DS:596

Roca bathroom Private limited, A-452-454,Phase-7, choupanki, RIICO Indl. Area, Tapukera, Distt. Alwar (Rajasthan) PIN-301707 , INDIA

Internship Report

Submitted by;Design Discipline

IIITDM Jabalpur

Freedom of Thought

Lokesh Verma M.Des 3rd sem 1110403

ABOUT COMPANY
Roca is a group of companies dedicated to the design, manufacture and commercialization of bathroom products addressed to the architecture, construction and interior design sectors. The group has production centres in four continents and some 21,100 direct employees all over the world. Roca is the world leader in the bathroom business, operating in over 135 markets. It also has an area, Roca Cermica, dedicated to the production and commercialization of floor and wall tiling. Roca is a multinational that works in all the world's time zones and communicates in dozens of different l a n g u a g e s a l l o v e r t h e w o r l d . Roca is a fully Spanish-owned company that in recent years has shown extraordinary international expansion based on the acquisition of companies in the sanitary ware sector in various countries around the world. Roca is the world leader in the sanitary ware industry. Roca Group began business in 1917 as Compaa Roca Radiadores S.A.This Company was dedicated exclusively to the manufacture of cast-iron radiators for home heating at its factory in Gav (Barcelona). The company entered the ceramic tiles sector in the 1980s. The acquisition of Cermicas del Foix, which became a subsidiary, was the start of the current Tiles area of business. In 1989 Roca purchased a sanitary ware factory in Portugal. In India, The corporate office is based in Chennai. Roca, Choupanki is the only taps unit of Roca group in India

Design Discipline
IIITDM Jabalpur

Freedom of Thought

PRODUCT FORMATION PROCESS

PROCESS CASTING

CORE MAKING
CASTING GATE CUTTING DECORING

A core is a device used in casting and molding processes to produce internal cavities and reentrant angles. The core is normally a disposable item that is destroyed to get it out of the piece. They are most commonly used in sand casting. The core is made by the Die (core box) made by the cast Iron metal. The machine used for the making of cores is The Automatic Core shooter machine. The sand which is used in making of cores is the mixture of Silica sand, Resin and Hardener. Heating time of die is 40-45 seconds. Sand is filled by the pressure filling process and temperature is 220-230 C.

WORK IN THE PLANT

Design Discipline
IIITDM Jabalpur

Freedom of Thought

PRODUCT FORMATION PROCESS

PROCESS CASTING CORE MAKING

A liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. Here, the GDC (Gravity Die Casting) is used for the production. Brass is used for the making of taps. In an Induction furnace, Brass melts at 9801020C, then it pours into Die and casting is done. Just before the pouring, die immersed in graphite solution for better flow of metal in die.

CASTING
GATE CUTTING DECORING

WORK IN THE PLANT

Design Discipline
IIITDM Jabalpur

Freedom of Thought

PRODUCT FORMATION PROCESS

PROCESS CASTING CORE MAKING CASTING

After the casting process, cooled piece is ready for the gate cutting. Gate cutting is the process in which the gate connected to the piece is cut.

GATE CUTTING
DECORING

WORK IN THE PLANT

Design Discipline
IIITDM Jabalpur

Freedom of Thought

PRODUCT FORMATION PROCESS

PROCESS CASTING CORE MAKING CASTING GATE CUTTING

In decoring process the core sand is removed from the cast product. Decoring process is done by the Automatic Decoring machine.

DECORING

WORK IN THE PLANT

Design Discipline
IIITDM Jabalpur

Freedom of Thought

PRODUCT FORMATION PROCESS

PROCESS Boring is the process of enlarging a hole that has already been drilled (or cast). MACHINING BORING AND FACING THREADING LEAKAGE TEST GRINDING BUFFING INSPECTION AND QUANTITY CHECK

Facing is part of the turning process. It involves moving the cutting tool at right angles to the axis of rotation of the rotating piece. These process are done on both outlet and inlet side of the piece as required by the workpiece and are done by capstan lathe or CNC VMC machine.

WORK IN THE PLANT

Design Discipline
IIITDM Jabalpur

Freedom of Thought

PRODUCT FORMATION PROCESS

PROCESS Threading is the process of creating a screw thread. MACHINING

Threading is done on the capstan lathe or CNC VMC machine.

