Intimate Machines Industrial Visiting / Training Report

INTIMATE MACHINES (P) LTD
MONVILA, KULATHOOR P.O

THIRUVANANTHAPURAM
Industrial Training Report
Submitted in partial fulfillment of the requirement

for the award of the
DIPLOMA IN MECHANICAL ENGINEERING

By
NAME:
REG NO:
DEPARTMENT OF MECHANICAL ENGINEERING

CENTRAL POLYTECHNIC COLLEGE
THIRUVANANTHAPURAM
August 2016
Industrial Training Report: Intimate Machines Pvt Ltd
CENTRAL POLYTECHIC COLLEGE

THIRUVANANTHAPURAM
DEPARTMENT OF MECHANICAL ENGINEERING
Certificate
Certified that this is a bonafide report of the Industrial Visit done by
Sri..of Fifth semester Mechanical Engineering with
Reg No. in fulfillment for the award of Diploma in Mechanical
Engineering during the academic year 2016-2017 From the Directorate of
Technical Education, Kerala.
Head of the Department Internal Examiner
Central Polytechnic College, Thiruvananthapuram 2

ACKNOWLEDGEMENT
This is a report on In-Plant training at Intimate Machines (P)
Ltd during 1st August 2016 to 12th August 2016 by 5th semester
Mechanical Engineering students of Central Polytechnic College,
Thiruvananthapuram.
We take this opportunity to express our hearty thanks to the
members of the organization who helped us a lot during this period.
Also sincerely thank our college and teachers for arranging the in-
plant training.

CONTENTS
1. Introduction
1.1 Company Profile
1.2 Origin and History
1.3 About Welbound
1.4 Vision Document The Purpose of Welbound
1.5 Mile Stones
2. Products Manufactured
3. Departmentation
3.1 Introduction
3.2 Production Department
3.3 Personnel Department
3.4 Commercial Department
3.5 Research and Development Department
3.6 Human Resource Development and Administration Dept.
3.7 Engineering Department
3.8 Finance Department
3.9 In process stores
3.10 Safety Department
4. Introduction to CNC
5. Conclusion

CHAPTER 1
INTRODUCTION
1.1 COMPANY PROFILE
Welbound Worldwide was established in 1989, by K.C
Sanjeev, a young entrepreneur, with N Kumar, a design engineer.
Their passion - developing state of the art equipment for the graphic
art industry, at affordable
prices. P Sajith, a marketing
professional joined the
Group as Director in 1991.
Welbound went on to
change the way books are
bound in India. Since then.
Welbound has developed
more than 15 products and
variants, with indigenous expertise. From folding to trimming, the
products complete the book binding cycle. The tie up with world
leaders in adhesives, Henkel Adhesives (erstwhile National Starch and
Chemicals) has helped Welbound deliver complete solutions to the
book binding industry. With their support, technical seminars and
application training sessions are hosted all over the country to
increase awareness in book binding techniques. Welbound designs
and develops majority of the products with indigenous expertise.
Welbound also has tie up with a few European manufacturers for the
production of their machines and accessories in India. A well-
established sales and service network takes care of installations and
training - on machine as well as application. Welbound has more than
2000 unique customers in India and neighboring countries. In addition

to this, Middle East Asia and Africa are the major export destinations.
Intimate Machines Pvt Ltd is the first branch of Welbound established
in 1989 in Manila Industrial Estate, Thiruvananthapuram. It is small
scale manufacturing industry. The firm consists of Research &
Development department, Manufacturing department and Assembly
department. The products of Intimate Machines are Post-Printing
equipments like Perfect Binder, Gathering Machine, Folding Machine,
Trimmer etc. Intimate Machines (P) Ltd won the Award for Quality
Products (State Level) from the President of India (for the year 1993).
The firm got ISO 9002 certification in 1999.
1.2 ORIGIN AND HISTORY

The idea of this product was conceived by two enterprising
individuals Sanjeev and Kumar. They started the manufacturing small
binding machine in the beginning as a small unit. The product was an
innovative one during that period and was widely accepted in the
market. The unit grew and was registered as a private limited
company- Intimate Machines. In the beginning, the company was
mainly the assembling unit in which the main components are
manufactured in Coimbatore. Afterwards the company started
manufacturing its components by themselves. In 1989, Impel
Machines was registered at Sasthamangalam, Thiruvananthapuram.
In the early stages, Impel machines got managerial, technical advices
from Intimate Machines. Since 1999 the company has been
functioning as an independent unit registered as independent
company to meet the following.
Service centers regional wise to meet service requirement
all over India and abroad.

