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PRAC TI CA L TRAI NI NG REPO RT

A TRAINING REPORT

Submitted by

ARNAB MIDYA

In partial fulfilment for the award of the degree

Of

BACHELOR OF TECHNOLOGY

IN
MECHANICAL ENGINEERING

At

JODHPUR INSTITUTE OF ENGINEERING & TECHNOLOGY

JODHPUR (RAJ)

RAJASTHAN TECHNICAL UNIVERSITY, KOTA


2010-11

1
BONAFIDE CERTIFICATE

This is to certify that Mr. ARNAB MIDYA of Mechanical Engineering


Department, Jodhpur Institute of Engineering & Technology having roll no.
07EJIME007 has completed his industrial training during the academic year
2010-2011 as partial fulfilment of Bachelor of Technology in Mechanical
Engineering affiliated from Rajasthan Technical University, Kota.

SIGNATURE

PROF. M.R. BAID

HOD – MECHANICAL ENGINEERING

JIET, JODHPUR

Internal Examiner _____________________

External Examiner _____________________

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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.

When I arrived Ingersoll-Rand, Naroda. I was asked to go through each


department, by my Mentor. This is the time when I have to look for the
opportunities to work with such a reputed multinational company. During my
training I came to know about the working of the company and also during
discussions, it appeared that they are facing lot of problems related to delivery
& quality of products from the suppliers. This was rather the first issue
discussed with me.

The time I reached my place, I received a warm welcome by department


members. During the meeting with the production manager of each department I
could feel the amount of expectation from me to carry the wave of
improvement, brought by the employees, to next level.

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ACKNOWLEDGEMENTS

Apart from my effort, the success of this training depended on the


encouragement and guidelines of many others. I take this opportunity to express
my gratitude to the people who have helped tremendously in the successful
completion of my practical training.

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 am thankful to Mr. Kalpesh Joshi, Head-Tactical Sourcing for his phenomenal


support and help. Without his guidance and encouragement towards the
training, the training would not have accomplished.

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.

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TABLE OF CONTENTS

Sr.No. CHAPTERS PAGE

01 PREFACE 04

02 ACKNOWLEDGEMENT 05

03 INTRODUCTION 07

04 COMPANY OVERVIEW 08

05 MANUFACTURING OF CENTRIFUGALCOMPRESSOR DEPT. 17

06 MANUFACTURING OF ROTARY COMPRESSOR DEPT. 28

07 MANUFACTURING OF SMALL RECIP. COPMRESSOR DEPT. 33

08 MANUFACTURING OF LARGE RECIP COMPRESSOR DEPT. 43

09 MANUFACTURING OF BUS A/C DEPT. 47

10 MANUFACTURING OF BLOWER DEPT. 51

11 MANUFACTURING OF COOLER DEPT. 62

12 STORES DEPARTMENT 64

13 HUMAN RESOURSE DEPARTMENT 77

14 INSPECTION & TESTING DEPARTMENT 84

15 QUALITY CONTROL DEPARTMENT 87

16 MAINTENANCE MANAGEMENT DEPARTMENT 95

17 PLANNING DEPARTMENT 96

18 SUGGESTIONS 97

19 REFERENCES 99

INTRODUCTION

In this report, description of the practical training completed in Ingersoll-Rand,


Ahmadabad is included. Practical training consists study of operations of
various departments of Ingersoll Rand, Naroda such as:

• Manufacturing of Centrifugal Compressors Department.

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• Manufacturing of Small Reciprocating Compressors Department.

• Manufacturing of Rotary Compressor Department

• Manufacturing of Large Reciprocating Compressors Department.

• Manufacturing of Bus Air Conditioner Department.

• Manufacturing of Blowers Department.

• Manufacturing of Coolers Department.

• Stores Department.

• Human Resource Department.

• Inspection & Testing Department.

• Quality Control Department.

• Planning Department.

• Maintenance Management Department.

COMPANY OVERVIEW

Company profile:

Ingersoll-Rand is a leading innovation and solutions provider for over 26 years


that have helped develop the industrial base and infrastructure of countries all
over the world. The company focuses on the major global markets of Climate

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Control, Industrial Technology, Infrastructure Development and Security and
Safety.

