SUMMER TRAINING REPORT 14th June to 5th July

SUBMITTED BYRAVI KUMAR 00214807411 5M6

TABLE OF CONTENTS
Pages 1. Acknowledgement...1 2. Preface ..2 3. About the Company...3-13
3.1.The Mission Statement 3.2 Vision 3.3 Company Introduction 3.4 Product Range 3.5 Working Condition 3.6 Safty Concern 3.7 A Graphical Overview 3.8 Awards & Recognitions 3.9 Customers

4. I.Q.C........14-16
4.1 Introduction 4.2 Verification of Purchased Product 4.3 Sampling Plan

5. MOULDING SHOP.......17-28
5.1 Introduction 5.2 Types of Plastic 5.3 Details of Moulding Machines 5.4 Measuring Instruments Details 5.5 Process Setting Parameters 5.6 Customer Complaint 5.7 Preventive Maintaince Of Moulds 5.8 Photo Gallery of Moulding Shop

6. PRESS SHOP.....29-39
6.1 Introduction 6.2 Theory of Cutting 6.3 Various Cutting Operations 6.4 Theory of Bending and Forming 6.5 Material Used 6.6 Process Flow Chart 6.7 Photo Gallery

7. TOOL ROOM....43-51
7.1 Introduction 7.2 Process Flow Chart 7.3 Machine Detail 7.4 EDM and Wire Cut EDM 7.5 Material Colour Code 7.6 Measuring Instruments

ACKNOWLEDGEMENT
With profound respect and gratitude, I take the opportunity to convey my thanks to complete the training here. I do extend my heartfelt thanks to Mr. R.S Yadav(Sr.Mgr. HR & IR) for providing me this opportunity to be a part of this esteemed organization. I am extremely grateful to all the technical staff of Elin Electronics Ltd. Ghaziabad (U.P.) for their co-operation and guidance that helped me a lot during the course of training. I have learnt a lot working under them and I will always be indebted of them for this value addition in me. I would also wish to convey my warm regards to Mr. Pawan Kumar for providing me with the entire knowledge database that I needed for this report. I would also like to thank Brig. S.K. Kakar (Retd.) Dean & Head - HR & Corporate Relations, Maharaja Agrasen Institute of Technology, Sector - 22, Rohini, Delhi for providing me this wonderful opportunity to work with the Elin Electronics Ltd.

PREFACE
This six weeks training is a part of our 4-year degree course. Practical industrial training mainly aims at making one aware of industrial environment, which means that, gets to know the limitation, constraint and freedom under which an engineer works. One also gets opportunity to see from close quarters that indicate management relation. This training mainly involves industrial and complete knowledge about designing, assembling and manufacturing of equipments. Excellence is an attitude that the whole of the human race is born with. It is the environment that makes sure that whether the result of this attitude is visible or otherwise. A well planned, properly executed and evaluated industrial training helps a lot in inculcating a professional attitude. It provides a linkage between the student and industry to develop an awareness of industrial approach to problem solving, based on a broad understanding of process and mode of operation of organization. During this period, the students get the real experience for working in the actual environment. Most of the theoretical knowledge that has been gained during the course of their studies is put to test here. Apart from this, the students get an opportunity to learn the latest technology, which immensely helps them in building their career. I had the opportunity to have a real experience on many ventures, which increased my sphere of knowledge to a great extent. I got a chance to learn many new technologies and was also interfaced to many new instruments and all the credit goes to Elin Electronics Ltd. Ghaziabad.

ABOUT THE COMPANY

The Mission Statement
WE COMMIT OURSELVES TO DELIGHT OUR CUSTOMERS AND MAINTAIN MARKET LEADERSHIP, THROUGH CONTINUAL IMPROVEMENT OF OUR QUALITY MANAGEMENT SYSTEMS BY : INTRODUCTION OF NEW PRODUCTS UPGRADATION OF QUALITY LEVELS UPGRADATION OF HUMAN RESOURCES COST EFFECTIVENESS OF OUR PRODUCTS AND ACTIVITIES

Vision: To meet and exceed customers expectation by products & services at offering high quality

competitive prices, in time all the time.

To be recognized as the largest & most efficient manufacturer in our product line in the Nation. To be a responsible corporate entity which recognizes and insures that its activities are sustainable and have a positive impact on its employees and society.

COMPANY INTRODUCTION
Year of Establishment Managing Director Chief Executive (Works) Executive (Works) 1969 Sh M.L Sethia Sh Kishor Sethia Sh Sanjeev Sethia Sh Vikas Sethia Dy Chief Executive General Manager Sh.S.K.Tandon Sh N.C.Agarwal

PRODUCT RANGE
Tape Deck Mechanism :For Stereo Players, High-Speed Recorders, Car Stereos, Portable Personal Stereos etc. D.C. Micro Motors : For Tape Deck Mechanisms - Single-Speed, Double-Speed, CD /VCD /DVD loading, Portable Personal Stereos etc.

Synchronous Motors & Stepper Motors :

For Air-conditioner louvers, Micro-wave tables, Rotary display tables etc.

Universal Motors & Eco Motors :

For food processors, Mixer & Grinder.

Free Power Generators :

For Transistors for Philips

Audio Systems :
Complete Audio System as Tape Recorder, Two in One, Walkman and Radio for Philips at Elin, Goa

Home Appliances :
Electric light weight Irons, Toasters, Mixer/Juicer/Grinders for Philips at Elin, Baddi.

