CHAPTER 1

INTRODUCTION
1.1 COMPANY PROFILE
By the end of Second World War, the govt. of India was confronted by a big problem of
disposing the colossal war waste. Ultimately a committee was constructed to enquire into the
possibilities to solve the problem. The committee report of 1948 proposed the establishment
of a govt. owned machine industry. This was expected to fulfill two aspects. The first being
the utilization of Rs 4000 million worth of metallic waste. The second was the incorporation
of a state owned infrastructure facility. The result was the birth of Hindustan Machine Tools
Ltd, which diversified I due course of time to the present status of a multicore multi location,
multi-unit industrial giant HMT Ltd.
The HMT Ltd was started as a single factory to produce Tool Room Lathes at Bangalore in
collaboration with Oerlikon of Switzerland in 1953 with a capacity to manufacture 400
machine/year. Since then different collaborations continued in house R&D and tremendous
marketing efforts brought HMT to the present status.
The growth of HMT Ltd was categorized by the forward and backward integration of
technology and product diversification. Thus the company which started with manufacturing
and selling lathes expanded its machine tool range to evolve as the ultimate solution in metal
cutting.
The product diversification efforts took the company of Watches in 1962, Tractors in 1971,
Printing machinery in 1972, Presses in 1972, Lamp and Lamp making in 1986, Ball screw in
1986 and Reconditioning in 1990.
The multi-product activities make its identity HMT Ltd. Today HMT Ltd has 16
manufacturing uits with 22 product divisions. HMT Ltd was restructured in 1992 to facilitate
better administration of the multi-product business activities. Accordingly the following
business groups were established:1. Machine Tool Business group, to concentrate on metal cutting machine.
2. Industrial Machinery Business Group, to deal with printing machine, die casting and
plastic injection molding machines, food processing machine and metal forming
machines.
3. Agricultural Business Group, to concentrate on tractor
1

4. Consumer Product Business Groups to deal with watches and lamps

In addition to business groups, the company own three subsidies as follows:1. HMT(International) Ltd, which undertakes overseas projects and exports
2. Praga Tools Ltd, which manufactures machine tools
3. HMT Bearings Ltd, which manufactures precision bearings in collaboration with
Koyo of Japan
1.2 THE PRODUCT RANGE OF MACHINE TOOLS BUSINESS GROUPS
Bangalore
1. Heavy Duty Lathes
2. Single and Multi Spindle automates
3. Radial Drilling Machine
4. Multi Spindle Drills
5. Gear Cutting Machines
6. CNC Turn Mill Centers
7. CNC Wire Cut EDM
8. Fire Boring Machines/SPMS
Pjore
1. FMS and FMC
2. Vertical Machining Centers
3. HorizontalMachiningCenters
4. Boarding Machines
Kalamaserry
1. CNC Turning Centers
2. Turn Mill Centers
3. Flexible Turning Cells
4. Copying Lathes
5. Offset Printing Press
Hyderabad
1. Special Purpose Machines
2. Horizontal Machining Centers
3. FMS
4. CNC Horizontal Boring Machines
2

5. Bed Type and Floor Boring Machines

Ajmer
1. Grinding Machines
2. SPM Machines
3. CNC Machines
Major machine/ inspection facilities available in different mtbs units
1. CNC Ram Type Plane Machines
2. Horizontal Milling Centers
3. Vertical Milling Centers
4. Vertical Jig Boring Machines
5. Horizontal Jig Boring Machines
6. CNC Turning Centers
7. Turn Mill Centers
8. Slide Away Grinders
9. Cylindrical Grinders
10. Precision Gear Shapers
11. Precision Gear Hobbers
12. Gear Grinders
13. Induction Hardening Machines
14. D-coordinate Measuring Machines
15. Internal Grinders.
1.3 THE KALAMASERRY COMPLEX OF HMT MACHINE TOOLS LTD
The kalamaserry unit, the 4th machine Tool unit was established in 1963 and started the
production in 1964. The unit originally manufactured only two types of center lathes viz.
H&LB, but later added several special purpose lathes like Copying and Turret Lathes.
Model L-20 was the first product in the history of the unit. The production of this
machine was later licensed by QECOS Ltd. The originalcenter lathe H&LB were replaced
by a new family of unified series of lathes which was designed and developed by the unit
incorporating the concepts of computer optimized design manufacturing, standardization
and unification. HMT has developed conventional machines of different sizes NH&NL
machines. Later the following products were added through collaboration with worldrenowned machine manufacturers
3

