Documente Academic
Documente Profesional
Documente Cultură
A TRAINING REPORT
Submitted by
ARNAB MIDYA
Of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
At
JODHPUR (RAJ)
1
BONAFIDE CERTIFICATE
SIGNATURE
JIET, JODHPUR
2
PREFACE
After a very short period of time when I joined J.I.E.T for engineering course,
recession started showing its effects. Even before a month of my training
program scheduled time very few companies were visiting in the campus and
those too with, not good opportunities. When Ingersoll-Rand offered internship
to the college, I found myself fortunate to get selected for the company which
has a huge brand name and great reputation in the world of business.
I’ve always been a mediocre student during my college days and don’t have any
industrial experience, so for me this one month was the only opportunity to
expand my maturity level and to mould my intellect according to the industry.
3
ACKNOWLEDGEMENTS
First of all I am extremely grateful to Mr. Rahul Wadhwa, Head H.R for
allowing me to understand the infrastructure governing the vast aspects of
compressed air solution at Ingersoll-Rand, Naroda.
I would also like to thank Mr. Vishal Kumar, Quality Assurance & Mr. Vijay.
V. Vagh, Supply Chain for their support.
Last but not the least; I extend my gratitude towards my institute, our director,
and the faculty members for providing me with this opportunity to accomplish
my undergraduate engineering training.
4
TABLE OF CONTENTS
01 PREFACE 04
02 ACKNOWLEDGEMENT 05
03 INTRODUCTION 07
04 COMPANY OVERVIEW 08
12 STORES DEPARTMENT 64
17 PLANNING DEPARTMENT 96
18 SUGGESTIONS 97
19 REFERENCES 99
INTRODUCTION
5
• Manufacturing of Small Reciprocating Compressors Department.
• Stores Department.
• Planning Department.
COMPANY OVERVIEW
Company profile:
6
Control, Industrial Technology, Infrastructure Development and Security and
Safety.
7
• Cisa
• Officine Meccaniche Industrialisrl (OMI), a leading European
provider of compressed-air treatment equipment.
Company facts:
8
2009 Net Revenues. $13.2 Billion.
Stock Symbol. “IR” listed on the New York Stock
Exchange since 1906.
Employees. Approximately 60,000.
Countries. Ingersoll Rand provides products
and services directly or through
distributors to customers in more
than 200 countries.
U.S. Executive Headquarters. Piscataway, New Jersey, and
Davidson, North Carolina.
Place of Incorporation. Hamilton, Bermuda.
Date of Formation. The Ingersoll-Sergeant Drill
Company and the Rand Drill
Company merged in 1905 to form
Ingersoll Rand.
Locations. As of December 31, 2008, Ingersoll
Rand conducts manufacturing and
assembly operations in 47 plants in
U.S; 28 plants in Europe; 18 plants
in Asia; 10 plants in Latin America
and 1 plant in Canada. Ingersoll
Rand also maintains offices,
warehouses and repair
centres throughout the world.
Company vision:
Ingersoll-Rand is a global industrial enterprise with market leading brands.
Ingersoll-Rand is dedicated to driving shareholder value by achieving:
• Dramatic Growth- By focusing on innovative solutions for Ingersoll-
Rand customers.
• Operational Excellence- By pursuing continuous improvement in all of
Ingersoll-Rand operations.
9
• Dual Citizenship- By bringing together the talents, energy and
enthusiasm of all Ingersoll-Rand people.
Ingersoll-Rand (India) Limited is a part of the Ingersoll-Rand Company, a
global innovation and solutions provider with powerful brands and leading
positions within its markets. Ingersoll-Rand (India) Limited has its presence in
India since 1921. The company established its first manufacturing plant in India
in 1965 and became a public limited company in 1977. Today, Ingersoll-Rand
(India) Limited has manufacturing facility in Ahmadabad that is ISO – 9001 and
ISO – 14001 certified. Ingersoll Rand products are widely appreciated in the
market for their superior quality and reliability. With a strong sales presence in
over 15 locations across the country and a strong national distributor network,
Ingersoll-Rand (India) Limited is a dominant player in its business of providing
solutions for the Infrastructure development, Industrial Solutions and Climate
Control markets. It is amongst the country's largest exporters of engineered
goods. 'Complete Solutions' Approach worldwide, Ingersoll-Rand Corporation
is witnessing a major shift in perspective. Simply put, it is a move from a
product centric approach towards a solutions centric approach. Ingersoll-Rand is
no longer an Engineering Company offering world class products, but a
Company that provides the customer with solutions based on these products,
solutions which go well beyond them. Ingersoll-Rand (India) Limited is among
the Country's largest exporters of engineered goods.
Business segments:
Ingersoll-Rand provides products, services and solutions to increase the
efficiency and productivity of industrial, commercial operations, homes & to
improve the security, safety, health and comfort of people around the world
through four global segments.
10
Ingersoll-Rand provides heating, ventilation and air conditioning (HVAC)
systems that enhance the quality and comfort of the air in homes and buildings
around the world. Under Ingersoll-Rand’s Trane and American Standard
Heating & Air Conditioning brands, company offers energy efficient systems,
services, parts, advanced building controls and financing solutions.
Industrial technologies:
11
Ingersoll-Rand Industrial Technologies provides products, services and
solutions that enhance customer’s energy efficiency, productivity and
operations. Ingersoll-Rand’s diverse and innovative products range from
complete compressed air systems, tools and pumps to material and fluid
handling systems and environmentally friendly micro turbines. The company
also enhance productivity through solutions created by Club Car, the global
leader in golf and utility vehicles for businesses and individuals.
