SUMMER INTERNSHIP REPORTAT CUMMINS INDIA LIMITED

Presented by: Sayali Mahajan

Nayan SonawaneCollege of Engineering, Pune.

INDEX

1) ACKNOWLEDGEMENT

2) INTRODUCTION

3) OBJECTIVES

3.1) Academic objectives

3.2) Project objectives

3.3) Academic accomplishments

4) KV BLOCK SECTION

4.1) KV Block structure

4.2) KV Block line

4.3) Operation on KV Block

5) WORK INSTRUCTION

5.1) Safety

5.2) Ergonomics

5.3) General instructions

5.4) Set up instructions

5.5) Work instructions

5.6) Set up verification

5.7) Fixture details

5.8) Process details

5.9) Reaction plan

5.10) Rework

5.11) Deburring instructions

6) OTHER OBSERVATION

6.1) Quality control chart

6.2) Lock out Tag out (LOTO)

6.3) Material Safety data sheet.

7) INSTRUMENTS OBSERVED

7.1) Gauges

7.2) Deburring instruments

7.3) Scissor lift

7.4) Upender

7.5) Tilting trolley

7.6) EOT cranes

7.7) Tackles

7.8) Roller conveyor

8) KV BLOCK APPLICATIONS

9) CONCLUSION

10) REFERENCE

ACKNOWLEDGEMENT

We are thankful to our Institution College of Engineering, Pune and Dr. Mohan S. Khond (Training & Placement Officer) for their valuable support.

We also extend our gratitude towards…..

Mr. Navnath Mane (Head of BU01)

Mr.Vinayak R Mahajan(Section Incharge of KV Cyl. Block)

Mr.Kishor H Sandge(Process Engineer of KV Cyl. Block)

We express our gratitude to Mr. Rajesh D. Bharambe for their humble support.

2) INTRODUCTION

Cummins is multinational corporation company producing engines, power generation systems and related products. Cummins India Limited (CIL) is a 51 percent subsidiary of Cummins Inc. USA, the world’s largest independent diesel engine designer and manufacturer above 200 HP. CIL is India’s leading manufacturer of diesel engines with a range from 205 hp to 2365 hp and value packages serving the Power Generation, Industrial and Automotive Markets. CIL also caters to the growing market for gas and dual fuel engines.

IEBU (Business Unit/entity intranets)It is the biggest section of CIL. IEBU is the main section because it’s the scope of

CIL. CUMMINS manufactures various types of engines which are KV 12, KV16, NHNT, N14, K6, NTBC, V28, SMALL CAM.

There are 7 BU units and two assembly units.

IEBU is gigantic with subsections of: NH/NT/K/KV Cyl Block Cylinder Head Con Rod, CNCs, Flywheel, Misc, Lub Pump, Cover GC, Bar Cap,V28 Cyl Block Fuel System (PT) Camshaft, Gear Heat Treat, Lever, Fabrication, Shot Blast

The assembly unit includes assembly of KV/K and NH/NT .The KV assembly section is different and very huge similar to the size of the block.

In Cummins the section allotted to us for our project was IEBU shop floor.

Scope : On shop floor we have done Project on KV Cylinder Block Of BU 01.

3) OBJECTIVE

3.1) ACADEMIC OBJECTIVE:

The main motive of joining this company was to get vocational training and clear understanding about application of various core subjects of mechanical sector and practical implementation of it.

3.2) PROJECT OBJECTIVE:

To update the WORK INSTRUCTIONS as per desired process of KV Block line work station.

This was accomplished by studying existing process with a revisit to existing work instructions. The updated Work Instructions expected was to be with tool list along with speed /feed, change schedules, safety instruction, process instructions.

To be precise, the objective was to make Work Instructions which would be more specific so that any person of the company or outsiders could easily access the process and various details.

3.3) ACADEMIC ACCOMPLISHMENTS:

Though the main objective was updating Work instruction, we came across many techno-commercial facts which added to our knowledge. We could easily relate our theoretical knowledge with the industrial experience.

