DECLARATION
An Internship report submitted to the department of Institute Of Business and Information Technology for Punjab University, Lahore in partial fulfillment of the requirement for the degree of BBIT.
DEDICATION
I dedicate my report to my esteemed teachers who motivate me, teach me and help me during making this report. I feel highly honored to present and express my respect and gratitude to my respected teachers whose behavior is always encouraging and sympathetic.
TABLE OF CONTENTS
CHAPTER 1 The Organization 1. History and background..8 o Vision.9 o Mission.10 o Our Values 2. Products & Services..12 o Roles played by MEL...12 3. Profile of the company..13 o Administration.13 4. Organizational Structure...14 o Aims and objectives.14 o Composition.16 o Management.....16 o Advisory committee.17 5. Description of various departments...17 o Commercial department.......17 o Information technology department....18 o Quality control and assurance department...18 o D&D department...19 o STORE department...19 o HRM department..20 o Heat treatment department...22 o Finance and accounts23 o Production department o Maintenance department.. 6. Appraisals and problems....24
ACKNOWLEDGMENT
First of all I am thankful to Allah Almighty for giving me opportunity, ability and courage to accomplish my internship report. I gratefully acknowledge and express my gratitude to my Parents for providing me unflinching encouragement and support in various ways whenever I felt low and dishearten. To my sisters and brothers, whose prayers and support were always there to help me. I owe my gratitude to number of people who help me to plan and write this internship report. This includes Mr. Mansoor, Director of IBIT who gave us an Opportunity to enhance our capabilities. This internship program has been very helpful for me because I have learnt a lot by applying theoretical knowledge in practical field. And I thanks to department supervisors who were very good to me as they guide me all mechanisms of department in which worked It is pleasure to pay tribute to my all treasured Friends for their emotional support and sincere advice
COMPANY INTRODUCTION
Millat equipment limited is, an ISO 9001:2008 certified company is the most technologically advanced transmission shaft and gears manufacturing company in Pakistan .The company acquired a Gear manufacturing setup from M/S ACGO LIMITED UK (owners of the Massey Ferguson brand of tractors) with and understanding to buy back the transmission components after meeting the local requirement of AGCO Licensee in Pakistan (M/S Millat Tractors Limited) M/S AGCO Limited provides all the technical support regarding products design, developments, specifications, and standards to produce world class quality components. Milllat Equipment Limited is equipped with complete in-house gear manufacturing facility supported by state of the art inspection and testing equipment to assure quality as per standards. Our modern manufacturing facility is located at 10 KM , raiwind road , Lahore, Pakistan.
MISSION STAEMENT
To be a preferred choice for customers and suppliers, competing in the domestic and overseas markets by continuously delivering value on a long term basis by high performance team driven by innovation and adherence of health, safety and environmental principles.
VISION
Millat to be a global group of companies, recognized for a range of quality products with innovative design capabilities.
OUR VALUES
1-Ethics employees are trained with full concentration and respect, the way you want to be 1. treated and moral values are always followed. There is open door policy every customer is welcomed very warmly. 2-Compassion employees as well as the customer ideas and suggestions are respected, listened and understood as they are our own; by putting yourself in others shoes. The communication gap is kept always minimum between the HODs and the employees to decrease the risks and to enhance the performance. 3-Team work the team work is an important value of the company all the employees work with each other in a friendly environment so that all the confusions and problems could be removed in a easy way. 4-Consistency being consistent in mastering and maintaining standards of the equipments is the main value of the company. 5-Innovation constant creativity in Research, Development and design for value addition and exceeding expectations of customers, and employees. The pipeline is made which equipments are under process.
COMPOSITION
Millat equipment limited is, an ISO 9001:2008 certified company is the most technologically advanced transmission equipment making company. Millat Equipment Limited (MEL) is part of Millat Group comprising of three other companies: Millat Tractors Limited (MLT), Bolan Casting Limited (BCL)& Millat Industrial product Limited (MIPL).
MANAGEMENT
There are total 139 executive staff which is running the company, managing operational work and inspecting all activities related to transmission parts and market which includes the CEO, 2 DGM, 4 SM, 6 managers, 14 DM, 28 AM, 57 JE, 10 JE who are managing and controlling all the production and operational activities.
