Gurgaon college of engg.

SUBMITTED BY:Pushpinder singh

ME(904044)

4 Month Industrial Training Report

Multi unit,multi product group that deals in broad range of sheet metal assemblies,die casting components and forging for the

domestic and export markets.Jbm group began its engg. Activity in 1983

with the establishment of gurera gas cylinder ltd and entered the auto component industries

with the inception of SUZUKI AUTO INDIA.Four plants in NCR.

ABOUT THE COMPANY

Click icon to add picture

OUTLOOK OF THE PLANT

J1

Outlook of plant j1

MAJOR LEARNINGS IN ENGINEERING DEPARTMENT• Types of Welding and guns used.

• Study of poka yoke.

• Implementation of 5-s.

• Understanding and study of control plan and engineering drawings.

• Study of idle time in ye-3 line.• Study of laser cutting machine.

TYPES OF WELDING AND GUNS USED Resistance welding

• Spot welding• Multi spot welding• Stationary spot welding• Portable spot welding

Projection welding

• Nut projection welding• Stud projection welding

RESISTANCE SPOT WELDING

• Resistance welding is a welding process which join the metals with the heat obtained from resistance offered by the work to the flow of electrical current through the parts being joined.

• A pair of copper alloy electrodes conducts electrical current through the two sheets pressed between the interface. The two sheets offer maximum resistance to the flow of current, this generates heat, the interface melts and consequently solidifies under the pressures of the two electrodes, thereby joining the two sheets at the spot that was under the two electrodes.

TYPES OF GUN USED IN SPOT WELDING• X- TYPE GUN

Also known as "scissors" or "pinch"

• C-TYPE GUN C guns are generally the cheapest and the most commonly used. 

PROJECTION WELDING

Nut projection welding

• Projection Welding Is A Type Of Resistance Welding. • High current in less time is the main feature of this welding.

Stud projection welding

• Stud is a form of spot welding where a bolt or nut is welded on another metal sheet.

STUDY OF POKA YOKE

Poka Yoke = Zero Defect • Basically the poke yoke is the Japanese technology. It is used to reduce the

manufacturing defects in the parts to zero.

• Poka Yoke sense that bolt then that process will occur otherwise that process will not occur.

Type of Defects for which Poka- Yoke can be used

• Part Miss, Nut Miss, Spot, Miss Hole miss.

• Part Shift.

• Nut Welded at wrong place.

• Color Difference.

SIGNALS PANEL

5S

THE JAPANESE APPROACH

• The 5- S is a JAPNESE technique used to establish and maintain quality environment in an organization.

• 1S- SEIRI

• 2S- SEITON

• 3S- SEISO

• 4S- SEIKETSU

• 5S- SHITSUKE

• 1S-SEIRI- Sort Out Unnecessary Items In The Workplace

• 2S-SEITON- Arrange Necessary Items In Order

• 3S-SEISO- Clean your work place completely

• 4S-SEIKETSU-Maintain high standard of housekeeping

• 5S-SHITSUKE-Train people to follow good housekeeping

CONTROL PLAN 

Control plan is the description of the process which contains the parameters of the process like:

• Weld current

• electrode force

• weld time

• hold time etc.

• Control methods

• Machine & jig used

• Frequency

• Poka-yoke        

LASER CUTTING MACHINE

• Six axis robotic machine worth rs I crore(abb company).• Yetteribium laser is used.• Yetteribium crystal produces light by

photoelectric effect.• Laser light get passed to robotic head

through optical fibre cable(TIR).• Yetteribium crystal contained in box

which is placed in room maintained at 22degree c.• Chiller cools laser head using distilled

water.• FRL removes moisture of air

• Working temp.of robotic head is 3000-4000 degree celsius.

• Used to cut elliptical cross section of axle to spiral.

• Oxygen helps in burning.• Nitogen takes care so that burr do not cover

the laser head.• Dot test performed once in six months to

centralize the laser beam.• There is ups which can run the laser

machine for half an hour after electricity is cut.

• Spiral profile gas 21 control points• Nitrogen pressure= 7 bar approx.• Oxygen pressure= 3.7 bar approx.• Air pressure= 5.40 bar approx.• Avg operating power= 1000W.

MAN-MACHINE CHART of YE-3

• Basically a man-machine chart is used to observe the working time and idle time of man-machine.

Total IDLE time

Readings period= 8 minutes

Total idle time of O/P 1= 130 sec

Total idle time of O/P 2= 130 sec

Total idle time of robot= 40 sec

THANK YOU