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E.C.B POLYTECHNIC COLLEGE,BIKANER
TRAINING REPORT
ON
INDUSTRIAL TRAINING
NATIONAL ENGINEERING
INDUSTRIES LTD.JAIPUR
SUBMITTED TO: SUBMITTED BY:
PROF. R.S.SEN
CHANDRA PRAKASH
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POLYTECHNIC(MECH.)
PREFACE
The study of engineering diploma course in recognized technica
institution makes up perfect in technical knowledge. An engineering
diploma should have actually theoretical as well as practically knowledge.
Training creates awareness of industrial approach and work culture we
were exposed to the real working condition. Industrial training enables a
student to open his own small-scale industry after the completion of
engineering diploma.
I had undergone my FIRST industrial training at NATIONAL
ENGINEERING INDUSTRIES LTD., JAIPUR.
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ACKNOWLEDGEMENT
I am very grateful to Mrs. Monika Joshi (DY. HR MANAGER ,NEI
Jaipur) for allotting me training in NATIONAL ENGINEERING
INDUSTRIES LTD, JAIPUR.
Engineers & consultants. I wish to express my per found thanks to ProfR.S.SEN for their suggestion, assistance and encouragement during the
training period.
I would like to give my thanks to all those who help and
guided my directly or indirectly during the course of training.
CHANDRA PRAKASH
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COMPANYS MILESTONES
1946 Company established as National Bearing Company (NBC) under Technical
Collaboration with Hoffman, U.K.
1950 Ball Bearing Production started
1951 Railway Bearing Production started
1957 Company name changed to National Engineering Industries Ltd., (retaining NBC as
Trade Mark)
1967 Tapered Roller Bearing production started
1981 Separate Factory for Ball Bearing at Gunsi (Newai)
1982 Cartridge Tapered Roller Bearing in Technical Collaboration with Brenco
Incorporated
of U.S.A.
1985 Technical Collaboration with NTN Corporation of Japan for Ball,Cylindrical &
Spherical
Roller Bearing
1995 ISO - 9001 Quality Management System Certification
1996 Technical collaboration with Izumi Kinzoku Kogyo Co. Ltd., Japan for Machine
Retrofitting
1997 Technical Collaboration with NTN Corporation of Japan for Tapered Roller Bearing
and
Hub Bearing
1999 Implemented - SAP , Solutions for ERP
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2000 ISO-14001 Environment Management System Certification
2000 QS-9000 Quality System Certification by
AWARDS AND PRIZES
NEI has been awarded with many Biz-awards in its tenure till date. Some ofrecent
awards won by the company are :
1. Winner of DEMING PRIZE 2010.
2. Grand Award for Cost in 2009-10 from Honda Motorcycle & Scooter
India Pvt. Ltd.
3. Award for TPM Excellence Category-A in 2009.
4. Vendor Performance Award in 2008-09 for Overall Commendation.
5. Certificate of Appreciation in 2008 from Maruti Suzuki India ltd.
6. Award for Challenge India Support (Engine Group) in 2003-04 from
7. Excellence Award in 2003 from IES.
8. The 4India Pro User Award 2002
9. Award for Excellence in 2001-02 from MICO Bosch Group.
10. Excellence in Performance in 2001-02 from Motors industries
Co. ltd.
11. The 3India Pro User Award 2001.
12. Indian Pro User Award 1999.
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13. Winner of Certificate of Excellence in Industrial Equipment
Category
from PTC.
The company is now preparing for the INDIAN MANUFACTURING
EXCELLENCE AWARD 2011(IMEA).
Technical Collaboration
BRENCO Incorporated of U.S.A.
Since 1982 - For Cartridge Tapered Roller Bearings for Railroad
applications.
NTN Corporation of JAPAN
Since 1985 - For Ball Bearings, Cylindrical & Spherical Roller Bearings,
JPU
Bearings, Double Row Angular Contact Bearings, Hub Bearings
Since 1997 - For Tapered Roller Bearings.
