G. H.

Raisoni College of Engineering, Nagpur

(An autonomous institute under UGC act 1956 )

Department of Mechanical Engineering

CASE STUDY PRESENTATION ON

Six Months Internship

(Badve Engineering Ltd.)
7th Semester B.E.
Submitted By:
Project Supervisor
Gaurav Talwekar (A-47)
Mr. Sachin Bhoinullu
Mr. V. G. Kolhe
Supported By:
Mr. S. Gaikwad
(HR)

INDEX

TITLE
PAGE NO.
1. Certificate (Photo)
3
2. Key Persons
4
3. About The Company
5-6
4. Major Costumers
7
5. Business Associates
8
6. Products & Services
9-10
7. Business Area & Production Process
11
8. Plant Layout
12
9. Technologies & Management
13
10. Various Chassis made in plant
14
11. CASE STUDY
16-21
a) Problems and Solutions
17-19
b) Cheaper Alternatives
20
11. Conclusion
21
12. References
22
13. Company Photos
23

Certificate (Photo)

KEY PERSONS
BADVE GROUP
MR. SHRIKANT BADVE
MR. V. V. KULKARNI
Managing Director

Senior Manager (HR & Admin.)

BADVE ENGINEERING LTD. (CHAKAN PLANT)

MR. V. G. KOLHE
Assist. Manager
Internship Supervisor

MR. SCHIN DETHE

Head HR

MR. SACHIN BHOINULLU

Production Manager

MR. SCHIN GAIKWAD

HR

ABOUT THE COMPANY

BADVE ENGINEERING LTD. (CHAKAN)
Badve Engineering Limited is a fabrication plant of Badve Group, situated
in the Chakan Industrial Area Phase-2 at Pune.
Here in BEL two wheeler chassis are fabricated from component parts to
a fully polished bike chassis. The chassis are for BAJAJ two wheelers range.
From commuter to sport bikes.
BEL has two plants, Plant 1 contains assembly, painting, fitting, etc. of
chassis. And plant 2 is a semi-automation plant, where chassis body is
fabricated with the combined efforts of automated robots and manpower
skills.

ABOUT THE COMPANY

BADVE GROUP
Badve Group grew from a Supplier and Manufacturer of Automotive
Exhaust Systems, Two and Three Wheeler Chassis and Aggregates to a
Manufacturer of diversified products inclusive of Four Wheeler Components,
Chassis and Aggregates. With Goods Components and Aggregates, They
have JOINT VENTURES with RENOWNED INTERNATIONAL
MANUFACTURERS for various products like Helmets, Security and Hardware.
Initially, They started as a small enterprise manufacturing small sheet metal
parts. TODAY, Badve group is the established and accomplished company,
ONE OF THE TOP Suppliers of Automotive Components and Aggregates.
They manufacture Sheet Metal, Fabricated, Plastic Molded Components, etc.
having facilities including Robotics and multiple Surface Treatments.
Today, Badve Group have Plants and Facilities all over India
Aurangabad, Waluj, Ranjangaon and Chakan (Pune) in Western India,
Dharwad, Banglore & Chennai in Southern India, Pantnagar and Bhiwadi in
Northern India and Indore in Central India.
6

MAJOR CUSTOMERS

Business Associates
Key business associates are

AKZO NOBEL COATINGS

JINDAL STAINLESS LIMITED

ASIAN PPG INDUSTRIES LIMITED

KANSAI NEROLAC PAINTS LIMITED

AUTO COAT ENGINEERING

KPIT CUMMINS INFOSYSTEMS LIMITED

BOLE PLASTIC MACHINERY SDN. BHD, MALASIYA

LARSON & TUBRO LIMITED

BRITISH CLEARING , UK

LG CHEM LTD, SEOUL

ELECTROPNEUMATICS & HYDRAULICS

3M INDIA LIMITED

ESSAR STEEL LIMITED

PRS PERMACEL PRIVATE LIMITED

FANUC INDIA PRIVATE LIMITED

SAP INDIA PRIVATE LIMITED

FERROMATIK MILACRON INDIA LIMITED

TATA STEEL LIMITED

HENKEL CHEMBOUND SURFACE

TAIKISHA, JAPAN

INEOS ABS (INDIA) LIMITED

VEMAR HELMETS SRL, ITALY

IWATA , JAPAN

WILLKINS & MITCHELL , UK

IWATANI INTERNATIONAL CORPORATION, THAILAND

WINDSOR MACHINES LIMITED

PRODUCTS & SERVICES

Badve Group mainly provides following products and parts:

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

Automotive Parts
Home Appliances
Helmets
Security Hardware
DG Power Set
Floriculture

1. Automotive Parts Are:

a. Exhaust Systems
b. Chassis (Badve Engg. Ltd.)
c. Suspensions
d. Trim
e. Other Parts

Two Wheeler Chassis are made in Badve Engineering Limited (Internship Plant)

Some of the Automotive parts are

10

BUSSINESS AREA & PRODUCTION

PROCESSES

Facilities for manufacturing were added from conventional Mechanical

Presses, Welding Equipment, and Nickel Chrome Plating to Automation,
Robotics, State of the art Surface Treatment Plants of Autophoretic, Plastic
Injection Moulding and Painting of Plastics.

Metal Processing: Metal Stamping & Pressing of HR, CRCA, IF, Stainless
Steel, Galvanised sheets, pre-coated metal, Electro galvanised sheets,
coils, CTLs & CTS material,etc.