1. S-Piolte and T-Piolte copying lathes in collaboration with Ernault Souma of

France
2. RTV 50 Drum Turret in collaboration with Coilder-meister of Germany
And the unit has developed a completely hydraulic heavy duty Front Chucker (FC-25).
During thr early 1980s HMT Kalamaserry designed, developed and introduced the
manufacturing of CNC Lathe. At present HMT has a wide range of CNC lathes which
crater the turning requirements of light and heavy machine industries.
Diversification of Kalamaserry and birth of Printing Machinery Division
During the period 1972-73, Kalamaserry unit has diversified its product range including
Printing Machines (PMK). The commercial entry of PMK was with two types of letter
presses viz. RTE&RTAE under collaboration with Neiolo of Italy. During the following
years, the Printing Machinery Division came up offset press viz. OMR in collaboration
with Neiolo. Later indigenous press viz. SOM P6 were introduced to the market.
The first two-colour machine from HMT was KPO in collaboration with Koening&Baner
of Germany. The latest development of PMK is the paper cutting Guilletine PG96, in
collaboration with Pivao Binders of Italy.
Table 1
PRODUCT
Offset Printing Machines

Paper Cutting Machine

MODEL
SOM 436
SOM 425
SOM 236
SOM 231
SOM 225
SOM 136
SOM 131
SOM 125 G
SOM 120
MOM 1015
MOM 1520
PG-92
PG-115

HMT Ltd-Holding Company presently comprises of the following subsidiaries:

1. HMT Machine Tools Ltd
2. HMT Watches Ltd
3. HMT Chinar Watches Ltd
4. HMT Bearings Ltd
4

5. HMT International Ltd

6. Praga Tools Ltd
The Kalamaserry unit of HMT is well known for development activities. Their product
have always fetched awards and prizes in different trade fairs. Few are in the IMTEX
fairs by different FC 25, SBC and SB CNC machines. The CNC lathe model STC 25 has
won the VASVIK Industrial Research Award in 1987.
Presently the manufacturing shops of Kalamaserry are supported by various industrial
facilities like High Technology CNC machining centers, testing facilities, foundry, heat
treatment, computer system CAD system etc. The company has a well-establishedtraining
system by personal of high technical and management skills.
The HRD program undertaken by HMT include:1. Management Development Program
2. Supervisory Development Program
3. Customer training programs to equip customers I

optimum utilization of HMT

machines
4. Periodic awareness programs for employees relating to safety, quality and technology
5. Multi-skill training to machine operators
6. Introduction and in-plant training to fresh recruits
7. Project guidance in management or Technology
1.4 THE MARKETING NETWORK OF HMT LTD
The machine tools marketing divisions with its headquarters at Bangalore and having a
wide network of Regional and Divisional officers spread throughout India caters to the
marketing needs of this unit at primary level. To co-ordinate the marketing activities at
unit level and to offer technical support to HMT, a strong sales and services team is
constituted at unit level. HMTs major customers include Defense, Railways,
Automobiles and other engineering industries in various sectors.
1.5 MAIN INLAND COMPETITORS FOR THE HMT PRODUCTS