Izumi Kinzoku of JAPAN
Since 1996 - For re-manufacturing, retrofitting and overhauling of
Grinding and Super-finishing machines for Bearing races.
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MAIN CUSTOMERS
Rolling Stock: -
DLW
CLW
ICF
RCF
DCW
CIMMCO
BEML
TEXMACO
BURN Standard
Automobiles-Cars/Jeep:-
Hindustan Motors Ltd.
Maruti Udyog Ltd.
Mahindra & Mahindra
Automobiles-LCV: -
Ashok Leyland
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Force Motors
Eicher Motors
TATA Motors
Automobiles-Two/ Three Wheelers:-
Bajaj Auto Ltd.
Hero Honda Motors Ltd.
Honda Motorcycle & Scooters India Ltd.
Suzuki Motorcycle India
Majestic Auto
Piaggio India Ltd.
Royal Enfield Ltd.
Yamaha Motors India Pvt. Ltd.
TVS
Tractors: -
Eicher
Escorts
HMT
International Tractor
Mahindra & Mahindra
Punjab Tractors
TAFE
VST Tillers
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Electric Motors & Pumps:-
Crompton Greaves
G.E. Motors
Kirloskar Electric
NGEF
MICO
Fans: -
Bajaj Electricals
Crompton Greaves
Khaitan
Orient
Polar
Large Dia Bearing Customers: -
Cement Plants
Earth Moving Equipment
Steel Plants
Thermal Power Plants
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NEIS PRODUCT RANGE
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BALL BEARINGS: -
Radial Ball Bearing
Angular Contact Bearing
Self Aligning Two Row Ball Bearing
Belt Tensioner
TAPERED ROLLER BEARING: -
Single Row & Double Row Tapered Roller Bearing
LARGE DIA SPECIAL BEARING: -
Single Row
Double Row Ball, Cylindrical and
Four Row Tapered Roller Bearing
Thrust Bearing
SPHERICAL ROLLER BEARING: -
RAILWAY BEARING
DEPARTMENT OF N.E.I.
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Railway bearing Deptt.
Ball bearing Deptt.
Taper Roller Deptt.
Machine building Deptt.
Ball department.
Large diameter bearing Deptt.
Research & Development Deptt.
Forging Deptt.
INFORMATION ABOUT THE PRODUCT
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PARTS OF BEARING:
Basically every anti-friction bearing consists of four basic parts
1. Outer ring : Outer ring for NBC spherical roller bearings are manufactured
from forged and rolled rings from bearing quality steel. It is through hardened and
precision ground all over. The track or roller surface of bearing outer ring is
spherical in shape for self-aligning.
2. Inner ring : Inner ring for NBC spherical roller bearing are also made from
bearing quality steel which is forged and rolled. Inner rings are also precision
machined heat-treated and precision ground. Inner ring have two rolling surface
which are ground together with high accuracy.
3. Balls or cylinders (Rolling Element) : These are either forged or machined
from bearing quality steel bars & then through hardened and ground to high degree of
accuracies. The rolling element on bearings can be balls, cylindrical rollers or taper rollers.
4. Cage : The cage keeps the rolling elements properly spaced out between two
rings. Cage may be of steel, brass or bronzed etc. depending upon the type &
application of the bearings. NBC spherical roller bearings are fitted with machined brass
cages. These cages are made from brass centrifugal castings and then precision machined.
Brass cages have advantage of assuring positive lubrication and cooler running of the
bearing therefore are best recommended for railway applications.
DIMENSIONS OF BEARING:
Among the various dimensions of the ball & roller bearings the most important
dimension is:
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Bore :-Use for suitability of shafts
Outer Diameter :-For Housing Suitability
Width or Thickness .
These dimensions are established by the industry under the IOS dimensions scheme.
TYPES OF BEARINGS
A BROAD RANGE BORN OF PRECISION
From a few mms to thousands of mms, from a few grams to a few tons, the NBC
range is hard at work in some of the most critical areas of Indian industry. There
are many types of bearings, each used for different purposes. These include ball
bearings, roller bearings, ball thrust bearings, roller thrust bearings and tapered
roller thrust bearings.