Electrical Light Fittings :

Electrical Luminaires for Philips.

CD Mechanism :
For Audio/Video Systems

Terminal Blocks :
For Refrigeration

Speakers :
For TVs, Audio Systems

Fan Blower Motor :

For Frost Free Refrigerators

Submersible Pump:
For Air Coolers

ISO IMPLEMENTATION: ISO 9001 : 2000 ISO 14001:2004 ISO TS 16949.2002 For Quality since 1996 For Environment since 2002 For specific requirement of Automobile Industries since 2005 CERTIFIED BY DNV (DET NORKSE VERITAS)

WORKING CONDITION
Canteen Lunch Timings - 11:30 to 2:00 PM. Coupens for lunch Provided in Canteen. Shift Timings Punctuality General/ A,B,C. 100%. 3 times late coming (10 min. ) are allowed in a month after 3 late coming half day will be marked Attendance marking Punching card has to be punched in

Recording machines which are maintained at main gate and second gate for all the times for maintaining incoming and out going time of persons. Gate Pass System ( Employees)Official / Personal

Security System

Workmen are Searched by Security and

staff as and when required. Bus Arrangement Only for Female Employees for which

approx. Rs. 350.00 will be deducted. Compensatory Payment - Jr. Staff upto Senior Engineers and

officers are entitled to compensatory payment if they are continuously staying on duty for more than 6 hrs. After 8 hrs. of working. They will be entitled for one days salary payment. Requisition for compensation to be submitted to HRD department after sanctioned from HOD and approval of Management. Performance Appraisal quarterly. Salary / Wages Payments Before 7 th of every month. Workers - Annually in April, for new person

are paid by cash and Staff through Bank. Tea Facilities (Staff) - Tea is provided free 2

times in a day. (Workmen) - Workmen have to pay subsidized cost for tea. Traveling Expenses Paid by the accounts deptt by

recommendation of HOD and approval of GM / Dy. C.E., as per rules available at Accounts deptt. Out door duty Authorization slip has to be submitted

in Personnel deptt. before or after finishing of assignment.

Leaves Facility

7 Causal Leave (CL), 7 Medical Leave

(ML,only for the persons out of ESI coverage ) Earned Leave - EL (1 day after 20 days working) EL can be accumulated upto maximum 45 days. Leave Available system Leave application is to be

submitted to Personnel deptt after Getting approval of HOD. Grievances Handling procedure has to be followed :1. HOD 4. C.E Loans and Advance Payment Loan may be granted once 2. Personnel 3. G.M / Dy. C.E. In case of Grievance , following

in two years to permanent employees . Max. 2 months salary which should be deducted within that year. Eligible person can put forward loan application to Personnel department after recommendation of HOD for approval from the management. Advance can be availed once in 3 months between 20th and 22nd of every month. Manpower Requirement Through Authorization slip

required by HOD, and approved by the GM. The slip has to be submitted to Personnel Deptt for arrangement of manpower. Selection of Manpower Selection committee will

take the interview of the candidate and if found suitable the application will be forwarded for approval to the Management for final interview and selection.

SAFETY IS OUR CONCERN

It is advised to use Personal Protective Equipments (PPE) for safe working in the factory Following PPE is being used in the departments. 1. Aprons Use for Painting work 2. Shoes Compulsory in Chemical working area 3. Goggles For machining jobs, welding jobs. 4. 5. 6. 7. 8. 9. Dress Helmet For girls, jacket and cap. Use while working on height or working on crane / lifter. Use during construction work , paints of Shad. Where fumes and gasses are used. Use where chemical is being used. Use where cut injury chances are there i.e. While unloading of CRCA sheet

Safety Ropes/ Safety belt Mask -

Rubber hand globes Thick Cotton hand globes -

SCHEME IMPLEMENTED IN COMPANY

Suggestion Scheme :-We value suggestion given by our employees and expect that every employee will give atleast 2 suggestion in a year. To encourage new ideas for improvement a suggestion scheme is running in the organization .The forms for giving suggestions are available in Personnel as well as with the departments head.After filling the forms it has to be put in the suggestion box outside the Personnel deptt. Persons whose suggestion are selected Rs. 300/cash as award given and if the suggestion is fully implemented and has resulted in cost saving an amount equivalent to 10% of saving or Rs. 5000 whichever is lower is given to the employees on 1st of January (Annual day)

A Graphical overview
Group Turnover

TURNOVER OF LUMINAIRE BUSINESS

Turnover(Crores)
80 70 60

Value (Cr.)

50 40 30 20 10 0 Turnover 2009 32.79 2010 39.11 2011 68.12

GSRS RATING

GSRS Rating for Elin

90 80 70 60 50 40 30 20 10 0

63.75 1

78.22

YEAR

SRS Rating of Philips For ELF

100.00 80.00 60.00 40.00 20.00 0.00
79.0 77.0 81.5 79.0 86.5 75.5 84.0 79.5 69.5 77.0 72.0

Scoring

Months

SRS Rating

Awards & Recognitions

1982 1991-92 1993 1994 1994 1996 1997-98 1997-98 1999-00 2001-02 2002-03 2003-04 2006 -07 2007-08 2008-09 2008-09 2009-10 2009-10 2009-10