Ingersoll-Rand is a $17 billion global diversified industrial company founded in


1871. The Ingersoll-Rand name came into use in 1905 through the combination
of Ingersoll-Sargeant Drill Company and Rand Drill Company. Ingersoll-Rand
is part of the S&P 500; one of the 13 companies in that index that is
incorporated outside the U.S.
Ingersoll-Rand is a global provider of products, services, and integrated
solutions to industries as diverse as transportation, manufacturing, construction,
and agriculture. Examples include refrigeration, biometric security systems,
medium to large scale air compressors, and compact vehicles for construction
and movement of people and goods. Mining and construction support
equipment such as mobile diesel generators and compressors is the primary
field identified with the Ingersoll-Rand brand, but they also manufacture many
products under other brand names, including:
• Club golf cars
• Hussmann refrigeration units
• Kryptonite locks
• Schlage locks
• Trane HVAC equipment
• Falcon locks
• LCN door closers
• Von Duprin exit devices
• Thermo King transport refrigeration units
• Interflex, German based leading European provider and
manufacturer of hardware and software for security solutions and
time management planning.
• Normbau

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• Cisa
• Officine Meccaniche Industrialisrl (OMI), a leading European
provider of compressed-air treatment equipment.

Company facts:

Founder. Simon Ingersoll.


C.E.O. Herbert L. Henke
Headquarters. Incorporation: Hamilton, Bermuda.
Operational and executive:
Montvale, NJ, USA.

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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.

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• 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.

Air conditioning systems and services:

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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.

Climate control technologies:

Providing equipment and services to manage controlled temperature


environments for food and other perishables, Ingersoll-Rand’s Climate Control
Technologies sector encompasses both transport and stationary refrigeration
solutions. Ingersoll-Rand’s product brands include Thermo King, a world leader
in transport temperature control systems & Hussmann, a manufacturer of
refrigeration and food merchandising equipment.

Industrial technologies:

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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:

Ingersoll-Rand’s Security Technologies Sector is a leading global provider of


products and services that make environments safe, secure and productive. The
sector’s market leading products include electronic and biometric access control
systems, locks and locksets, door closers, floor closers, exit devices, steel doors
and frames, portable security devices, decorative hardware, cabinet hardware
and time, attendance and personnel scheduling systems from well-known brands
like Schlage.

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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

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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.

The CENTAC air compressor is a reliable and efficient, integrally geared,


multistage centrifugal compressor that is designed to provide oil-free
compressed air or nitrogen, for indoor or outdoor applications.
CENTAC air compressors are designed as fully packaged units including an air
end, a driver, an air cooling system, a self-contained lubrication system, and an
Ingersoll Rand developed state-of-the-art control panel with PLC.

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.

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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.

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Application:
1. Iron & steel industry.
2. Air Separation.
3. PET Blow Moulding.
4. Textile industry.
5. Chemical industry.

Department structure:

Module
Manager

CCBU CCBU Associates


Manager Engineer

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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.

• Conducted Naroda designed prototype cooler test successfully.

• Record number of 18 machine package testing done in duration within 6


months.

• Global productivity sustained for CC700 & C950.

• Reduced rework activity by pre- balancing of CC700 & C950 rotor sets.

• Maximum number of finished lines bores produced in Nov,09 in portal


machining centre.

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Product range:

Model 3 Stages of Compression


Air Flow Range- Maximum Operation pressure- Maximum

M3/Hr CFM BAR PSI


Start End Start End Start End Start End
2ACII 9005 11044 5300 6500 7.0 10.5 100 150
C950 9514 11044 5600 6500 7.0 10.5 100 150
3CII 10194 15291 6000 9000 7.0 10.5 100 150
C700 12056 17345 7400 10000 7.0 10.5 100 150
C3000 15291 25485 9000 15000 7.0 10.5 100 150
5CII 21238 50970 12500 30000 7.0 10.5 100 150
3C 9345 16990 5500 10000 10.5 42.7 150 610
4C 15291 25485 9000 15000 10.5 42.7 150 610

Major customers with model no.:

Maruti Udyog Ltd. 2AC11


Gujarat Polymer C700
L.S.Mills C700
Pragati Glass C700
Neutral Glass C700
Rajeshree Glass C950

Productivity of the company:

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120

100

80

60
e
s.fM
in
h
a
c N
o

40

20

0
2003 2004 2005 2006 2007 2008 2009 2010 (Plan)

Year

Special type of machines:

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.

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Specification

• Manufacturer – CARL ZEISS, Germany.

• Model – Prismo.

• Serial no. – 104540.

• Calibration date – 03/09/2009.

• Dimension capacity - X = 1200 mm, Y = 1800 mm, Z = 1000 mm.

• Weight of job that it can measure – 2000 kg maximum.

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• Resolution - 0.0005 mm.

• Accuracy - U1- 2.7+ (L/300) µm.

Portal Machining Centre (PMC):

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.

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Specification

Manufacturer – Hindustan Machine Tools.

Rapid traverse – 5 meter/min.

Positioning accuracy - ±12 microns.

Repeatability - ±8 microns.

Spindle RMP – 4500.

Spindle taper – MAS 403 1982.

Table size – 1800*3000 mm.

Rotary table – 1540 mm diameter.

Table capacity – 5000 kg.

Spindle power – 30 HP ( continuous ) & 50 HP ( intermittent ).