We modified Work Instructions of

HOMMA 1& 2

DMG

HOMMA 3

FINISH CRANKBORE SPM

MAZAK 1

MAZAK 2

FINAL WASH

HOMMA 4&5

We observed different types of

CNC machines, measuring instruments, various mechanisms used in transfer of block like tilting, upender & chain conveyor and even E.O.T cranes (ergonomical aspect).

IC engine: - Cooling system, Lubrication and other working of engine through KV block.

Assembly of KV Block:- Study of different parts and engine operations.

Machining:- different tools like inserts, drills, taps, reamers, accessories (holders , collets , cartridge )etc and even instruments like different gauges and vernier used for inspection which added to our practical knowledge.

Revised programming used for operating CNC machines and also programs of Siemens & Mazatrol. We studied efficiently the separation of oil, coolant and burr and there maintenance so as to reduce pollution. We studied how quality is maintained and its process control charts.

Accuracy: - Its importance and how small error any time may cause huge losses.

We learned the management of production of KV cylinder block. Apart from this we acquired the application of machine design which included ergonomics and aesthetics.

4) KV CYLINDER BLOCK SECTION

4.1) KV BLOCK DESCRIPTION

In KV Block section KV 12 & KV 16 are machined. The block consists of various faces according to which the machining categorized. The block is divided as follows:

1. TOP FACE/ WATER HEADER2. HEAD FACE R.B. & L.B3. BOTTOM FACE4. KIM START5. PAN FACE6. CAPSEAT7. CAM BOX8. GEAR END9. FLYWHEEL END/ REAR END

WATER HEADER

HEAD FACE

LUB OIL COOLANT

TOP UP POSITION

PAN FACE

REAR END

CRANKBORE

CAMBORE

BOTTOM UP POSITION

KIM START

CAMBOX

LOH

GEAR END

4.2) KV BLOCK LINE (KV 12/16)

1. LOH SPM2. HOMMA #1,#23. DMG4. MITSUBISHI5. UPENDER6. HOMMA #37. MITHRAA8. NUT RUNNER9. FINISH CRANK BORE SPM10. SEMI FINISH CAM BORE SPM11. OIL GALLERY SPM12. MAZAK 113. MAZAK 214. CBH 100 SPM15. PEGARD 1,216. KTM DRILL TAP SPM17. KTM ROUGH LINER SPM18. INGERSOLL FINISH LINER SPM19. HOMMA 4,520. RADIAL DRILL21. ASQUITH BUTLER22. SNCH23. FINAL DEBURRING24. PT/WT/FT/LHT25. INSPECTION26. REWORK (SPARKONIX )27. BUSH PRESS28. FINAL WASH29. MILLIPORE30. CLEARANCE

5 ) GENERAL WORK INSTRUCTIONS

5.1) SAFETY INSTRUCTIONS

The key for efficient employee productivity is to keep them motivated. Employees can be satisfied if they feel safe and happy at their workplace and if they are been appreciated.

It is only when the employees feel safe at work that they can work at their fullest capacity and explores the best of their potentials at work. It involves the formation and implementation of safety programs.

Workplace safety involves training programs that are meant to teach the employees to handle risks. They need to be trained for impending dangers, if any; to face risks and deal with accidents at work.

Safety instructions and PPE are strictly followed in CUMMINS which includes:1. Safety goggles2. Ear plugs3. Safety shoes4. Hand gloves5. Helmet wherever necessary

The above safety components are compulsory for an employee & a machine operator on shop floor.

5.2) ERGONOMICS

Ergonomics in the workplace is of utmost importance from the point of view of employee’s comfort and their safety. Ergonomics can help reduce costs by improving safety.

Engineering psychology is an interdisciplinary part of ergonomics and studies the relationships of people to machines, with the intent of improving such relationships. This may involve redesigning equipment, changing the way people use machines, or changing the location in which the work takes place.