ELCINA award for Excellence In Exports 1991-92 Philips (C.E.) the Best Co-maker award. Elin R & D Recognised by Deptt. of Science & Technology, Govt. of India. Two Star Industries award from Directorate of Industries Import Substitution award from All India Radio and Electronic Association Excellence in Electronics award from Govt. of India. ISO 9001 certification by DNV (Netherlands) ELCINA award for Indigenous Development of Capital Goods ESC award for Excellence in Export. ELCINA award for Export Growth. ELCINA award for Excellence in Quality. National award for Excellence in Electronic Components from Deptt. of Electronics (Govt. of India) ELCINA award for Indigenisation of Capital Goods for Manufacture of Electronic Products. ELCINA award for Research & Development Work in the field of electronic components. 2001-02 ELCINA award of Excellence for Environment Management ELCINA award for Quality Quality Excellence Award from Institute of Trade & Industrial Development Certificate of Green Partner from Sony Japan (ROHS Compliance) Best Delivery Performance Award from Denso MSME National Award -2008 Ministry of Micro, Small & Medium Enterprises, Govt. of India for outstanding efforts in Entrepreneurship FICCI-SEDF Corporate Social Responsibility Award 2009. Jury Commendation Award Category: Small & Medium Enterprises (SMEs) Award for Best Performance in Outstanding support from Denso Award For Best Performance in Cost from Denso HR Excellence Award for The Year 2009-10 Gold Award for Innovation In RETENTION STRATEGY.

CUSTOMERS

INCOMING QUALITY CONTROL(I.Q.C) DEPTT.

It is the job of the IQC to conduct inspections and handle quality problem before the manufacturing process starts.

Specific tasks of IQC include:

To perform approved list check To evaluate supplier quality records To perform sampling of incoming material based on the IS-2500 Part-1 1991 ISO2589-1:1989 Verifying accuracy through calibration Assess dimension, visual & functional inspection of significant deviations. Continually Enhance the IQC process Evaluation of online rejection Co-ordination with suppliers for quality problem To short quality related problem in shop floor. Evaluation of new parts & report generation. To recover salvageable class component from broken / damaged To carry out aging test of components. To conduct suppliers end audit for factory evaluation and to made 4M agreement.

VERIFICATION OF PURCHASED PRODUCT

SAMPLING PLAN
LOT SIZE CODE ACCEPTED REJECTED SAMPLE LATTER SIZE

2-8 9-15 16-25 26-50 51-90 91-150 151-280 281-500 501-1200 1201-3200 3201-10000 10001-35000 35001150000 150001500000 500000OVER

A B C D E F G H J K L M N P Q

2 3 5 8 13 20 32 50 80 125 200 315 500 800 1250

0 0 0 0 0 0 0 0 0 1 2 3 5 7 10

1 1 1 1 1 1 1 1 1 2 3 4 6 8 11

MOULDING SHOP
Mould: - is the common term used to describe the production tooling used to
produce plastic parts in injection Moulding machines.

Mould Design: 1) Core 2) Cavity

Mould is separated into two halves :-

Main Parts of Moulds:S.No. Parts S.No. Parts S.No. Parts

1 2 3 4 5

Mould Base Location Ring Sprue Bush, Core & Cavity insert Ejector pins

6 7 8 9 10

Riser (Spacer) Slider Feeding Bush Core Pin Guide pin

11 12 13 14 15

Limit Bolts Spring Cooling Channerls Nylon Bush Guide Bush

Type of Injection Moulds:S.No. Types Two plate moulds 1 (Standard moulds) Three plate moulds (stripper plate 2 moulds) 3 Split cavity moulds 4 Hot runner moulds

Type of Mould Maintenance:a) Preventive Maintenance :- Each time the mould is removed from the injection moulding m/c preventive maintenance is done. b) Rectification Maintenance :- When any part of mould has broken, damage, bend and wear out then damage parts are repaired or replaced by new .

PLASTIC
Plastics are Macromolecular structured Polymer. Polymer is made up of many repeating simple chemical units, known as Monomer. All Plastics are Polymers- But All Polymers are not Plastics, they may be Fibers , Elastomers (Rubbers) or adhesives. In simple words plastic is one of the family members of polymers. TYPE OF PLASTIC 1. THERMOPLASTICS:-Thermoplastics are materials that can be repeatedly heated, melted and converted into a product. 2. THERMOSETS:-Thermosets undergo a chemical reaction during conversion into a product.The product cannot be re-melted and converted into another product again. CLASSIFICATION OF THERMOPLASTICS :1. Commodity Plastics The Plastics which are used in Non critical applications. 2. Engineering Plastics The Plastics which are used in Engineering applications.
ADVANTAGES OF USING PLASTIC Light in weight Higher strength to weight ratio Wider design freedom Easy Processability Low Energy Required for Manufacturing Minimum post finishing required Corrosion Resistant. Low creep Better aesthetics

DETAILS ON PLASTIC
TYPE OF PLASTICS TYPE OF THERMOPLASTICS MECHANICAL PROPERTIES PROPERTIES APPLICATIONS

Poly Propylene (PP)

Very Low Density (0.890-0.905 g/cm3) Melting range - (1600C-1650C) Good surface hardness and scratch resistance Good dimensional stability Transparent, ( light transmission up to 89% ) High-gloss ; good mould surface reproduction High Rigidity Good chemical resistance Heat deflection temperature >90 C High dimensional accuracy and stability Good Electrical insulation Transparent, ( light transmission up to 89 % ) High-gloss ; good mould surface reproduction