Security technologies:
12
IR NARODA PLANT
13
The company features a portfolio of worldwide businesses comprising an
enviable roster of leading industrial and commercial brands, such as Bobcat
compact equipment; Club Car, Golf cars; Hussmann stationary refrigeration
equipment; Ingersoll-Rand industrial and construction equipment; Kryptonite
locks; Power Works micro turbines; Schlage locks and Thermo King transport
temperature-control equipment. These, and many other Ingersoll-Rand brands,
are positioned as number one or two in the markets. The breadth of the
company’s products enables participation in virtually every industrial activity
that society engages. This diversity increases opportunities to serve customers
more broadly in select markets, such as automotive, construction and general
industries, and from a financial perspective, helps minimize the effect of
downturns in any given market. The rapid industrialization of the country after
14
independence and the increasing demand for its engineering products promoted
the Indian Company to commence local manufacturing plant. In January 1965,
Ingersoll-Rand India’s first manufacturing plant-started production at Naroda,
Ahmedabad. Manufacturing activities ushered in a new phase in the
organization’s history; it has exhibited sustained growth in its operation and
earnings ever since. The company further expanded its manufacturing base with
a second plant Bangalore in March 1978. From the outset, it has encouraged and
assisted the growth ancillary industries, giving a boost to employment
generation.
15
MANUFACTURING OF CENTRIFUGAL
COMPRESSOR DEPARTMENT
Ingersoll-Rand is a worldwide leader in centrifugal technology. Since 1911,
Ingersoll-Rand has designed and manufactured centrifugal compressors to meet
industry requirements. These design capabilities led to the creation of the
CENTAC product line in 1968. In 1980s centrifugal technology expanded to
several different applications. In 1968 first packaged centrifugal compressor
was introduced. In 2005 Ingersoll-Rand offered the first centrifugal compressor
for standard industry. In 2007 Ingersoll-Rand was first to be ISO 8573-1:2001
Class- 0 certified for centrifugal technology tested by TÜV Rheinland®, a
global leader in independent testing and assessment services.
16
An Ingersoll Rand centrifugal compressor comes with a capacity advantage of
as much as 15% above competitive two-stage, oil-free compressors. This
advantage increases to as much as 30% as our capacity remains consistent,
while other technologies degrade by up to 15%.
Principle of operation:
1. Air enters the compressor through the machine-mounted inlet control
valve and flows to the first stage where the impeller imparts velocity
energy to the air.
2. The air proceeds through the diffuser section, which converts velocity
energy into pressure energy.
3. The built-in intercooler removes the heat of compression, which
improves efficiency.
17
4. Air passes through a stainless steel moisture separator in a low velocity
zone to remove condensate.
5. Moisture carryover is eliminated when the air is forced to change
direction 180º to enter the next stage.
Advantages:
1. Less is More- Fewer moving parts mean more reliable, safer compressor
with less downtime and less maintenance. With multi-stage compressors,
one can hit required performance easily and with less wear & tear than
with any other compressor on the market. Greater efficiency, reliability
and unique features and controls provide an unbeatable combination of
energy savings and trouble free life.
2. Balanced and Stable Rotor Assemblies- Impellers feature a vane
geometry that allows maximum pressure control over the widest
operating range. Each rotor assembly is dynamically balanced between
two hydrodynamic bearings to ensure low vibration and peak operating
efficiency.
3. Superior Bearings and Carbon Ring Seals- Because rotors are so stable,
simple bearings can be used with no moving parts. The rotors never
contact the bearings, but rather spin on a film of oil. This permits long
intervals between scheduled maintenance checks. The compressors also
feature full-floating, non-contact carbon ring seals to minimize air
leakage and prevent oil from migrating up the rotor shaft.
4. Vertically Split Casing- The exclusive vertically split casing permits easy
opening for servicing the compressor components as well as for setting
running clearances externally, without opening the unit.
18
Application:
1. Iron & steel industry.
2. Air Separation.
3. PET Blow Moulding.
4. Textile industry.
5. Chemical industry.
Department structure:
Module
Manager
19
Achievements 2009-10:
• Highest number of machine (21) shipped in the month of December
2009.
• Package test implemented for SC11 frame machine shipped in Feb 2010.
• Reduced rework activity by pre- balancing of CC700 & C950 rotor sets.
20
Product range:
21
120
100
80
60
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40
20
0
2003 2004 2005 2006 2007 2008 2009 2010 (Plan)
Year
Coordinate-measuring machine
A coordinate measuring machine (CMM) is a device for measuring the physical
geometrical characteristics of an object. This machine may be manually
controlled by an operator or it may be computer controlled. Measurements are
defined by a probe attached to the third moving axis of this machine. Probes
may be mechanical, optical, laser, or white light, among others.
Uses
• Dimensional measurement.
• Profile measurement.
• Angularity or orientation measurement.
• Depth mapping.
• Digitizing or imaging.
• Shaft measurement.
22
Specification
• Model – Prismo.
23
• Resolution - 0.0005 mm.
A PMC featuring a fixed cross-rail is a portal type 5 face machining centre for
increased productivity with total automatic operation & to reduce machining
lead time & cost. It stabilize high accuracy & heavy duty machining capability
with a one piece totally enclosed ram & rigid constructed saddle & a box type
rib structured bed, column & cross rail for minimizing heat.