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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.

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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.

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Features:

• Reduced Maintenance.

• High Compression Ratios.

• Accommodates Wide Operating Ranges.

• Smaller Package Sizes.

• Lower Vibration.

Application:

• Automotive industries.
• Textile industries.
• Fibre industries.
• Chemical industries.
• Refinery industries.

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• Power Generation.
• Glass manufacturing.
• Metal industries.
• General industries.

Department structure:

Project
Head

Production Apprentice
Associates
Manager Engineer

Product range:

INFINITY – 7HP, 10HP, & 15HP.

SMALL UP – 4KW, 5KW, 7KW, 11KW.

PEGASUS – 15KW, 18KW, 22KW.

PANTHER – 40HP, 50HP.

PEG2 – 30KW, 37KW.

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COUGER – 45KW, 65KW, 75KW.

COBRA – 90KW, 110KW, 132KW, 160KW.

EIGER – 90KW, 110KW, 132KW, 160KW.

Mr.ED – 200KW, 250KW.

Among these the SMALL UP series is highly demanded because of these


reasons :-

Less noise, Less connections, Less motor RMP, Less space, Less time to
maintain, Less overall expenses.

Productivity of the company:

120

100

80

60
e
s.fM
in
h
a
c N
o

40

20

0
2003 2004 2005 2006 2007 2008 2009 2010 (Plan)

Year

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MANUFACTURING OF SMALL RECIPROCATING
AIR COMPRESSOR DEPARTMENT

A reciprocating compressor or piston compressor is a positive-displacement


compressor that uses pistons driven by a crankshaft to deliver air at high
pressure.

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.

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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.

Ingersoll-Rand, Naroda annual business is about 22 million USD from small


reciprocating compressor and annual production rate is about 80,000
compressors per annum. The production of small reciprocating facility
commissioned in 1965. There are around 6 assembly & test line classified on
the basis of valve configuration. The production range is from 1 HP to 30 HP.
The major customers of Ingersoll-Rand, Naroda are Air Solutions
Cambellsville, U.K, China, and Singapore. Domestic sales direct to OEM like
Wartsila & Cromton, all the domestic sales are done through channel partners.

Features:

• Two-stage Design: Delivers pressures upto 175 psig.

• Radial Fins for Maximum Cooling: Even 360° cooling of barrel cylinders
eliminates hot spots.

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• One-piece Connecting Rod: Fewer wearing parts.

• Low Oil Level Switch: Provides constant protection

• Centrifugal Un loader: Ensures load less starts, for maximum starter


protection.

• Integral Fan Blade/Finned Copper Intercooler: Runs cooler, even in the


most demanding conditions.

• Overhung Crankshaft: Precision balanced to run smoothly and quietly;


simplifies maintenance and wear-sleeve replacement.

• Splash Lubrication: Simple and reliable.

• 100% Cast Iron: Designed for a lifetime.

Features of single-stage air compressor:

• Industry-leading 5,000-8,000 hour design life


• Industrial-quality cast iron construction
• Fully-balanced crankshaft that reduces vibration
• 135 psi max. discharge pressure
• Honda engine-driven wheel barrow compressor

Features of two-stage gas powered air compressor:

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.

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• Available with easy-starting Honda, or Kohler engines
• Fuel-efficient idle control
• Advanced safety features including low oil level shutdown for gas
engines.

Features of electric driven duplex air compressors:

Ingersoll Rand duplex reciprocating air compressors offer two individual


compressor pumps and two motors mounted on a single tank, providing 100%
built in backup or additional air power for those larger capacity jobs. Includes
the legendary T30 pump with value added features in a space saving design
ideally suited for tight spaces
• Durable cast iron design for 100% continuous duty application.
• Automatic duplexing or alternating of compressors.
• Individually cast cylinders, overhung crankshaft and one piece
connecting road for ease of maintenance.
• 175 psig maximum operating pressure.

Application:
• Automotive Shops.
• Light Manufacturing.
• Construction.
• Commercial Applications.
• Fabrication.
• Pneumatic Equipment.
• Processing Lines.

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Department structure:

Module Manager

Production Manager

Assistant Manager

Associates & Apprentice Engineer

36
Product range:

F Line series.

Model > 2340 2475


Bore size (inch.) 3 & 1.75 4 & 2.5
Stroke (inch.) 2.75 2.75
Min. r.p.m 700 575
Max. r.p.m 1575 1600
BHP 1.7-5 4.5-8.2
PSI 75-250 75-250
No. of cylinders 2 2

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.

Model> 7T2HP 7T4HP 15T2HP 15T 7100 7100CR 7V 15V


Bore 5&2 3&1 5.5 & 3 5&5 5.5 & 5.5 & 3 5.5 & 5.5 &

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

Elite 200 series.