Ball bearings, as shown below, are probably the most common type of bearing.
These bearings can handle both radial and thrust loads, and are usually found in
applications where the load is relatively small.
In a ball bearing, the load is transmitted from the outer race to the ball, and form
the ball to the inner race. Since the ball is a sphere, it only contacts the inner and
outer race at a very small point, which helps it spin very smoothly. But it also
means that there is not very much contact area holding that, so if the bearing is
overloaded, the balls can deform or squish, running the bearing.
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Roller bearings like the one illustrated below are used in applications like conveyer
belt rollers, where they must hold heavy radial loads. In these bearings, the roller is a
cylinder, so the contact between the inner and outer race is not a point but a line.
This spreads the load out over a larger area, allowing the bearing to handle much greater
loads than a ball bearing. However, this type of bearing is not designed to handle much
thrust loading.
A variation of this type of bearing, called a needle bearing, uses cylinders with a very small
diameter. This allows the bearing to fit into tight places.
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Roller Thrust
Roller thrust bearings can support large thrust loads.
They are often found in gear sets like car transmissions between gears, and
between the housing and the rotating shafts.
Tapered Roller Bearings
Tapered roller bearings can support large radial and large thrust loads.
Tapered roller bearings are used in car hubs, where they are usually mounted in
pairs facing opposite directions so that they can handle thrust in both directions.
BEARING MATERIAL:
Bearing contains varying amount of carbon, iron, chromium, manganese,
phosphorus, sulphur, silicon etc. chromium and carbon allows deep hardening. The
combination of chromium carbon & iron helps to minimize failure. As they
increase the surface resistance to abrasion and wear increase.
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ELEMENT AMOUNT
Manganese -0.25 to 0.35
Silicon -0.025 to 0.35
Sulphur -0.025 max
Phosphorous -0.025 max
Nickel -0.025 max
Copper -0.35 max
Molybdenum -0.10 max
RAW MATERIAL:
A variety of steel and brasses are used for different components for bearing
depending upon the properties required in the final product.
Balls -Ni-Cr steel wire
Rollers -High carbon chrome steel rods
Cage -Brass and mild steel
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HEAT TREATMENT PROCESS
FLOW CHART OF CHUGAI-RO FURNACE
JOB
/
PRE WASHING(60C)
/
HARDENING BY ENDO (AIR+LPG+CATALYST)
/
ZONE 1ST (840C)
/
ZONE 2ND (850C)
/
ZONE 3RD (850C)
/
ZONE 4TH
(850C)/
QUENCHING IN OIL TANK AT 120C, MIXING IS DONE BY AN AGITATOR
/
AIR COOLING
/
COOLING FROM WATER AND AIR
/
TEMPERING IN A FURNACE AT 170C (90 MINUTES)
/
AIR COOLING
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DEPARTMENT ALLOTED IN NBC:-
BALL BEARING DIVISION- LPE DEPTT.
Grinding processes in Bearing
manufacturing
Face Grinding
Centreless Grinding
External Grinding
Track grinding (I/R)
Internal Grinding
Bore Grinding (I/R)
Track Grinding (O/R)
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BALL BEARING GRINDING
STEP BY STEP PROCEDURE FOLLOWED IN GRINDING
Grinding can be defined as the process of the removal of excess material
from the surface of the job. Grinding is done after the heat treatment
process. Heat treatment is done separately in a work shop.
The operational steps in the grinding are:-
1) Facing
2) OD Grinding
3) OR Track Grinding
4) OR Track Honing
5) IR Track Grinding.
6) Bore grinding.
7) IR Track Honing.
8) Washing
1) FACE GRINDING PROCESS:-The face grinding machine is employed to
face the outer and inner races of bearing material by the application of two
grind wheels. The collant which is used for this process is water soluble
chemical coolant.