Company Secretary Mian Muhammad Saleem Chief Financial Officer Sohail Ahmed Nisar Auditors Ilyas Saeed & Co (Chartered Accountants Lahore) Legal Advisors Walker Martineau Saleem (Advocate & Legal Consultants) Registered Address 8.8-K.M. Lahore Sheikhupura Road, Shahdra, Lahore. Plant Site 10-K.M. Raiwind Road, Lahore. Principal Bankers Habib Bank Limited Bank Al-Habib Limited Habib Metropolitan Bank Limited MCB Limited
4.Organizational Structure
Chairman
Director
CEO
Sr.Manager Maintenance
AIMS
MELs primary goal is to ensure customer satisfaction by improving its manufacturing processes, Eliminating waste, Delivering product on time at a competitive price through a committed team,
Innovation and adhering to Health & Safety Standards for MEL team.
Balancer Unit -MF No. 4111K059 Axle Shaft- MF No. 1678303 M1 Wheel Axle Standard Duty-MF#884850 M
Our Products :
5.
ORGANOGRAM
Rafey Zaman Durrani SR.Manager D&D
JE (2 No.)
SERVICES
New development Vender Development Design Services Testing equipments Tool room services and prototyping
COMMERCIAL DEPARTMENT
FUNCTIONS Procurement Purchase of all products Cash out flows/ inflows is done here Purchase goods and services Effective and efficient procurement in order to increase the overall competitiveness of company
ORGANOGRAM
JE Local Procurement
SERVICES All the works related to the procurement during the projects is handled with the help of production department
FUNCTIONS Compensation Recruitment/selection Insurance Performance appraisals Training and development program Administration and security Over time duties maintenance Night shifts Attendance Fulfillment of shortage of employees
ORGANOGRAM
Ch.Asif Ali AM HR
Kishwar JE Payroll
Shafiq AM HR
Finance department
Functions
Daily basis the cash position is recorded and made and the current status is sent to the CFO and DGM . Recording and reporting is included in general activities. Income tax and shield tax is managed here. Stock flows Facilitating the venders Time recorded payments Input output flow of cash
Services
Prepare financial projections Budgeting Insurance Future forecasting
ORGANOGRAM
Je/Trainee Finance-06 No
SERVICES Heat treatment of the equipments and simply the soft and hard production is done here
Asif Javed-Am CNC Tauqeer Ahmad-AM SG M Rohan-AM CWP Raheel Rafiq-AM Hyd Pump Naveed Matloob-AM Shaft
Assistant MM-01
ORGANOGRAM
SERVICE The basic service of this department is to store the products at the safe place.
ORGANOGRAM
Zagham Ali DM IT
JE Network
AM Programming-01 No.
Rayyan(AM)
JE Incoming Inspections
ORGANOGRAM
Abdul Munnan DM HT
JE HT-01
SERVICES The main function of the heat treatment department is the hard production and soft production the maintenance of the heat and amount of the carbon management produced during the production.
MAINTENANCE DEPARTMENT
FUNCTIONS They maintain and repair the machinery. They recycle the oil drained in the lower plates Check the quality of the oil and maintain the carbon level to the minimum level. Take the report from the quality control department and maintain the quality standards and the policies. Maintain the product design throughout the production.
Planning operations, Managing execution of events, Management of assets (parts, tools and equipment inventories), Knowledge-base data on:
o o o
Maintenance service history, Serial numbered parts, Reliability data: MTBF, MTTB (mean time to breakdown), MTBR (mean time between removals),
o o
Kashif Siddiqui DM
JE Mechancial(05 No.)
Assistant P&D
SERVICES
WEEK 1
In the second week I worked under MAM ASMA and deeply analyzed all the departments in the mean while I was told to make a detailed report on the quality control department.
Quality Control Department: It is concerned with the checking of product to the specifications, within an aim of providing that product is defect free and to detect & eliminate errors which may be present
Quality Assurance: It involves the all planned and systematic actions necessary to provide adequate confidence that a product or service will satisfy any given requirements for quality.