Model > 2000LUBE 2000


Bore size (inch.) 5.5 & 5.5 & 4 5.5 & 5.5 & 4
Stroke (inch.) 4.75 4.75
Min. r.p.m 550 550

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.

Model > SS3


Bore size (inch.) 2.76 & 2.75
Stroke (inch.) 2
Min. r.p.m 580
Max. r.p.m 1250
BHP 1.4-3.2
PSI 90-135
No. of cylinders 2

Productivity of the company:

40
90000

80000

70000

60000

50000

40000
e.fM
in
h
a
c N
o

30000

20000

10000

0
2003 2004 2005 2006 2007 2008 2009 2010(Plan)

Year

MANUFACTURING OF LARGE RECIPROCATING


COMPRESSOR DEPARTMENT

Ingersoll-Rand reciprocating product line offers greatest degree of parts


interchange ability between various compressor frames. Because of inherent
design advantages, such as rugged construction, slow operating speed, high
efficiency, and simple maintenance, Ingersoll-Rand reciprocating compressors
have served worldwide industries since 1872. The design of Ingersoll-Rand
reciprocating compressors has incorporated all modern technological advances
such as state of the art materials, microprocessor control, and finite element
analysis of complete compressors and individual parts.

41
The following types of machines of different models that Ingersoll-Rand
manufactures:

• Indigenious Horizontal Engine (Multi stage air compressors) – IHE.


• Eston Stationary Horizontal (Single stage air compressors) – ESH.
• Eston Stationary Vertical (Single stage air compressors) – ESV.

Indigenious Horizontal Engine:

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

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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

Eston Stationary Horizontal:


Specification:
Model Speed Piston Maximum Weight
(rpm) Displacement Working (kg)
cfm Pressure
(m3/min) Pressure
12 x 7 600 546 (16.74) 45 (3.10) 1396
14 x 7 600 744 (21.07) 35 (2.41) 1633
16 x 7 600 973 (27.55) 20 (1.38) 1750

Eston Stationary Vertical:


Specification:
Model Speed Piston Maximum Weight

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(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

Major customers with model no.:

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:

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Project Leader

Production
Associates Mentors
Manager

BUS AIR CONDITIONAR MANUFACTURING


DEPARTMENT
Reason for expenditure:

• 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.

• Through local manufacturing Ingersoll-Rand can eliminate significant


import cost (inbound freight, customs charges, etc), reduce manufacturing
cost & improve market penetration (new base volume 445/annum with
15% year over year growth). The net results of these actions are a positive
OI business with a quick return on investment.

• Ingersoll-Rand plan to use 200m2 of free space in the existing Industrial


Technologies sector facility to establishing a manufacturing. Present

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investments in assembly & testing equipment are limited to USD 95.6K
& onetime expense of USD 111.6K.

• The Naroda facility has available space for building expansion as


Ingersoll-Rand’s business grows in both retail & transport markets.

• 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.

2) Import full kit from Kolin & assemble in Naroda.

• Kolin ship unit without mounting fans, blowers, controls & harnesses in
order to reduce labour.

• Naroda make final assembly & test.

• 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%).

• So unfortunately no change in duty.

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3) Import main component from Kolin or direct from global suppliers.

• Localize hoses, harnesses, skinning etc. In India.

• Naroda make assembly & test of HVAC unit. Crate & skip to OEM/
dealer.

4) Full local manufacturing using local & global sourced material.

• Naroda make assembly & test of HVAC unit. Crate & ship to OEM/
dealer.

• Kolin get benefit of low country cost sourcing.

Shipment Tracking:

XRT unit Jan,10 Feb,10 March,10 April,10 May,10


Plan for 45 45 53 47 45
shipment
Actual 34 35 3 47 23
shipment

Plant layout:

• Frame preparation & Evaporator assembly :-

In this section assembly of frames & insulation of frame, sealing of all the
joints takes place using Sikaflex 221.

• Brazing & Helium leak testing :-

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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.

• Harnessing & Electrical Testing :-

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).

• Skinning & Packaging :-

In this station subassembly of skinning parts & packaging takes place for final
shipment.

Special type of machines used in this unit:

• Heavy duty fumes extraction machine.

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.

Make – Techflow Enterprises, Gujarat.

Power – 415 volts at 50 Hz.

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Motor – 3 phase, 1 HP at 50 Hz.

Air displacement – 1000 CMH .

Inlet diameter – 100 mm .

DBA – 80 db .

Rating – Continuous .

Filter – 99.9 % efficient.

Weight – 75 kg .

Serial number – 308091001 .

• Helium Leak Detector.

It is used to detect the leakage in the pipe of the whole product.

Make – Inficon.

Model – P3000XL .

Price – 2.5 Lakhs .

Major Customers: Volvo, TATA, Mercedes, Ashok Leyland, Private


Operators.