2) OD GRINDING PROCESS:-The center less grinding machine is used for this
process (MICRON MACHINE). It uses a grinding wheel whose maximum
speed is 2700 rpm and wheel size is 405 mm. This machine removes the
material from the outer diameter of both the inner and outer races with the
action of grind wheel.
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3) OR TRACK GRINDING PROCESS:- The process removes the material from
the track of the outer race. A grinding wheel is used in this process.
4) OR TRACK HONING PROCESS:- This process is accomplished with the help
of a special grinding machine where the surface of outer race is super
finished with the help of specific stones
5)IR TRACK GRINDING PROCESS:-This process is accomplished with the help
of grinding machine. Here the track of inner races is grinded so as to
achieve the required finish. Oil is used as a coolant.
6)BORE GRINDING PROCESS:-The bearing is now subjected to the bore
grinding machine where the material is removed from the bore of the
bearing job.
The coolant is water soluble chemical.
7)IR TRACK HONNING PROCESS:-This process is accomplished with the help
of a special grinding machine where the surface of inner and outer races of
bearing job are polished from both surfaces and oil is used as a coolant.
8) WASHING:- After the grinding process the inner and outer races are
washed before sending them for the assembly.
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BALL BEARING ASSEMBLY
PROCEDURE FOLLOWED IN ASSEMBLY:
1. Transportation from Grinding shop by automation.2. Demagnetizer:-The bearing so obtained is passed through a
Demagnetizer which reduces
the magnetic effects of the job.
3. Washing.
4. Size checking
Bore checking for INNER.
O.D. checking for OUTER.
5. Auto ring pairing:-The outer and inner parts of bearing are matched
properly and inner is placed inside the outer part of the bearing.
6. Automatically filling of balls:-The balls are filled in between the inner and
outer part of bearings by a ball filling machine.
7. KN-705 auto caging and caulking
Checks number of balls.
Separate balls.
Provides equal spacing between balls.
8. 1st Washing.
9. Visual Inspection:-The bearing is now checked for Defaults like black face,
bad riveting, double stamping, pin missing Etc.
10. RADIAL CLEARENCE testing.
11. ID/OD testing.
12. 2nd washing.13. DRYER (removal of kerosene from the surface of ball bearings).
14. Noise testing.
15. Laser marking machine.
16. Grease filling and seal fitting (R.S. and D.S.).
17. Anti-rust oil coating machine.
18. Packing:-Finally the bearing is packed with some poly material.
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Dresser for Grinding wheel dressing
Type of Dresser :
1. Single point type : Diamond point is mounting on a shank . Shank is
clamped to a holder and arm (shaft). Diamond dresses the wheel in a
Arc or Straight line.
2. Diamond roll dresser : In rotary dresser a diamond roll of the same
shape as the work is required to be ground is used . The shape is justmirror image of the track being ground
SINGLE POINT DRESSER
ROLL DRESSER
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TOTAL PRODUCTIVE MAINTENANCE(T.P.M.)
THE T.P.M. POLICY:
Enhancing the profitability of the company, customer satisfaction andcreatingfavorable working environment for all employees by eliminating accidents,defectsand breakdowns.
T.P.M 8 PILLARS:1. Individual Improvement.2. Autonomous Maintenance.3. Planned Maintenance.4. Quality Maintenance.5. Education and Training6. Initial Flow Control (development management).7. Safety and Healthy Environment.8. Office T.P.M
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JAPANI- WORD
5 S
The company follows the 5 S principle of JAPAN:-
The 5-S are the virtues of tidiness orderliness and cleanliness at all timesand atevery place. These account for the clinically clean shop floors and also in
theirpersonal habits. It is the practice of good housekeeping.
The term 5S represents 5 Japanese words
SEIRI
Means - Sort out items and discard the unnecessary
5 QUESTIONS ABOUT SEIRI
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1. Do you find items scattered in your workplace?