Procurement centre to procure items from established

suppliers and quality assurance system in place.
1.3 ABOUT WELBOUND

Impel Marketing Services was
established in 1989, as a part of the
Intimate-Impel group. The idea was to
develop a Company with focus on
marketing products to the Book Binding
and Manufacturing Industry. It is now part of India's Largest Post
Press/Book Binding Equipment Manufacturing Group. The group had
already lined up few products for the Industry and it was found
necessary to have a separate entity to look after the Sales and
Services. Impel Marketing Services established Sales and Service
Centers in all key locations of the country. They became the channel
for flow of information from the Market to Manufacturing Product
developments and modifications could be at fast pace because of such
a medium.

1.4 VISION DOCUMENT - THE PURPOSE OF WELBOUND

The Vision of the group is entwined with the Future of Graphic
Art Industry. A small step has been made in the right direction to bring
in State of the Art Technology for Book Binding to India. This
document on Our Vision is being posted here, because we know that
we need your partnership in achieving our Goals. We are making our
aims transparent for you to join hands and guide us towards achieving
them.
To develop more solutions for the Book Binding Industry; be it
hard or soft covered.
To make Perfect Binding the most accepted form of Binding in
India and the developing Nations
To make available cost effective solutions for making a Well
Bound Book.
To make Binderies in India wore Receptive to the Dynamics of
the Binding Requirements.
To look at opportunities in Related Fields within the Graphic Art
Industry.
To represent Technology Driven Companies in the Graphic Art
Equipment Fields in India.
To look at Opportunities for Marketing the Current products
outside India.

1.5 MILE STONES

1989 - K C Sanjeev, a young Marketing Professional, teams up with N
Kumar, an inventor, to float Intimate Machines (P) Ltd, in Trivandrum-
a coastal town in India.
1990 - From the drawing boards, the Prototype of a Perfect Binding
Machine is developed. They decide to call it WELBOUND.
1991 - After a few Road Shows and modifications, the first commercial
model is brought out. The factory is set up in approx. 2000 sqft with
few crucial plant & machinery. A few machines are sold in Kerala, their
home, and neighboring States.
1992 - P.Sajith, another Marketing Professional joins as the full time
Director for Sales. Branches are opened in Delhi and Madras. The
product undergoes changes, based on Customer Feed-back. Around
25 machines are installed by then.
1993 - Participates in a major Exhibition, at Delhi, in conjunction with
the WORLD PRINT CONGRESS. Receives excellent response and
decides to open more Branches to look after Sales & Service Activities,
A Regional Business Centre is set up in Bombay to look after the
business interests in the West & North Indian Regions. Develops After
Sales Support as the IJSP.
1994 - Efforts put in for Market Development. This included meeting
the Print Buyer, Viz, Publisher, Text Book Corporations etc., and
dispelling any fear they have on Un-Sewn binding. Publisher -Machine
User/Service provider meetings were arranged on a regular basis.
These activities resulted in a fairly good demand for the product -
WELBOUND. Intimate Machines (P) Ltd wins the Award for Quality

Products (State Level) from the President of India (for the year 1993).
Completes the construction of the new Factory (over 30000 sq.ft in
area) and modern. P&M added on.
1995 - Intimate Machines (P) Ltd, wins the National Award for Quality
Products (All India Basis) from the President of India (for the year
1989). Ties up with Hindustan Lever Ltd (Unilever Group), the largest
Corporate Entity in India, for the distribution (and for providing
Technical Support) of the adhesives manufactured by them in
Collaboration with National Starch & Chemicals, A separate company
is floated for this Activity, Impel Marketing Services, with Bombay as
the Head Office. Conducts Seminars with the help of experts from NSC,
like Tony Clark, in different parts of the country for building awareness
on Perfect Binding Technique, with the arrival of this tie up , a lot of
adhesive -- machine related Binding Problems were identified and
sorted out. Started extending technical support to competitors
installations, till then unheard of in this Industry in India, for binding
related problems. The NSC- HLL Experts trained our Service Engineers
on different models of Perfect Binders from reputed manufacturers.
1995 - Also saw unprecedented demand for WELBOUND and the
Installation Base grew to 150.
1996 - 2 more products (prototypes) were demonstrated to the
Industry, TRIDENT - A stand-alone Three Knife Trimmer & WELBOUND
2000 - A five Clamp Perfect Binder. WELBOUND becomes the Industry
standard for Perfect Binding in India. Adhesive Sales grow by 200%.
Installation base reaches 230 machines.
1997 Installation base reaches over 300 machines. Plant geared up for
a production of 10 machines per month.

1998 - The group takes over a Unit engaged in the manufacture of CNC
Machines in Chengannur, Kerala. This plant gets allocated for the
manufacture of higher end machines.
1999 - In print Pack 99, New Delhi, a Modular Signature Gatherer
called PickWell was unveiled. INTIMATE MACHINES Private limited is
conferred ISO 9002 certification, thereby making it one of the very few
companies in Graphic Art Industries in India to achieve the same.
2000 - Ties up with NATIONAL STARCH & CHEMICAL As an Exclusive
Agent for their Hot Melt Adhesives (Book Binding Grades) for India.
The installed base of Welbound has grown over 800 machines.