Installation of machines at desired height, design of fixture to reduce fatigue etc are some few changes made at workplace considering ergonomics. Ergonomics is about making things more efficient. One of the best benefits of ergonomics is saving time as well as cost.

5.3) GENERAL INSTRUCTIONS

General instructions are the key instructions to be followed by the operator of a machine. These summarize all the details about actions, precautions and observations to be followed on machine.

There are instructions regarding Steps to be taken for loading/unloading of the block. Use of tackle for handling of block Use of EOT for shifting of block Safe distance to be maintained from machine while handling block. Information about coolant used.At first we observed the movements of the operator of machine .After studying his

movements we noted down some points and then checked for those points in previous work instructions and made changes accordingly.

5.4) SETUP INSTRUCTIONS

While installing a new part it needs to follow some definite steps. These steps are nothing but the setup instructions of the part. They include how the part is installed, where it is installed, whether it is correctly installed or not, how it is calibrated etc.

Setup instructions on a machine generally include instructions for establishing a system & mounting a fixture on table palette. For this firstly its X, Y &Z coordinates are checked with plunger dial. It is fixed in dowel pins provided to palette. After mounting the fixture its alignment and orientation is checked by probe.

5.5) WORK INSTRUCTION

Standard work instructions are used to maintain and improve productivity, quality and safety. These are the standards accepted by the company for its production. They provide a documented process sequence to perform work with the most efficient method in the designated (cycle) time.

Kaizen initiatives highlights opportunities to make improvements in working procedures to reduce non value adding work content.

Work instruction is guide line to operator which suggests how to do the work efficiently and effectively. Work instruction includes

Program no. for different operations Tackle to be used Procedure of mounting block on fixture Information of precaution taken during loading & unloading block. Procedure to restart the block operation Methods of tool setting.

Standard work instructions are updated timely to reflect the changes.

5.6) SETUP VERIFICATION

If we shift the operations of one block on a machine then the setup needs to be verified before machining. This is done by taking the reading from all sides of the block using a probe. If the readings are in given limits (with accepted tolerance) as decided then further machining starts.

After the machining is done, we first check the block. If operation stops in middle by any problem then block should be checked first & then further machining should be done.

If any problem arises then line manager should be informed.

5.7) FIXTURE DETAILS

A fixture is a work holding or support device used in the manufacturing industry. The main purpose of a fixture is to locate and in some cases hold a work piece during either a machining operation or some other industrial process.

Every machine has a different fixture, as per their need. It is designed considering the parameters of the block. It contains butting pads for supporting the block, dowel pins for locating the correct position of block, clamps for fixing, locating pins etc for clamping the block.

They can be operated manually or hydraulically. Hydraulic fixtures are easy to operate and reduce efforts. It has AIR SENSING UNIT which detects the gap (if any) between butting pads and block. It helps in checking whether the block is loaded correctly or has some misalignment.

Manual fixtures are handled with ratchet (socket wrench).

5.8) PROCESS DETAILS

Process details convey to the reader how a change takes place through a series of stages.  The process description examines an event time to time.

It gives us overviews of all necessary parameters considered during machining like speed, feed, tool used its different attachments& accessories, tool life frequency .A sample of Process details is attached at the end of report.

5.9) REACTION PLAN

Reaction plan is included in work instruction because it is a guideline for any operator to solve any problem.

If any drills, taps (or any operation) exceeds a given specific limit, then the block has to be reworked. If any drill becomes oversize or any tool breaks in middle of machining then line manager is to be informed.

5.10) REWORK

Rework is a process to salvage any defective block as per defined standard. It is usually done when some process parameters do not meet specifications ass per part drawing. Salvage is done to arrest manufacturing as well as vendor defect.

Oversized holes are reworked by fitting sleeve and then further machining it again. Broken drill or tap is removed on SPARKONIX machine. Even Radial Machine is used for rework.

If the reworked block still does not fit in salvage standard then it is scarped by marking it red.