BORING AND FACING THREADING LEAKAGE TEST GRINDING BUFFING INSPECTION AND QUANTITY CHECK

WORK IN THE PLANT

Design Discipline
IIITDM Jabalpur

Freedom of Thought

PRODUCT FORMATION PROCESS

PROCESS Leakage testing is process in which the leakage of the piece is measure by the MACHINING water and air flow. BORING AND FACING THREADING LEAKAGE TEST GRINDING BUFFING INSPECTION AND QUANTITY CHECK

Air flow is provided by the pneumatic leak testing machine and water flow is provided by a special Washing machine.

WORK IN THE PLANT

Design Discipline
IIITDM Jabalpur

Freedom of Thought

PRODUCT FORMATION PROCESS

PROCESS Grinding is an abrasive machining process that uses a grinding belt as the cutting MACHINING tool. Grinding is done in two part, First is rough grinding BORING AND Second is finishing grinding. FACING THREADING LEAKAGE TEST GRINDING BUFFING INSPECTION AND QUANTITY CHECK

The aim of grinding is to give a smooth surface to the material

WORK IN THE PLANT

Design Discipline
IIITDM Jabalpur

Freedom of Thought

PRODUCT FORMATION PROCESS

PROCESS Polishing or buffing are finishing processes for smoothing a workpiece's surface MACHINING using an abrasive and a work wheel. BORING AND FACING THREADING LEAKAGE TEST GRINDING BUFFING INSPECTION AND QUANTITY CHECK

Buffing is also done in two parts, First is rough buffing Second is finish buffing Rough buffing is done by the fully automatic buffing or polishing machine and finish buffing is done by the manual machine

WORK IN THE PLANT

Design Discipline
IIITDM Jabalpur

Freedom of Thought

PRODUCT FORMATION PROCESS

PROCESS In this section, the inspection is done to check that the piece is ready for MACHINING Electroplating or not. BORING AND FACING THREADING LEAKAGE TEST GRINDING BUFFING INSPECTION AND QUANTITY CHECK

The rejected pieces polished again, and again inspection is done on them. In quantity check, the quantity is checked that how many pieces are OK and sending to the Electroplating.

WORK IN THE PLANT

Design Discipline
IIITDM Jabalpur

Freedom of Thought

PRODUCT FORMATION PROCESS

ELECTROPLATING (45min process)

After Grinding and polishing, piece is ready for the electroplating process. The first step in electroplating process is washing.

WASHING
NICKEL PLATING

Washing start from the soap cleaning. Pieces are taken to soap solution for 3min and then go to hot water bath. After that, workpieces go to ultrasonic cleaner And remain in solution for 3min. And then workpieces go to clean water and wash three times in different three tanks. After this, pieces go to the acid solution (H2SO4) whose density is 8-10gm/liter. Then again, pieces go to water cleaning in two different tanks.

WORK IN THE PLANT

Design Discipline
IIITDM Jabalpur

Freedom of Thought

PRODUCT FORMATION PROCESS

ELECTROPLATING

WASHING NICKEL PLATING

Nickel electroplating is a technique of electroplating a thin layer of nickel onto a metal object. The nickel layer can be decorative, provide corrosion resistance and wear resistance. Nickel plating process is of 16min. and the electricity used in this process is of 8V and 1600A. After this, pieces go to D.M(demineralized) water for cleaning. Then R.O water for cleaning and then go to SOFT water for cleaning.

WORK IN THE PLANT

Design Discipline
IIITDM Jabalpur

Freedom of Thought

PRODUCT FORMATION PROCESS

PROCESS ASSEMBLY After Electroplating, taps send to the assembly lines. Assembling taps start from BOP(bought out parts) receiving from the store INNER HEAD FITMENT LASER MARKING LEAK TEST HANDLE AND TIKKI FITMENT PACKAGING

Inner head is that part by which we can assume that whole mechanism of the Tap is concentrated So, in this step of assembly, inner head is fitted manually

WORK IN THE PLANT

Design Discipline
IIITDM Jabalpur

Freedom of Thought

PRODUCT FORMATION PROCESS

PROCESS ASSEMBLY Laser marking is the practice of using lasers to engrave or mark an object. INNER HEAD FITMENT LASER MARKING LEAK TEST HANDLE AND TIKKI FITMENT PACKAGING

Here, laser marking is used for writing the logo of the company on the tikki(small plate) of knob.