Functions of Incoming section of Quality Control Approval of New Components Inspection of components according to approved drawings First piece approvals(FPA) Inspection of Raw Material Inspection of Forgings and castings according to approved drawings Liaison with supplier regarding problematic components Coordination with production line to avoid production loss due to forging/casting fault Inspection of semi-finished components Inspection of semi-finish components as per approved drawings and QC plans Liaison with supplier regarding problematic components Development of gauges from vendor for components inspection Resolve production line problems to avoid production loss Surveillance of storage & packing of incoming material
Pilot Lot
Vendor/Supplier
Forging/Finish blanks
Casting
Hardware
Semi-Finish
Store
Quality Control
Forging/Casting/Hardware
Semi-finish
Reporting to
Development
Store
Finance
Supplier
Metrological Observations In-Coming Inspection Part Name Chec k No Elemen t Detail Drawin g call off Sample -1 Sample -2 Sample -3 Sample -4 Sample -5 Sample -6
Functions of Line inspection Stage wise inspection as per stage QC plan Inspection of Soft components Inspection of Hard components Finish Dispatch to store with FTN note Documentation of Data for OK, rejected,CA & Re-work parts Advising and facilitating corrective actions on production line Vigilance on stocking of WIP on production line
Non Confirmatory Report(NCR) Quality Control Part No. QTY Received Operation Drawing Observed Error QTY Description Call Off
Quality Control Department Inspection Master Card Part Description MF# Local# Name: Sr# 1 2 3 4 5 Spline 25T 6 7 Gear 69.65 69.70 --Characteristics Groove Dia Groove Width Bearing Dia Bearing Dia Prepared By: Reviewed By: Date: Rev No. D.C.O. Maximum(mm) Minimum(mm) 47.24 47.04 1.829 41.579 50.19 1.729 41.523 50.089
Gauges Required Description Number Special Caliper G.10245 Slip G.1019 G. Caliper Gauge G.24984 Spline Gauge G.10091 Spline Ring G.16520 Gauge(GO) Spline Ring G.16519 Gauge(NonGo) Pin Size 6.27mm G.8900
Store
Production
Line Rejection
Quality Control(Metrology)
Re Work
HT Rejection
Heat Treatment
Rejection
Quality Control(Meatllography)
HT Re Work
Production(Finishing operation)
Rejection
Quality Control
Re Work
Store
Functions of Laboratories: Metallurgy lab Hardness testing: In case of incoming material, Surface hardness of forgings checked on brinall tester confirming to specified value while after heat treatment in production line this test
involves surface hardness of heat treated components checked in Rockwell tester to specified limit. Traverse Hardness (Depth) is measured by Micro-Vickers Hardness tester Metallographic Analysis: It involves Grain size, Grain flow, Inclusion of Non metallic materials, Heat treatment pattern & required Micro-structure analysis.
Chemical Analysis: Here it is tested chemical composition of material used for forging and other related supplies. Mechanical Lab Calibration of gauges and Measuring instruments
Chemical Analysis Report(Ferrous Alloys) To: Date: Sr # 1 2 3 4 5 6 7 8 Description Grade Required %C %P %S Department: Vendor Name: %Cr %Mg %Mn Remarks
Sampling Plan Lot Number of Samples 2.5% AQL Upto 90 5 D=0 91-150 8 D=0 151-280 13 D=0 281-500 20 D=1 501-1200 23 D=2 1201-3200 50 D=3 3200-Over 50 D=5 AQL=Acceptance quality level. AQL 4% for forging AQL 2.5% for Turned Comp D= Defective Level 4% AQL D=0 D=1 D=2 D=2 D=3 D=5 D=5
Equipment Available: Metallurgical lab: Present: Testers: 1. Brinall Hardness Tester(01) 2. Rockwell Hardness Tester(01) 3. Micro-Hardness Tester with Monitor(01) Machines for surface preparation 1. 2. 3. 4. 5. Belt type rough Grinder(01) Stationary Grinder (04 stations) Rotary grinders & polishers dual (with 8 disc. Dia with & without head unit)(02) Hot mounting press ,pneumatic(01) Microscope with digital camera(01)
Chemical Lab: Glassware, weighing scale, Muffle furnace, Distillation paint, Carbon Sulpher apparatus Other Equipment: 1. Ultrasonic Flaw Detector(01) 2. Coolant Cutoff Machine 12 wheel(with complete re-circulation system)(01) 1. Future: 2. Rockwell Hardness Tester(01) 3. Magnaflux crack detector(01)
4. Cutting Machine Local Mechanical Lab. Present: Involute profile tester(up gradation in progress) Conventional Measuring instruments Conventional & special Gauges(Spline gauges, master gears, comparators etc) Future Roll Tester Universal Measuring machine Machine to measure over pin/ball dia. Inspection Frequencies: In-coming: Forging and Semi-finish components as per sampling plan Production line: As per frequencies defined in Quality plans (as per MF QC plans, inspection of 1 piece carried out in case of Tool change, power failure) Laboratory: Metallographic & chemical analysis: A: Forging: 01 piece out of lot received. 01 piece out of 500 pieces (from one month supply. If lot rejected then next two successive supplies will be checked) B: In-House Heat treated components: Normal frequency is 01 out of 500 pieces Critical components: CW, pinion & cross= as per QC plan
Hardness testing: Applied on each supply @ 5% for incoming and in-house production
WEEK 2
In the third week i was supervised by the MAM ASMA RAHEEM who told me to do the SWOT analysis of the MILLAT EQUIPMENT LIMITED to highlight the internal and external factors.