5.11) DEBURRING INSTRUCTION

It means removal of burr. It is done after machining of block. This operation is done to remove sharp edges and foreign particles in a block. or removal of chips & coolant, vacuum cleaner is used. Deburring is also carried out to avoid injuries to operators which can be caused by sharp edge of machined block.

Deburring tools are:- Sand paper / Polish paper Pneumatic sander Speeders NOGA tool Oil stone Smooth half round file.

6) QUALITY INSTRUCTION

6.1) QUALITY CONTROL CHART

Quality control chart indicates that the process is currently under control (i.e. is stable, with variation only coming from sources common to the process). Data from the process can be used to predict the future performance of the process.

If the chart indicates that the process being monitored is in control then operations are carried out in limit. If the chart indicates that the process being monitored is not in control, analysis of the chart can help determine sources of variation, which can then be eliminated to bring the process back into control.

A control chart is a specific kind of run chart that allows significant change to be differentiated from the natural variability of the process. The control chart can be seen as part of an objective and disciplined approach that enables correct decisions regarding control of the process, including whether or not to change process control parameters. Process parameters should not be adjusted for a process that is in control, as this will result in degraded process performance.

The control chart is one of the basic tools of quality control.Below is the big Q showing progress of all the days

RED – Defect generated GREEN- No defect

SAFETY INSTRUCTION

6.2) LOCKOUT TAGOUT (LOTO)

Lockout / tag out (LOTO) refer to specific practices and procedures to safeguard employees from injury due to the unexpected energizing or startup of machinery and equipment, or the release of hazardous energy during operations, service, or maintenance activities.

LOTO is also used as a method of equipment status control for conduct of operations using different tags and locks to protect the equipment/program or to provide operating information for devices and equipment.

Lock and tag is a safety procedure which is used in industry to ensure that dangerous machines are properly shut off and not started up again prior to the completion of maintenance or servicing work. There is LOTO solution on every machine for preventive maintenance.

LOTO sheet contains the voltage and current ranges, energy conversions taking place in the machine , precautions to taken i.e. covering the electric circuit area by a box in order to prevent accidents.

6.3) MSDS (MATERIAL SAFETY DATA SHEET)

MSDS (material safety data sheets) are a widely used system for cataloging information on chemicals, chemical compounds, and chemical mixtures. MSDS information may include instructions for the safe use and potential hazards associated with a particular material or product. These data sheets can be found where chemicals are being used.

Each MSDS must contain sixteen sections:1. Product information: product identifier (scientific name, common name), name of

the manufacturer and supplier, addresses, emergency phone numbers 2. Composition / Information on Ingredients 3. Hazards Identification: data on flammability, reactivity, chronic hazards.4. First-Aid Measures: description of recommended first-aid measures in case an

incident occurs, for example, in case of ingestion or inhalation of the substance, or in case of contact of the chemical product with eyes or skin.

5. Fire Fighting Measures: recommended fire fighting apparatus, methods and products, flash point of the substance, fire-fighting class, upper and lower flammable limit (ULF - LFL), dangerous combustion products, recommendations for preventing explosions and fires .

6. Accidental Release Measures: measures to be taken in case of the accidental release of the chemical substance or mixture into the environment: soil, rivers, waterways, sources of potable and non potable water, see, etc.

7. Information on Recommended Handling and Storage Conditions: recommended procedures for the handling, storage and usage of the chemical substance or mixture.

8. Exposure Controls / Personal Protection: this section often contains the exposure limits per country (classified by form of exposure or overexposure), as well as the personal protection equipment (PPE) recommended or required by law (respiratory protection, skin protection, eye protection, face mask, etc.)

9. Physical and Chemical Properties: product properties such as vapor pressure, vapor density, specific weight, water solubility, appearance, odor type, boiling point, pH value, viscosity, evaporation rate, freezing point.