1. Mysore Kirlosker Ltd

2. ACE Designers
3. NC Machine Private Ltd
4. Lakshmi Machine Works

1.6 MAIN FOREIGN COMPETITORS FOR THE HMT PRODUCTS

1. Okuma, Japan
2. Noji Saiki Co Ltd, Japan
3. Muzak, Japan
4. Ikegai, Japan
5. GDM, Geramany
6. Chruchill, England
7. Victor, Taiwan
8. EMAS, Geramay
1.7 HMT MACHINE TOOLS LTD KALAMASERRY UNIT ORGANISATION

OFFICERS
1. GENERAL MANAGER(GM)

PSIX

2. JOINT GENERAL MANAGER(JGM)

PSVIII

3. DEPUTY GENERAL MANGER(DGM)

PSVII

4. ASSISTANT GENERAL MANAGER(AGM)

PSV

5. SENIOR ENGINEER/MANAGER

PSIV

6. ENGINEER/DEPUTY MANAGER

PSIII

7. DEPUTY ENGINEER/OFFICER

PSII

WORKERS
1. WORKERS SUPERVISOR

WSI

2. WORKER GRADE

GVI

3. WORKER GRADE

WGV
6

4. WORKER GRADE

WGIV

5. WORKER GRADE

WGII

6. WORKER GRADE

WGI

1.8 HMT ORGANISATION CHART

PRESIDENT OF INDIA
MINISTERY OF HEAVY INDUSTRIES
BOARD OF DIRECTORS
CHAIRMAN AND MANAGINIG DIRECTOR
MANAGING DIRECTOR
(SUBSIDARY

CHEIFS)

DEPARTMENTS-

FINANCING/HRM/
MARKETING/R&D/TECHNOLOGY
DEVELOPMENT

1.9 DIFFERENT SECTIONS IN THE INDUSTRY

PATTERN MAKING AND FOUNDARY

HEAVY PARTS
TOOL ROOM
7

 PRODUCTION PLANING TOOLS

HIGH TECHNOLOGY CENTRE
CNC ASSEMBLY
PLANT SERVICE
SHEET METAL AND WELDING
HEAT TREATMENT PLANT

CHAPTER 2
PATTERN MAKING AND FOUNDARY
A foundry is a factory that produces metal castings. Metals are cast into shapes by
melting them into a liquid, pouring the metal in a mold, and removing the mold
material or casting after the metal has solidified as it cools. The most common metal

processed here is cast iron. In this process, parts of desired shapes and sizes can be
formed.

PROCESS
In metalworking, casting involves pouring liquid metal into a mold, which contains a
hollow cavity of the desired shape, and then allowing it to cool and solidify. The
solidified part is also known as a casting, which is ejected or broken out of the mold
to complete the process. Casting is most often used for making complex shapes that
would be difficult or uneconomical to make by other methods.
FOUNDRY PROCESS
PATTERN MAKING
MOULDING SAND PREPARATION
Moulding And Core Making
Assembly The Cores And Closing The Moulding
Preparation Of Metal
Pour the Metal
Natural Cooling Of Casting
Knocking The Mould
Decoring Of Casting
Fettling
Shot Blasting The Casting
Painting
Inspection
2.1 PATTERN MAKING
The replica or duplicate of the model to be cast is called a pattern. It includes
a) SOLID PATTERN: Simplest form of pattern making without joints.
b) SPLIT PATTERN: Many pattern are usually are split not as a single piece.
c) LOOSE PIECE PATTERN: Casted piece cannot be withdrawn as such. Such patterns
are called loose pattern.
9

MATERIALS USED FOR PATTERN MAKING

a) Thermocol
b) Wood
c) Metal
d) Plastic
e) Plates
f) Wax
ALLOWANCE PROVIDED IN PATTERN
Pattern are not made of exact size of demand due to
a) SHRINKAGE ALLOWANCE: As molten metal solidifies, it shrinks and contract in
size. In component function the pattern is made larger than the finished cooling for
shrinkage allowance.
b) DRAFT ALLOWANCE

