:

We manufacture Buckets for Excavators, Back Hoe Loaders, Wheel Loaders and all other construction equipment machineries. Size of Buckets manufacture by us ranges from 0.2 Tons to 120 tons and weight from few kgs to above 8000 kgs.

Attachments:

We manufacture attachments like Linkages, Arms, and Booms etc.for all construction equipment machineries like Excavators, Back Hoe Loaders, and Wheel Loaders etc.

Structures:

We manufacture Frames like Main Frame, Revolving Frame, Front Frame, Rear Frame, Centre Frame etc for Excavators, Back Hoe Loaders, and Wheel Loaders.

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MACHINE MAKE & SPECIFICATION

Sr. No. Machine Name

Manufactured By Model & Specification

1CNC Cutting Machine

MESSER, Germany

220-240 Volt, 1 Phase, 50-60 Hz

2Plasma Cutting M/c

KJELLBERG, Germany 220-240 Volt, 130 A

3CNC Rolling machine DAVI,Italy 400 Volts, 50 Hz, 15 HP

4CNC Boring Machine TAL

450 Volt, AC, 3 Phase,50 Hz

5 Welding Robot IGM, Austria 280-320 Volt

6 GMAW Setup ESAB India Ltd.280-320 Volt, 28-32 A, Gas Flow 18-20

7Grinding &Sandering

MAKHITA, BOSCH

220-240 Volt, 50-60 Hz, 2200 W

8 Lathe PATHAK220-240 Volt, 50 Hz, 1 Phase

9PUG Cutting / Chamfering ESAB India Ltd. 220-250 Volt, 0.35 A

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CNC OXY CUTTING MACHINE

CNC ROLLING MACHINE

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Page 11: INDUSTRIAL TRAINING REPORT BY ShRiDhAR KaDaM

CNC BORING MACHINE

MIG WELDING MACHINE

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CNC PRESS BRAKE MACHINE

ROBOTIC WELDING MACHINE

MAINTENANCE OF VARIOUS MACHINES12

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MAINTENANCE of CNC CUTTING MACHINE Check and clean the guiding and carrying wheelsCheck and clean the guiding and running wheelsCheck the Racks and clean itCheck the tracks, racks and steel belt on the transverse beamCheck the functions of limit switches for transfers movementCheck the height adjusting equipment, rack and pinioncheck all side guides clean & adjust if necessaryCheck all hose & hose connections & Tighten itCheck all the valves and the connectionsCheck sliding surface of lifting shafts and greasingCheck engaging surface of transverse rack and gearCheck transverse rail lubricating oilCheck bearing of band drive system greasingCheck longitudinal rail lubricating oilCheck bearing for longitudinal drive greasing

MAINTENACE OF PUG CUTTING MACHINE

Check the electrical connections for there for there any loose connectionCheck the stability of m/c on AL railCheck the gas hoses for there any leakages and arrest itCheck and clean the nozzle

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Page 14: INDUSTRIAL TRAINING REPORT BY ShRiDhAR KaDaM

MAINTENANCE OF CNC BORING MACHINE

PneumaticCheck and cleaned pneumatic filtersPump UnitOperation status of fan coolerIs there any abnormal heatSpindle-R & LMeasure the clearance between front cap and spindle (0.06-0.13) mmCheck the spindle capOil/Air lubrication unitCheck and clean the filter elementsCheck and refill the all lubricantsEletricalCheck and Retighten the power cablesCheck the limits Switches and Proximity SwitchesAxisCheck the axis X, Y & Z square GuideCheck the axis X, Y & Z Ball Screw, is there any chips presenceCoolant UnitCheck and clean the coolant filterCheck is there any coolant leakage

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MAINTENANCE OF WELDING ROBOT

Robot

Check the axis zero position (pinning position)Check the torch safety functionCheck the liners ,rollers & house packageCheck and lubricate the Axis (if required -500hrs)External axis

Check and lubricate the rail and slidingCheck the axis zero position Inspect the axis movement ,is there any abnormal noiseManipulator

Check and lubricate the moving partCheck and lubricate the negative brushesCheck the axis zero positionElectrical

Check and clean the KUKA &RCI panelsCheck and clean the coolers filtersCheck the earthing connection, check the 'V' between N-E (if required)Check the stabilizer I/P & O/P voltagePower source

Check and clean the water unitCheck and clean the linear and roller

Page 15: INDUSTRIAL TRAINING REPORT BY ShRiDhAR KaDaM

MAINTENANCE & INSPECTION OF MIG WELDING

The maintenance and inspection should be carried out only after the switches in the switch box are certain turn off

Try to maintain and inspect the set regularly as per the following guide line regular Inspection.