COMMODITY PLASTICS

Poly Styrene (GPPS, HIPS)

Shrinkage :Processing temp :Mould temp. :Dry temp. :Dry time :Shrinkage :Processing temp :Mould temp. :Dry temp. :Dry time :-

1.5 % 250-270C 50-75 C 40-90 C 2-3 Hrs 0.60 % 170-280C 10-80C 60-80C 2-4 Hrs

Clamp Seal,Top Housing, Protector Wiper

TRD KNOBS

Shrinkage Mould temp. Dry temp. Dry time Dehydrification

:- 0.50 % :- 50-80C :- 70-85C :- 2-4 Hrs

Processing temp :- 180-270C JAR

High Rigidity Styrene Good chemical resistance Acrylonitrile (SAN) Heat deflection temperature >90 C High dimensional accuracy and stability Good Electrical insulation Highly Transparent Hard,Rigid,Strong ,Stiff Good Impect strength Good Chemical Resistancc

Poly Methyl Methacrylate (PMMA)

Shrinkage :Processing temp :Mould temp. :Dry temp. :Dry time :Dehydrification

0.1-0.4% 210-240C 50-70C 70-80C 3-5 Hrs

LENSE

TYPE OF PLASTICS

TYPE OF THERMOPLASTICS

MECHANICAL PROPERTIES

PROPERTIES

APPLICATIONS

Good rigidity and hardness Good dynamic fatigue resistance High impact strength, even at low temperatures Poly Amide Toughness improved by water (Nylon 6, 66,12) absorption

Shrinkage

:- 1.20%-1.5%

Processing temp :- 240-290C Mould temp. Dry temp. Dry time Dehydrifica :70-120C Many type Gear of Deck machanism, U.V Moror Fan Knob Wiper

:- 75-80C :- 4-6 Hrs

ENGINEERING PLASTICS

High heat resistance Excellent electrical properties Virtually no stress cracking (stress relaxation Glossy surface finish Low dust attraction / Rigid Good shock and fracture resistance Acrylonitrile Good Chemical resistance Butadiene Heat resistance up to 105 C Styrene (ABS) High Dimensional accuracy and stability Good Electrical insulation Good flowability / Readily electro High tensile, impact, and stiffness Outstanding fatigue endurance Excellent resistance chemicals Poly Oxy Methylenes Excellent dimensional stability Good electrical insulating (POM) characteristics Poly Acetal Good resilience and resistance to creep Good abrasion resistance

Shrinkage :Processing temp :Mould temp. :Dry temp. :Dry time :-

0.50% 210-270C 50-90C 80-90C 2-3 Hrs

ELF TOP and BOTTOM,Deck parts, Eveready parts,Submersab le comp.Mindarika parts

Shrinkage :Processing temp :Mould temp. :Dry temp. :Dry time

2.0% 200-210C 40-100C 90-100C

:- 2-3 Hrs

CDS,EN-97,EN77,EN-303,EN57,EN-36, TRD, DC Motor,Sync.Moto r,Mindarika parts

TYPE OF PLASTICS

TYPE OF THERMOPLASTICS

MECHANICAL PROPERTIES

PROPERTIES

APPLICATIONS

Excellent transparency

Shrinkage Mould temp. Dry temp. Dry time Shrinkage Mould temp. Dry temp. Dry time

::- 80-100C :- 110-120C :- 2-3 Hrs :- 1.75% :- 60-80C :- 120-140C :- 3-4 Hrs 6352 (DC MOTOR) 37511,6877,6858, (SYNC .MOTOR) Terminal parts of LG

ENGINEERING PLASTICS

High strength and toughness up to 140oC

Processing temp :- 280-320C

Poly Carbonate Very High Impact and break resistant (PC) Very good heat resistance
High Weathering Resistance Good processing characteristics PBT :- High strength & rigidity High impact resistance High heat resistance

Processing temp :- 240-260C

Thermoplastic Excellent dimensional stability Polyesters Excellent flame resistance (PET,PBT) Good electrical insulation
Good abrasion resistance High gloss, good moulded surf Resistant to fuels, lubricants

PP Dana PP Dynapurge

Processing temp :- 220-280 c Knob wiper,Sync.Motor, Sub.pump,TRD Knob,DC Motor Wings,45914,Jar