: When pattern is drawn from mould, there is some

probability of injuring the edge of the mould. So to avoid an allowance is given and is
called as draft allowance.
c) MACHINING ALLOWANCE: The amount of metal provided on the surface to be
machined.
MOULDING:- For producing a casting it is necessary to have a pattern which can be made of
two mould and the process is called moulding.
CORE MAKING:- It is the process of producing out for the production of exact internal
shape of a core box. Cores so formed must be such that when they are assembled the liquid
metal must be paired around it.
2.2 MOULDING SAND PREPARATION
a) DRY SAND:- Bentonite + Dextrin + Liquid coal + Dust + Water
b) PARTIAL OR FAKE SAND:- Binder + Acid A + Acid B
c) NO BAKE SAND:- Binder + Activator
The return sand are mixed with oil and additives to form mould.

CHAPTER 3
HEAVY PARTS
It is the shop which gives the shape to the castings which come from the foundry in this shop
after being painted rough. In this section various operations are performed by the help of
planners, milling and Plano milling machines. In it first of all the jobs are marked, checked so
10

that machining time is saved if the casting size is oversized. Different type of operations is
done by using different machines including various machines devicesHeavy parts is the
section in the HMT Kalamassery which deals with the different machining process in which
parts like NL lathes, NH lathes, CNC Lathes are being manufactured. The heavy parts can
again be classified into the following sections.
1. Marking section
2. Planing operation section
3. Surface grinding machine
4. Milling machine
5. Boring machine
6. Honing machine

3.1 MARKING SECTION

The machine parts like head stock, apron after casting from the foundry department after
casting are marked in the marking section for oversize etc. The marking is done using the
following instruments are
1. HEIGHT GAUGE
2. TRY SQUARE

3.2 PLANING OPERATION SECTION

Planning machine the art is done by the movement of large bed with stationary table. In
planning machines speed and feed are controlled automatically and hydraulically.

11

Machi
ning of a machine bed in planing machine

3.3SURFACE GRINDING MACHINE

It is a process of removing material in form of small chips by the abrasive action of revolving
wheel on the surface of work piece the wheel used for performing the grinding action is
called grinding wheel.

It is basically a finishing process used for producing close

dimensional and smooth surface finish. Aluminium Silicate grinding wheels are used for
grinding HSS (High Speed Steel). Carbide tools are grinded by Diamond cutters. SFC
25CNC is the grinding machine used in heavy parts section. The tool used in surface grinding
machine are the grinding machine of diameter 500mm.

A: rotation of grinding wheel

B: reciprocation of worktable
C: transverse feed
D: down feed

C
B

12

3.4 MILLING MACHINE

Milling is the process of removing metal by feeding the work against a rotating multi-point
cutter. In milling operation the rate of metal is rapid as cutter rotates at a high speed and has
many cutting edges. Large CNC automatic machines that have larger magazine which can
hold 60 tools at a time are used. The speciality of this machine is that it can do more
operation in a given time.
The milling cutter is a multipoint cutter revolving tools. The teeth of milling cutter may be
parallel to the axis or at an angle known as helix angle. Helix may be right or left. Various
types of cutter used in this machine are:1. Plain milling cutter: These cutters have straight or helical teeth. They are used to
machine flat surfaces.
2. Face mulling cutter: It is also used for machining flat surfaces.
3. Plain slit saw: It resembles plain milling cutter but has small width. It is used for
cutting-off and slotting operations.
4. Side milling cutter: They have teeth on their periphery and also one of its sides it may
have plain, helical or staggered teeth.
5. Angle milling cutter: The cutters have their cutting teeth at an angle. Single angular
cutter is used for cutting dovetail.
6. End mill cutter: They have teeth on end as well as periphery the peripheral teeth may
be straight or helical these are used for light milling operations like cutting slots,
machining accurate holes and for profile milling operations.
3.5 BORING MACHINE
Boring section consist of enlarging an already drilled hole. The holes are pre drilled as in
castings only the operations of boring can also be done on small scale on lathe .Boring is the
process of enlarging and finishing of the casting as per the given dimensions. After the boring
process reaming is done which gives finishing to the hole produced during boring.

