SETCO AUTOMOTIVE LTD.

A REPORT ON OPERATIONS IN KALOL PLANT

Sarthak Parnami

Contents
MACHINE SHOP FLOW PROCESSES .......................................................................................................... 4 ADJUSTING NUT .................................................................................................................................. 4 EYE BOLT ............................................................................................................................................. 9 LOCK NUT .......................................................................................................................................... 11 PRESSURE PLATE PIN (PP Pin) ............................................................................................................ 11 EYE BOLT PIN ..................................................................................................................................... 12 DRIVING LUG ..................................................................................................................................... 12 BEARING SLEEVE ................................................................................................................................ 12 HUB ................................................................................................................................................... 14 COVER ............................................................................................................................................... 16 MACHINES USED ................................................................................................................................... 18 SAP (Systems, Applications & Products) ................................................................................................. 21

MACHINE SHOP
In machine shop power driven machine tools such as saws, lathes, milling machines, and drill presses, are used with a sharp cutting tool to physically remove material to achieve a desired geometry. These processes are a part of subtractive manufacturing which can be done on any metal products and also on materials such as wood,plastic,ceramic and composites. A person who specializes in machining is called a machinist. A room, building, or company where machining is done is called a machine shop.

The three principal machining processes are classified as turning, drilling and milling. Other operations falling into miscellaneous categories include shaping, planing, boring, broaching and sawing. Turning operations are operations that rotate the job as the primary method of moving metal against the cutting tool. Lathes are the principal machine tool used in turning. Milling operations are operations in which the cutting tool rotates to bring cutting edges to bear against the job. Milling machines are the principal machine tool used in milling. Drilling operations are operations in which holes are produced or refined by bringing a rotating cutter with cutting edges at the lower extremity into contact with the job. Drilling operations are done primarily in drill presses but sometimes on lathes or mills. Miscellaneous operations are operations that strictly speaking may not be machining operations, but these operations are performed at a typical machine tool. Burnishing is an example of a miscellaneous operation.

Machining operations usually divide into two categories, distinguished by purpose and cutting conditions: Roughing cuts, and Finishing cuts

MACHINE SHOP FLOW PROCESSES

In Machine Shop different types of components of both Disc Plate Assembly & Cover Assembly are processed. Every part undergoes a set of operations. These operations are described with the help of visualization below for each part processed in machine shop.

ADJUSTING NUT
Process for adjusting nut involves following steps : 1. Turning TRAUB MACHINE

2. R.T.D Grinding CENTER LESS GRINDER

3. Roll Threading ROLL THREAD MACHINE

4. Counter Boring CAPSTAN MACHINE

5. SLOTTING MILLING MACHINE

6. Drilling & Tapping CAPSTAN MACHINE

7. Facing & Re-Threading CAPSTAN MACHINE

8. Move to Heat Treatment

EYE BOLT
Process for eye bolt involves following steps : 1. Turning TRAUB MACHINE

2. Facing - CAPSTAN MACHINE

3. 4. 5. 6.

Pilot Drilling DRILLING MACHINE Final Drilling DRILLING MACHINE Chemfer DRILLING MACHINE Reamer DRILLING MACHINE

7. Roll Threading ROLL THREAD MACHINE

LOCK NUT
Process for lock nut involves following steps : 1. Drilling 2. Boring & Chemfering 3. Tapping RADIAL DRILL MACHINE

4. Move to Heat Treament

PRESSURE PLATE PIN (PP Pin)

Process for PP Pin involves following steps : 1. 2. 3. 4. 5. Turning First Cut Grinding Grooving & Facing Rough Final Grinding C.L Grinder Final Grinding C.L Grinder

EYE BOLT PIN

Process for eye bolt pin involves following steps : 1. 2. 3. 4. 5. 6. Turning & Facing First Cut Grinding Second Cut Grinding Move to Heat Treatment and Back Rough Final Grinding C.L Grinder Final Grinding C.L Grinder

DRIVING LUG
Process for driving lug involves following steps : 1. 2. 3. 4. Parting Rough Grinding Milling Final Grinding SURFACE GRINDER

5. Hardness Inspection 6. Deburring VIBRATOR MACHINE

BEARING SLEEVE
Process for eye bolt pin involves following steps :

1. 2. 3. 4. 5. 6. 7. 8.