24
25
Specification
Repeatability - ±8 microns.
26
MANUFACTURING OF ROTARY COMPRESSOR
DEPARTMENT
The rotary screw air compressor has become the most popular source of
compressed air for industrial applications. A major reason is its simple
compression concept. Air enters a sealed chamber where it is trapped between
two contra-rotating rotors. As the rotors intermesh, they reduce the volume of
trapped air and deliver it compressed to the proper pressure level. This simple
compression concept, with continuous contact cooling, allows the rotary screw
air compressor to operate with temperatures approximately one half that
generated by a reciprocating compressor. This lower temperature enables the
rotary screw air compressor to operate in a "fully loaded" continuous duty cycle
24 hours per day, 365 days per year, if necessary. Its ability to operate for
extended periods of time makes the rotary compressor ideal for demanding
industrial applications.
Principle of operation:
Rotary screw compressors use two screws to compress the gas. The screws are
driven through a set of synchronization gears. Gas enters at the suction side and
moves through the threads as the screws rotate. Clearances between the threads
decrease and compress the gas. The gas exits at the end of the screws. The
effectiveness of this mechanism is dependent on precisely fitting clearances
between the helical rotors and the chamber for sealing of the compression
cavities. In an oil-flooded rotary screw compressor, lubricating oil bridges these
gaps, providing a hydraulic seal.
27
In an oil-free compressor, the air is compressed entirely through the action of
the screws, without the assistance of an oil seal. They usually have lower
maximum discharge pressure capability as a result. However, multi-stage oil-
free compressors, where the air is compressed by several sets of screws, can
achieve pressures of over 150 psig, and output volume of over 2000 cubic feet
(56.634 cubic meters) per minute (measured at 60 °C and atmospheric
pressure).
In an oil-flooded rotary screw compressor, oil is injected into the compression
cavities to aid sealing and provide cooling sink for the gas charge. The oil is
separated from the discharge stream, then cooled, filtered and recycled. The oil
captures non polar particulates from the incoming air, effectively reducing the
particle loading of compressed air particulate filtration. It is usual for some
entrained compressor oil to carry over into the compressed gas stream
downstream of the compressor.
28
Features:
• Reduced Maintenance.
• Lower Vibration.
Application:
• Automotive industries.
• Textile industries.
• Fibre industries.
• Chemical industries.
• Refinery industries.
29
• Power Generation.
• Glass manufacturing.
• Metal industries.
• General industries.
Department structure:
Project
Head
Production Apprentice
Associates
Manager Engineer
Product range:
30
COUGER – 45KW, 65KW, 75KW.
Less noise, Less connections, Less motor RMP, Less space, Less time to
maintain, Less overall expenses.
120
100
80
60
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20
0
2003 2004 2005 2006 2007 2008 2009 2010 (Plan)
Year
31
MANUFACTURING OF SMALL RECIPROCATING
AIR COMPRESSOR DEPARTMENT
The intake air enters the suction manifold, then flows into the compression
cylinder where it gets compressed by a piston driven in a reciprocating motion
via a crankshaft, and is then discharged.
32
In this unit assembly, testing, painting & packaging of small reciprocating
compressor takes place. The whole assembly unit is divided into two parts, one
is N line assembly & other one is T line assembly. This division has been done
depending upon the size of the compressor. Each line is divided into 5 stations
on which assembly of different parts takes place. The testing of both the lines is
done separately. The testing is usually takes place in two phases, in first phase
leakage testing takes place & in second phase the proper working of the
compressor is tested. If any defects found on any model then that particular
model will be marked as a rejected piece. Before assembly all the bare parts that
are imported from different other shop directly goes to the paint booth for
painting. After all testing is over the model transferred to packaging shop where
the final packaging is done for the shipment to different customer according to
their order for the particular model.
Features:
• Radial Fins for Maximum Cooling: Even 360° cooling of barrel cylinders
eliminates hot spots.
33
• One-piece Connecting Rod: Fewer wearing parts.
Ingersoll Rand’s two stage gasoline engine driven air compressors are designed
to provide compressed air where electric power is not readily available. They’re
used in fleet and field service applications, remote pneumatic applications and
emergency production lines.
34
• Available with easy-starting Honda, or Kohler engines
• Fuel-efficient idle control
• Advanced safety features including low oil level shutdown for gas
engines.
Application:
• Automotive Shops.
• Light Manufacturing.
• Construction.
• Commercial Applications.
• Fabrication.
• Pneumatic Equipment.
• Processing Lines.
35
Department structure:
Module Manager
Production Manager
Assistant Manager
36
Product range:
F Line series.
N Line series.
37
Model > 231HP 2545 2545CR V235 V244 V255
Bore size 3 & 1.25 5 & 2.75 5 & 2.75 3&3 4&4 5 &5
(inch.)
Stroke 2.75 3.5 3.5 2.75 2.75 3.5
(inch.)
Min. 400 400 400 350 300 300
r.p.m
Max. 660 1050 1050 800 800 750
r.p.m
BHP 1.9-2.3 5-11 11 - - -
PSI 300-500 75-250 170 - - -
No. of 2 2 2 2 2 2
cylinders
T Line series.
38
size & 1.63 & 3.5 3 5.5 5.5 &
(inch.) 5.5
Stroke 4 4 4 4 4 4 4 4
(inch.)