SWOT ANALYSIS
Strengths
o o o o o Good team work Capability to produce low volumes Environmentally friendly machines carbon eliminators are used Capacity of Technical ability Training and development programs for employees
o o o o o o o o
o o o o o o
Qualitative and standardize material is usage Recycling of oils High level of motivation Awareness to quality Active and young staff Regulation of the rules Strong business relationship with its partners Specific, knowledgeable and experienced employees. Capability to produce low volumes competitively and capture niche markets Presence of world class automotive manufacturers in each segment Availability of low cost human resource OEMs quality standards are largely achievable High growth and demand in the market Good entrepreneurial skills Good mechanical skills CNC, HT, Machining, AGCO machinery, are key feature of MEL.
Opportunities
o One of the best Pakistani company making gears and shafts o We dont have to extensively market our products when we launched our company because we already had a customer in market due to Millat tractors o In house development o Increased product line o High caliber technical strength of employees o Back up support o High quality material from best companies of Pakistan o Potential for high market growth due to wide gap in population to vehicle ratio o Export potential in niche markets o Domestic replacement parts market (if smuggling curtailed) o Global spare parts market of discontinued vehicles o Emerging Afghanistan, Nepal, o Bangladesh, Iraq, Sri Lanka markets o Great potential all over the world for tractors and trailer parts market
Weaknesses
o o o o o o o o
Problems in awareness of quality No internal hiring Not all the employees are experienced and knowledgeable engineers Manufacturing failures in the equipment production Human errors contribute significantly to excessive waste and quality Need of worker empowerment Need to strengthen the HR Need to increase the loyalty and motivation level
problems
o No long term vision or policy o Product design & engineering capabilities constrained due to absence of economies of scale o Lack of Tooling and die manufacturing facilities o Lack of skilled manpower for modern machinery o Lack of well equipped facilities for product testing and research & development o High cost of utilities o High cost of financing and leasing o Availability of raw material especially steel o Absence of membership in any Trade Block e.g., Steel Mills o Too many regulatory & taxation agencies
Threats:
o o o o o o o o o o o o o o A new competitor in the home market Price wars with local competitors A competitor has a new, innovative product or service Competitors has a superior access to distribution channels Taxation is introduced on product and services Routine becomes more standardizes procedures Lack of awareness in customers Poor image of the country Regional conflicts Smuggling, under-invoicing and dumping of auto parts Phasing out of administrative control under WTO regime Continuous depreciation of rupee against top world currencies Curtailment of Gas
WEEK 3
In the third week i was supervised by the MAM ASMA RAHEEM who told me to compare the big 4 competitors companies facilities and product line.
FACILITIES
MS is providing three types of facilities Design Forging Machining
ROLE
Toughness and safety are the hallmarks for the forged components. Our diverse manufacturing program enables us to forge, heat treat and machine products of reasonable complexity through: A variety of forging press lines ranging from 250 to 4000 MT. Through case hardening in temperature controlled salt bath furnaces providing close hardness ranges and better metallographic structures. CNC machining and turning centers which ensure the precision required to produce components in accordance with the technical requirements of the customer's specifications. State of the art inspection and measuring equipment which can satisfy the quality demands placed by the buyers.