BLOWER MANUFACTURING DEPARTMENT

Blowers are used where require relatively constant air flow rate at varying
discharge pressures.

Principle of operation:

It consist of a pair of involutes profiled (shaped of 8) lobes rotating inside an


oval shaped casing, closed at ends by side plates. One lobe is driving lobe which

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.

The main fields of use of blowers:

• Water purification (oxygenation of basins )

• Pneumatic transportation ( under pressure & under vacuum )

• Filtration

• Paper mills & sugar works

• Chemical industries (gas loops, blowers, etc.)

• Numerous special applications (methane carries, mechanical compression


of steam, evaporators, etc.)

Specification:

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S2H22>S2H52 series:

• Flows from 35 m3/h (20 cfm) to 1 150 m3/h (675 cfm)


- Pressures to 1 bar g.* (14.5 psig)
- Vacuum to 500 mbar abs (15 “Hg)
• Two lobe construction.
• Four bearings standard with drive shaft suitable for V-belt and direct
drive.
• Bearing life: 50 000 hours.
• Available in 50 mm (2“), 75 mm (3“), 100 mm (4“) and 125 mm (5“)
gear sizes.

Truckstar Blowers:

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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:

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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

Process of Blower Assembly, Test & Shipment:

• Critical parts are to be checked on CMM with traceability.

• All parts are to be cleaned before assembly.

• Documented & approved assembly procedure.

• Calibration of assembly tools.

• Assembly clearance sheet acceptance criteria posted.

• Test standard acceptance criteria posted.

• Assembly check list & process document filled up before & after test.

• Final assembly check list updated &filled up.

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• Perform HOT & SLIP test.

• Blower serial no. Punched.

• Free rotation of shaft checked before painting.

• Outgoing check list filled up after painting.

• All documents attached before shipment.

• Authorized release for shipment.

Slip test procedure:

• Mount the machine on slip test rig.

• Connect the drive attachment to the machine shaft.

• Connect the unit with the motor shaft.

• Insert coupling at discharge connection.

• Start the panel & take RPM reading at 69 mbar in pressure gauge & the
RMP should be within specific range.

Description sheet for S2H series:

Impeller size Clearance Specified Minimum RPM range at 69


mbar
IN mm
2” Inlet tip 0.003 0.007 S2H22- 410 to 554

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Outlet tip 0.003 0.007 S2H23- 342 to 462
2” Front interlobe 0.006 0.153

Back interlobe 0.006 0.153

Locating end 0.001 0.026

Free end 0.003 0.077

3” Inlet tip 0.003 0.076 S2H31- 288 to 389

Outlet tip 0.003 0.076 S2H32- 259 to 351


3” Front interlobe 0.007 0.178

Back interlobe 0.007 0.178

Locating end 0.001 0.026

Free end 0.003 0.077

4” Inlet tip 0.004 0.102 S2H41- 160 to 230

Outlet tip 0.004 0.102 S2H42- 140 to 190

4” Front interlobe 0.007 0.178

Back interlobe 0.007 0.178

Locating end 0.002 0.051

Free end 0.004 0.102


5” Inlet tip 0.004 0.102 S2H51- 131 to 177

Outlet tip 0.004 0.102 S2H52- 110 to 150

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5” Front interlobe 0.008 0.204

Back interlobe 0.008 0.204

Locating end 0.002 0.051

Free end 0.005 0.127

Hot Test Procedure:

• 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.

• Check the oil level from the sight glass.

• Fix the oil plugs.

• Start the blower at no load condition.

• Gradually increase the speed till the blower reaches the speed of 2150
r.p.m.

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• 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.

• Let the blower run at this pressure for 10 mins.

• Note the reading.

• Slowly close the gate valve & increase the differential pressure to 500
mbar.

• Note the reading after 10 mins.

• Slowly close the gate valve & increase the differential pressure to 1100
mbar.

• Note the reading after 20 mins.

• Note the reading.

• Slowly open the gate valve & decrease the differential pressure.

• When the pressure is released fully, gradually decrease the speed.

• Turn off the blower.

• Dismantle the universal joint & coupling.

• Remove the bolts from the suction side first.

• Then remove the bolts from the discharge side.

• Take the blower out from the two flanges.

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Hot Test Rig:

Model R.P.M Pressure (mbar)

S2H22 3000 200

500

700

S2H23 1500 150

300

400

S2H31 3000 350

550

750

S2H32 3000 350

500

650

S2H33 3000 150

250

350

S2H41 3600 350

750

1000

S2H42 3600 250

500

600

S2H43 3600 150

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200

300

S2H51 2500 300

600

1000

S2H52 2500 200

400

600

S2H53 1500 200

350

500

Blower package (Targets):

• Product- Blower PD.

