Industrial Case Study Report at

8/7/2019 Industrial Case Study Report at

1/14

Industrial Case Study Report at:

AGROFAB MACHINERIES PVT. LTD

By-

Roll no. 19 to 28

VI SEM. SEC. A

GUIDE: S. B. SAHARE


2/14

DEPARTMENT OF MECHANICAL ENGINEERING

YESHWANTRAO CHAVAN COLLEGE OF ENGINEERING,

WANADONGRI, NAGPUR.

CERTIFICATE

This is to certify that the INDUSTRIAL CASE STUDY at AGROFAB

MACHINERIES PVT. LTD.is completed and a satisfactory account of it is given in

this report in academic year 2010-11.

Submitted by:-

ROLL NO. 19 to 27

6th

SEM.

SECTION A

Under the guidance ofS. B. SAHARE

DR. S. P. UNTAWALE S. B. SAHARE

(HOD, Mech. Dept.) (Lect. In Mech. Dept.)


3/14

ACKNOWLEDGEMENT

We take this opportunity to express our deep sense of

gratitude towards our teacher and project guide S. B. SAHARE

for guiding the industrial case study and helping us in our

difficulties.

We also express our sincere thanks to our respected

Head of Department, Dr. S. P. UNTAWALE for providing uswith vital instructions, necessary directives and valuable

advice in various phases of gigantic work.

We are highly obliging to our parents, friends and non-

teaching staff members of the department of their utmost

support and inspiration during the project work.


4/14

CONTENTS:

y INTRODUCTIONy ORGANIZATION STRUCTUREy PROCESSES UNDERTAKENy PROCESS FLOW CHARTy MACHINES USEDy INSPECTIONy PACKAGING

CASE STUDY:

y PROBLEM I & ITS SOLUTIONy PROBLEM II & ITS SOLUTION


5/14

INTRODUCTION:

AGROFAB MACHINERIES PVT. LTD. is a reputed industry in MIDC area at

Higna Road Nagpur. The main outputs of the industry are machined parts for

tractors of Mahindra & Mahindra tractors located at Nagpur. Over the years

company has successfully provided the required tractor assembly parts to the

company and is continuing their good streak in manufacturing industry. The

company has been able to get accreditation of ISO 9001:2000. The variousproducts under its manufacturing hood are:

a) C. V. Cylinder Headb) Differential Gear Housingc) Distributor Housingd) Valve Body

The company has very high quality CNC machines from AMS synchronized

with Distributed Control System from FANUC. With this quality of machines

hardly there are any mistakes that could happen during manufacturing. Though

we have tried to take an effort and found out some problems that could be

solved by certain easy measures, thus helping factory to save time and labour.

Let us know more about industry and work carried under it.


6/14

ORGANISATION STRUCTURE:

The structure of organization is primarily hierarchical. The organizational

structure of the industry is given as follows:

DIRECTOR

ACCOUNTANT

ASSISTANT

GENERALMANAGER

Q. A. MANAGER

Q. C. ENGINEER

INSPECTOR

PRODUCTIONMANAGER

PRODUCTIO ASST.MANAGER

SHIFT INCHARGE

MACHINEOPERATOR

PURCHASEMANAGER

PURCHASE ASST.

DEVELOPMENTMANGER

ASSISTANT

MANITENANCEMANAGER

TECHNICIANS

ADMINSTRATIONAND HR MANAGER


7/14

PROCESSES UNDERTAKEN:

y Inspection of raw material: Here temporary inspection of raw material isdone. Just by finding any visual defects.

y Facing: It is operation of moving the cutting tool at right angles to the axisof rotation of the rotating workpiece.

y Spot Facing: It is a machining operation where material is removed froma surface to make it flat and smooth, usually for a fastener or bearing.

y Drilling: Itis used to remove material from the inside of a workpiece.y Reaming: It is used to create an accurate sized hole. y Threading: It is the process of creating a screw thread.


8/14

PROCESS FLOW CHART:

NOTE: INSPECTION IS DONE AT ALL STAGES.