13

Fig:3.1 Horizontal Boring Machine

Fig:3.2 Vertical Boring Machine

Horizontal Boring Machine

In the horizontal boring machine operations are performed in which relatively large pieces
which cannot be rotated and require operations on its many surfaces. The worktable can be
transverses along and across the machine bed. It is possible to machine a flat surface with the
based hole by mountings a facing head over the spindle.
Vertical Boring Machine
This type of machine is large in size and vertical. They are used to machine work pieces like
steam turbines etc. the size of such a machines is given by the diameter of largest work pieces
which can be mounted on it.

3.6 HONING OPERATION

It is a super-finishing operation which is used to get super finished internal surfaces. It is

done after boring process. It gives a better surface finish than that of internal grinding. It has
an allowance of 0.05mm. In this operation the tool is inserted into the internal surface where
the tool rotates within it.

14

CHAPTER 4
TOOL ROOM
Tool Room is considered as the back bone of an industrial organisation. For example in case
of machine tool as well as automobile industry , tool room is not directly related to the
production of an industry but they actually assist and accelerate the production of an industry.
The tool room production is characterised by high accuracy and firm finish . They are
so important

because the tool room products demand high quality .For acquiring the

mentioned quality level, systematic management and highly skilled workers are needed . The
purposeful use of these tooling actually enables an industry to manufacture their products
within time and great accuracy result in profit in production .
4.1 OBJECTIVES OF TOOL ROOM
To complete the following activities with specified accuracy and within right time.
1.Manufacturing of product toolings such as jigs ,fixtures, special cutting tools, tool holders,
mandrels, bushes ,gauges , inspection and assembly aids ,shop equipments etc . suitable for
the machine and components to produce it in minimum time and to the required accuracy.
2.Manufacturing of customer tooling such as special fixtures , locators , tool holders ,boring
bars , collects ,hard jaws , soft jaws special centres etc for the tooled up machines to an
acceptable time limits.
3 .Re-work , rectification and alternations of existing tooling based on the altered drawing.
4. Manufacturing of high precision components of different machines.
5. Miscellaneous work like re-work of machine parts and manufacturing of new components
are done .

15

4.2 TOOL MANUFACTURING PROCESS (FLOW CHART)

16

The major products of our tool room are jigs, fixtures, cutting tools, mandrels, bushes,
gauges, assembly equipments , inspection equipments, collets, hard jaws, soft jaws, locators,
boring bars, tool holders and other production and assembly enhancing devices . The
development and completion of products from the raw material state to finished level takes
place mostly in the section itself . so for the manufacturing of special toolings, number of
operations such as turning , milling , drilling, grinding, boring etc are to be done in the raw
material. To satisfy these condition our tool are well equipped with different types of
machines such as laths, milling machines , drilling machines, grinding machines and to
ensure the accuracy level demanded special machines such as jig boring machine, precision
universal grinding machine, are also employed . Functional layout is adopted in tool room.
Functional layout consist of grouping of machines that do similar work, like turning section,
milling section , fitting, drilling, and assembly section, grinding section , jig boring room .
4.3 WORKING PROCEDURE OF HMT TOOL ROOM
While preparing the operation lay out the production planning people decide whether
a special tool is required or not for that operation .If required they give a departmental order
(D/o) for design , manufacture/ procurement of a special tool for that particular operation to
tool design section . The tool design section designs the special tool according to the
requirements of production planning. This is known as product toolings.
The special tool requirements for the consumer is identified by the sales engineering
department and they give a departmental order D/o for design, manufacture / procurement a
special tool for that particular operation to tool design section . The tool design section
designs the special tool according to the requirements of sales engineer this is known as
customer toolings. The tool drawing and departmental order is handed over to chief of tool
engineering the chief of tool engineer decides whether the special tool is procured from
outside or manufactured in tool room .If decided to manufacture in tool room the tool
drawing and departmental order is handed over to tool room.
The activities of tool room starts with the receipt of D.O . and drawing of special tools from
tool design. The material planning of each manufacturing components are carried out
according to the material dimensions, surface finish , heat treatment etc. mentioned in the tool
drawing and a raw material request is prepared . This raw material request is given to material
cutting section for arranging raw materials if a special forging is required the request is given
17