Inspection portion Inspection point Maintenance method

Fuse boxFastening & looseness at the connection, confirmation of

proper fuse

Refer to the equipment capacity

Input and output terminals

Fastening & looseness at the connection, confirmation of

insulationFasten first and tape

Electro-magnetic contractor

Confirmation of abrasion at contact points

Replace with new ones

Interior of welding power source

sedimentation of dust trace of overheat

Blow off dust with compressed air

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Measuring Instruments & their Applications

1) Vernier Calliper: Small length, thickness & O.D. as well as I.D.2) Micrometer/ Setting ring: Especially for internal dia.3) Fillet Gauge: For welding inspection, leg length &throat length inspection.4) Measuring Tapes: To measure length.5) Feeler Gauge: Measuring gap between two gaps.6) Bore Dial Gauge: To check/ inspect the ovality.7) Height Gauge: To take vertical height of point from ground level.8) Air Plug Gauge: To explore uniform readings.9) D.F.T. : To measure paint thickness.10)SRR (Digital): To measure Surface Roughness.

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Name of Major Components Produced in Industry

CATERPILLAR 2021 BUCKET ASSY. - 1.53RK

CATERPILLAR 2021 BUCKET ASSY.- 1.7GP

CATERPILLAR 2021 BUCKET ASSY. - 1.7RK

CATERPILLAR 2021 BUCKET ASSY. -2.5GP

CATERPILLAR 2021 BUCKET ASSY. 3.0GP

CATERPILLAR 2021 ARM ASSY

CATERPILLAR 2021 FRAME ASSY. WELDED

CATERPILLAR 2021 FRAME ASSY. FRONT

CATERPILLAR 2021 OSCILLATION MTG.

CATERPILLAR 2021 LEVER ASSY. FAB.

CATERPILLAR 2021 LINK ASSY. FAB

CATERPILLAR 2021 PLATE

TELCON EX200 BUCKET GP

TELCON EX200 BUCKET HD(0.8 CUM)

TELCON EX110 WIDER BUCKET

TELCON TATA 315V LOADER BUCKET

TELCON EX110 BUCKET HD

TELCON Z-AXIS 120 BUCKET GP(0.7CUM)

TELCON Z-AXIS 120 BUCKET HD(0.6CUM)

TELCON 76 HP 0.25 CUM BACKHOE BUCKET

TELCON 86 HP 0.25 CUM BACKHOE BUCKET

JCB 1.5 CUM 1.5 CUM. GP BUCKET

JCB 1.7 CUM W.A. SHOVEL 1.7 M.Z-BAR

JCB 1.7 CUM W.A. SHOVEL 1.7 M.Z-BAR

JCB 1.7 CUM 1.7 CUM Z-BAR BUCKET

JCB 1.7 CUM 1.7 CUM Z-BAR BUCKET

JCB 1.9CUM 1.9 CUM G.P. BUCKET (WELDED TEETH)

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JCB 2.5 CUM W.A. SHOVEL 2.5 CUM M-ZBAR-P107

JCB 3.0 CUM 3.0 cum SHOVEL BUCKET

RAW MATERIAL USED

1. M.S.-(mild steel)

2. Sailma-350HI

3. Sailma-450HI

4. Hardox-400

5. Weldox-700

6. Welten-80

7. Welten-60

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Inventory Control

Inventory Control is the supervision of supply, storage and accessibility of items in order to ensure an adequate supply without excessive oversupply.

It can also be referred as internal control - an accounting procedure or system designed to promote efficiency or assure the implementation of a policy or safeguard assets or avoid fraud and error etc.

Inventory control may refer to:

In economics, the inventory control problem, which aims to reduce overhead cost without hurting sales

In the field of loss prevention, systems designed to introduce technical barriers to shoplifting

Applications

An inventory control system may be used to automate an order fulfillment process. Such a system contains a list of orders to be received, and then prompts workers to pick the necessary items, and provides them with packaging and shipping.

An inventory system also manages in and outwards material of hardware.

Real-time inventory control systems may use wired, mobile terminals to record inventory transactions at the moment they occur. A wired LAN transmits the transaction information to a mobile network.

Physical inventory counting and cycle counting are features of many inventory control systems which can enhance the organization.

