ME0329 INDUSTRIAL TRAINING I

NAMES OF STUDENTS G.SHREYAS

REGISTRATION NUMBER

10208191

DEPARTMENT

MECHANICAL ENGINEERING

YEAR

3rdYEAR

SECTION

MEC - C

SUBJECT

ME0329 INDUSTRIAL TRAINING I

SUBMITTED ON

2nd November 2010

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INDEX
SL.NO PARTICULARS PAGE NO.

1. 2. 3. 4. 5. 6.

CERTIFICATE ABOUT INDUSTRY ABOUT TRAINING DEPARTMENTS TRAINING DETAILS OBSERVATIONS MADE KNOWLEDGE GAINED

3 4 5 7 12 13

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ABOUT SIMPSON & CO:

In1840, Mr Simpson, a Scotsman, foresaw potential in developing India as a major centre for building coaches and carriages. With little spirit he nudged his dream and Simpson & Co was born. Simpson became a pioneer in manufacturing Railway coaches, Motor cars, Steam Passenger Buses, Public service vehicles. India's Road Transport Industry was ushered into a new era. Simpsons became the first to recognize the potential of diesel as a fuel, and selfstarted the diesel era in the country in 1951. And in 1955, Simpsons became the first Indian Company to indigenously manufacture diesel engines for surface transport vehicles. Simpson is perhaps one of the oldest business establishments in the country, its origins dating back to 1840. During the period 1840 to 1950, Simpsons was involved in building coaches and carriages, railway coaches, motor cars, steam passenger buses and public service vehicles in India - all pioneering activities. Simpsons ushered in Diesel Engines in India in 1955 through a Sales & Distribution Agreement with Perkins Ltd., Peterborough, U.K. Simpsons was the first Indian company to indigenously manufacture diesel engines for surface transport vehicles and today, it is a leading manufacturer of high performance diesel engines. Simpsons has two manufacturing facilities - at Anna Salai and Sembiam, Chennai - with state-of-the-art process technology and cell layout, resulting in flexibility, speed and cost efficiency. Simpsons manufacture in-house critical components - crankshafts, cylinder heads, cylinder blocks, connecting rods and camshafts - and over the decades, has developed reliable sources for all bought out components. The quality efforts of the company h ave resulted in obtaining BS EN ISO 9001:1994 and QS-9000 (Third Edition of March 1998) from LRQA, UK. The Company has also been certified for IS 14001 Environment Management System. Simpsons has well-equipped and modern product development and engine testing facilities. Simpsons Diesel Engines are used in a variety of applications - Tractors, Automobiles, Fork Lifts, Gensets, Wheel Loaders and Life Boats.

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ABOUT TRAINING DEPARTMENTS

The Simpsons Factory consists of the following main sections

Cylinder Block Bay

Here, the Cast Blocks, which are un-machined and unprocessed, brought here and the machining, which include Milling, Grinding, Drilling and Tapping is done on the block. These processes vary according to the number of cylinders the block has the type of Engine it is. The Cylinder Block Bay has the maximum number of functional machines and also has the largest Employee and Apprentice strength when compared to other departments in the Factory.

Cylinder Head Bay

The Cylinder Head Bay is in charge of machining Cast Heads and making them usable in the Engine. The Cylinder Head is machined as precisely as possible as it contains Valves, Injectors, Camshaft which play a vital role in the performance of the engine. The Cylinder Head Bay also caters to a va riety of Heads which are specified to every engine type. The Block and the Head bay work at par to prevent Backlog or Traffic of materials.

Crankshaft Bay
The Crankshaft, which is the only form of power transfer from Piston to the vehicle, is processed here. The primary duty of this department is to produce Wellmachined, Well-balanced, Flawless crankshafts which are later assembled in the Assembly section. Balancing and Crack-detections is carried out in this section to ascertain whether the Crank is free from faults and is well balanced. Crankshafts are processed in different size depending upon the number of cylinders.