Min. 550 550 550 550 750 750 300 300
r.p.m
Max. 800 800 900 1080 1100 1100 900 800
r.p.m
BHP 9-10.2 4.3-5 10.2- 16- 8.5- 13.5- - -
16.4 22.5 16.3 16.3
PSI 300- 600- 300- 125- 75- 75-175 - -
500 1000 1000 250 250
No. of 2 2 3 3 2 2 2 3
cylinders
39
Max. r.p.m 1000 1000
BHP 18-27.5 18-26
PSI 125-256 72-93
No. of cylinders 3 3
SS Line.
40
90000
80000
70000
60000
50000
40000
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30000
20000
10000
0
2003 2004 2005 2006 2007 2008 2009 2010(Plan)
Year
41
The following types of machines of different models that Ingersoll-Rand
manufactures:
Specification:
Model Speed Piston Maximum Weight
(r.p.m) displacement Working (Kg)
Cfm Pressure
(m3/min) Pressure psig
(Barg)
12 & 7 x 7 750 681 (19.29) 125 (8.62) 2150
IHE-5
14 & 8 x 7 750 930 (26.34) 135 (9.31) 2300
IHE-7
16 & 10 x 7 750 1216 (34.44) 125 (8.62) 2600
42
IHE-10
7&7x7 750 457 (12.94) 75 (5.17) 1500
IHE-S4
10 & 10 x 7 750 943 (26.71) 60 (4.14) 2050
IHE-S7
12 & 12 x 7 750 1363 (38.60) 45 (3.10) 2150
IHE-S10
14 & 14 x 7 750 1800 (50.98) 40 (2.76) 2600
IHE-S15
43
(rpm) Displacement Working (Kg)
cfm Pressure
(m3/min) Pressure
7x5 750 164 (4.65) 125 (8.63) 620
8x5 750 215 (6.10) 100 (6.90) 681
9.5 x 5 675 274 (7.78) 60 (4.14) 718
8x7 650 260 (7.36) 135 (9.31) 840
9x7 650 330 (9.33) 110 (7.59) 840
11 x 7 650 498 (14.10) 100 (6.90) 1354
Model Customer
8 x 7 ESV Liquors India Ltd.
7 x 5 ESV Aircon Engineers
16 x 7 ESH Equipments & Spares
9.5 x 5 ESV Bhusan Steel Ltd.
9.5 x 5 ESV MRF Ltd.
12 x 7 IHE Auronext Pharma Pvt. Ltd.
7 x 5 ESV Firdos & S.Cambatta Co.
8 x 7 ESV IRCT
Department structure:
44
Project Leader
Production
Associates Mentors
Manager
• The current India bus HVAC business model is based on importing KRS
units from Shenzhen, China. This model has resulted in limited market
penetration (300/annum, with 70 for OEM & 230 for private operators)
due to inflated sales price. The sales price is a result for high transfer
price from Shenzhen & import duty / VAT.
45
investments in assembly & testing equipment are limited to USD 95.6K
& onetime expense of USD 111.6K.
• As ESA are launching a new lower cost modular HVAC unit is called X-
900, IR want to introduce this to the Indian market under name of XRT.
Project phases:
1) Import complete unit from Kolin in order to introduce into Indian market.
• Kolin ship unit without mounting fans, blowers, controls & harnesses in
order to reduce labour.
• NOTE: Full kit change customs code from “Bus HVAC unit” (HST
8415.20.10 with duty of 10%) to “Bus HVAC parts” (HST 8415.90.00
with duty of 10%).
46
3) Import main component from Kolin or direct from global suppliers.
• Naroda make assembly & test of HVAC unit. Crate & skip to OEM/
dealer.
• Naroda make assembly & test of HVAC unit. Crate & ship to OEM/
dealer.
Shipment Tracking:
Plant layout:
In this section assembly of frames & insulation of frame, sealing of all the
joints takes place using Sikaflex 221.
47
In this station brazing of various pipe joints using oxygen & acetylene & leak
testing of all the pipe joints using Helium Leak Detector takes place. For
brazing Electronic gas saver is used.
In this station harnessing & electrical connection to fans & blowers takes place.
Conduction of electrical testing is done by simulating compressor load at
different fan & blower speeds & it is done according to Thermoking standards
(TKS 19003). Harnessing is also done with care according to Thermoking
standards (TKS 19003).
In this station subassembly of skinning parts & packaging takes place for final
shipment.
It is used to exhaust all the fumes produced in the shop due to brazing by
filtering & transforming it into fresh air to the atmosphere.
48
Motor – 3 phase, 1 HP at 50 Hz.
DBA – 80 db .
Rating – Continuous .
Weight – 75 kg .
Make – Inficon.
Model – P3000XL .
Blowers are used where require relatively constant air flow rate at varying
discharge pressures.
Principle of operation:
49
is driven by external power while the driven lobe is driven by a pair of equal
ratios gear. Both the lobes thus, rotate in same speed but in opposite direction.
As the lobes rotate, air is drawn into inlet side of the cylinder & forced out the
outlet side against the system pressure. With each revolution four such volumes
are displaced. The air which is forced out is not allowed to come back due to the
small internal clearances within the internals of the machine except a very small
amount called slip. There is no change in the volume of air within the machine
but it merely displaces the air from the suction end to the discharge end against
the discharge system resistance. Since the lobes run within the casing withy
finite clearance, no lubrication is required. The air thus delivered is 100% oil
free. These blowers deliver practically constant flow rate independent of
discharge pressure conditions. The flow rate is dependent largely on the
operating speed.