Purging Material

MASTER BATCH PIGMENT

Master batch used for colour change

2 -4 %

Pigment used for colour change

0.10%

Details of Moulding Machines

S.N NAME OF M/C O. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TOSIBA IS 130 TOSIBA IS 80 TOSIBA IS 170 DEMAGE 50 DEMAGE 150 SUPPER MASTER 90 (TOGGLE) SUPPER MASTER 90 (HYDRAULIC) SUPPER MASTER 50 SUPPER MASTER 220 JSW 15 JSW 70 MULTIPLAST SUMITOMO CN 50 CN 75 FEROMATIC 350 NO. OF M/C 1 1 1 2 1 2 2 2 1 1 1 1 1 1 1 1 CLAMPING FORCE 130 TON 80 TON 168 TON 50 TON 150 TON 90 TON 90 TON 50 TON 220 TON 15 TON 70 TON 50 TON 7 TON 50 TON 75 TON 350 TON MIN. MOULD HT.(MM) 265 220 295 210 240 125 200 100 250 145 278 200 145 200 250 300 OPENING STOCK 560MM 400 MM 720 MM 370MM 500 MM 270 MM 500 MM 220 MM 760 MM 200 MM 195 MM 195 MM 150 MM 410 MM 450 MM 675 MM SPACE MAX. BETWEEN TIE DAYLIGHT BAR H*V 750MM 620MM 950 MM 610 MM 950 MM 620 MM 670 MM 540 MM 1000 MM 350 MM 295 MM 295 MM 210 MM 580 MM 610 MM 1475 MM 460*460 MM 390*390 MM 560*510 MM 355*355 MM 490*490 MM 360*360 MM 360*360 MM 310*310 MM 510*510 MM 225*225 MM 320*320 MM 320*320 MM 140*140 MM 320*320 MM 340*340 MM 722*722 MM SHOT WT.(PS) 83GMS 72 GMS 150 GMS 55 GMS 280 GMS 156 GMS 132 GMS 55 GMS 424 GMS 14 GMS 72 GMS 55 GMS 6 GMS 55 GMS 60 GMS 200 GMS

ALL MACHINE ARE PROGRAMABLE LOGIC CONTROL MACHINE

Measuring Instruments Details

Sl.
1 2 3 4 5 6 7 8

Instruments
Dial/DIGI. CALIPER Micrometer DIGI. HT. GAUGE Height Gauge Pappy Dial Profile Projector Std.Pin Gauge Std Slip Gauge

Least Count
0.01 mm 0.001mm 0.001 mm 0.01mm 0.01 mm 0.001 mm 0.01mm 0.01

Range
0-150 mm 0-25mm 0-50 mm 0-10 mm 0-0.80 mm 1.50-7.00 mm

Characterstic
Length,Width,Thickness O.D.Thickness Depth,Height Depth,Height FRO FRO,RRO,Radius,Angle I.D Slot

Calibration Frequency
6 Month 6 Month 6 Month 6 Month 6 Month 6 Month 6 Month 6 Month

Flow Diagram of Production

Monthly Production Plan from PPC
Not O.K.

Receipt of Work Order from PPC Receipt of Raw material from Store

Check the availability & condition of tools

Corrective Action

Short

Capacity Assessment
OK

Make the alternate Arrangement

Preparation of Daily M/c Loading Plan

Provide drgs., specs., process inspn. Sheets, Work Instructions etc.

Loading of Tools & take the Set up samples

Not O.K.

Corrective Action

Set up sample Inspection

O.K.

Component Production
Yes

Parts Process Inspection

Scrap

If reusable
No

Deposit to Store Send to Scrap Yard

Unloading of Tools & send to Tool

Final Inspection O.K.

Not O.K.

Rework Scrap

Component Deposit in Stores/Excise

Process Setting Parameters

S.NO. 1 2 3 4 5 6 7 8 9 10 11 Process Parameter Ejector Temperature Material Injection pressure Injection speed Injection time Holding pressure Holding time Cooling time Back pressure Screw rotation LESS Comp.not eject proper EFECTS MORE Ejector mark &mould not closed Material burn Flash Flash Burn mark Catching problem Flash &catching problem Catching problem Production loss Nozzle choke Flash

Filling problem&screw broken problem Shrinkage&short moulding Short moulding& weld line Weld line Comp. Not fill properly Dim. Varying &Warpage Warpage & ejector mark Warpage Silver mark No effect

Customer Complaint
CUSTOMER COMPLAINTS RECORD FOR OEMS PART FROM JAN ~ SEPT. 2007
S.NO DATE CUSTOMER PART NAME
KNOB WIPER

PHOTO

PROBLEM
Flash observed on Locking Rib Area

CAUSE

ACTION

12/2/2007

MINDARIKA

New angular ejector has made Angular ejector worn out (Hardness 45-46 HR) and new design .Hardness of angular ejector is under development for flash free was less Hardness 32-33 lock area and new OGS made for HR) checking criticality of Lock After power failure operator will kept 5 shots separately and one more stage added for100% visual inspection in PFD and this point add to Quality check sheet

21/02/07

DENSO

DENSO PLATE

Arm Short Moulding

Due to power failure

8/3/2007

MINDARIKA

KNOB WIPER

Blow hole observed inside Knob Wiper

Design problem, component Component run on best parameter not fill properly inside neck condition and material increased in area component and weight 28 gm fixed

15/03/07

MINDARIKA

BODY 21028, 21029

Short Moulding

Start up rejection mix

100% Inspection to be done at packing stage before despatch and start up pcs will be kept in red bin

15/05/07

MINDARIKA

STATOR VOLUME

Component Dia found oversize

Process not stable

Process parameter established as per dim. Requirement

CUSTOMER COMPLAINTS RECORD FOR OEMS PART FROM JAN ~ SEPT. 2007
S.NO
6

DATE
22/05/07

CUSTOMER
MINDARIKA

PART NAME
KNOB WIPER

PHOTO

PROBLEM
Cover fitment NG with Knob Wiper

CAUSE
Dim. 5.73 +/-0.05 observed 6.10 over size Tool rectified

ACTION

11/6/2007

MINDARIKA

BODY 21007

Short filled pcs

Due to power failure

Make new OGS for operator, After power failure operator will checked 5 shots and verify by process inspector

20/07/07

MINDARIKA

BODY 21007

Flash observed

Cutting gauge made to cut feeding Flash observed due to not point precisely and Mould matching at proper matching at slot area slot area corrected for flash