CHAPTER 2
PRODUCTS MANUFACTURED
SINGLE CLAMP PERFECT BINDER
WELBOUND BLUE
MULTY CLAMP PERFECT BINDER
WELBOUND 2000
WELBOUND 3600
GATHERING MACHINE
PICKWEL
FOLDERS
DIPLOMA 4Z3X
DOCUMENT BINDERS
MICROBINDER 330
STITCHER WITH ONLINE TRIMMER
SWITCHWEL COLT
OFFLINE THREE KNIFE TRIMMER
TRIDENT3

2.1 SINGLE CLAMP PERFECT BINDER

2.11 WELBOUND BLUE
Salient Features
Single clamp Perfect Binder
with easily adjustable book
clamp.
Milling station with cutter,
notching teeth and a
powerful dust extractor
Gluing - various options available (See technical data below)
Cover nipping station with facility to control the nipping pressure
Timers for adjusting feed-in time, cover nipping duration and delivery.

2.2 MULTI CLAMP PERFECT BINDER

2.21 WELBOUND 2000
Salient Features
6 book clamps traveling in
an oval shaped path,
where the spine is in line
with the crucial binding
station.
Calibrated book clamps
with thickness indicators;
single knob adjustments.
Easy job change over.
Continuous flow of clamps to the feed-in station with "No book-No
cover" system.
Special type milling cutter which removes paper in "strips" form
(which has commercial value) and avoids generation of paper dust.
Three roller gluing system with reverse spinner; calibrated head & tail
end cut-offs to avoid adhesive squeeze out.
Separate side gluing station with tank & gluing discs. A thin & even
layer of glue is spread along the side adding value to the book finish.
Automatic, pile type cover feeder with on-line creasing attachment.

2.22 WELBOUND 3600
Welbound 3600, a 12-clamp perfect binder meets higher

production demands. The machine is equipped with dual milling
station, three roller gluing system with head and tail cut off and
separate side gluing tank, pre-melter tank, Drum type cover feeder
with online creasing, downhill delivery and vertical stacker.
Removable glue tank for easy cleaning, calibrated book clamps and
calibration of important machine settings are some make-ready
features.
Salient Features
Calibrated book clamps with 'thickness indicators'. Single knob
adjustments leading to easy job change over.
"No book-No cover" system.
Two milling stations- One with "strip" cutter and other with
"roughener" (user selectable) for better spine preparation.
Dial indicators provided to measure depth of milling.

Removable glue station. Easy to clean and maintain.

Three roller gluing system with reverse spinner; accurate head &
tail end cut-offs to avoid adhesive squeeze out. Measuring dials
provided for height adjustment.
Separate side gluing station with tank and gluing discs. Width of
side glue is adjustable.
Separate premelt tank (of 25 Kgs Capacity) for spine glue.
Temperature of premelter, main glue tank and side glue tank can
be independently preset.
Automatic, drum type, cover feeder with on-line creasing
attachment. Cover alignment table before creasing. The gaps
between all four creases are adjustable.
Cam operated cover station which can handle high speeds with
accurate cover registration.
Downhill delivery facility keeps the book spine damage-free.
Vertical stacker with jam detector.

2.3 GATHERING MACHINE

2.31 PICKWEL
Pickwel is an offline gathering system incorporating the rotary

principle which ensures correct pick up and handling of the most difficult
signatures. The machine is equipped with latest fault detection system for
no signature and multiple signature detection. A rejection tray ensures
elimination of faulty gathered signatures without stopping the machine.
Salient Features
PLC controlled system; Operations through touch screen panel.
Offline gathering - Base model of 8 stations with delivery unit,
expandable up to 24 stations.
Manual feed station provided.

Error detection protocols provided for missing and multiple

signatures
If an error is detected the corresponding signatures are
rejected into a rejection tray, without stopping the Vertical
zigzag delivery
Optional side stitching
2.4 FOLDERS
2.41 DIPLOMA 4Z3X
AUTOMATIC PAPER FOLDING MACHINE
Diploma 4Z3X is an automatic folding machine that delivers quality

with productivity. A combination folding machine with four buckles and
three knives enable various folding formats. Built on open-architecture
system, the machine can accept third party attachments according to
customers requirements.