• Filtration
Specification:
50
S2H22>S2H52 series:
Truckstar Blowers:
51
The Truckstar range has been developed specifically for dry bulk transfer
applications on trucks for the cement, fly ash, lime, flour, powder, sugar, plastic
pellets, sand grain industries.
- Flows of 1100-1700 m3/h (647-1000 cfm)
- Pressure to 1.2 bar (17.4 psig) gauge
- Vacuum to 500 mbar abs (15 “Hg)
■ Tri-lobe construction with pulsation control ports for smoother operation.
■ Clockwise and anti-clockwise rotation.
■ Oil splash lubricated bearings and large capacity sumps.
■ Double ring feder and gear retainers for more input torque capability.
■ Heavy duty casting ribbed for rigidity and noise attenuation.
■ Built in melting plugs for temperature protection.
Models of Blowers:
52
Model Length Height Width Weight Nominal
(kg) CFM
TS07 595 405 310 153 700
TS10 672 405 310 162 1000
S2H22 260 280 222 19 60
S2H23 311 280 222 21 130
S2H31 314 335 283 34 120
S2H32 336 335 283 38 175
S2H33 402 335 283 48 300
S2H42 437 370 313 60 350
S2H43 502 370 313 73 485
S2H51 479 465 387 95 265
S2H52 530 465 387 102 530
• Assembly check list & process document filled up before & after test.
53
• Perform HOT & SLIP test.
• Start the panel & take RPM reading at 69 mbar in pressure gauge & the
RMP should be within specific range.
54
Outlet tip 0.003 0.007 S2H23- 342 to 462
2” Front interlobe 0.006 0.153
55
5” Front interlobe 0.008 0.204
• Let the blower is mounted on the hot test bed between the suction.
• Insert & fix the bolts with washer on the machining surface of the
discharge side first.
• Insert & fix the bolts with washer on the machining surface of the suction
side.
• Connect the motor shaft & the blower shaft with the coupling & universal
joint.
• Insert the coupling on the shaft & connect the universal joint & coupling
with the bolts & fix the bolts properly.
• Remove one of the oil plugs on both the gear & the shaft end to pour oil.
• Gradually increase the speed till the blower reaches the speed of 2150
r.p.m.
56
• Let the blower run at this condition without load for 5 mins.
• Close the gate valve gradually till the differential pressure across the
blower shows 200 mbar.
• Slowly close the gate valve & increase the differential pressure to 500
mbar.
• Slowly close the gate valve & increase the differential pressure to 1100
mbar.
• Slowly open the gate valve & decrease the differential pressure.
57
Hot Test Rig:
500
700
300
400
550
750
500
650
250
350
750
1000
500
600
58
200
300
600
1000
400
600
350
500
• Objective- To achieve targeted cost & apply learning to the other blowers
of same family.
59
• Current cost of manufacturing- 81550 INR.
• Forecasting for 2010- 250 (current forecast for entire S2H blower
family).
In the last quarter of 2009 the Naroda team launched Ingersoll Rand India’s first
ever IPAC cooler & CENTAC CC-700 heat exchanger set, another testimony to
the changing product landscape in the plant. Heat exchangers are vital
constituents of compressor package & until the recent in house development IR
were heavily dependent on a couple of exclusive vendors. In fact for the large
reciprocating machines being exported, the heat exchangers were largely being
imported due to lack of an ASME certification to Ingersoll-Rand’s facility. Not
satisfied with the progress Ingersoll-Rand’s project team had gone ahead &
60
released the design of the 8*7 & 9*7 coolers & are now working assiduously to
procure the critical ASME certification by June 2010 to cater to Ingersoll-
Rand’s export strategy. The broader objective of this initiative is to be self
reliant & enhance customer satisfaction by reducing lead time & improving
product performance.
The products that Ingersoll-Rand manufactured are 7*5ESV IPAC cooler &
CC700 heat exchanger but with the new development 8*7 & 9*7 coolers
material received & under localization. 3C2 under development of designing
process. So ultimately the saving per cooler can be calculated as follows:
• CC700 – 1229$
61
This shop is also divided in to various sub-stations, where different type of
activity takes place such as Tube bundle assembly, Tube bundle & shell
assembly, Expansion & Tube to tube sheet expansion. Expansion of pipe is
done so that the coolant (water) that will flow through heat exchanger will not
come out from the circumferential spacing of the tube. The machine that are
used for the expansion is called Expander & the specification of the expander
are given below:-
Wattage – 400.
STORES DEPARTMENT
In this department the supplier are the outside vendors, machine shop &
assembly. The goods received may be finished & semi finished. It may be
inspected or may not be inspected. If inspected goods are there then it directly
shifted to rack where all inspected goods are kept. Even store have to supply
goods to the assembly & machine shop whenever required. For this the planning
department gives a pick list to store department in which each & every item
description, their location i.e. rack no. & bin no. Are printed & even number of
62
quantity required is printed. Stores department have to supply those items to the
respective department. Now if any item is missing i.e. if there is any scarcity of
any item then the store department have to consult with the planning
department. In short store department is attached to machine shop, assembly,
inspection & testing, purchase & planning department.
Organisation chart:
MANAGER
INCHARGE
STORES
63
SEMI SENIOR
CLERK CLERK
HELPERS
JOB DESCRIPTION:
In charge stores:
• Allotment of work.
64
• To coordinate management decision on stores staff & implementation of
new procedures.
Senior clerk/clerk/semi-clerk:
• To operate computer.