Business inventory

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Reasons for keeping stock

There are four basic reasons for keeping an inventory

1. Time - The time lags present in the supply chain, from supplier to user at every stage, requires that you maintain certain amounts of inventory to use in this lead time. However, in practice, inventory is to be maintained for consumption during 'variations in lead time'. Lead time itself can be addressed by ordering that many days in advance.

2. Uncertainty - Inventories are maintained as buffers to meet uncertainties in demand, supply and movements of goods.

3. Economies of scale - Ideal condition of "one unit at a time at a place where a user needs it, when he needs it" principle tends to incur lots of costs in terms of logistics. So bulk buying, movement and storing brings in economies of scale, thus inventory.

4. Appreciation in Value - In some situations, some stock gains the required value when it is kept for some time to allow it reach the desired standard for consumption, or for production. For example; beer in the brewing industry

All these stock reasons can apply to any owner or product

Purpose:

Inventory proportionality is the goal of demand-driven inventory management. The primary optimal outcome is to have the same number of days' (or hours', etc.) worth of inventory on hand across all products so that the time of runout of all products would be simultaneous. In such a case, there is no "excess inventory," that is, inventory that would be left over of another product when the first product runs out. Excess inventory is sub-optimal because the money spent to obtain it could have been utilized better elsewhere, i.e. to the product that just ran out.

The secondary goal of inventory proportionality is inventory minimization. By integrating accurate demand forecasting with inventory management, rather than only looking at past averages, a much more accurate and optimal outcome is expected.

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Integrating demand forecasting into inventory management in this way also allows for the prediction of the "can fit" point when inventory storage is limited on a per-product basis.

Quality System Employed in Industry: KAIZENWhat is Kaizen?Kaizen is the practice of continuous improvement. Kaizen was originally introduced to the West by Masaaki Imai in his book Kaizen: The Key to Japan’s Competitive Success in 1986. Today kaizen is recognized worldwide as an important pillar of an organization’s long-term competitive strategy. Kaizen is continuous improvement that is based on certain guiding principles:

Good processes bring good results Go see for yourself to grasp the current situation Speak with data, manage by facts Take action to contain and correct root causes of problems Work as a team Kaizen is everybody’s business And much more!

KAI = CHANGE

ZEN = GOOD

Kaizen = Continuous Improvement...By Everybody! Everyday! Everywhere!

Why Kaizen?

To remain competitive we need to change for better.

We may become worse by not using our ability to think.

Make our job simpler, safer and faster.

Improves customer service and makes them happier.

Improves productivity and quality.

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Helps achieve growth of the organization.

To get satisfaction by seeing our idea being implemented.

Work smarter, not harder.

5S METHODOLOGY

Tools drawer at a 5S working place

5S is the name of a workplace organization method that uses a list of five Japanesewords: seiri, seiton, seiso, seiketsu, and shitsuke. Transliterated or translated into English, they all start with the letter "S".

The list describes how to organize a work space for efficiency and effectiveness by identifying and storing the items used, maintaining the area and items, and sustaining the new order.[2] The decision-making process usually comes from a dialogue about standardization, which builds understanding among employees of how they should do the work.

The 5 S's

o 1. Seiri (sort)o 2. Seiton (straighten or streamline)o 3. Seiso (shine)o 4. Seiketsu (standardize)o 5. Shitsuke (sustain)

Additional S's

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o 2.1 Safetyo 2.2 Security

The Origins of 5S

The 5 S’s: There are five primary 5S phases: They can be translated from the Japanese as Sort, Systematize, Shine, Standardize and Self-Discipline. Other translations are possible.1. Seiri (sort)

Remove unnecessary items and dispose of them properly

Make work easier by eliminating obstacles Reduce chance of being disturbed with unnecessary items Prevent accumulation of unnecessary items Evaluate necessary items with regard to dept/cost/other factors.2. Seiton (straighten or streamline)

Arrange all necessary items in order so they can be easily picked for use

Prevent loss and waste of time Make it easy to find and pick up necessary items Ensure first-come-first-serve basis Make work flow smooth and easy Can also be translated as "set in order"3. Seiso (shine)

Clean your workplace completely Use cleaning as inspection Prevent machinery and equipment deterioration Keep workplace safe and easy to work Can also be translated as "sweep"4. Seiketsu (standardize)

Maintain high standards of housekeeping and workplace organization at all times

Maintain cleanliness and orderliness

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Maintain everything in order and according to its standard.5. Shitsuke (sustain)

To keep in working order Also translates to "Self-Discipline" meaning to do without being told

Additional S's

Other phases are sometimes included e.g. safety, security, and satisfaction. These however do not form a traditional set of "phases" as the additions of these extra steps are simply to clarify the benefits of 5S and not a different or more inclusive methodology.