Salient Features
PLC controlled with soft touch display
Various folding formats up to 4 parallel and 3 cross folds
Digital sheet to sheet distance regulation
Easy job change-over with the help of digital position indicators
Creasing / perforation / slitting attachments before each knife
Electronically controlled folding knives with independent servo
motors
Third knife (or final fold) mobile type unit
Ready to be upgraded with attachments and add-ons

2.5 DOCUMENT BINDERS

2.51 MICROBINDER
Salient Features
Document Binder using hot melt
adhesives
Economic, user friendly, versatile
and compact
An ideal offline perfect binder for
Digital Printing Units
Automatic Clamping of loose
sheets / signatures
Milling cutter with notching teeth;
Suction device for extraction of dust
Optional pad making attachment
Roller type adhesive applicator
nipping can be controlled to match the cover & book thickness
Automatic control mechanisms Book, Cover Sensing.
Specifications
Speed Mechanical Speed 200 cycles per hour
Book Size Spine Thickness 2 to 25 mm
Spine Length -70 to 330 mm
Power Single Phase Motors 2 HP, Heater 1 KW

2.6 STITCHER WITH ONLINE TRIMMER

2.61 STICHWEL COLT
Stitchwel colt, the modular

saddle stitcher is ideal entry level
saddle stitching system to produce
superior quality centre stitched
books. It occupies minimum space
and is equipped with an online
three knife trimmer which trims one
book at a time to produce perfectly
square books every time.
Salient Features
Two feeding stations are provided which can be used
simultaneously.
Both stagger and straight stitching possible.
In case there is no signature under the stitching head it is sensed
and the stitching head will not be activated.
Easy machine set up.
On line trimming - Trims one book at a time for superior quality.
Each knife has its own built-in clamp, which actuates prior to
trimming.
Books can be deflected after stitching for off line trimming

ADMINISTRATIVE DIAGRAM OF
INTIMATE MACHINES

CHAPTER 3
DEPARTMENTATION
3.1 INTRODUCTION
Departmentalization is the efficient and effective grouping of jobs into
meaningful work units to coordinate numerous jobs-all the expeditious
accomplishment of the organizations objectives. This creates Flexibility,
Adaptability and unit of action within the firm. The various departments in
Intimate Machines Pvt Ltd are as follows:
Production Department
Personnel Department
Commercial Department
Financial Department
Research and Development Department
Engineering Department
Human Research Development and Administration Department
Safety Department
3.2 PRODUCTION' DEPARTMENT

The products of Intimate Machines are Post-Printing equipments like
Perfect Binder, Gathering Machine, Folding Machine, Trimmer etc. The
production department of Intimate Machines has may important
functions, which are as follows
To prepare detailed production plan in consultation with General
Manager (works) which must be consistent with company's production
objective.
To prepare detailed raw material plans and ensure the incoming quality
standards their proper usage etc.
Constantly evaluating alternate source of raw materials, direct trails of
the same and to help the management to firm up the sources.

Integrating the department itself with Research and Development

department for identifying solutions to long-term problems.
Carryout investigations and guide management on long term measures
towards achievements of the goals of expansion in the areas of
production and quality.
Integrate production efforts with maintenance to ensure
implementation of production and maintenance schedules and to
avoid breakdowns by helping maintenance under take jobs on time
basic etc.
3.3 PERSONNEL DEPARTMENT

Human Recourse is the main asset of any organization. Therefore
managing the human resources is the most important functions of any
organization. So it is essential for any organization to fix a separate
department for the management of human resources. Intimate Machines
has an efficient Personal Department. This departmental is mainly
responsible for personal functions of the company for resulting in timely
action for maintaining smooth industrial relations leading to employee's
morale and productivity. The personal department renders all personal
and establishment services to all personal and establishment services to
all persons. The primary objective of the personal department includes
establishment of industrial relations, welfare, salaries and wages,
recruitment etc. the other objectives of the department includes. To
provide leadership for management of industrial relations and employee's
welfare functions of the company.
To provide basics for corporate strategies and policies for
maintenance of industrial peace and for workers motivation
For evolving system of prompt attention and redressal of employee's
grievance and prevention of the same.
Administering the different committees for employee's participation.

Evolve and update practices for checking incoming and outgoing of

material and persons.
Implementing the standing orders pertaining in the company
The personal department has many important functions to do. The Staffing
Functions of personal department following activities
.
1. Man power planning & identification
One of the major functions of this department is the planning of the
required manpower and identification of the vacancies present in the
company. The number of employees required for the company was
planned by this department.
2. Recruitment
Another important function of personal department is the
recruitment of the right persons in the right place at right time, It is time
first process by which employment is provided to the adequate
manpower resources: It is the positive process of searching for
prospective employees and circulating them to apply tiff the jobs.
3. Selection
It is a process of choosing the right person among the applications.
4. Performance Appraisal
Performance appraisal a systematic evaluation of present potential
capabilities of personnel by their superiors. It is the process of estimating
or judging value status of a person. The main objectives of performance
appraisal are
To provide systematic judgment to back up salary increments,
transfers etc.