to PPM, and for casting the request is given to foundry the process planning and preparation
of process control card for each manufacturing component is done . after receiving the raw
materials each item is given for manufacturing along with drawing and process control card .
The raw materials have undergone series of operation both in tool room and

production

sections . The standard items are arranged from stores assembly of special tools starts after
completing all the manufacturing components . The completed tools are inspected by the tool
room inspection after the tool inspection is over the product toolings are handed over to sales
execution section.
The operator from shop side can take the tool in from PPT and after the work is over the
special tool is returned to ppt. Where as after completing the customer toolings, it is given to
the assembly and it is mounted on the machine. After the successful completion of job
trials/rework or modification if any and acceptance by the customer the special tool
despatched to customer along with the machine.
Conventional and special purpose machines and equipments for turning, milling, drilling,
boring, grinding, etc are employed in the tool room to produce high accuracy toolings.

18

CHAPTER 5
CNC ASSEMBLY
This is one of the most important and lucrative shop for the plant where CNC is assembled.
The products prepared at other shops, purchased and imported items form the various
countries are combined here and the output is known as CNC. As far discussed about design
lab, the o/p of that lab is used here. The design of CNC machine according to application and
as per demand is taken and the operation starts. The parts are prepared in Hi-tech Small Parts
shops. Then they are combined to from Head, column, bed, ATC Assembly etc. electrical
wiring is then made. Electric cabinet of machine is taken from the concern shop and then
attached to the machine.
After attaching the operating system and computer hardware then the next job refers to
Electronics lab.The concern deptt.Examines the exact circuitry and wiring of the machine. If
the machine is working well then the last mode is to check the accuracy of the operation and
the minimum time of various operations. After all of these activities its time to decorate and
surround it for its good looking and for safety purposes. Now the machine is ready for SALE.
Ever increasing demands the need for high accuracy scrap reduction etc have pushed the
development in the field of machining and manufacturing. All these have led to the invention
of CNC machines. CNC machines can give accuracy upto one micrometer at a modest cost.
Hmt in the very beginning started the production of CNC machines.
The CNC assembly centre can be divide into
1. Group assembly
2. Pre final assembly
3. Final assembly

5.1 GROUP ASSEMBLY

19

This is the place where assembling of headstock, tailstock, turret-indexing unit etc is done.
The main CNC machine produced in the HMT are STC-15, STC-20, SBCNC-30 etc.
The CNC group assembly unit is equipped with various testing apparatus it includes the
headstock testing unit, turret indexing testing unit.
The head stock is run at different speed and several parameters are noted down. Only after
temperature stabilized it is shifted to next speed. This is continued until maximum speed is
achieved.
5.2 PREFINAL ASSEMBLY

This is the section where the assemblies of various components of the CNC lathe head stock
takes place to the lathe bed once the various parts are put together the CNC is taken to the
final assembly.
5.3 FINAL ASSEMBLY

As the lathe is brought from the prefinal assembly, various electrical components required
for the functioning of lathe are installed and the computer techniques are also installed at this
section.
5.4 PARTS OF CNC LATHE
Bed: Most of the CNC lathe in HMT is of slant bed type there are many reasons behind such
a design, thermal growth during machine can be considerably reduced by using slant beds.
Chip removal becomes easier when it comes to slant bed.
Headstock: Unlike the headstocks of conventional lathes CNC do not have speed gears in
coporated. Since the DC servometer used power the spindle are of variable speed type. Few
models have hydraulic controlled gears so as to optimize the speed range
Drivers: The machine contains three servomotors one for main spindle other for bed and third
one for cross slide. These servomotors arespecially designed so as to reduce the internal
efforts and to save time provide constant torque at all speeds.