65
• To file documents required to file & maintain proper filling system.
• To enter required data in register for incoming & outgoing receipt of out
station.
Helper:
• To take out material from respective location & move to the required/
specified area as per instructions given.
• To operate forklift & move material from one place to another as per
requirements.
66
• To apply preservative on machined components, pack with plastic bag/
sheet as per requirement, tie up identification tag of quantity &
reservation.
• To take out items from stores locations as per pick list & issue/ move
material the area where required.
• To bin heavy & big items on vertical storing rack with necessary
preservative.
• Signing on challan.
Inputs (inwards):
67
2. Duplicate with gate entry.
3. LR copy (transporter).
Controls (inwards):
4. Preservation.
5. LR marking.
6. Inspection report.
Mechanisms (inward):
1. Workmen/ supervisor.
4. Inspection tags.
5. Reservation stickers.
6. Inward register.
7. FS system, computer.
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Output (outwards):
1. Preparation of stores.
• Transport co-ordination.
Inputs (inwards):
2. IMTR (QC/assembly).
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Controls (inwards):
2. Necessary documents.
Mechanism (inwards):
2. Printer.
3. Packing material.
4. Preservative.
5. Handling equipments.
6. Transportation.
Outputs (outwards):
1. Replacement (assembly/shipping).
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Inputs (inwards):
Controls (inwards):
Mechanism (inwards):
1. Workmen/ supervisor.
2. Computer.
3. Printer.
Outputs (outwards):
The above process is followed when the pick list is received from planning
department to the store department. In this pick list each information of every
part is given & also the location of that part is given i.e. the rack no. & so on.
According to the pick list the parts are issued to the assembly department. Also
the data is entered in the computer & as such the no. Of parts becomes lesser &
lesser. If any of the part is not there then the planning department is to be
concerned & according to the planning department the procedure follows.
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Planning department here follows the ABC analysis.
• Receipt of material.
• Issue of material.
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Opening of Preparation
cases stores receipt
Unloading of
material &
Verification moving to
respective Moving material
places to QC for non
Making insp. parts &
inspection tag ok parts to
respective area
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Issue of Process flow chart (issue of material):
material Generating
packing note
Release documents
when
acknowledgement is
Issue to vendor Take out received
material from
location/
respective area
as per pick list Necessary
verification of
reserved parts
Issue to inter
departmant as Entry of pick in
per pick list system
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Model 100-180-44
Overall floor space required. 2660*1360 MM.
Floor space required with drive unit & 2660*1760 MM.
Work table
Machine height 5060 MM.
Shelf dimensions 2160*420*180 MM.
Necessary room height 5160 MM.
Type of shelf Plain type shelves without any slots or bins.
No of shelf 44
Capacity of each shelf 100 kg.
Total capacity of machine 4400 kg.
Allowable unbalance 500 kg.
Work table height 1000 MM.
Work table depth 400 MM.
LED identification no. 24
Colour Corner angles: Oxford blue.
Rest of the parts: Munshell gray.
Chain 1” Simplex.
Control MC 200A control.
Drive motor Power: 2 HP.
RPM: 1405 r.p.m.
Make: Crompton
Gear box Ratio- 40:1.
Type: A337
Brake Type: FDB 15
Make: Emco
HUMAN RESOURCE DEPARTMENT
In this department all the functions related to human welfare i.e. related to employees
are carried out. The different functions of this department in Ingersoll-Rand, Naroda
plant are given as under.
1. Compliance of statutory requirements.
2. Recruitments.
3. Attendance.
4. Probation & confirmation.
5. Annual increment.
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6. Miscellaneous items.
7. Leave encashment.
8. Outdoor duty.
9. Scholarship claim.
10. Compensatory OFF.
11. Dispatch of mail/ documents.
12. Leave travel concession.
13. Communication.
14. Termination.
This department has to look out about the employees that whether the rules &
regulations of the company are followed by them or not. The government in favour of
both employees & also the company also makes various laws, these have to be
followed by the employees. This is the function given under compliance of statutory.
The other is the recruitments of any new employee is also done by this department.
Personnel interview & test are been taken. Whenever the company is in need of any
employee whether it may be in the administrative level or at the worker level then the
company may either give advertisement in the newspaper or any other media & may
also consult with the consulting agents. According to the requirement of the company
the recruitment is done. Say for example if any technical staffs are required then it is
being interviewed by the technical staff & also by the HR department. In the second
round the HOD’s of other department is interviewing him. If the employee is as per the
requirement of the company then & then recruitment is done. In some cases campus
interview is being carried out if any apprentice is required. Here the HR department is
most responsible. GD may be done if necessary.
HR department is also responsible for the attendance of all the employees working in
the company. Whether the employee is coming regularly or not is being checked. Here
in Ingersoll-Rand, Naroda plant punch card system is there. Every employee punches
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his/ her when he/ she enter into the company. The time & date is automatically entered
into the company’s data.
The company also does sometimes annual increment in the salary of the employees in
order to motivate employees. This depends on the type of employee.
HR department is also responsible to check out the stock of various miscellaneous
items like medicines for first aid, stock of papers needed for fax, printers, etc & also
the general stationary is to be look out by the HR department.
If any employee wants to have a leave for any specific period of time then HR
department is responsible for this job.
Dispatch of important mail & other documents to other departments, suppliers, outside
vendors, etc is also the function of HR department.
Sometimes employees at the administrative level have to out of station for any official
work. For this also HR department is responsible.