2. Are there boxes, papers & other items left in a disorganized manner?
3. Are there equipment and tools placed on the floors?
4. Are all items sorted out and placed in designated spots?
5. Are tools and stationery properly sorted and stored?
SEITON
Means Arrange - A place for everything, Everything in its place
5 Questions about SEITON
1. Are passage ways and storage places clearly indicated?
2. Are commonly used tools and stationery separated from those seldom
used?
3. Are containers and boxes stacked up properly ?
4. Are fire extinguishers and hydrants readily accessible?
5. Are there grooves, cracks or bumps on the floor which hinder work or
safety?
SEISO
Means - Clean your workplace thoroughly
5 Questions about SEISO
1. Are the floor surfaces dirty?
2. Are machines and equipment dirty?
3. Are wires and pipes dirty or stained?
4. Are machine nozzles dirtied by lubricants and ink?
5. Are shades, light bulbs and light reflectors dirty?
SEIKETSU
Means Maintain a standard
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5 Questions about SEIKETSU.
1. Is anyones informs dirty or untidy?
2. Are there sufficient lights?
3. Is the noise or heat at your workplace causing discomfort?
4. Is the roof leaking?
5. Do people eat at designated places only?
SHITSUKE
Means - Train people to be disciplined.
5 Questions about SHITSUKE.
1 Are regular 5S checks conducted?
2 Do people clean up without reminders?
3 Do people follow rules and instructions?
4 Do people wear their uniform and safety gear properly?
5 Do people assemble on time?
5S Benefits
Happier employees with high morale.
Greater people involvement.
Low employee turnover
Increase number of suggestions.
Better use of floor space.
Less work in progress and inventories
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Better flow of work
Low machine breakdown rates
Low accident rates
High yield of materials
High product quality.
JOB RESPONSIBILITIES DURING TRAINING
To take process maturity status of bore size on grinding machines three
times a day, daily and to make report file on MS-excel about the variation
of a machine.
To make control chart of the variation observed in the machine and to
take out the value of Process performance & Process capability.
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To obtain Reproducibility and Reproductivity of radial clearance checking
machines in assembly line.
To monitor the status of the Post Process (PP) gauge daily and make a
report file on MS-excel for the same.
PROCESS CAPABILITY
A measure of the capability of a process achieved by assessing the
statistical state of control of the process and comparing the amount ofrandom variation present with the tolerance allowed by the specification.
The Process Capability is a measurable property of a process to the
specification, expressed as a process capability index (e.g., Cpk or Cpm) or as
a process performance index (e.g., Ppk or Ppm). The output of this
measurement is usually illustrated by a histogram and calculations that
predict how many parts will be produced out of specification (OOS).
Steps followed:-
1. Collection : Gather data and plot on a chart.
2. Control :
Calculate trial control limits from process data.
http://en.wikipedia.org/wiki/Process_capability_indexhttp://en.wikipedia.org/wiki/Process_performance_indexhttp://en.wikipedia.org/wiki/Histogramhttp://en.wikipedia.org/wiki/Process_performance_indexhttp://en.wikipedia.org/wiki/Histogramhttp://en.wikipedia.org/wiki/Process_capability_index -
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Identify special causes of variation and act upon them.
3. Analysis and Improvement : Quantify common cause variation; take
action to reduce it.
These three phases are repeated for continual process improvement.
FOR VARIABLE DATA
X - R chart (Control chart for mean & Range)
X - S chart (Control chart for mean & Standard Deviation)
Median - R chart (Control chart for Median & Range)
FOR ATTRIBUTE DATA
p - chart (For proportion non-conforming)
np - chart (For number non-conforming)
c - chart (For numbers of non-conformities)
u - chart (For number of non-conformities/unit)
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PROCESS PERFORMANCE INDEX (Pp)
It is defined as the tolerance width divided by the process performance,
(irrespective of process centering). This is expressed as
Pp= [USL-LSL/(6s)]
n = (x - x)/(n-1)
i=1
Ppk
This is the performance index which accounts for process centering and is
defined as the minimum of (USL-X)/3 sigma or (X-LSL)/3 sigma.