Engine Assembly
The assembling of the machined and the procured parts are carried out here. The assembly line is divided into two. The Pre-Build assembly line is operated manually and components like Crankshaft, Oil pump, Main Bearing, Idler gear are fitted. In the J-Hook assembly line, the pre-assembled block is fully assembled with all other components like Piston, Camshaft, Fuel Injection Pump, Water Pump, Sump, Hoses, Injector, Oil filter, H.P.P filter, Rocker Shaft etc. The J-Hook assembly line is

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automatic and the Employees have a limited amount of time in which they are required to assemble the components. So, timing is crucial in this departments, as any bottle-necks can cause the shutting down of the assembly line and delay in manufacturing.

Test Shop
Test shop is having the facilities for testing the Engines that are assembled. The manual test rig can accommodate up to 16 Engines and the Automatic up to 6 engines at one time. The Testing department is always active having 3 shifts that translate to 24 hours a day. This enables the Company to test all the Engine quickly without compromising on its quality.

Maintenance, Material and Tools Department

The Maintenance department is responsible for periodic inspection of the machine and also to repair Breakdowns, if any. It is also responsible replace machines to prevent bottle necks in production. The Maintenance department also calibrates the instruments and sets it right in working order. The Materials Department maintains an Inventory of materials used in assembly and also the finished good. It is also responsible for procurement of goods like Blocks, Heads, Washers and Nuts. The Tools department takes care tool management, procurement of new tools, and also Sharpening of the tools to be reused and Scrapping of old new , if rendered unusable.

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TRAINING DETAILS

Cylinder Block Bay

Cylinder blocks of varying number of cylinders like 2,3 and 4 cylinders are procured from a Casting industry and are machined accordingly. The Cylinder Block section consists of both manually operated machines and CNC machines. We had seen the working of both these machines simultaneously. T he CNC machine was used preferably as the time taken by these machine to machine a product is comparatively less than the manual machine. But the bottle-neck in these machines is the time taken to load and unload these machines. Such bottle necks are avoided by automatic loading and unloading. The Cylinder Block procured, is then machined sequentially. The majority of the machining is done on the Cylinder Block is done to accommodate other parts which will be assembled at a later stage. Machining is also carried out to create holes which are used as the Induction and Exhaust manifolds. Holes and Taps are created to accommodate the Cylinder Head, Flywheel, Starter Motor, Lubrication system and also the Cooling system. The number of holes drilled and the process of machining depends upon the type of the Engine and the number of cylinders it consists of. There is another CNC machine which is used exclusively to Drill holes and Taps on the block. The Main bearing caps are the fitted, which reduce friction due to rubbing and the Liners are Pressed after the Bore recess for the Liner is machined. The Liner is used in the Cylinder to prevent direct rubbing between the Cylinder Block and the Piston under normal working conditions. The block is the numbered according to a Numbering algorithm. This is especially useful for management of inventory and identifying Blocks, in case any machining error is noticed.

Cylinder Head Bay

In an internal combustion engine, the cylinder head sits above the cylinders and consists of a platform containing part of the combustion chamber and the location of the valves and Fuel Injector. In the overhead valve head, the top half of the cylinder head contains the camshaft in an overhead cam engine, or another mechanism (such as rocker arms and pushrods) to transfer rotational mechanics from the crankshaft to linear mechanics to operate the valves (pushrod engines perform this conversion at the camshaft lower in the engine and use a rod to push a rocker arm that acts on the valve). The Cylinder Head again, is not manufactured On-Site, but procured form a Casting Industry. Since the Cylinder Head also contains a part of the Combustion and the actuating Valve mechanism, the tolerance is set lower than any other process. The tolerances and fits are carefully taken into account because presence of the Valves and Fuel Injectors which it houses. Any Error of Misfit can drastically reduce the engine performance and can

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also cause Misfire or reduce the Efficiency of the Engine, which is paramount when the Engine is used in Farm Tractors, Automobiles, Fork Lifts, Gensets( Generators ). The valves, springs, Rocker mechanism are all fitted to the Cylinder head. A Hardening process is also carried out to increase the working life of the Cylinder head. A leak test is finally carried out to ascertain whether the Head is water tight, which implies better seal, which implies better performance. If the Cylinder head is found to be defective, then it is returned to be reworked. If Reworking is possible, it is carried out. Else, it is scrapped.