Communication between the various departments is to be looked out by HR
department. Here in Ingersoll-Rand, Naroda plant various communications channels
like inter-com, telephone, telex-lines, photocopier, etc are used. HR department is
responsible for this communication network.
If any employee is to be terminated then it is the function of HR department to take all
the items which have been given by the company like ID card, credit card if any given
to employee, car, house etc. Also HR department is responsible to note down the
reason why the employee is been terminated & also keep his/ her personnel
information if required in the future.
The organizational structure of HR department in Ingersoll-Rand, Naroda plant is
given as under.
• Public relations.
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• Administration of work relating to recruitment, termination & other
related work.
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• Check contractor’s bill.
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Job description (Semi-Clerk):
• To collect the mail/ faxes from all department & to sort it & to deliver all
collected/ received mails/ faxes to concerned employers &/ or to keep at
specified location.
HR is also responsible for the safety & security of employees & also the
property of the company. Various safety instruments like fire safety, goggles,
shoes, helmet, etc is made compulsory as the working environment of the
employee. If the worker is working at some height then he is asked to wear
helmet. Each & every employee is given training about using various safety
instruments. Here in Ingersoll-Rand, Naroda plant fire may be caused due to
cotton, clothes, etc. For each every type of fire the fire extinguishing material is
different. So training is given to each & every employee in the company. In case
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of emergency there are some areas, which are decided by HR department at
which everybody has to meet in order to save their lives. Even posters are
attached on the walls of each & every department of how to use fire
extinguisher. Even in the manual also it is been mentioned about safe use of
each & every instrument. Even they are made aware if the instrument is not
used properly. The HR department is having a great responsibility.
In this department various job after coming from outside vendor, machine shop
& assembly is been inspected & tested. Sometimes the part is inspected & tested
by the outside vendors & so not necessary to be inspected, such parts are
directly moved to store department. The parts if any defect or fault is observed
then are rejected & again send back to respective department. Here in Ingersoll-
Rand, Naroda plant non destructive testing is been carried out like:
• Hydro testing.
• Dye testing.
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• Ultrasonic testing.
• Magnetic testing.
Hydro testing:
This testing is done in order to check whether there is any leakage in the part or
not. In this test the part under consideration is filled with water. Actually the
various parts used in compressor like cylinder is having a water jacket, this is
because the temperature while working goes so much high that it has to be
cooled & so water is being circulated inside the water jacket & thus it becomes
cool. In this hydro test water is filled inside this jacket at some pressure & then
is kept for some time, if the pressure decreases then it is said that there is any
leakage or somewhere else. If the defect is seen by naked eyes then it is ok but
if not seen by naked eyes then it is again tested under dye testing which is
another non destructive testing.
Dye testing:
This type of testing is done in order to find out is there any discontinuity in job
or not. Such testing is done on crankshaft, connecting rod, etc. In this testing as
special type of chemical is applied on the surface of job & is allowed to make
dry. There after it is removed & again another chemical is used. If there are any
discontinuities then the first chemical applied is absorbed inside the job & the
defect can be seen with naked eyes. Dye testing can be used only to find defects
on the upper surface of the job, but if there is any inter defect then ultrasonic
testing is used.
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Ultrasonic testing:
It is done in order to find out if there are any discontinuities on the inner surface
of the job. Say for example a cylinder is having a bore if there is any defect on
inner surface then we can’t apply dye on the inner surface, even we can’t apply
dye inside the water jacket. So this type of testing is done. In this testing
ultrasonic wave is passed from the surface of the job & according to frequency
of the reflected waves the discontinuities can be find out. A special instrument
like CRO is used. The same technique used in radar for finding out the height of
aeroplane in aviation is used here.
Magnetic testing:
This is done in order to find out internal discontinuities of any job. Here
magnetic iron powder of very small grade i.e. having very minute granules is
spread on the surface of the job and a magnetic field is set on the job. If there
are any discontinuities then this iron powder form circles at the area where there
are discontinuities. This is because of difference in EMF. But this type of
testing is has a limitation that it can be applied only on ferrous material.
Material made of aluminium, copper, etc cannot be tested.
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QUALITY CONTROL DEPARTMENT
This department is responsible to check out the quality of the job manufactured.
Ingersoll-Rand, Naroda is an ISO 9001, ISO 14001 certified company & so this
department is very important & fruitful to the company. This department is
attached to all the other departments. In Ingersoll-Rand, Naroda quality of final
job is checked & also the quality of the work & the job is being checked when
the manufacturing is going on. This is done because if there is any change
required in the job while it is been in process then it can be done at that
instance. Thus rejection level can be decreased to minimum level.
This department is also responsible to check out that every employer is working
properly or not. Nobody should forget his/ her duties & also should follow the
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rules & regulation of the company. In the below diagram we can see the
attachment of this department with the other departments.
Quality control
department
Quality control:
The Ingersoll-Rand facility in Naroda, Ahmedabad shall design, manufacture &
package process compressor with associate accessories for industrial application
develop & provide technical solutions & support the clients utilizing a quality
system that satisfies the requirements of ISO 9001 & ISO 14000 as a minimum.
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This quality manual outlines the system & procedures necessary to achieve the
Naroda plant requirements. Deviation or alteration from these systems &
procedure are not permitted without written authority of the general manger
operation/ head quality assurance.
1. Accessories.
• Pressure vessel.
• Heat exchangers.
• Instruments.
• Piping (valves).
• Cylinder.
• Piston.
• Distance piece.
• Connecting rod.