PROCESS CAPABILITY INDEX (Cp)
It is defined as the tolerance width divided by the process capability,(irrespective of process centering). This is expressed as
USL - LSL
Cp = -----------------------6 (R/d2)
R = -----------
Cpk
This is the capability index which accounts for process centering and is
expressed as minimum of (USL-X)/3 sigma or (X-LSL)/3 sigma.
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Note : Cp is calculated from long term study based on measurement
collected over a period of time, in such a way as to include all expected
source of variation. At least 100 sample parts and a minimum of 20
subgroups should be taken for study to be conducted over a period of 2~3
days. Cp is calculated to assess the ability of a process to satisfy customer
requirements over a long period of time.
In addition to reducing waste, SPC can lead to a reduction in the time
required to produce the product or service from end to end. Process cycle
time reductions coupled with improvements in yield have made SPC a
valuable tool from both a cost reduction and a customer satisfaction
standpoint.
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R&R
This is a technique to measure the precision of gages and othermeasurement systems. The name of this technique originated from the
operation of a gage by different operators for measuring a collection of
parts. The precision of the measurements using this gage involves at least
two major components: the systematic difference among operators and the
differences among parts. The Gage R&R analysis is a technique to quantify
each component of the variation so that we will be able to determine whatproportion of variability is due to operators, and what is due to the parts.
A typical gage R&R study is conducted as the following:
A quality characteristic of an object of interest (could be parts, or any well
defined experimental units for the study) is selected for the study. A gage or
a certain instrument is chosen as the measuring device. J operators are
randomly selected. I parts are randomly chosen and prepared for the study.
Each of the J operators is asked to measure the characteristic of each of the
I parts for r times (repeatedly measure the same part r times). The
variation among the m replications of the given parts measured by thesame operation is the Repeatability of the gage. The variability among
operators is the Reproducibility.
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Gage repeatability and reproducibility studies determine how much of your
observed process variation is due to measurement system variation. The
overall variation is broken down into three categories: part-to-part,
repeatability, and reproducibility.
The Repeatability is the uncertainty among replications of m measurementsof a given part made by the an operator. Since part and operator are fixed,
the variance component for the repeatability is the random error, s 2. On the
other hand, the reproducibility is the uncertainty among operators for
measuring the same part. Therefore, the variance component for the
reproducibility is
2 2
+
2 2
2 2 2 2 2
2 2 2 2
,