Crankshaft
The crankshaft, sometimes casually abbreviated to crank, is the part of an engine which translates reciprocating linear piston motion into rotation.The Crankshaft is numbered for Inventory Management. Induction Hardening is carried out for Journals and Pins. The Crankshaft is Tempered and checked for Straightness. Checking for Straightness is considered important because an unbalanced Crankshaft can cause unwanted Vibrations. Balancing is then performed to ascertain whether the Crankshaft is balanced. Balancing is done by a special Dynamic Balancing machine. The unbalance, if any, is corrected by removing material in some cases and by adding an extra weight, if need be. Crack detection is finally carried out. Holes are drilled on the Crank. These holes are used to lubricate the Crankshaft and also cool them. Chamfering and Slotting of Keyways are also done at this stage. These keyways are used to connect the Crank with the Flywheel. The presence of a Crack can seriously impair the Longevity of the Crank. Crack detection is carried out in a special chamber by the use of Electro-Luminesce powder. Any crack will show up as a streak. The Crank is corrected if possible or it is discarded, as material life is important. Tolerances are checked for and the Crank is stored for later use.

Maintenance Department
The Maintenance Department carries out three critical activities, Machinery Maintenance, Calibration of Equipment and Electrical Maintenance. Maintenance is carried out on a regular basis. Preventive maintenance will be done as per schedule and according to the work instructions and check sheets. If any parts found damaged, it will be changed. Breakdown maintenance process will start on the receipt of repair order from the Production Department. Necessary repair will be performed and machine will be handed over to the Production Department. Using past experiences and SPC study predictive maintenance schedule will be planned. After the preparation of the plan, the concerned dept has to be informed about the plan. Necessary maintenance will be performed and the critical parameter data collected. Data will be analyzed and will check whether it falls within the specified limits. If not, necessary actions will be taken. Afterwards

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all the records will be updated. This data can be used in future. The critical data available from predictive maintenance are the data regarding the critical area susceptible to wear and damage and the critical spares. Calibration of instruments will be performed when the instruments are received. Each instrument is checked for its usability. If it can be used then an OK sticker will be affixed on the instrument. Afterwards the instrument calibration record will be updated and issues the instrument back to the user departments. Three transformers are installed in the plant (One 1500kva, one 750kva and one 250kva transformer). The 11 kV supply will be step downed to 440V. All the machines will work at this voltage. AVR (Automatic Voltage Regulator) will control the voltage fluctuations in the supply so that all machines will be protected against the fluctuations. In case of shortage in power supply, generators will supply the necessary power required. Three generators are provided towards this requirement (one 1000kVA, one 515kVA, and one 500kVA).

Tool Management
Tools play an important role in any industry which concerns only to machining. The tools must always be in perfect working conditions. The quality of the tool governs the quality of the finish and ultimately the finished product. Tools are procured according to requirements for suppliers. The schedule of Shortage or Requirement is prepared. Tools are then procured accordingly. Inspection of the Procured tools is performed and if found satisfactory, are added to the inventory. If the tools do not meet the standard, the tools are returned to the supplier for replacement or correction. Tool life is monitored periodically. A tool analysis chart is updated based on this analysis. Tool life is judged by two factors, Working hours and number of components produced. The tools are judged accordingly. Sharpening is done of possible and totally scrapped if the Tool has reached its working limit.

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Engine Assembly
Engine Assembly line at Anna Salai plant is divided into
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Pre-Build Assembly Line J- Hook Assembly Line

1. Pre-Build Assembly line

Pre- Build assembly line is having a manual roller type conveyor belt for the movement of engine block from one station to the next station for the assembly. The operator will remain stationary in this line. The major components fitted at this section are the following.
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Crank Shaft Main Bearing Lubrication oil pump Timing case Idler gear Rear end oil seal

Each component is fitted according to the same order as listed above. The station at which each component fitted is named after the component itself. For example, crankshaft is fitted at crankshaft fitment station. At the start of this section the operator loads the cylinder block onto the conveyor belt and punches the engine no. on the block. Then both the cylinder block and the main bearing cap is cleaned either by spray cleaning equipment or vacuum drying equipment and are dried by air. Crankshaft has to be cleaned and checked manually before assembly. The critical fittings like balancing weight, machine block, REOS, gears etc. has to be fitted at the specified torque. After assembling crankshaft, each component is assembled according to the order given above and then it is unloaded from the belt and fixed onto the J-Hook.