Parting Facing & O.D Turning First Drilling Second Drilling Boring First Side Turning Final Inspection Adjusting Ring Welding WELDING MACHINE

9. Grinding CYLINDRICAL GRINDING MACHINE

HUB
Process for PP Pin involves following steps : 1. Spline Broaching BROACHING MACHINE

2. 3. 4. 5. 6.

Move to Press Shop Notching Shaving Move to Machine Shop O.D Turning LATHE MACHINE

7. Run Out LATHE MACHINE 8. Hole Drilling MULTI HEAD DRILLING MACHINE

9. Chemfering DRILLING MACHINE 10. Deburring DEBURRING MACHINE 11. Move to Heat Treatment

COVER
Process for Cover involves following steps : Turning/Facing/Back Facing/Boring CNC MACHINE

1st Set up Drilling VMC MACHINE

Lug Milling VMC MACHINE

2nd Set Up Spot facing VMC MACHINE

MACHINES USED
1. TRAUB MACHINE This machine is used to perform multiple functions at once. As seen in the eye bolt turning process it uses 5 different tools for that processes and perform facing, shaping, chemfering and cutting.

2. ROLL THREADING MACHINE This machine is used to roll thread the surface of different parts such as Eye bolt, Adjusting nut etc. 3. CAPSTAN MACHINE This machine has its job fixed and the tools to be used move. As seen in adjusting nut processes of Counter boring, Drilling & Tapping and Facing & Re-Threading is done on this machine.

4. CENTER LESS GRINDER This grinder is different from other grinding machines as in this the there is no center of the grinding machine but there is job in the center of the machine. The job is placed and is grinded by two grinding wheels turning on both the sides of the job.

5. CYLINDRICAL GRINDER Cylindrical jobs are grinded on this machine with job being rotated on its axis and the grinding tool also rotating on its axis. Rotation of both the job and the tool leads to grinding of the surface of the job. It is exactly opposite to Center Less grinder in terms of the position of the Job & Tool.

6. DRILLING MACHINE Every type of Drilling & Chemfering is done on this machine. For each operation the tool is changed and the process is carried out. It can carry out different processes such as Chemfering, Drilling, Multi-Drilling, Reaming etc. 7. MILLING MACHINE In this machine job is milled by the movement of job against the rotating milling cutter. The job can be moved in horizontal or Radial direction based on the need of the job. It is opposite of drilling machine where the tool is moved and job is fixed.

8. RADIAL DRILL MACHINE The action of this machine is similar to the Drill machine but the advantage of this machine is that this machine can move across an arm that radiates from the machines column. This helps in operating over a large area without the problem of clamping & unclamping.

9. COMPUTER NUMERIC CONTROL MACHINE (CNC) This machine is an automatic machine which is used to perform different function by use of multiple tools at once. The tool holder can have an option of clamping 10-12 tools at once. In this machine the the tool can move in only two axiss that is X & Z. The tool is moved according to the need. We can see the use of this machine in the process of Covers turning/facing etc.

10. VERTICAL MILLING CENTER (VMC) This machine is used in many processes but the difference from CNC is that this machine can move in many more axiss than the CNC. It is used for Lug Milling, 1st set up drilling, 2nd set up drilling in the cover.

SAP (Systems, Applications & Products)

SAP is the common system used across the plant for materials management and movement of goods. It smoothens the operations for the company. Few main functions for the SAP for various departments are : STOCK OVERVIEW (nmbe) This function helps in looking around for the stock of either consumables, raw materials, finished products etc. It helps in gaining knowledge about the position of the material in the flow list.

REM BACKFLUSH (nmfbf) This function allows the daily production to be updated from a particular department. Once updated in the system the next department will know of the availability of the material.

ENTER TRANSFER POSTING (nmb1b) The system is updated in this function when the material is physically transferred to its next department.

MATERIAL DOCUMENT LIST (nmb51) It gives the information about the materials in the system. For eg. 00 means the product is final and is ready to go to the Assembly, 1M means one more department is left before being transferred to the Assembly etc.

CREATE RESERVATION : NEW ITEMS (nmb21) This function is used to demand for the raw materials to be used in the particular shop to the Stores. For materials which is not available in the stores and have to be bought from the outside vendor a Purchase Requistion have to be raised and then purchase department will handle the request.

RESSERVATION LIST INVENTORY MANAGEMENT (nmb24) This function helps in displaying the reservation made by that particular department.