Means of telling the employees how he is doing or performing his

work and suggesting the needed changes in his behavior.
It is used as a base for coaching and counseling the individual by
his superior.
5. Promotion
Advancement within an organization is ordinarily labelled as
promotion, winch involves a change from one job to another that is
better is terms of status and responsibility. Change to higher job is
accompanied by increases in pay and privileges
6. Transfer
Transfer refers to shifting of a person from one job to another
without reference to change in responsibility or remuneration.
7. Retirement
Retirement means the situation when the employee being
terminated service on reaching a fixed age. The age of retirement of
Intimate Machines is 60 years. At the time of retirement the employee
will provided with provided fund, gratuity etc.
Wages & Salary
Intimate Machines gave fair remuneration to its employee in
order to increase their morale thus by increasing the productivity.
Incentives & Rewards
Intimate Machines also gives incentives and rewards to
employees. On festivals like Onam etc., the employee's get
performance cum motivation.

Canteen
intimate Machines directly running and industrial canteen to cater
the needs of the employees at free or subsidized rates functions inlet
the control of personal department, works round the clock is headed by
canteen Superintendent, A flat rate system has been introduces and
deduction is made from salary/wages of the employees.
3.4 COMMERCIAL DEPARTMENT

In Intimate, the Purchasing department, Sales and contract
department are came under one department namely, Commercial
Department. The job of this department is procurement of all materials
and services and sales of finished goods resulting in fulfilment of
production and sales objectives of the company.
Purchasing Section
Purchasing is the most important function of materials
management as the moment an order is placed for the purchase of
materials, a substantial part of company's finance is committed which
affects cash flow position of the company. The main objective of
purchasing department is to see that the required quantities at the
appropriate time and of reduced price. The purchasing department
concerned with purchase of all spares and materials except raw
materials for all department.
The main Objectives of' the department include
That financial and legal interests of the organization related to
purchase activities are safeguarded and that timely supply is
guaranteed.
The quantity of materials purchased should be tested and certified by
a competent officer from the department/stores.

To develop good suppler relationship which will ensure the best terms
of supply of materials.
To serve as an Information Centre on the materials knowledge
relating to price, source of supply, mode of delivery etc.,
To make continuous availability of materials so that there may be
uninterrupted flow of materials for production.
To make purchase in reasonable quantities to keep investment in
materials at minimum.
3.5 RESEARCH AND DEVELOPMENT DEPARTMENT
Research is an ongoing process. For the development of any
organization, research is a prime factor. So in any reputed organization,
there is a special wing for research and development. Intimate also has a
well-equipped and efficient R & D Manager concerned with Quality control
and Pollution monitoring, Technical services, Research and pilot plant
respectively. The department was concerned with the research or study of
new processes or techniques for the company. By the findings of these
departments, the company was able to find long-term solution to certain
problems of process and quality. The R & D Manager was responsible for
guiding, directing, initiating and executing all the jobs in the department.
The ISI analysis of the products and raw materials also came under this
department. Research and Development activities are concerned with raw
material substitutions, usage norms, surface coating, development of new
products and pollution control. Intimate gave prior importance to the
quality of product. Their product was well known for its quality. Intimate
has a well-established Quality Policy is as follows.

"Our company strives achieve the following:

Quality customer focused product quality
Cost products- at optimum cost
Delivery delivery at committed dates:"
The main Objectives of R & D department are:
Render in process, stage wise testing and trouble-shooting service

acting as a necessary adjunct to production.
Undertake development projects both for process and product
improvement and diversification to help General Manager and
advice management on new process, products and projects.
Identifying the changing needs of customers through regular
interactions.
Maintaining quality at incoming in process and final product stages.
Implementing and maintaining a quality management system.
The department has mainly some Functions which are
Taking samples at various stages starting from raw material till the
end product.
Analyzing the samples, finding the variance in production.
Studying the variance.
To improve the quality as well as quantity of products.
Monitoring the plant performance and pollution.
Maintaining quality at all stages of products.
Providing service to customers.

3.6 HUMAN RESOURCE DEVELOPMENT AND ADMINISTRATION

DEPARTMENT
The department is headed by the Chief Manager (HRD and
Administration). The department mainly concerns with the whole
development of work force. For any organization, employees are the hidden
assets. Without these employees no company can work effective. For the
effective working, these employees and employers need development. This
department is mainly concerned with the worker's training and executive
development. Human resource is a complex one. So there is proper training
for his working. This department of Intimate functions in very efficient
manner in this case. This department aims at increasing the attitude, skill
and abilities of the workers to perform specific tasks. Every training
programme has a well-defined specific objective. The different Stages in
Training as follows.
1. Induction Programme
Induction programme is training with specific objectives. It aims
at creating awareness to the new comers about the organization and its
products, different sections, rules and regulations they have to follow etc.
2. Orientation
This is the second stage in training programme. After induction
programme is carried out, feedback is obtained after three months. This is
orientation. This helps the trainers to learn new methods, skills and
techniques.