PRODUCT RANGE
Products are divided into 6 major categories: Motorcycles Cars/Suvs Agriculture Tractors Off highway axels Industrial Conveyor System/ Fifth Wheels Engine Value Train
1-Motorcycles
This category contains 5 major products Bridge Fork Connecting Rod Crankshaft Folk Shifter
2-Cars/Suvs
Arm Braccio Brake Cam Connecting Rod End Yoke Flange Flange Yoke Hub (Daihatsu) Pitman Arm Right Arm Spring Seat Steering Knuckle Steering knuckle (Suzuki) Suspension Arm Tube Yoke Tube Yoke & End Yoke & Flange Yoke Wheel Hubs
3-Agriculture Tractors
Arm Hyd Lift Assy Dust Sheild Assy Dust Sheild
Cam Shaft Connecting Rod Differential Cross Gear Blank Hub MF Rear Axle Shaft Shifter Fork
FACILITIES
Designing
CAD / CAM Solution CAE / Linear / Non Linear Static & Dynamic Analysis Reverse Engineering
Forging
Forging is a process in which a metal is heated and placed in a die and a compressive force is applied.
Heat treatment
Induction hardening, Hardening & tempering using neutral salt baths, Liquid Carburizing. Stress Relieving
Machining
CNC Turning Centers, CNC Machining Centers CNC Drilling Tapping Centers, Horizontal and Vertical Grinning
PRODUCT RANGE
Tractor parts Massey Ferguson
Crank Shaft Cam Shaft Carrier Unit-Reduction Unit Clutch Assembly Clutch Assembly (18867438M91) Clutch Assembly(<>) Brake Actuator Connecting Rod Tie Rod /Draglink Worm Shaft Oil Pump Knuckle Leveling Box Hydraulic Pump
New Holland /FIAT Tractors Crank Shaft Clutch Assembly Clutch Assembly (5145715) Cam Shaft Gear reduction/driven/PTO Axle Shaft Sleeve Splitter Planetary Housing Connecting Rod Oil Pump Break Actuator Lever Relay Worm Shaft
FACILITIES
Design Centre Machining Tool Room Material Testing Heat Treating Forging Machine Tool Rebuilding
PRODUCT RANGE
PMTF Products range include:
2 CNC MACINES:
CNC Lathe C4N Economical Solution CNC TURNING CENTRE LC3 CNC Milling Machine LN2 for Training Institute Desktop CNC Lathe LC0 for Training Institute Turret Milling Machine LK5N CNC Vertical Machining Center LN7
3 TRANSMISSION:
Gear and Shafts for Agriculture Tractors like Massey Ferguson (MF 240, MF 375),and Fiat (Fiat 480, Fiat 640). Traction Gears and Pinions for Locomotives
Gears for various Industrial applications Components for Bedford Trucks & Buses etc.
5 MISCELLANEOUS:
Gears for various Industrial Applications. Spares for various plants/machinery. Machines / Equipments as per customer's design / requirement. Wind Mill (Upcoming Project
FACILITIES
Heat Treatment is another operation in MEL which include continuous and batch type gas carburizing, gas nitriding and induction hardening facility. Heat treatment equipment also includes tempering furnaces, rotary health Furnaces with endothermic gas generator for controlled atmosphere.
Endo Gas Generator: ENDOTHERMIC gas generator for constant supply of endothermic gas to Gas Carburizing Furnaces Continuous Carburizing Furnaces: Continuous gas carburizing furnaces for hypoid gears and shaft, with double track and computerized control. Firtst of its type in Pakistan. Batch Carburizing Furnaces: 5 batch type sealed quench furnaces for all type of gear, shaft and pinion. Each furnaces has oxygen probing system for controlling surface carbon potential of the components during the process which ensures a high standard of quality. Nitriding: Electrically heated gas nitriding furnace for nitriding of ring gears. Rotary Heath Furnace: Gas fired rotary hearth furnace for reheating of gears in inert atmosphere. Quenching Press: Quenching presses for hypoid and other gears. Induction Hardening: Induction hardening of ring gears and shaft having power range from 35 to 300 KW. Tempering Furnace: Continuous and bath type tempering furnace having temperature range for 0C - 500C. Shot Blasting Machines: Shot blasting machines for gears and shafts. The bed dia of machines ranges from 8 to 10 ft with dust extractor unit. Sand Blasting Machines: Manually operated to clean left over scale by shot blasting in narrow corners. Phosphating Plant: There is a line of phosphating process used for gear of differential casing