10. Stability and Reactivity Data: information on the stability of the substance, conditions to avoid, incompatibility with other substances or materials, hazardous decomposition products, etc.

11. Toxicological Information: information on the acute and chronic toxicity of the chemical substance, possibly data on the known carcinogenic properties, or labs tests.

12. Ecological Information: information on the ecotoxicity of the chemical product, analysis of its components, biodegradability in different environments, etc.

13. Disposal Considerations: this section often contains references to local legal requirements regarding the disposal of hazardous chemical products.

14. Transport Information: shipping name, hazard class, UN number, package group. 15. Regulatory Information: classification of the substance according to TSCA, SARA.

CERCLA, S- and R-Phrases

16. Other Information: this section often presents a list of abbreviations used in the MSDS, references to EU Directives en European or international (ISO) standards, version management of the MSDS, a disclaimer.

7) INSTRUMENTS OBSERVED

7.1) GAUGES

While doing inspection we can across different types of gauges used to inspect the block like Plain plug gauge, thread plug gauge, ring gauge, air pressure gauge, dial bore gauge, snap gauge & measuring instruments like vernier, micrometer (ball), depth vernier.

A ring gauge is a cylindrical ring of steel whose inside diameter is finished to gauge tolerance and is used for checking the external diameter of a cylindrical object. Ring gauges are used for comparative gauging as well as for checking, calibrating or setting of gauges or other standards. Individual ring gauges or ring gauge sets are made to variety of tolerance grades in metric and English dimensions for master, setting, or working applications. There are three main types of ring gauges: go, no go, and master or setting ring gauges.

GO-NO GO GUAGE

A Go-No Go gauge refers to an inspection tool used to check a work piece against its allowed tolerance the gauge has two tests; the check involves the work piece having to pass one test (Go) and fail the other (No Go).

It is an integral part of the quality process that is used in the manufacturing industry to ensure interchangeability of parts between processes, or even between different manufacturers.

A Go- No Go gauge is a measuring tool that does not return a size in the conventional sense, but instead returns a state. The state is either acceptable (the part is within tolerance and may be used) or it is unacceptable (and must be rejected).

They are well suited for use in the production area of the factory as they require little skill or interpretation to use effectively and have few, if any, moving parts to be damaged in the often hostile production environment.

In the right hand image, the top gauge is a thread gauge that is screwed into the part to be tested, the labeled GO end will enter into the part fully; the NOT GO end should not. The lower image is a plain plug gauge used to check the size of a hole, the green end is the GO, red is the NO GO. The tolerance of the part this gauge checks is 0.30mm where the lower size of the hole is 12.60mm and the upper size is 12.90 mm, every size outside this range is out of tolerance. This may be initially expressed on the parts drawing in a number of styles, three possibilities may be:

12.75mm +/- 0.15mm 12.60mm +0.30 -0.00 12.90mm +0.00 -0.30

SNAP GUAGE

The usage of this gauge may be more intuitive than the plug type. A correctly machined part will pass the first set of jaws and stop at the second end of test. In this manner a part may be checked in one action, unlike the plug gauge that needs to be used twice and flipped to access the second gauge.

DIAL BORE GAUGE

A dial or vernier bore gauge measures a bore directly. The gauge has three symmetrical anvils that protrude from the gauge body that are connected to the dial or micrometer mechanism. As the knob is rotated it moves the anvils in or out with respect to the measurements. The knob usually has a slipping mechanism to take the feel out of the device and increase reliability between measurements.

DIGITAL VERNIER CALIPER & MICROMETER

7.2) DEBURRING INSTRUMENTS

While updating Work Instruction we came across various instruments used to debur the block. From left

Half round file Oil stone

No go tool

Pneumatic sander

Speeder

7.3) SCISSOR LIFT

A scissor lift is a raising/lowering device that is supported or stabilized by one or more pantograph leg sections.