3.7 ENGINEERING DEPARTMENT

One of the major departments in Intimate is the Engineering
Department. The Engineering Department is responsible for the installation
of all factory structures, plants, equipment and their proper maintenance
and upkeep as well as optimum production of products. Intimate has a well
efficient Engineering Department.
The Engineering department performs various functions very
smoothly. It has co-ordination will other departments also. The Objectives
of the Engineering Department includes.
Planning, arranging and initiating preventive maintenance
programmers and repair of equipments and installations in the
factory including vehicles.
Ensuring proper upkeep maintenance and installation of estate.
To advice the Management to take decision on all Engineering
matters.
To arrange planning of engineering equipments and stores
materials required for the factory.
Preparation of technical specifications and assist the Commercial
Department in technical scrutiny of offers and arranging purchase
and stock of materials.
Preparation of plants.
Preserve the working life of plants.
To safeguard investments.
Maintaining safety and efficient working condition.
To achieve minimum break downs.
Inspection of jobs at successive stages of production.
Ensure normal productivity.
Ensure availability of machine, building etc.

3.8 FINANCE DEPARTMENT

Finance department is the lifeblood of the business. So in any
organization the most important department is the Finance
Department. Without this department no company can work smoothly.
Intimate also has an efficient department for Accounts and Finance
headed by Finance Controller. Finance Department is concerned with
planning and controlling of the firm's financial resources.
The important objectives of the finance department include.
Preparation of corporate plans annual plans and budgets.

Financial planning cost control and ensuring uniform and
correct observance of financial disciplines of the company.
Monitoring the progress of budget achievements.
Providing accounting service to all levels ensuring updating of
systems procedures for the same.
Advising management on funds utilization and its
implementation.
Vetting of all investment proposals, certain of new assets, new
posts etc., from the point of financial feasibility.
Evolve an audit manual
The finance department preforms various functions very effectively. The Main
functions of this department include:
To collect all sums due to the company in time as per sales,

orders etc.
To make timely payments to creditors, suppliers, contractors,
employees, Government statutory bodies, service Provides etc.
Timely dispersant of salary / wages / perks to employees as per
agreement, MOU etc.
To assist all types of audit work.

To prepare MIS as required by management.

To complete all Budget work.
To manage cash properly to maintain proper liquidity.
To assist all departments in providing financial administration of
all transactions.
To make proper entries in boos of accounts and extract reports
like Trial Balance, P & L A/c, Balance sheet on a time bound basis.
3.9 IN PROCESS STORES

Component / sub assembly / final assembly
Verify the quality of item with pending stock taking register.
Follow up of the pending items from further process (in housing).
Stock acceptance in ERP and move the items to desired location.
Indent generation in consumable item in periodic intervals.
Issue of items against WO (for production) / store request
(consumable item).
Follow up of the shortage component in work in progress and if the
shortage of component is due to pending supplies, then inform
planning department.
Shortage component generation by ERP based on available stock,
pending supplies, work in progress
Check / verify physical stock with EFRP stock
Assembly rejection / damage return front QCD with NC report.
Stock acceptance / damaged item and replacement of shortage item
against store request with NC report number
Issue of damaged items to strap issue register in ERP
Disposal of damaged component as scrap
Assembly return for rework
Stock acceptance of the component against preparation of
component as raw material.

RECORDS
Copy of WO (ERP file)
Store request
NC reports (file)
NC register
REPORTS
Stock statement (monthly).
Pending stock taking more than 15 days (weekly)
Pending WO more than one month (monthly).
Non-moving items more than three months (monthly).
NC register cum status report (weekly).
3.10 SAFETY DEPARTMENT

Workers are the hidden assets of any organization. So Intimate
gives prior importance to the safety of its employees. The safety
department is concerned with this function. Safety management is a
statutory requirement in any organization and its objective is to ensure the
safety in the factory premises. This department has an advisory function,
which gives advice to different department such as Production
Department, Engineering Department etc., and also to top management on
various safety matters. They also give advice to workers handling Machines
and tools ibis department is mainly concerned with control of accidents
and losses occurred within the company. This department defects unsafe
conditions and actions and they report it to the top management.

The main Objectives of the department include

To control accidents and losses.
To detect and prevent work related accidents.
To give instructions to work force about safe working methods &
conditions.
Providing and maintaining safety equipments and guards
To advise and assist the factory management for fulfilment of its
statutory obligation.
Monitoring the potential health and safety problems and carrying
safety inspections
To carry out the company's safety policy smoothly.
The company's Safety Policy should also set out the health and safety
rules covering.
Safe working health.
Inspection of new equipments.
Testing of equipments.
Inspection of the working premises etc.
The various Personal Protective Equipments that the company provided for the
employees are:
Protective Equipments
Helmet For head
A Goggles For eyes
A Mask For face
Respiratory Apparatus for Breathing
Gloves For Hand
Apron For Body
Safe Shoe For Foot

Above all these, the safety department has peculiar functions of

its own which makes it an important one. These Functions are the
following.
To direct unsafe conditions and actions in the working premises and
report it to top management.
To control the losses and accidents that occurred within the company.
Give medical and other type of assistance in accidents.
To provide preventive action, which include plant safety inspection,
safety audit, periodic training programme for accident prevention etc.
To create safety awareness among the employees.
To conduct investigation about the accidents that occurred.
To analysis the accidents occurred in a year and calculate the severity
rate.