WORK IN THE PLANT

Design Discipline
IIITDM Jabalpur

Freedom of Thought

PRODUCT FORMATION PROCESS

PROCESS ASSEMBLY On the assembly line, leak testing is done by the leak testing machine on which leak is tested by pressure of air applying in Tap and checks leakage of Tap and show that, piece is ok or not. INNER HEAD FITMENT LASER MARKING LEAK TEST HANDLE AND TIKKI FITMENT PACKAGING

WORK IN THE PLANT

Design Discipline
IIITDM Jabalpur

Freedom of Thought

PRODUCT FORMATION PROCESS

PROCESS ASSEMBLY In this section of assembly, handle or knob of workpiece or tap is fitted. Tikki is a part of Handle and it is also fit in this part of assembly INNER HEAD FITMENT LASER MARKING LEAK TEST HANDLE AND TIKKI FITMENT PACKAGING

It is the last process of assembly. In this, piece is packaged into the box and send to the warehouse for sale

WORK IN THE PLANT

Design Discipline
IIITDM Jabalpur

Freedom of Thought

STUDY ON.....STYLING
A CASE STUDY ON COMPANY

1.

GROHE

Company follow three design styles 1. Cosmopolitan - Influenced by the Modern architecture - Fuse bold geometric shapes with advance engineering

2. Contemporary Industry Sanitary Fittings - Influenced by unite timeless design Headquarters Dsseldorf, Germany - Practical features to create an inviting Number of locations 130 national representatives, 23 bathroom distribution companies (2011) Area served Worldwide 3. Authentic Website www.grohe.com - Influenced by the Classic architecture, traditional interiors 2. 3.

Design Discipline
IIITDM Jabalpur

Freedom of Thought

STUDY ON.....STYLING
ANALYSIS ON THE GEOMETRIC FORMS

PRODUCTS
MOBILE PHONE LAPTOP

Design Discipline
IIITDM Jabalpur

Freedom of Thought

STUDY ON.....STYLING
ANALYSIS ON THE GEOMETRIC FORMS

PRODUCTS
MOBILE PHONE LAPTOP

Design Discipline
IIITDM Jabalpur

Freedom of Thought

STUDY ON.....STYLING

TIMELINE ANALYSIS ON STYLING

Design Discipline
IIITDM Jabalpur

Freedom of Thought

STUDY ON.....STYLING

TIMELINE ANALYSIS ON STYLING

Design Discipline
IIITDM Jabalpur

Freedom of Thought

STUDY ON.....STYLING

TIMELINE ANALYSIS ON STYLING

Design Discipline
IIITDM Jabalpur

Freedom of Thought

PROJECT WORK

PROJECT 1: TAP DESIGN

Design Discipline
IIITDM Jabalpur

Concepts : Stage1

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PROJECT WORK

PROJECT 1: TAP DESIGN

Design Discipline
IIITDM Jabalpur

Concepts : Stage1

Freedom of Thought

PROJECT WORK

PROJECT 1: TAP DESIGN

Design Discipline
IIITDM Jabalpur

Concepts : Stage 2

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PROJECT WORK

PROJECT 1: TAP DESIGN

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IIITDM Jabalpur

Concepts : Stage 3

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PROJECT WORK

80mm X 80mm Area for designing a knob.

PROJECT 2: KNOB DESIGN

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IIITDM Jabalpur

Concepts

Freedom of Thought

PROJECT WORK

PROJECT 2: KNOB DESIGN

Design Discipline
IIITDM Jabalpur

Concepts

Freedom of Thought

PROJECT WORK

PROJECT 2: KNOB DESIGN

Design Discipline
IIITDM Jabalpur

Concepts

Freedom of Thought

PROJECT WORK

PROJECT 2: KNOB DESIGN

Design Discipline
IIITDM Jabalpur

Final concept

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PROJECT WORK

PROJECT 2: KNOB DESIGN

Design Discipline
IIITDM Jabalpur

Rendering

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Thank you

Design Discipline
IIITDM Jabalpur

Freedom of Thought