• Crankshaft.
• Piston rings.
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These items are been designed by project & engineering department & the
indent, which includes drawing, & specification is passed to purchase
department for buying these items. There after the purchase department function
starts. This department rises inquires that how many vendors are available &
what are various price rate & specification given by them. Then the sorting of
the vendor is done i.e. which vendor is to be selected. This type of procedure is
done for all the items measured above. This inquiry raise is done through the
previous data or through site, magazines, etc. This department also does
negotiation with the vendor. Also other factor like what are delivery schedule of
the vendor, what are the requirements used by the vendor, etc are taken into
consideration. The quality control department after the manufactured of the
product visits at the vendor place in order to check whether the job assigned to
vendor is at the specified dimensions. Inspection & testing is done at that time.
This is called vendor assessment & performance ration of vendor. The purchase
department has to be in co-ordination with various departments like.
• Co-ordination with stores for clearing the rejection & also placing new
orders for rejected items.
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2. Vendor development/ assessment/ audit.
3. Co-ordination with site & shop contracts & purchase order placement
for the same.
Scrutiny of requirement:
Controls (inwards):
• Specification: Technical specification/ standards/ specific requirement
with quality & delivery requirement.
Inputs (inwards):
• Information: Indent/ purchase requisition in any form technical
specification, customer request for quotation, approved vendor list,
quality requirements, and all related standard data.
Mechanism (inwards):
• Equipment: Computer, FAX, copier.
Output (outwards):
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• Clear requirements to forward to supplier.
Control (inwards):
• Specification: Technical specification & drawing/ specific requirements.
Inputs (inwards):
• Information: Indent/ purchase requisition in any form.
Mechanism (inwards):
• Equipment: Computer, phone.
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Outputs (outwards):
• Releasing of techno- Commercially clear order.
Controls (Inwards):
• Specification: Basic guidelines about items to be develop with the
supplier.
Input (Inwards):
• Information: D-R requirements.
Mechanism (Inwards):
• Equipment: Computer, internet, phone, fax.
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• People: Suppliers, purchase representative, quality representative,
purchasing clerk.
Output (Outwards):
• Supplier rating.
Controls (Inwards):
• Speciation: Drawing, article of stores.
Input (Inwards):
• Material: Tools & measuring instruments.
Mechanism (Inwards):
• Equipments: Computer
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Staff category (Procurement or Purchase):
1. Manager – Procurement.
3. Executive – Procurement.
This department is responsible for the entire breakdown if there is any in the
company. Generally the breakdown occurs in the machine shop department. So
this department is a part of machine shop department. It is also situated in
machine shop. This department is connected with the stored department. If there
is any break down in the machine shop then the faulty part is replaced which is
stored in the stores. So maintenance department has to be in continuous
coordinated with stored department. The various processes to be carried out by
maintenance department are as follow:
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Maintenance management processes:
• Prevention maintenance
• Condition monitoring
• Material management
PLANNING DEPARTMENT
The department is responsible for planning all the activities of the machine shop
and all the release of order for the stores and assembly. In this department the
factory order receipt from outside vendor then it is been entered into the
planning department computer. Software named ZMRL is used. Here the goods
are classified and is entered into various categories like semi finished, finished,
casting and forged. According to the type of good the data is been entered. Then
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if any goods are to be inspected then it is shifted to inspection and testing
department and if not required then shifted to store; assembly or machine shop.
These decisions are to be taken by planning department. The planning
department also decide the inventory levels in the stores. The technique used is
ABC analysis. Here the goods are classified according to cost. Goods like
cylinder; piston; connecting rod; crankshaft and distance pieces are not stored in
bulk quantities and goods like piping; values; nut bolts; and other miscellaneous
are stored in bulk quantities.
After receiving the factory order receipt from project department the planning
department produces a pick list and gives to the stored department. The list
consists of all items required for manufacturing the compressor. Then the stores
department issues all the items mentioned in the pick list to assembly where the
final compressor is manufactured. Planning department also receives the bill of
material from CE and QAP (QUALITY ASSURANCE PLAN) receipt from
project department. The planning department is to work in coordination with
other department also like machine shop, assembly, purchase, engineering, etc.
SUGGESTIONS
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• As CTQ, Dynamic Torque analyzer is suggested, and associate must be
motivated to analyze the respective torque values in morning.
• It is also observed that pneumatic guns used in the assembly also have its
own torque. So these Guns should also be analyzed after regular intervals
of time.
3. Currently for planning is done for a single day only. As assembly line has
been established for light industrial services so we should focus on
constant feeding of the respective line.
• Currently we are only focusing on one day production and feed the
line (LIS) acc. to one day plan only, as a result assembly line is
stopped when one days target is achieved resulting in fresh
beginning on the line. But assembly line should be fed constantly
so 2 days plan is must.
• Whenever there is man power shortage for the line, we start
assembling machine on a single station only, result of which line
concept is broken and thus affects the output when sufficient man-
power is available. Therefore, I strongly suggest that in place of
assembling the machine on a single station we should focus on
assembling the machine on line, at different stations. This will help
the continuous feeding and also when our work force will be
sufficient, on next day, we need not to start from the scratch to run
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the line. Continuous flow of the line would help in maintaining the
frequency of the line.
REFERENCES
www.ingersollrandproducts.com
www.ingersollrand.com
www.ingersollrand-india.com
www.ingersollrand-india.com/airsolutions/index.asp
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www.google.com
www.wikepedia.com
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