20

Saddle: It carries the turret and slides over the bed. It is powered by the servomotor and it
helps in the movement of turret and hence the cutting tool.
Turret: It is that part of CNC machine that holds various tools and would position the
required tool to perform the cutting operation. It is placed over the saddle and is controlled by
servomotors. The required tool position is done in high precision and accuracy and is called
indexing.
Lubricating system: Ensuring sufficient lubrication for the rotating as well as sliding parts to
maintain smooth running for the machine as well as to reduce heat generated and errors.
Axis alignment: This is done on every machine produced at HMT but for a CNC machine it is
of slightly improved because the accuracy of machine is determined by this process.

Advantages:
1

High Repeatability and Precision e.g. Aircraft parts

Volume of production is very high

Complex contours/surfacesneedtobemachined.etc

Flexibility in job change ,automatic tool settings, less scrap

More safe, higher productivity, better quality

1

Less paper work, faster prototype production, reduction inlead

time

Disadvantages:
6

Costly setup, skilled operators

Computers, programming knowledge required

Maintenance is difficult

21

CHAPTER 6
PLANT SERVICE
The plant service department is responsible for maintaining the machines and equipment of
the unit in optimum condition of performance so as to make them available for production.It
has got the responsibility of erection and commissioning of the machines in the plant. It also
looks after the internal transport functions.
6.1 OBJECTIVES

(1) Erection, commissioning, repair, and maintenance of all the machines and equipment used
for production.
(2) Maintenance of the EOT cranes.
(3) Housekeeping activities in shop floors.
(4) Material movement in shop floors and maintenance of internal transport vehicles and
equipment.
(5) To arrange and coordinate contract workers in connection with any of the above activities.
6.2 RESPONSIBILITIES

(1) HOD has to ensure

(a) Administration.
(b) Maintenance.
(c)Internal transport and housekeeping.
(d) Ensure safety aspects as per factories act.
(2)Section in charge
(a) Erection, commissioning and maintenance of all machines and equipments, cranes
etc.
(b) Preventive maintenance of all critical machines and equipment under his control.
(c) Reconditioning of all critical machines and equipments.
(d) Testing of EOT cranes.

22

(e) Identifying training needs of employers under his control.

(f) Lubrication services.
(g) Housekeeping and internal transport services.
6.3 MATERIAL HANDLING

OBJECTIVES:
(a) Minimize the movements involved in production operation.
(b) Minimize the distance moved by adopting shortest routes.
(c) Employ mechanical aids in place of manual labourin order to speed up the material
movements
(d) Utilize gravity for assisting material movements wherever possible.
SELECTION OF MATERIAL HANDLING EQUIPMENT
(a) Material to be moved:The size of material,its shape,nature(solid,liquid,gas)and its chances
of getting damaged during damaged should be considered.
(b) Plant buildings and layout: Widths of doors, height of ceiling, strengths of floors and
walls etc. to a great extent influence the choice of material handling equipment.
(c)Type of productionmachines: Different machines have different outputs per unit time. The
material handling equipment should handle the maximum output.
(d)Type of material flow pattern: A vertical flow pattern will require elevators, conveyors,
pipes etc. whereas a horizontal flow pattern well need truck, overhead bridge cranes etc.
6.4 TYPES OF MATERIAL HANDLING EQUIPMENT

FUNCTIONS
(a) Minimize the total handling time
(b) Promote easier,safe and cleaner handling.
(c) Eliminate idle time of workers and machines.
(d) Make materials move fast.
(e) Decrease fatigue incurred by workers.
(f) Add to safety.
(g)Operations can be automated to increase production.