CHAPTER 4
INTRODUCTION TO CNC
DEFINITION
Computer Numerical Control (CNC) is one in which the functions
and motions of a machine tool are controlled by means of a prepared
program containing coded alphanumeric data. CNC can control the
motions of the work piece or tool, the input parameters such as feed,
depth of cut, speed, and the functions such as turning spindle on/off,
turning coolant on/off.
APPLICATIONS
The applications of CNC include both for machine tool as well as
non-machine tool areas. In the machine tool category, CNC is widely used
for lathe, drill press, milling machine, grinding unit, laser, sheet-metal
press working machine, tube bending machine etc. Highly automated
machine tools such as turning center and machining center which change
the cutting tools automatically under CNC control have been developed.
In the non-machine tool category, CNC applications include welding
machines (arc and resistance), coordinate measuring machine, electronic
assembly, tape laying and filament winding machines for composites etc.
ADVANTAGES AND LIMITATIONS

The benefits of CNC are
(1) High accuracy in manufacturing,
(2) Short production time,
(3) Greater manufacturing flexibility,
(4) Simpler fixturing ,
(5) Contour machining (2 to 5 axis)
(6) Reduced human error.

The drawbacks are

(1) High cost,
(2) High maintenance, and the
(3) Requirement of skilled part programmer.
ELEMENTS OF A CNC
A CNC system consists of three basic components
1. Part program
2. Machine Control Unit (MCU)
3. Machine tool (lathe, drill press, milling machine etc)
A typical numerical control system for a milling machine

Part Program
The part program is a detailed set of commands to be followed

by the machine tool. Each command specifies a position in the Cartesian
coordinate system (x,y,z) or motion (workpiece travel or cutting tool
travel), machining parameters and on/off function. Part programmers
should be well versed with machine tools, machining processes, effects of
process variables, and limitations of CNC controls. The part program is
written manually or by using computer assisted language such as APT
(Automated Programming Tool).
Machine Control Unit
The machine control unit (MCU) is a microcomputer that stores
the program and executes the commands into actions by the machine tool.
The MCU consists of two main units: the data processing unit (DPU) and
the control loops unit (CLU). The DPU software includes control system
software, calculation algorithms, translation software that converts the
part program into a usable format for the MCU, interpolation algorithm to
achieve smooth motion of the cutter, editing of part program (in case of
errors and changes). The DPU processes the data from the part program
and provides it to the CLU which operates the drives attached to the
machine lead screws and receives feedback signals on the actual position
and velocity of each one of the axes. A driver (dc motor) and a feedback
device are attached to the leadscrew. The CLU consists of the circuits for
position and velocity control loops, deceleration and backlash take up,
function controls such as spindle on/off.
Machine Tool
The machine tool could be one of the following: lathe, milling

machine, laser, plasma, coordinate measuring machine etc. Figure 3
shows that a right-hand coordinate system is used to describe the
motions of a machine tool. There are three linear axes (x,y,z), three
rotational axes (i,j,k), and other axes such as tilt (9) are possible. For
example, a 5-axis machine implies any combination of x,y,z, i,j,k,and .

PART PROGRAMMING FOR CNC
The transfer of an engineering blueprint of a product to a part

program can be performed manually using a calculator or with the
assistance of a computer language. A part programmer must have an
extensive knowledge of the machining processes and the capabilities of
the machine tools. In this section, we describe how the part programmers
execute manually the part programs.
First, the machining parameters are determined. Second, the
optimal sequence of operations is evaluated. Third, the tool path is
calculated. Fourth, a program is written. Each line of the program,
referred to as a block, contains the required data for transfer from one
point to the next.
A typical line for a program is given below.
N100 G91 X -5.0 Y7 .0 F100 S200 T01 M03 (EOB)

The significance of each term is explained below.
Sequence Number, N
Consisting of typically three digits, its purpose is to identify the specific
machining operation through the block number particularly when testing a
part program.
Preparatory Function, G
It prepares the MCU circuits to perform a specific operation. The G-codes
(some) are shown in Table 1 . G91 implies incremental mode of operation.
Dimension Words
(1) Distance dimension words, X,Y,Z
(2) Circular dimension words, I,J,K for distances to the arc center
(3) Angular dimensions, A,B.C
Feedrate, F
It is expressed in in/min or mm/min and, is used in contouring or point-to-
point or straight-cut systems. For example, a feedrate of F100 implies 100
in/min or 100 mm/min. Feedrates are independent of spindle speed.