2. J-Hook Assembly Line

This is an automated assembly line. The operator has to move with the line and has to fit the component within the given time. The major components fitted in this line are the following

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y y y y y y y y y y y y y y y

Piston Connecting rod nut Suction Pipe and delivery pipe Camshaft Fuel injection pump Sump Cylinder head Rocker shaft Timing cover Water pump Hoses IMF oil filler Injector H.P.P. filter Oil filter

Before insertion of piston, piston has to be connected to the connecting rod with gudgeon pin. Then piston rings are installed on the piston groove. This has a separate line running in parallel to the piston fitment station. After the fitting of FIP, the spill timing has to be set. There is an earmarked station for setting the spill timing. Then the engine is led to the sump neck packing station where corks are pasted for sump packing. Cylinder head is fixed next at the cylinder head/ Torque station. After the completion of the entire assembly, the engine would be unloaded and moved to the testing premises. All Assembled engines are given an Unique identification number.First letter S denotes Simpson. 2 nd Digit denotes no. of cylinders it has. 3rd and 4 th Digit denotes the capacity of the engine and the last digits denotes the batch number.

Test Shop
Test shop is having the facilities for testing the engines that are assembled. All of the engines assembled will be tested before pasting the tested OK sticker. Mainly two types of tests are done at the test shop.
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Performance Test Leakage Test

All engines assembled are tested for its performance. At the test center engines are connected to the test center and engine will be run for 55 min and its performance is noted and compared to the specification. If the engine conforms to the specifications then it will be moved to paint shop. Otherwise it has to be moved to rework station.

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OBSERVATIONS MADE

The following observations were made during the Training period in Simpsons& Co.

The working atmosphere of an Real Factory and the dynamism which is involved in it.

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The systematic and orderly working conditions of a Factory. High capacity machines which could handle huge loads at a short interval of time.

CNC machines which could automatically perform Machining tasks with very little human interference.

The relative ease with which the materials and Components are transported for one part of the Factory to another by either Conveyor belts or Fork-Lifts.

Industry Standard compressors which supply compressed air steadily throughout the factory at the same pressure.

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The importance to tolerance and the sincerity with which it is maintained Micro-finishing processes like Honing, Buffing, which are carried out not only to obtain a good surface finish, but also to improve the Performance of the engine. Example: Honing is done on the Cylinder Liners to produce Scratches inclined at angle of 15. This regulates the oil pressure as the oil flows through the scratches. This also improves the lubrication of the cylinder.

Hardening Processes like Induction hardening, Tempering, for which we had only Theoretical knowledge. The practical applications were previously alien to us.

Balancing of Shafts, the concept which was previously alien to us, was seen and learnt by us.

The concept of maintenance and its importance in an Industry was introduced to us. The outcome of Periodic maintenance and its effect on Production sustainability was explained to us.

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KNOWLEDGE GAINED
As a outcome of the Industrial Training, which we underwent, the Knowledge gained was immense. We had experienced the dynamism which was involved in a Machine shop which was absent in the Universitys machine shop. We learned the importance of tolerance and its effect on the final product. We learned the importance of safety while working and the importance given to it by both the Company and the Workers. We had learntthe process of Material handling, both finished components and also the un -finished components. We had learned the ways and means by which the machined product was checked for tolerance and the steps taken thereupon to correct the dimensional inaccuracy. We had interacted with the Engineers, who had explained to us the needs of the Industry and the Skills that we needed to acquire to suit ourselves to the industry. We had, in the Engine assembly shop, personally witnessed the Assembly of the Engine from nothing more than Parts to an full -fledged working engine. We had, in the Engine test shop, witnessed the testing of the engine and computation of its Performance by analyzing its parameters. We had, in the Storage bay, seen how the finished was carefully packed and how the Bay was kept clean of Hazardous materials which are inflammable. Finally, we had an insight of what the Industry expects from us, Engineers and we had experienced how a Career in this industry would be like.

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