Further more, the overall uncertaity of a mesurement is
NOTE :
T
repeatability reprodicibilty
overall reproducibility repeatability
overall
= = +
= + + = +
= + +
he proportion of uncertainty due to Repeatability and Reproducibility can be obtain.
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GAUGE R&R FOR RADIAL CLEARENCE TESTING
MACHINE ON A-9 ASSEMBLY LINE
Measurement system - Operation :- Radial Clearance
Spec. LimitUSL LSL
22 7
Total Tol. 15
Part No.Trial
1
Tria
l 2Trial 3 Range
Averag
e
1 12.9 12.3 10.9 2 12.03
2 11.7 11.8 12.1 0.4 11.87
3 11.3 12.4 11.7 1.1 11.80
4 11.5 11.5 10.6 0.9 11.20
5 11.7 16.8 17.4 5.7 15.30
6 28.7 23.3 22.9 5.8 24.977 11.1 11.3 10.9 0.4 11.10
8 9.1 10.2 9.8 1.1 9.70
9 8.4 7.8 7 1.4 7.73
10 13.2 9.4 8.5 4.7 10.37
R bar = 2.35
Part
Variatio
n =
17.2
Sigma
R&R =
1.37026
2
Sigma
PV =
5.42090
7
Sigma
TV =
5.59140
8
% GRR with respect to
60% of tolearance= 91.350826
% GRR with respect to
TV=
24.506569
5
ndc = = 5.5781129
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6
RESULT:- ndc = 5.58
GAUGE R&R FOR RADIAL CLEARENCE TESTING
MACHINE ON CA-2 ASSEMBLY LINE
Measurement system - Operation :- Radial Clearance
Spec. LimitUSL LSL
22 7
Total Tol. 15
Part No.Trial
1
Tria
l 2Trial 3 Range
Averag
e
1 53.8 52.4 54.1 1.7 53.432 52.7 54 53.8 1.3 53.50
3 53.8 54.6 53.6 1 54.00
4 51 52.8 52.3 1.8 52.03
5 54.8 53.7 54.5 1.1 54.33
6 57.2 58.4 57.2 1.2 57.60
7 56.8 56.9 55.9 1 56.53
8 58 56.5 57.7 1.5 57.40
9 53.1 53.5 54.8 1.7 53.80
10 55.6 54.5 56.7 2.2 55.60
R bar = 1.45
Part
Variatio
n =
5.6
Sigma
R&R =
0.84548
1
Sigma
PV =
1.75104
7
Sigma
TV =
1.94448
1
% GRR with respect to
60% of tolearance=
56.365403
3
% GRR with respect
toTV=
43.481075
4
ndc = =2.9202033
4
RESULT : - ndc=2.92
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GAUGE R&R FOR RADIAL CLEARENCE TESTING
MACHINE ON A-7 ASSEMBLY LINE
Measurement system - Operation :- Radial Clearance
Spec. LimitUSL LSL
29 15
Total Tol. 14
Part No.Trial
1
Tria
l 2Trial 3 Range Average
1 20 29 28 9 25.67
2 21 24 20 4 21.67
3 27 20 18 9 21.67
4 20 25 22 5 22.33
5 24 21 21 3 22.00
6 27 20 26 7 24.33
7 22 22 28 6 24.00
8 28 20 27 8 25.00
9 21 27 20 7 22.67
10 24 24 25 1 24.33
R bar = 5.9Part
Variation
=
4.0
Sigma
R&R =
3.44023
3
Sigma
PV =
1.25823
8
Sigma
TV =
3.66310
9
% GRR with respect to 60%
of tolearance=
245.73094
5
% GRR with respect toTV =93.915670
7
ndc = =0.5156961
1
RESULT: - ndc = 0.52
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GAUGE R&R FOR RADIAL CLEARENCE TESTING
MACHINE ON A-15 ASSEMBLY LINE
Measurement system - Operation :- Radial Clearance
Spec. LimitUSL LSL
22 7
Total Tol. 15
Part No.Trial
1
Tria
l 2Trial 3 Range Average
1 12.5 11.7 13.8 2.1 12.67
2 11.7 13.2 12.2 1.5 12.37
3 13.4 12.7 12.9 0.7 13.00
4 14.3 11.9 13.9 2.4 13.37
5 13.4 12.1 15.3 3.2 13.60
6 14.4 14.6 14.3 0.3 14.43
7 13.2 14.1 14.6 1.4 13.97
8 16 16.5 16.4 0.5 16.30
9 15.7 15.8 15.9 0.2 15.80
10 12.7 13.7 12.7 1 13.03
R bar = 1.33
Part
Variation
=
3.9
Sigma
R&R =0.77551
Sigma
PV =
1.23726
7
Sigma
TV =
1.46022
1
% GRR with respect to 60%
of tolearance=
51.700680
3
% GRR with respect toTV =53.109097
1
ndc = =2.2495465
8
RESULT: - ndc = 2.25