23

6.5 CLASSIFICATION

Industrial trucks - Fork Lift Trucks

The forks are attached to a column on the truck. Forks can be lifted to desired height along
with the material on them and the material can be stacked at the proper place. They are used
for short distances (40 to 70 meters) travel and find internal applications normally.
Cranes
Cranes are used for lifting and lowering bulky items and packages or cases. They find
application in heavy engineering. They provide overhead movements. An overhead crane,
commonly called a bridge crane, is a type of crane found in industrial environments. An
overhead crane consists of parallel runways with a traveling bridge spanning the gap. A hoist,
the lifting component of a crane, travels along the bridge. If the bridge is rigidly supported on
two or more legs running on a fixed rail at ground level, the crane is called a gantry crane.
Conveyors
It is employed to transport materials, over a fixed path which may be horizontal or inclined,
to different locations in a factory. They prove economical if the flow of material is
continuous.
In a belt conveyor, the belt may be flat or trough shape of hold (granular) materials which
may tend to fall from flat belt. Fixed conveyor belt are on the mass production shop floor.
Tractors and trailers
They are IC engine driven 4 wheeled vehicles generally used for outdoor applications.
Material is loaded on the trailers which are attached to the towing tractors. Trailers can either
be uncoupled from the tractor train, or material loaded in them can be dumped out, at
respective stations. Tractor trains are very helpful in big industries.
6.6 MAINTENANCE
The proper maintenance of material handling equipment is very essential. Production line
flow can be maintained only if the material handling is in the proper working order.
Preventive maintenance is by far one of the best maintenance techniques suggested for
material handling equipments. By preventive maintenance, the equipments can be kept
running thereby minimizing costly interruptions in the production schedule. A little periodic
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maintenance and minor adjustments may be enough to prevent equipment breakdown.

Preventive maintenance consists of frequent inspections and examination of the material
handling equipments with special attention to the components requiring it. The aim is to
uncover conditions leading to breakdown. Preventive maintenance also include lubrication,
adjustment, or repair while still in the minor stage of the defect.
Breakdown maintenance is maintenance performed on equipment that has broken down. It is
based on a breakdown maintenance trigger. Breakdown maintenance may be either planned
or it can be unplanned. An example of planned breakdown maintenance is run-to-failure
maintenance, while examples of unplanned maintenance include corrective maintenance and
reactive maintenance. Breakdown maintenance can be more costly than preventative
maintenance.
MAINTENANCE OF MATERIAL HANDLING EQUIPMENTS
Hoists and Cranes
(a) Inspection: All parts, open or covered are inspected for wear and tear. Worn out or
unworkable components like wire ropes, wheels, bearings, bolts etc. are removed. Brakes are
adjusted and lubrication is provided wherever necessary.
(b) Repair: The repairable parts of the system, after inspection are corrected for small repairs
and minor defects are rectified. Systems like open gear transmission, couplings, riveted and
bolted joints, trolley, brake guards etc. may be repaired.
(c) Overhaul: Overhauling involves dismantling the complete mechanism and replacing all
the damaged components. Crane structure, buffers, rails, open gear transmission, pulley
blocks may be replaced and various sub mechanisms may be aligned and adjusted.
Conveyors
(a) Inspection: Belts or rollers are inspected for tensions and wear and tear. Gear box is
properly lubricated, various fasteners are tightened and safety guards are checked.
(b) Repairs: Rollers and belts are checked adjusted or repaired. Couplings, safety guards,
steel structures, gear transmission bearings, fasteners joints, threaded components etc. are
adjusted as per their conditions.
(c) Overhaul: The conveyor system is completely dismantled. Components, worn out and
beyond repair like belts, bearings, oil seals, rollers, drums, fasteners and couplings are
replaced. Structures, safety guards, etc. may be repaired as per their conditions.
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