23/08/07

LIFE LONG

CLAMP SEAL

Lag bend problem

Handling/ packing problem

Packing standard changed

10

12/9/2007

MINDARIKA

KNOB UPPER RH

Parting line height observed Mould problem more

Mould rectified

11

24/10/07

MINDARIKA

KNOB UPPER RH

Moving slider interchanged Insert change to during mould cleaning as opposite both sliders are symmetrical direction &same size . There is no identification on sliders

Mark will be embossed on slider & housing as 1,1 &2,2.so every time during assembly marking to be matched .Check point added in OGS

PROCESS FLOW CHART FOR PREVENTIVE MAINTENANCE OF MOULDS

Receipt of Tool with History Card after Production

OK

Condition of Tool & Quantity Produced

NG

Only Cleaning and Lubrication required

Complete Preventive Maintenance Required

Sent to M/s Maint. Dept.

Cleaning, Lubrication and Preservation ( Shrink Film Wrapping)

Performing Preventive Maintenance as per checklist and other Problem noticed

Updating Tool History Card

Handing over to Tooling

History Card to Comp. file

Storage and Updating Tool Storage register Updating Tool History Card

PHOTO GALLERY OF MOULDING SHOP:-

CNC MOULDING MACHINE

MOULDING SHOP

PART MANUFACTURED IN MOULDING SHOP

PRESS SHOP
Elin Electronics is a world class manufacturer and exporter of sheet metal components, precision engineering components, and Deep Drawn Components in India with our clients spread all across India and overseas. The unit is equipped with all necessary production machinery and various equipments for quality control. Presses available also include high speed presses up to 600 spm. Secondary operations like projections welding, liquid painting and powder coating are also available in house that adds value to our supply portfolio. More than 60 stamping machines from 10 tons to 300 tons give us flexibility to serve vast range of customers having varied requirements. Our specialization in offering customized solutions as per clients specifications also helps us to add value to our customers product portfolio.

THEORY OF CUTTING
When cutting sheet metal in a die the forces applied to the sheet by the punch and die are basically shear forces, that is, equal and opposite forces spaced at a small distance apart on the metal and produce the cutting. The cutting or separation of the sheet metal is effected through the following stages of shearing Roll over Penetration Fracture

From both punch side and Die side simultaneously the spacing or the small distance of the two shearing planes is called clearance. It will be generally about 8 - 10% of metal thickness for MS Sheets.

THEORY OF BENDING AND SPRING BACK

BENDING
Bending is the process of folding a sheet about a straight line axis which lies in the neutral plane. Bends are made in sheet metal to gain rigidity, to produce a part of desired shape & perform a particular function etc. The cross section of the bend inward from neutral axis is in compression, outward from neutral axis is in tension as shown in the fig.

SPRING BACK
During bending the metal nearer to the neutral axis is stressed to the values below the elastic limit. This phenomenon creates a narrow elastic band on both sides of the neutral axis. The metal further away from the neutral axis is stressed beyond the yield strength and is plastically deformed and permanently set. When the bending force on the metal is released the elastic band tries to return to the original flat condition but cannot return fully due to the restrictions of the plastically deformed zones. Some slight return does occur as the elastic and plastic zones come to equilibrium and this return is known as spring back. The amount of spring back mainly depends on the ratio of bending radius to stock thickness. Spring back can be reduced by over bending, Bottoming or stretch bending.

THEORY OF FORMING
Forming is the process in which the shape of the punch and die is directly reproduced in the metal with little or no metal flow. Forming, Bending or drawing actions may be combined in a die and is classified as Form die or Draw die depending on the dominant action of Process The decision to use a form die instead of a Draw die will depend largely on the complexity of the shape & geometrical criteria. The use of draw die may be indicated, if the form die would cause the metal to tear because of excessive tensile strain (stretch) or form objectionable wrinkles because of excess crowding of metal etc defects.

VARIOUS TYPES OF FORMING OPERATIONS

THEORY OF DRAWING
Drawing is a process in which the punch causes a flat , precut metal blank in to the die cavity to assume the shape of seamless hollow vessel without excessive wrinkling, thinning, or fracturing. METAL FLOW IN DRAWING PROCESS when the punch of draw die forces a portion of metal blank through the bore of draw ring, different forces such as radial tension, circumferential compression and bending & frictional forces come in to action as shown in the fig.These forces cause a complicated plastic flow of the material in the blank.

The volume and the thickness of the component remain constant and the final shape of the cup will be similar to contour of the punch. The progressive stages of cupping are schematically shown in fig. After a small stroke of the punch, Cupping stage A, the metal elements 2, 3, 4, & 5 of the blank move radially toward the center of the blank. The flow of these elements goes on till the final stage C of the cup is reached. Thus by the end of the draw of the cup area 1 is unchanged in shape and size in the bottom of the cup. The areas 2, 3 & 4 change from the shape of angular segments to longer parallel-sided shapes and area 5 also changed in its size and shape. Due to this metal flow phenomenon in drawing operation, Blank holding pressure is to be applied on the blank in such a way that the metal flow will be a controlled one so as to avoid wrinkling, tearing, thinning etc.