• IR model- S2H31 of 7.5 HP.

• KAY model- 53AC of 7.5 HP.

• Objective- To achieve targeted cost & apply learning to the other blowers
of same family.

• Scope- Covers the complete package from design to manufacturing.

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• Current cost of manufacturing- 81550 INR.

• Target cost- 54400 INR.

• Saving due to teardown proposal- 33308 INR.

• % cost reduction- 40.8.

• Revised price as per CSR 0.8- 60300 INR.

• KAY selling price- 68000 INR.

• Proposed selling price- 65000 INR.

• Revised proposed CSR- 0.71.

• Forecasting for 2010- 250 (current forecast for entire S2H blower
family).

• Total potential annual saving- 9371829.5 INR.

• Average % saving- 39.17.

COOLERS MANUFACTURING DEPARTMENT

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:

• 7*5 ESV – 295$

• CC700 – 1229$

CENTAC Heat exchanger delivery plan for year 2010:

July Aug. Sept. Oct. Nov. Dec.


CC700 1 1 1 1 1 1
C950 4 4 5 5
3C11 4 6 1 1

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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.

Trip time – 5 seconds.

Reverse time – 1 seconds.

Pause time – 3.9 seconds.

Mode – trigger, auto, fast.

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

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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.

Different job is assigned to different employers working in the store department


& that is called description. This is shown as under.

Organisation chart:

MANAGER

STORES & SHIPPING

INCHARGE

STORES

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SEMI SENIOR

CLERK CLERK

HELPERS

JOB DESCRIPTION:

In charge stores:

• Overall supervision of stores activities.

• Maintaining all records.

• Allotment of work.

• Planning of proper storage facilities.

• Co-coordination with other departments like planning, production,


maintenance, shipping & development.

• Raising requirement for stores required items.

• Planning to proper stores activities for receipt, issues & binning.

• Planning & arranging for annual inventory for store items.

• Co-coordinating of stores work between clerks & helpers.

64
• To coordinate management decision on stores staff & implementation of
new procedures.

• Co-coordinating with management to improve facilities for smoother


working stores workmen.

• To sign documents generated by stores & arrange for realizing to concern


department.

• Leave approval of stores personnel.

Senior clerk/clerk/semi-clerk:

• To allot work to stores workmen.

• To acknowledge the receipt to material to suppliers & other departments.

• To prepare documents related to receipt, issues & sending material to


vendor.

• To supervise workmen’s activities.

• Co-ordination with other departments for issue, delivering material


receipts.

• Daily job allotment on the basis of priority & presence.

• Co-ordination with stores workmen, solve their discrepancies, help in


searching items for smoother & efficient working.

• To follow store procedure & instructions given by supervisors.

• 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.

• Co-ordination with other departments & supervisors in the absence of


stores in charge.

• Additional supervision/ coordination.

Helper:

• To load/unload material from a vehicle of supplier/ transporter.

• To count quantity, verify part no., preservation of material report


discrepancies to concern supervisor.

• To take out boxes received, count quality of receipt, report quantity


discrepancies/ damages & breakages of received items.

• To take out material from respective location & move to the required/
specified area as per instructions given.

• To count & issue consumable items as & when required. If required to


move material to respective locations as per requirements with help of
forklift or hand pallet truck.

• To pack material in box, to do marking, weighing of the box.

• To operate forklift & move material from one place to another as per
requirements.

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• To apply preservative on machined components, pack with plastic bag/
sheet as per requirement, tie up identification tag of quantity &
reservation.

• To arrange material on pallet/ cage/ bin as per requirement.

• 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.

• To work clerical as & when required. Help in binning & verifying


material received from other department.

Key process for the receipt of material:

• Verification as per FS requirement.

• Entering of LR in inward register.

• Opening of cases, verifying quantity as per challan, raising discrepancies.

• Making inspection tags.

• Moving the material to respective locations.

• Signing on challan.

Inputs (inwards):

1. Supplier challan in.

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2. Duplicate with gate entry.

3. LR copy (transporter).

4. Excise gate pass (supplier or transporter).

Controls (inwards):

1. Verification on physical part.

2. Part no. & vendors identification.

3. Packing in small quantity where required.

4. Preservation.

5. LR marking.

6. Inspection report.

Mechanisms (inward):

1. Workmen/ supervisor.

2. Material handling equipments.

3. Case opening equipments.

4. Inspection tags.

5. Reservation stickers.

6. Inward register.

7. FS system, computer.

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Output (outwards):

1. Preparation of stores.

2. Receipt QC/ stores.

3. Material movement to respective area of stores/ QC or as per pick.

Work instruction process in case of rejected material to be sent back


to supplier:

• Verifying documents/ material.

• Replacement (if asked).

• Preparing necessary packing notes.

• Necessary packing preservative & movement of parts as EPR


requirement.