Safety

The phase, "Safety", is sometimes added. There is debate over whether including this sixth "S" promotes safety by stating this value explicitly, or if a comprehensive safety program is undermined when it is relegated to a single item in an efficiency-focused business methodology.

Security

The phase, "Security", can also be added. To leverage security as an investment rather than an expense, the seventh "S" identifies and addresses risks to key business categories including fixed assets (PP&E), material, human capital, brand equity, intellectual property, information technology, assets-in-transit and the extended supply chain. Techniques adapted from those detailed in Total security management (TSM) or the business practice of developing and implementing comprehensive risk management and security practices for a firm’s entire value chain.

The Origins of 5S

5S was developed in Japan and was identified as one of the techniques that enabled Just in Time manufacturing.

Two major frameworks for understanding and applying 5S to business environments have arisen, one proposed by Osada, the other by Hirano. Hirano provided a structure for improvement programs with a series of identifiable steps, each building on its predecessor. As noted by John Bicheno, Toyota's

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adoption of the Hirano approach, was '4S', with Seiton and Seiso combined. However, Toyota now uses the 5S as a standard.

Although the origins of the 5S methodology are in manufacturing, it can also be applied to knowledge-economy work, with information, software, or media in the place of physical product.

Information about CUSTOMER & COMPETITOR

Customer

1. TATA HITACHI CONSTRUCTION EQUIPMENT LTD2. CATER PILLAR LTD3. JCB INDIA LTD

Competitor

1. APEX AUTO LTD2. RSB LTD3. ASHWA ENERGY PVT LTD4. FERRUM EXTREME ENGINEERING PVT LTD

Tata Hitachi Construction Machinery Company is an India based joint venture between Tata Motors and HCM, Japan. It was previously known as Telco Construction Equipment Co. Ltd.

It has more than half of the market share in the excavator segment.[2] The company has its corporate office at Bangalore and three manufacturing bases in Jamshedpur, Dharwad and Kharagpur. It also has two subsidiaries Serviplem S.A. and Lebrero in Spain. The annual turnover of the company is 2300 Crores.

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Caterpillar Inc., is an American corporation which designs, manufactures, markets and sells machinery and engines and sells financial products and insurance to customers via a worldwide dealer network. Caterpillar is the world's leading manufacturer of construction and mining equipment, diesel and natural gas engines, industrial gas turbines and diesel-electric locomotives. With more than US$89 billion in assets, Caterpillar was ranked number one in its industry and number 44 overall in the 2009 Fortune 500.

Caterpillar stock is a component of the Dow Jones Industrial Average. Caterpillar Inc. traces its origins to the 1925 merger of the Holt Manufacturing Company and the C. L. Best Tractor Company, creating a new entity, the California based Caterpillar Tractor Company. In 1986, the company re-organized itself as a Delaware corporation under the current name, Caterpillar Inc. Caterpillar's headquarters are located in Peoria, Illinois, United States.

Caterpillar machinery is recognizable by its trademark "Caterpillar Yellow" liveryand the "CAT" logo.

J.C. Bamford Excavators Limited, universally known as JCB, is a British multinational corporation, with headquarters in Rocester, Staffordshire, manufacturing equipment for construction, demolition and agriculture. It is the world's third-largest construction equipment manufacturer. It produces over 300 types of machines, including diggers (backhoes), excavators, tractors and diesel engines. It has 22 factories across Asia, Europe, North America, and South America; its products are sold in over 150 countries.

JCB was founded in 1945 by Joseph Cyril Bamford, after whom it is named; it continues to be owned by the Bamford family. In the UK 'JCB' is often usedcolloquially as a generic description for mechanical diggers and excavators and now appears in the Oxford English Dictionary, although it is still held as a trademark.

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COMPETITOR :

RSB is a fast growing global engineering organization with business interest ranging from design to manufacturing of aggregates and systems related to commercial vehicles, passenger cars, construction and farm equipment and a wide variety of automotive and off-highway equipment.