OPN 20

M/C

OPN 35

M/C

OPN 20

M/C

OPN 30 M/C

STANDBY

OPN 40

VMC

OPN

67/50

M/C VMC

OPN 96 & OPN 100

M/C MCV 350

OPN 125 M/C

OR 1133

OPN 160

PACKAGING AND

FORWARDING

OPN 40

VMC

(STAND

BY)

TO

M&M

RECEIVE

CASTINGS

FROM

SOURCE

OPN 10 RECIEVING

AND INSPECTION OF

CASTINGS

OPN 30, 35,

110 MCV

OPN 65

M/C

OPN

50/67BLIND

BORE

OPN 140

DEBURRINGTABLE

OPN 150

INSPECTION

TABLE


9/14

MACHINES USED:

Different kinds of machines from conventional drilling to CNCs both kind

of machines can be found in this plant.

Some of those machine are stated and their purpose is explained below:

CNC LATHE:

The machine is controlled electronically via a computer menu style

interface; the program may be modified and displayed at the machine, along

with a simulated view of the process. The setter/operator needs a high level of

skill to perform the process, however the knowledge base is broader compared

to the older production machines where intimate knowledge of each machine

was considered essential. These machines are often set and operated by the

same person, where the operator will supervise a small number of machines.


10/14

CNC MILLING:

Most CNC milling machines are computer controlled vertical mills with the

ability to move the spindle vertically along the Z-axis.CNC machines can exist in

virtually any of the forms of manual machinery, like horizontal mills. The most

advanced CNC milling-machines, the multiaxis machine, add two more axes in

addition to the three normal axes (XYZ). Horizontal milling machines also have a

C or Q axis, allowing the horizontally mounted workpiece to be rotated,

essentially allowing asymmetric and eccentric turning. The fifth axis (B axis)

controls the tilt of the tool itself. When all of these axes are used in conjunctionwith each other, extremely complicated geometries, even organic geometries

such as a human head can be made with relative ease with these machines. But

the skill to program such geometries is beyond that of most operators.

Therefore, 5-axis milling machines are practically always programmed with CAM.


11/14

Milling Machine:

A milling machine is a machine tool used to machine solid materials. Milling

machines are often classed in two basic forms, horizontal and vertical, which

refer to the orientation of the main spindle. Both types range in size from small,

bench-mounted devices to room-sized machines. Unlike a drill press, which holds

the workpiece stationary as the drill moves axially to penetrate the material,

milling machines also move the workpiece radially against the rotating milling

cutter, which cuts on its sides as well as its tip.Workpiece and cutter movement

are precisely controlled to less than 0.001 in (0.025 mm), usually by means of

precision ground slides and leadscrews or analogous technology.


12/14

INSPECTION & SAMPLING:

An inspection is, most generally, an organized examination or formal

evaluation exercise. It involves the measurements, tests, and gauges applied to

certain characteristics in regard to an object or activity. The results are usually

compared to specified requirements and standards for determining whether the

item or activity is in line with these targets. Inspections are usually non-

destructive.

In this industry various types of gauges to maintain accuracy and precision

at various stages of machining are performed. Each stage involves checking of

dimensional accuracy. The commonly used gauges at plant are:

a) Go-Nogo gaugeb) Calipers ( inside caliper, vernier caliper )c) Micrometer screw gauged) Pneumatic gauge

i) INSPECTION USING PNEUMATIC GAUGE ii) GO-NOGO GAUGES


13/14

PACKAGING & TRANSPORTATION:

The final product after going through inspection & sampling is oiled for

protection against corrosion. And then product is finally packed inside a plastic

bag. Thus the final product is ready to be transported to other industry.

CASE STUDY:

y The case study was carried out at AGROFAB MACHINERIES PVT. LTD.,MIDC, Hingna Road, Nagpur.

y The raw material was provided by Mahindra & Mahindra procured fromcasting unit at Chennai.

y Various machining processes were carried out to make castings fit to use.y The plant runs 24 hours a day. The production work is carried out in 4

shifts and each shift consists of 6 hours.y The production rate of the industry is 800 parts per day.


14/14

PROBLEMS:

PROBLEM 1: Blind boring

A through bore was sunk across the thickness of the part.

SOLUTION:

The bore was required only upto a certain depth.That process was unnecessary

and was consuming more time, power and labour.

This could be overcome by just attaching a stopper with drill bit at the optimumrequired length. This will reduce time, save labour & avoid unnecessary wearing

of tool.

PROBLEM 2: Chip disposal

SOLUTION:

Centralized chip disposal system can be suggested over this problem. We suggest

that the disposal of chips can be carried out by using a conveyor disposal system.This system will run periodically to carry chips to disposal area.

Industrial Case Study Report at

Documents

Transcript of Industrial Case Study Report at