• Transport co-ordination.

Inputs (inwards):

1. Rejected SRS (QC).

2. IMTR (QC/assembly).

3. Rejection memo (assembly/ machine shops/ shipping).

4. Material (QC/ assembly/ machine shop/ supplier/ stores/ shipping).

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Controls (inwards):

1. Necessary marking on physical parts.

2. Necessary documents.

Mechanism (inwards):

1. Workmen/ supervisor FS system.

2. Printer.

3. Packing material.

4. Preservative.

5. Handling equipments.

6. Transportation.

Outputs (outwards):

1. Replacement (assembly/shipping).

2. Releasing documents (excise transporter/supplier).

3. Loading parts to send to supplier.

Key process for issue of reserved parts of bare compressor:

• Taking out reserved parts & verification by stores clerk.

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Inputs (inwards):

1. Pick list with reserved parts from planning department.

Controls (inwards):

1. Pick list reserved parts.

Mechanism (inwards):

1. Workmen/ supervisor.

2. Computer.

3. Printer.

4. Material handling equipment.

Outputs (outwards):

1. Correct issue of assembly.

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.

71
Planning department here follows the ABC analysis.

In the following pages the process flow chart of

• Receipt of material.

• Issue of material.

Process flow chart (Receipt of material):

72
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

Departmental objectives- stores


• S.R stores to QC average life time to reduce.

• To improve correct reserved parts issue.

• Process improvement to reduce non valve added activities.

• Direct storing to end user for cycle time reduction.

• Re use of wooden & packing material received.

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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

Vertical storage machine is used to store various components in a single


machine unit & which can be retrieve automatically when needed. Here in
Ingersoll-Rand, Naroda there are two such machines whose details are given
below:
Machine 1 Machine 2
Year of manufacture 1999 2000
INR Rs. 4.18 lakh. Rs. 5.46 lakh.
Asset card no. 2158 2183

Specification of Vertical storage system:


Make Intech

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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

76
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.

Organisational chart of HR:


Manager HR
&
Chief assistance Receptionist Clerk Semi-clerk
HR Administration
cum telephone
& operator 77
Administration
Job description (Manager HR & administration):

• Management of HR & administrative services at Ingersoll-Rand, Naroda


plant.

• To maintain industrial relations & activities under the guidance of


managing director.

• Compliance of statutory requirement.

• Health, safety & welfare of employees.

• Public relations.

• To control on security responsibilities.

Job description (Chief assistance HR & administration):

• To maintain employee personal files.

• To work/ exercise on increment, promotion, grade changes of employees.

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• Administration of work relating to recruitment, termination & other
related work.

• To work for the administration of company’s various schemes.

• Co-ordination of work between administration department & other


department.

• To maintain stock & consumption of general stationary, cleaning material


& medicines.

• To maintain confidentially of records/ events.

• To assist in mail service work if required in emergency.

• To do all time keeping activities like leave, attendance, etc.

• Procurement & maintenance of office equipment like copier, fax


machine, etc.

• To carry out any other work assigned by the supervisors.

Job description (Receptionist cum telephone operator):

• To receive visitor with courtesy & contact the officers/ employees


concerned telephonically or otherwise direct the visitor as necessary.

• Receive message & transmit them promptly as necessary.

• Furnish general information sought by visitors.

• To operate the telephone board.

• Maintain register for all calls made.

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• Check contractor’s bill.

• Verify telephone bills for payment & register complaints in respect of


defects & ensure prompt rectification.

• Ensure efficient working & communication system.

• To supervise housekeeping activities.

• To prepare the welcome board as per the instructions.

• Arranging facilities for seminars, conference, foreign visitors, etc.

• To carry out other work assigned by the supervisor.

Job description (Clerk):

• To supervise mail services.

• Maintain confidentially of HR records.

• Make entries of general expenses/ purchase/ bills passed through HR


department.

• To fill employees papers in their personnel files.

• To scrutinize candidates application & track the papers till selection.

• To make arrangement in conference rooms if any meeting/ seminar is


organised.

• To carry out general instruction given by officers.

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Job description (Semi-Clerk):

• To clean office equipment.

• To carry files, register, documents, mail, packages articles, bag, etc.

• 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.

• To serve water to officers, visitors are required.

• To handle outdoor work such as local/ out of station delivery of letter/


parcel/ tickets/ materials/ articles etc.

• To carry out general instruction given by officers.

• Maintain smart appearance & alertness at all times.

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.

INSPECTION & TESTING DEPARTMENT

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

Machine shop Assembly Stores Inspection & Planning


department department department testing department
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.

The implementation of quality system requires a total commitment from


employee at all organizational level. It requires that only materials & services,
which fully meet the specified requirements, are processed to the next stage of
manufacture or shipped to the customer. Every employee is encouraged to give
creative ideas to improve processes. Every employee has the responsibility &
the right to request or review any process at any point of time if there is a
question related to quality or safety.