Plastic Processing: Injection moulding by processing GPPS, HIPS, PP,

ABS, HDPE, LDPE etc using regular moulding, stack moulding, insert
moulding techniques, Other plastic processing.

Surface Treatment:Heat resistant liquid painting on metal to meet Salt

spray standard tests. Autophoretic painting for achieving corrosion
resistance
11

PLANT LAYOUT
1- Product Display Area
2- Meeting Area
3- Inventory Store
4- Chassis/Project
Storage
5- Quality Test Dept.
6- Stamp Checking and
welding
7- Maintenance Dept.
8- Water
9- Wash Rooms
10-Welder Training
Room(Proposed)
11- STAMP Line
K8,K16A,K16B- Chassis
Production Lines of
various products

12

Technologies & Management

Concept
1. Implemented SAP, Worlds Leading Systems Software.
2. Systems of INTERNATIONAL ORGANISATION for STANDARDISATION
(ISO); ISO 9001 Quality Systems, Environmental Management Systems, Total
Quality Management Systems as Applicable to the Automotive Sector have
also been implemented at all Plants
3. The world renowned and recognized as tough to implement and continue ,
the Japanese innovated - "TOTAL PRODUCTIVE MAINTENANCE (TPM)
SYSTEM" is followed in words and spirit in all our Plants achieving
SYNCHRONISED MANUFACTURING FLOW.
4. Automation machineries are implemented in the production

13

Various Chassis made in

plant

Front View

Side View

14

Chassis during production

End product
(after completion)

During Production

Note:
Source: www.badvegroup.com

The above images are not of same chassis

15

CASE STUDY
Topic: Improving Productivity and efficiency of plant
During the period of internship, various aspects of production and
management are studied and then I came across the following problems
(issues) in the industry.
PROBLEMS IDENTIFIED:
1. Reduction of REWORK AND REJECTED STAMP material.
2. Quality checking in Inward material
3. Shop floor management
Solving this issues can be greatly beneficial to the industry.
Some of the solutions and cheaper alternatives are discussed in this report
that may help in the production.

16

Problems and Solutions

Alternatives on company issues are provided as follows
1. REWORK AND REJECTED STAMP
Due to the following problems the stamps produced gets damaged and rework
On such stamps is to be done in order to remove damage.
2. Improper (NOT OK) inward material
3. Operator or technical error in Robo (Automated welding arm machine)
4. Improper handling by workers
This problem can be solved by the following implementation.
Extra rework stations can be created in parallel with the main STAMP assembly
line. That will reduce the total time required to produce a single unit of chassis.
Hence the speed of total production will increase and seamless production on the
main assembly line is possible.
Cheaper alternatives are provided further.
17

2. Quality checking in Inventory material

There are certain issues regarding the quality check in inward
material of STAMP Line. Because of which sometimes NOT OK material
will also came on the production line. Human error is the most probable
reason for this situation to happen.
It can be dissolved by the following implementation.
Electronic material checking (Laser scanning) machines can be
installed in the inward section, which is readily available in the market.
And many of the big corporations are largely benefited by it.
Installation of such scanners will minimize the human error in
checking the material on large scale. Which increases the speed of
production and decreases chances of damage to the chassis during
assembly on the line. Hence continuous production is possible.
Cheaper alternatives are provided further.
18

3. Shop floor management

On the shop floor of Stamp line, Improper distribution, storage and
handling of stamp parts (LH & RH) trollies is a major issue.
This causes the below problems:
o. Damage to Stamps
o. Occupies excessive space on floor
o. Inconvenience for staff to move around
o. Consume more time to rearrange Stamps according codes (i.e. K8, K16)
Hence below alternate SOLUTION can help dissolve this problem
Specified storage rack system can be installed as per the stamp size
and shape. This type of racks are available in some leading automotive
industries.
In such racks the worker can only store a specific component in a
compartment for which it is designed, thus with little efforts mixing of
stamps can be prevented.
On the floor metal guide route can be installed and if it is made
electromagnetic then by small amount of electricity racks can be moved
in a liner direction from one place to another, thus it reduces the number
of workers and also reduces the chances of human errors and misplacing
the material.
19

Alternative Solutions
The solutions provided until now may take some time to implement due to
many reasons such as technical, economical, etc. So a cheaper alternative to
solve many of the listed problems up to certain extent is LABOUR SKILL
DEVELOPMENT PROGRAM as discussed below.
1. Rework problem can be minimized my training the labor about the proper
handling of stamps, storage, grinding and other processes.
2. Appointing a company trained person for the checking and passing of inward
material can be beneficial and cost effective rather than the installation of
scanner machine.
3. Painting the shop floor area with different color lines such as red, blue, yellow
to arrange, and distribute stamps can be helpful to maintain the cleanness and
neatness in the floor area
4. Various colored and coded stickers can be used to stick on stamps that will
make it easy to recognise and distribute the stamps.
As the workers in the plant are on contract basis hence the training
program should be designed as short as possible such as 1-2 day training.
And must be revised and conducted once in 2-3 months
20

Conclusion
In this period of internship, I have found certain issues in the industry,
and performed Case study on the same. There probable solutions as I
found are discussed with supervisor and HR managers.
Some of this problems are dissolved in the company by taking proper
improvement measures, others are in progress and hope they will be
solved soon.

21

REFERENCES
All the information is collected from the following sources:

1. Discussion with company staff, supervisors and H.R. Manager

2. www.badvegroup.com (Images and Information)
3. Case Study analysis (Self-Suggested).

22

Company Photos

With internship supervisor V. G. Kolhe In front of the plant entrance

23

THANK YOU

24