The brothers, R. K. Behera and S. K. Behera, from a humble beginning, scripted the story of the RSB in 1975 at Jamshedpur. Three decades later, headquartered at Pune, it has grown into a pulsating institution with manufacturing setups at Jamshedpur, Pune, Dharwad, Chennai, Pantnagar, Cuttack, Homer (USA) and Belgium (Europe).

RSB comprises of four different companies, namely, RSB Transmissions (I) Ltd., RSB Transmissions North America Inc. (Formerly known as Miller Brothers Manufacturing) , I-Design Engineering Solutions Ltd. and Ivitesse Technologies Pvt. Ltd.

All RSB manufacturing units are ISO/ TS16949, ISO: 14001 and OHSAS: 18001 certified.

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Apex Auto Ltd is the largest domestic manufacturer of finished fabricated structures to the earth-moving and construction equipment industry in India. We are presently manufacturing components for top selling excavators, back hoe loaders, cranes, compactors, transit mixers, underground drilling, crushing & screening equipments for the domestic and international market. We also have facilities that can cater to the general engineering requirements of other sectors like railways, power, shipping and aerospace.

Apexhave facilities across five plants located in India in Jamshedpur, Dharwad, Bangalore and Kharagpur.

Ashwa Energy Private Limited is situated in Dharwad industrial growth center, Belur industrial area in dharwad, Karnataka – India, near Poona Bangalore national highway. Dharwad is about 430kms by road from Bangalore & Poona and connected by road & rail. Ashwa energy private limited commenced its commercial production in the year 2008.

Ashwa Energy Private Limited engaged in the manufacturing of chemical pumps and industrial valves namely gate, globe. Swing check valves and high performance butterfly valves in association with M/s. Akay industries, hubli& for valves tied up with M/s valtek corporation, dharwad.

Ashwa Energy Private Limited has manufacturing facility equipped by modern equipments suitable for higher size and higher class valves with a area of 18,000 sq.mtrs.

The company caterers to the needs of the needs of major industries like fertilizer, pulp and paper, thermal, chemical, nuclear and many other process industries.

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Subsequently the board of visionaries decided to bring Shri Rajesh Goel, who is an MBA as a chief of the Ferrum Extreme Engineering Pvt. Ltd. (FeRRUM) and he has worked with his vision and with his entry FeRRUM has achieved a position in the market in the field of extreme engineering of structures and components within a very short period of one year but always with the prime consideration of utmost time management and not to take excuse on the pretext of shortage of time with no compromise & relaxation in quality control and to maintain this it is an ISO-9001 Certified and ISO 14001: 2004 and ISO Engineering Unit.

FeRRUM is managed by professional stable management comprising visionaries with vision of utmost balance of skill and business to promote technological fineness, international standard, hair-line accuracy, need based result.

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Conclusion

After the completion of industrial training we enhanced competencies & competitiveness in our respective area of specialization. We tried to relate the experience in the workplace with knowledge learned in the institute & applied the knowledge on the job under supervision.

Here, we gained the experience & knowledge that can be used for suitable job without delay after studies.

We learned to hone soft skills appropriate to the work environment. Also get improvised in communication skills. We assessed career ability, knowledge & confidence as well as enhanced our marketability to be more competitive.

With experience, knowledge & skills acquired during industrial training we will be better prepared to face working world.

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OPINION ABOUT INPLANT TRAINING

In plant training provides the industrial exposure to the students how to face the industry once they foot out from the campus. The industrial knowledge is essential for all students to get success in their job. Once students step into the industry they should ready to face competitive world with knowledge. The core competence area extending its boundary daily as technology grows.

Student need to update day to day stuff from various innovative technologies.

On successful completion of our in plant training students be skill enough & ready to shine. Job opportunity for students who has certificate on the in plant training is high compared to the non-trained student, because company will know that student’s knowledge will be boosted by in plant training.

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INDUSTRIAL TRAINING REPORT

ON

HEAVY FABRICATIONINDUSTRY

AT

HAPL DHARWAD

DIRECTOR: SUPERVISED BY:

MR. HARBHAJAN SINGH MR. MANISH SINGH (PROCESSING DEPT)

MR. RANVIJAY PRASAD (PROCESSING DEPT)

MR. AMIT KALIA (DEVELOPMENT DEPT)

MR. MRITYUNJAY KAGADAL

(MACHINING DEPT)

MR. PRAKASH B. (QUALITY DEPT)

PARTICIPANTS:

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GAURAV KUMAR SINGH

SHRIDHAR KADAM

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