Spindle speed, S
Programmed in rev/min, it is expressed as RPM or by a three-digit code
number that is related to the RPM.
Toolword, T
Consisting of a maximum of five digits, each cutting tool has a different code
number. The tool is automatically selected by the automatic tool changer
when the code number is programmed in a block.
Miscellaneous Function, M
Consisting of two digits, this word relates to the movement of the machine
in terms of spindle on/off, coolant on/off etc shown in Table 2.
EOB
The EOB character is used at the end of each block to complete a line.
Table.1 Preparatory commands (G-code) Table.2 Miscellaneous commands (M-code)
G00 Point-to-point positioning M00 Program stop

G01 Linear interpolation M01 Optional stop
G02 Clockwise circular interpolation M02 End of program
G03 Counter-clockwise circular interpolation M03 Spindle start clockwise
G04 Dwell M04 Spindle start counter-clockwise
G05 Hold M05 Spindle stop
G33 Thread cutting, constant lead M06 Tool change
G40 Cancel tool nose radius compensation M07 Mist coolant on
G41 Tool nose radius compensation - left M08 Flood coolant on
G42 Tool nose radius compensation - right M09 Coolant off
G43 Cutter length compensation M10 Clamp
G44 Cancel cutter length compensation M11 Unclamp
G70 Dimensions in inches M13 Spindle clockwise, coolant on
G71 Metric dimensions M14 Spindle counter-clockwise, coolant on
G90 Absolute dimensions M30 End of tape, rewind
G91 Incremental dimensions
G92 Datum offset

CHAPTER 5
CONCLUSION
The Intimate Machines Pvt Ltd is a well reputed, profit making
Indian Company. The major asset of this company is skilled staff.
Moreover the efficient management of the resources have helped them
to overcome the slump in the sales over the last few years. Through this
In-Plant training it was able to fulfil the objective of our study. Detailed
study on the processes was made possible by giving emphasis on the
practical side of the theory. All together it was a good experience to see
the company and various processes carried out in the plants and the
various functions of the company.

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Industrial Training Report

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DIPLOMA IN MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

CENTRAL POLYTECHIC COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING

Head of the Department Internal Examiner

Central Polytechnic College, Thiruvananthapuram 2

Central Polytechnic College, Thiruvananthapuram 3

Central Polytechnic College, Thiruvananthapuram 4

Central Polytechnic College, Thiruvananthapuram 5

1.2 ORIGIN AND HISTORY

Central Polytechnic College, Thiruvananthapuram 6

Procurement centre to procure items from established

1.3 ABOUT WELBOUND

Central Polytechnic College, Thiruvananthapuram 7

1.4 VISION DOCUMENT - THE PURPOSE OF WELBOUND

Central Polytechnic College, Thiruvananthapuram 8

1.5 MILE STONES

Central Polytechnic College, Thiruvananthapuram 9

Central Polytechnic College, Thiruvananthapuram 10

Central Polytechnic College, Thiruvananthapuram 11

Central Polytechnic College, Thiruvananthapuram 12

2.1 SINGLE CLAMP PERFECT BINDER

Central Polytechnic College, Thiruvananthapuram 13

2.2 MULTI CLAMP PERFECT BINDER

Central Polytechnic College, Thiruvananthapuram 14

2.22 WELBOUND 3600

Welbound 3600, a 12-clamp perfect binder meets higher

Central Polytechnic College, Thiruvananthapuram 15

Removable glue station. Easy to clean and maintain.

Central Polytechnic College, Thiruvananthapuram 16

2.3 GATHERING MACHINE

Pickwel is an offline gathering system incorporating the rotary

Central Polytechnic College, Thiruvananthapuram 17

Error detection protocols provided for missing and multiple

Diploma 4Z3X is an automatic folding machine that delivers quality

Central Polytechnic College, Thiruvananthapuram 18

Central Polytechnic College, Thiruvananthapuram 19

2.5 DOCUMENT BINDERS

Central Polytechnic College, Thiruvananthapuram 20

2.6 STITCHER WITH ONLINE TRIMMER

Stitchwel colt, the modular

Central Polytechnic College, Thiruvananthapuram 21

Central Polytechnic College, Thiruvananthapuram 22

3.2 PRODUCTION' DEPARTMENT

Central Polytechnic College, Thiruvananthapuram 23

Integrating the department itself with Research and Development

3.3 PERSONNEL DEPARTMENT

Central Polytechnic College, Thiruvananthapuram 24

Evolve and update practices for checking incoming and outgoing of

Central Polytechnic College, Thiruvananthapuram 25

Means of telling the employees how he is doing or performing his

Central Polytechnic College, Thiruvananthapuram 26

3.4 COMMERCIAL DEPARTMENT

Central Polytechnic College, Thiruvananthapuram 27

Central Polytechnic College, Thiruvananthapuram 28

"Our company strives achieve the following:

Render in process, stage wise testing and trouble-shooting service

Central Polytechnic College, Thiruvananthapuram 29

3.6 HUMAN RESOURCE DEVELOPMENT AND ADMINISTRATION

Central Polytechnic College, Thiruvananthapuram 30