MATRIAL USED Material Thickness Used for Problem

UV Motor CRCA- Cold Rolled Comtrolled Annealed 0.5-2 mm E.L.F(Electro Light Fitting) Thickness variation

EGCC-Electrical Gr. Carbon content

0.4-2 mm

Deck Port Auto Part

Width Variation Rust Problem

GPSP-Galvanized plated Skin Pass

1.5-3 mm

Auto Part

Deep Scratches

Aluminum

0.4-1 mm

Steam Cover

Dent

0.2 mm Phosphorous Bronze

Leaf Switch

Blackish Shed

Product Gallery

Varios Part Mfg. in Press Shop

Part Manufactured By Progressive Press

Varios Part Mfg. in Press Shop

Hydraulic Press

Press Shop Overview

TOOL ROOM
With more than three decades of experience in tool design and tool manufacturing. Elin is known to its customers as manufacturer of critical tools. Tool room infrastructure includes CNC machining center (3 no), 3 CNC wire cut, 2 CNC EDM, high precision surface grinder and host of conventional machines. Standard room is equipped with CMM, Smartscope from Mitutoyo along with other standard equipment for making accurate inspection reports. Elin tool room has capacity to deliver more than 200 critical tools in a year and also has tie-up with oversees tool maker which doubles its capacity.

PROCESS FLOW CHART

MACHINE DETAIL
1.CNC EDM DIE SINKING:Accuracy-0.005 mm Axis Trevel-350*250*250 Max.Weight-200kg Max. Electrode Weigth-50kg

2.CNC Milling M/c:Accuracy-0.005 mm Bed size-600*350*400 R.P.M-8000 Axis Trevel-500*350*450 Max. Weight of Job-400kg

3.CNC WIRE EDM:ELECTRONICA

Accuracy-0.005 mm Bed size-400*250*400 Axis Trevel-375*240*350 Max.Weight-500kg

4.EDM CNC
Accuracy-0.01 mm Axis Trevel-300*200*250 Max. Weight of Job-300kg Max. Electrode Weigth-30kg

5.CNC WIRE CUT 7.CYLINDERICAL GRINDER

Accuracy-0.005 mm

6.CNC EDM DIE SINKING 8. SURFACE GRINDER

Accuracy-0.005 mm

9. CNC MILLING WITH AUTOMATIC TOOL CHANGER

EDM & WIRE CUT EDM

What is EDM? EDM is a machining method primarily used for hard metals or those that would be impossible to machine with traditional techniques. One critical Limitation, however, is that EDM only works with materials that are electrically conductive. EDM or Electrical Discharge Machining is especially well-suited for cutting intricate contours or delicate cavities that would be difficult to produce with a grinder, an end mill or other cutting tools. Metals that can be machined with EDM include hast alloy, hardened tool-steel, titanium, carbide, Inconel and kovar. EDM is sometimes called "spark machining" because it removes metal by producing a rapid series of repetitive electrical discharges. These electrical discharges are passed between an electrode and the piece of metal being machined. The small amount of material that is removed from the workpiece is flushed away with a continuously flowing fluid. The repetitive discharges create a set of successively deeper craters in the work piece until the final shape is produced. Wire Cut EDM In wire EDM a very thin wire serves as the electrode. Special brass wires are typically used; the wire is slowly fed through the material and the electrical discharges actually cut the workpiece. Wire EDM is usually performed in a bath of water. If someone was to observe the wire EDM process under a microscope, he would discover that the wire itself does not actually touch the metal to be cut; the electrical discharges actually remove small amounts of material and allow the wire to be moved through the workpiece. The path of the

wire is typically controlled by a computer, which allows extremely complex shapes to be produced. Diagram:

MAJOR COMPONENTS A Wire EDM system is comprised of four major components. (1) Computerized Numerical Control (CNC) Think of this as The Brains. (2) Power Supply Provides energy to the spark. Think of this as The Muscle. (3) Mechanical Section Worktable, work stand, taper unit, and wire drive mechanism. (This is the actual machine tool.) Think of this as The Body. (4) Dielectric System The water reservoir where filtration, condition of the water (resistivity/conductivity) and temperature of the water is provided and maintained. Think of this as The Nourishment.

PRINCIPLE OF WIRE ELECTRICAL DISCHARGE MACHINING The Spark Theory on a wire EDM is basically the same as that of the vertical EDM process. In wire EDM, the conductive materials are machined with a series of electrical discharges (sparks) that are produced between an accurately positioned moving wire (the electrode) and the workpiece. High frequency pulses of alternating or direct current is discharged from the wire to the workpiece with a very small spark gap through an insulated dielectric fluid (water). Many sparks can be observed at one time. This is because actual discharges can occur more than one hundred thousand times per second, with discharge sparks lasting in the range of 1/1,000,000 of a second or less. The volume of metal removed during this short period of spark discharge depends on the desired cutting speed and the surface finish required. The heat of each electrical spark, estimated at around 15,000 to 21,000 Fahrenheit, erodes away a tiny bit of material that is vaporized and melted from the workpiece. (Some of the wire material is also eroded away) These particles (chips) are flushed away from the cut with a stream of de-ionized water through the top and bottom flushing nozzles. The water also prevents heat build-up in the workpiece. Without this cooling, thermal expansion of the part would affect size and positional accuracy. Keep in mind that it is the ON and OFF time of the spark that is repeated over and over that removes material, not just the flow of electric current.