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GAUGE R&R FOR RADIAL CLEARENCE TESTING
MACHINE ON A-16 ASSEMBLY LINE
Measurement system - Operation :- Radial Clearance
Spec. LimitUSL LSL
22 14
Total Tol. 8
Part No.Trial
1
Tria
l 2Trial 3 Range Average
1 21.4 18 19.7 3.4 19.70
2 17.3 22.4 22.8 5.5 20.83
3 19.1 16.5 19 2.6 18.20
4 16.8 19.7 23.6 6.8 20.03
5 24 21.8 23.5 2.2 23.10
6 21.1 20.4 17.7 3.4 19.73
7 18.4 24.5 21.4 6.1 21.43
8 23.2 21.3 21.8 1.9 22.10
9 21.4 22.9 20.2 2.7 21.50
10 19.7 19 24.6 5.6 21.10
R bar = 4.02
Part
Variation
=
4.9
Sigma
R&R =
2.34402
3
Sigma
PV =
1.54134
1
Sigma
TV =
2.80538
4
% GRR with respect to 60%
of tolearance=
293.00291
5
% GRR with respect toTV =83.554466
4
ndc = = 0.9271626
RESULT: - ndc = 0.93
GAUGE R&R FOR RADIAL CLEARENCE TESTING
MACHINE ON CA-4 ASSEMBLY LINE
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Measurement system - Operation :- Radial Clearance
Spec. LimitUSL LSL
72.2 15.2
Total Tol. 57
Part No.Trial
1
Tria
l 2Trial 3 Range Average
1 24.8 25.3 24.4 0.9 24.83
2 24.6 22.3 23.9 2.3 23.60
3 26.2 23.9 24.6 2.3 24.90
4 22.2 25.4 20.5 4.9 22.70
5 22.9 20.7 22.5 2.2 22.03
6 23.4 24.1 24.5 1.1 24.00
7 25.5 24.1 23.2 2.3 24.27
8 24.6 23.6 26.5 2.9 24.90
9 24.7 26 25.2 1.3 25.30
10 22.3 24.2 26.1 3.8 24.20
R bar = 2.4
Part
Variation
=
3.3
Sigma
R&R =
1.39941
7
Sigma
PV =
1.02756
1
Sigma
TV = 1.73615
9
% GRR with respect to 60%
of tolearance=
24.551173
9
% GRR with respect toTV = 80.604184
ndc = =1.0353315
7
RESULT: - ndc = 1.04
GAUGE R&R FOR RADIAL CLEARENCE TESTING
MACHINE ON CA-5 ASSEMBLY LINE
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Measurement system - Operation :- Radial Clearance
Spec. LimitUSL LSL
99.6 62.9
Total Tol. 36.7
Part No.Trial
1
Tria
l 2Trial 3 Range Average
1 89.7 88.6 89.3 1.1 89.202 86.7 86 85.8 0.9 86.17
3 82.3 81.4 82.5 1.1 82.07
4 78.2 78.5 80.4 2.2 79.03
5 80.8 80.9 86.9 6.1 82.87
6 87.6 88.2 81.5 6.7 85.77
7 81.2 80.1 81.9 1.8 81.07
8 81.8 80.4 88.7 8.3 83.63
9 84.3 84.9 85.2 0.9 84.80
10 86 86.8 85.8 1 86.20
R bar = 3.01
Part
Variation
=
10.2
Sigma
R&R =
1.75510
2
Sigma
PV =3.19802
Sigma
TV =
3.64797
4
% GRR with respect to 60%
of tolearance=
47.822943
9
% GRR with respect toTV = 48.111687
ndc = =2.5692003
2
RESULT: - ndc = 2.57
SUMMARY
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I completed 4 weeks of my training at NATIONAL ENGINEERING INDUSTRIES
LTD., JAIPUR. During this period I learnt many aspects of practical
applications in industries. I acquired knowledge about the working and
functioning of such a huge factory.
I learnt about various machines , grinding lines, production lines and also
the concepts of management such as PROCESS CONTROL, TOTAL
PRODUCTIVE MAINTENANCE(TPM), TOTAL QUALITY MANAGEMENT(TQM),
STATISTICAL PROCESS CONTROL(SPC), PROCESS CAPABILITY and
REPRODUCTIBILTY & REPRODUCIBILITY(R&R).
I also worked upon some machines to understand them better and to gain
some practical knowledge.
Working at the NEI was a very good experience and I gained a lot from the
engineers, foremen and workers of the company.
I am heartily thankful to all the NEI family for providing me an opportunity
to work here.