A scissor lift can usually move vertically upward & downward. The mechanism used to achieve this is a series of criss-cross folding supports, forming an "X" pattern. The upward motion is achieved by the application of pressure to the outside of the lowest set of supports, elongating the crossing pattern, and propelling the work platform vertically. The platform may also have an extending bridge to allow closer access to the work area (because of the inherent limits of vertical only movement).

When extended, a scissor lift can reach anywhere from 21 to 62 feet (6.4 to 18.8 meters) in the air, depending on its size and purpose. It can be powered by hydraulics or an electric motor, but a scissor lift's design prevents it from traveling at a constant speed. It travels faster in the middle of its journey and slower with more extension.

7.4) UPENDER

Upenders, sometimes called coil positioners, rotate loads though 90 degrees in either direction. They are used in a variety of production and maintenance applications.

Upenders have a round cradle frame that is placed on four machined rollers. A gear motor driving a single or dual chain sprocket provides the ability to rotate. Brake motor and gear reducer drive a sprocket and roller chain giving a smooth rotating cycle.

• Wired to operate on your available power supply.• Complete electric controls; disconnect switch, and push button station mounted on unit.• Limit switches automatically control rotation

7.5) EOT CRANES

Crane which lift objects by a hoist which is fitted in a trolley and can move horizontally on a rail or pair of rails fitted under a beam. An overhead travelling crane, also known as an overhead crane or as a suspended crane, has the ends of the supporting beam resting on wheels running on rails at high level, usually on the parallel side walls of a factory or similar large industrial building, so that the whole crane can move the length of the building while the hoist can be moved to and fro across the width of the building

This comprises of a motor of sufficient power a totally enclosed helical gear box, a rope drum coupled to the gear box by a specially designed flexible geared coupling.

The motor is coupled through flexible geared coupling to the gear box and on the other end an electro- magnetic/electro hydraulic thruster brake is provided which comes into operation as soon as the power is switched off (i.e. fail to safe type operation).

The gear box is having casting body incorporating all machine/hob cut helical gear trains and is splash lubricated.  The use of totally enclosed helical gear boxes though rather expensive more than justifies the extra price in view of the advantages of high transmission efficiency, less meshing noise and longer life.

7.6) ROLLER CONVEYOR

In BU 01 roller conveyors are used for transferring the block from one machine to another. It makes the work easy by saving time and labour (by easy transmission). Here Chain driven roller conveyors are used.

Chain Driven Roller Conveyors

The chain driven roller conveyors can handle heavy loads. They are also used to convey heat, oil, grease, etc. The chain driven roller conveyors have a sprocket on one end. The sprocket and the drive chain maintain continuous rotation of the rollers to easily convey goods.

Chain Driven Live Roller conveyors are the cornerstone of unit load conveying systems. The conveyor is driven by separate loops of chain that connect each pair of double sprocket carrier rollers. This simple, rugged, and reliable design is ideal for transporting pallets, containers, drums, and fixtures. Our modular based design offers easy segmentation

of the conveyors into controllable drive zones, accumulation zones, and simple insertion of transfers and other accessory devices.

Advantages of this conveyor are quiet operation, as well as easy installation and maintenance. They can be manufactured for almost all applications, at relatively low expense.

8) KV BLOCK APPLICATIONS

KV12 & KV16 engine are in demand these days. This block has various applications as given below:

Cummins Diesel engines for Gen-set application For Construction , Mining, Compressor & other industrial application For Gas Engines for Compressor , Irrigation & Refrigeration application For Locomotive and Rail application For Marine Main Propulsion For Marine Gen-set For Fire Fighting Pump application For Industrial Pump application Oil field application

9) CONCLUSION

We completed updating the work instructions according to existing process and even made other changes like safety instructions, Deburring instructions and reaction plan as per required. We also updated Process details according to a format which covered all the required details on machine.

We got a thorough understanding of practical implementation which helped us to enhance our vision of knowledge and understanding. We look forward for such projects in future and continue our learning process.

10) REFERENCE

Old work instruction sheets Inspection check sheets Tool frequency file Google