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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.

This department is responsible for purchasing the various parts necessary in


manufacturing the compressors. Basically the parts of compressors are divided
into two categories.

1. Accessories.

• Pressure vessel.

• Heat exchangers.

• Motors (prime mover).

• Panels (electrical equipments).

• Instruments.

• Piping (valves).

• Other miscellaneous items.

2. Bare compressor parts.

• Cylinder.

• Piston.

• Distance piece.

• Connecting rod.

• Crankshaft.

• Piston rings.

• Other miscellaneous items.

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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.

• Co-ordination with quality control for deviation asked by suppliers.

• Co-ordination with engineering for clearing from inspection.

• Co-ordination with project engineering for drawing/ data sheet.

• Co-ordination with industrial engineering department for sending tools/


instruments/ gauges required.

• Co-ordination with transporters for material receipt.

• Co-ordination with planning department.

• Co-ordination with import for division for customs clearance/ payment.

The major functions of purchase or procurement department is shown below:

1. Purchasing of items as per requirement.

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2. Vendor development/ assessment/ audit.

3. Co-ordination with site & shop contracts & purchase order placement
for the same.

4. Co-ordination with account/ projects/ quality control/ planning/


industrial engineering.

5. Monitoring vendor performance.

Scrutiny of requirement:

Controls (inwards):
• Specification: Technical specification/ standards/ specific requirement
with quality & delivery requirement.

• Training: On job training.

• Objectives: To have clear requirements to forward to supplier for


quotation.

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.

• People: Engineer, purchasing clerk, customers, suppliers.

Output (outwards):

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• Clear requirements to forward to supplier.

Purchase orders releasing & maintaining:

Control (inwards):
• Specification: Technical specification & drawing/ specific requirements.

• Training: On the job training.

• Objectives: To release & maintain purchase orders.

Inputs (inwards):
• Information: Indent/ purchase requisition in any form.

• Information: QAP/ drawing/ specification.

• Information: Approved vendors list.

• Information: Customer/ consultant approved vendor list.

• Information: Techno-commercially clear offer.

• Information: Negotiated price.

• Information: Delivery commitment, quality & documentation.

Mechanism (inwards):
• Equipment: Computer, phone.

• People: Purchase personals.

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Outputs (outwards):
• Releasing of techno- Commercially clear order.

Supplier selection, evaluation & re-evaluation:

Controls (Inwards):
• Specification: Basic guidelines about items to be develop with the
supplier.

• Training: On the job training.

• Objectives: To provide guidelines for the supplier selection, addition,


approval & evaluation.

Input (Inwards):
• Information: D-R requirements.

• Information: Supplier’s performance.

• Information: Approved vendors list.

• Information: Supplier information from various means like media,


advertisement, exhibition, magazine, direct introduction, information
from other.

Mechanism (Inwards):
• Equipment: Computer, internet, phone, fax.

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• People: Suppliers, purchase representative, quality representative,
purchasing clerk.

Output (Outwards):
• Supplier rating.

• Approved vendor list up-gradation.

Sub- contract item:

Controls (Inwards):
• Speciation: Drawing, article of stores.

• Training: On the job training.

• Objectives: To define the procedures & responsibilities associated with


sub- contract purchase orders.

Input (Inwards):
• Material: Tools & measuring instruments.

• Information: Approved vendor list, suppliers, drawings.

Mechanism (Inwards):
• Equipments: Computer

• People: Purchase engineer.

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Staff category (Procurement or Purchase):
1. Manager – Procurement.

2. Executive – Foundry purchase.

3. Executive – Procurement.

MAINTENANCE MANAGEMENT DEPARTMENT

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

• Maintenance planning and scheduling

• Root cause analysis

• Material management

• Reliability and Maintenance Audit

Prevention maintenance is a process in which maintenance of the machine is


done every weekly or everyday as per the requirement. This type of
maintenance does not start when the breakdown of machine occurs. This helps
in serious break down and helps in the process of production. Actually in
Ingersoll-Rand, Naroda India Ltd. The machine shop is so much well handled
that maintenance is very low and has minimum work.

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

1. It is observed that lot of time is lost due to material shortage, so need to


focus on internal planning of Production Department more to avoid such
time losses.

2. Considering ‘Torque’ issue in the assembly, application of correct torque


in assembly is important but more important is to maintain that calibrated
Torque value on tools.

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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.

4. Resistance to change is found among associates in Rotary, so HR


department is requested to arrange some employee awareness program so
that they can understand how beneficial and important it is.

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

Ingersoll-Rand’s each department six sigma board.

Machine user manual from various departments.

Ingersoll-Rand online database.

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