Application: Prototype production The EDM process is most widely used by the mold-making tool and die industries, but is becoming a common method of making prototype and production parts,[25] especially in the aerospace, automobile and electronics industries in which production quantities are relatively low. In Sinker EDM, a graphite, copper tungsten or pure copper electrode is machined into the desired (negative) shape and fed into the workpiece on the end of a vertical ram. Coinage die making For the creation of dies for producing jewelry and badges by the coinage (stamping) process, the positive master may be made from sterling silver,

since (with appropriate machine settings) the master is significantly eroded and is used only once. The resultant negative die is then hardened and used in a drop hammer to produce stamped flats from cutout sheet blanks of bronze, silver, or low proof gold alloy. For badges these flats may be further shaped to a curved surface by another die. This type of EDM is usually performed submerged in an oil-based dielectric. The finished object may be further refined by hard (glass) or soft (paint) enameling and/or electroplated with pure gold or nickel. Softer materials such as silver may be hand engraved as a refinement. Small hole drilling On wire-cut EDM machines, small hole drilling EDM is used to make a through hole in a workpiece in through which to thread the wire for the wirecut EDM operation. A separate EDM head specifically for small hole drilling is mounted on a wire-cut machine and allows large hardened plates to have finished parts eroded from them as needed and without pre-drilling. Metal disintegration machining Several manufacturers produce EDM machines for the specific purpose of removing broken tools (drill bits or taps) from work pieces. In this application, the process is termed "metal disintegration machining". Advantages: 1) Complex shapes that would otherwise be difficult to produce with conventional cutting tools 2) Extremely hard material to very close tolerances 3) Very small work pieces where conventional cutting tools may damage the part from excess cutting tool pressure. 4) There is no direct contact between tool and work piece. Therefore delicate sections and weak materials can be machined without any distortion.

5) A good surface finish can be obtained. 6) Very fine holes can be easily drilled. Disadvantages: 1) The slow rate of material removal. 2) The additional time and cost used for creating electrodes for ram/sinker EDM. 3) Reproducing sharp corners on the workpiece is difficult due to electrode wear. 4) Specific power consumption is very high. 5) Power consumption is high. 6) "Overcut" is formed. 7) Excessive tool wear occurs during machining. 8) Electrically non-conductive materials can be machined only with specific set-up of the process.

MATERIAL COLOUR CODE

SR.NO 1. MATERIAL HIGH CARBON HIGH CHROMIUM STEEL(HCHCK) 2. OIL HARDNING NON SHRINKAGE STEEL(OHNS) 3. 4. 5. 6. 7. KE-355 EN-24 MOULD STEEL SILVER STEEL EN-8,EN-19 HIGH TENSILE STEEL HIGH CARBON SPRING STEEL HIGH SPEED STEEL VOILET NATURAL WHITE RED YALLOW/DARK GREEN 8. 9. HOT DIE STEEL MILD STEEL RED/YALLOW BLACK DARK GREEN COLOUR CODE YELLOW

MEASURING INSTRUMENTS
SR.NO INSTRUMENT NAME QUANTITY MANUFACTURER LEAST COUNT
1.

CMM(Beyond-A504) CMM(600/9205) PROFILE PROJECTOR (10*120*100)

1 1 1

Mitutuyo Metrology Mitutuyo

0.001 0.001 0.05

2. 3.

4.

CONCENTRICITY GAUGE

Universal Punch

0.05

5.

HIGHT GAUGE(0310mm)

Accurate

0.001

6. 7.

MICROMETER(0-25mm) MICRIMETER POINTED(0-25mm)

1 1

Mitutuyo Mitutuyo

0.001 0.01

8. 9. 10.

MICROMETER(25-50mm) 1 MICROMETER(50-75mm) 1 MICROMETER(75100mm) 1

Mitutuyo Mitutuyo Mitutuyo

0.01 0.001 0.01

11.

MICROMETER FLANGE(0-25mm)

Mitutuyo

0.01

12.

DIAL CALLIPER(0150mm)

Mitutuyo

0.01

13.

DIAL CALLIPER(0200mm)

Mitutuyo

0.01

14.

VERNIER CALLIPER(0350mm)

Mitutuyo

0.02

15. 16. 17.

DIAL GAUGE(0-10mm) DIAL GAUGE(0-1mm) DIAL CALLIPER(0150mm)

1 1 1

Mitutuyo Mitutuyo Mitutuyo

0.01 0.01 0.01

18. 19.

DIGI MICRO(0-30mm) DIAL THICKNESS GAUGE

1 1

Mitutuyo Nikon

0.01 0.01

20.

HIGHT GAUGE(0300mm)

Mitutuyo

0.01

21. 22. 23. 24. 25. 26. 27. 28.

SLIP GAUGE(0.5-100mm)

Mitutuyo Micronix Mitutuyo Mitutuyo Mitutuyo Mitutuyo Mitutuyo Mitutuyo

0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01

FILLER GAUGE(0-10mm) 1 PIN GAUGE(0-10mm) PIN GAUGE(7.05-12mm) PIN GAUGE(5.01-7mm) PIN GAUGE(3.01-5mm) PIN GAUGE(1.51-3mm) PIN GAUGE(1.001.49mm) 1 1 1 1 1 1

29. 30. 31.

PIN GAUGE(0.5-0.99mm) PIN GAUGE(7.02-10mm)

1 1

Mitutuyo Mitutuyo Mitutuyo

0.01 0.01 0.01

PIN GAUGE(10.02-12mm) 1

CO-ORDINATE MEASURING MACHINE(CMM)

CNC MILLING MACHINE

MANUFACTURING OF EDM ELECTRODE