INDUSTRIAL TRAINING REPORT

(B-Tech)

Name of company: Federal Mogul Goetze India Limited.
Address: Rajpura road, Bahdurgarh, Patiala,
Punjab - 147001
Department: Tool room.
Duration of training: Six week.


FEDERAL MOGUL GOETZE INDIA LIMITED

TECHNICAL TRAINER SUBMITTED BY
Signature: Parminder Singh
Name: Mr Silas Singh Mechanical
Seal: 11115273



ACKNOWLEDGEMENT


Before getting into thick of things I would like to point that it was a great
pleasure and privilege for me as a mechanical engineering student to have got
the opportunity of undergoing training at FEDERAL MOGUL GOEZE INDIA
LIMITED for a period of six weeks. I would like express our unfeigned
appreciation to MR. MANJEET SINGH LANDAR and all other authorities of our
college for creating the opportunity to undergo six weeks industrial training.
I am extremely thankful to MR. SILAS SINGH, who were instrumental in
creating an opportunity and under their able guidance it was possible to
understand all the things in this esteemed organization.
I am, sue that knowledge and information that I have gained during this period
would be of immense value for the growth in the field of production,
industrial, management and safety.


PARMINDER SINGH
11115273
B-Tech, ME
MAHARISHI MARKENDESHWAR UNIVERSITY
MULLANA, AMBALA.






QUALITY POLICY

Federal Mogul power train is committed to providing
products and services that meet or exceed our customers
requirements by maintaining a management system
compliant with ISOI TS 16949, ISO 9001, or AS/EN/JISQ
9100.
We accomplish this by fostering commitment training
and excellence in our people and continual improvement in
our products and processes

















ENVIRONMENTAL HEALTH AND SAFETY


FMGIL Patiala plant is committed to clean & conserve environment for
sustainable development, to provide safe & healthy work environment to their
employee, visitors, contractors and customers in relation to its operations &
associated activities, through prevention of occupational injuries, illness &
continual improvement of work environment .We commit for the guiding
principles.

Conserve resource, reduce wastage and introduce technology, processes
and materials that are environment friendly and safe.

Implementation of Aspects, Impacts, Hazard identification & Risk
assessment.

Comply will all be applicable.


Raising Environment, Occupational health & Safety awareness through
continual, training.

Establish & maintain Emergency management plan.

Audit & monitoring for Assessing EHS continual improvement.



TOTAL PRODUCTION MAINTENANCE


We at FMGIL Patiala to improve operations to achieve high
efficiency with total employee participation through TPM
(Total production Maintenance) in a safe working
environment which makes us competitive in business by
enhancing productivity, Quality and reducing cost.


Together we excel











5(S) PLAN


1
st
(S): SORT
Clearly distinguish needed items and eliminate the later

2
nd
(S): SET IN ORDER
Arrange the necessary item in a proper order so that they can be easily picked
up for use.

3
rd
(S): SHINE
Clean your workplace completely so that there is no dust anywhere.

4
rth
(S): STANDARIZE
Maintaining a high standard of housekeeping at all times .

5
th
(S): SUSTAIN
Train people to follow good housekeeping discipline independently.





5 (S) ACTIVITY

THREE- MINUTE
Check your own clothing.
Check for any leakage or droppage and pick up any parts, trash on the
floor.
Wipe the temperature tables .Position the marking and other important
places.
Wipe up any water oil or whatever that may have spilled or leaked.
Reliably any things is out of plan


FIVE- MINUTE
Clean up the plates and label and make sure they are clearly legible.
Wipe the main places on the machining with ray.
Make sure all of the bits and tools are where they should be.
Get rid of anything that is not needed there.

TEN-MINUTE
Wipe the key parts and other places on the machining with ray
Fix any labels that might be coming off.
Clean the floor.
Get rid of trash in the trash bins
Check the labels, instructions and oil inlets and for anything that is
amiss.













TOOL ROOM










LABOUR DATA OF TOOL ROOM

HEAD OF DEPARTMENT: Mr. Arvind Ghai

INCHARGE: Mr. Daya Singh

SHIFT SUPERVISOR: 2

STAFF: 1

APPRENTIX: 3

CASUAL LABOUR: 3

TOTAL EMLOYEES: 40

AVERAGE QUALIFICATION OF WORKERS: ITI






TOOL ROOM MOTO


ALL PRODUCTION SHOPS ARE OUR CUSTOMERS
THEIR SATISFACTION IS OUR CONTINUAL TARGET














TOOL ROOM ACTIVITIES

PRODUCTION TOOLING FOR ALL SHOPS

Tool room provides service to various departments. In tool room
same copy of machine can be created .So the tools which are used in
other departments are manufactured by Tool room. In tool room the
factory makes four types of tools.

(1) Production tools.
(2) Cutting tools.
(3) Machine tools.
(4) Maintenance tools.


PRODUCTION TOOLS:
The production tools operating resources that are required to
perform an activity an activity and can be used repeatedly. For
example Production tools include jigs and fixture, measurements
instruments.
CUTTING TOOLS:
The cutting devices used in machining work pieces on regular turret
and vertical lathes, boring and slotting machines, planers, gear


shaping machines and special machine tools. It consists of a shank
compressing a head with the cutting element and a holder that
secures the cutter to the machine tool.
MACHINE TOOLS:
Machine jobs are the jobs which are the parts or accessories of the
machines which are used in factory like gears, pulleys etc.

MAINTAINANANCE TOOLS:
The activities required or undertaken to conserve as nearly and as
long, as possible the original condition of a machine or resource
while compensating for normal wear and tear, so the tools used for
maintenance of machines are known as machine tools.
MISCELLANEOUS JOBS:
The jobs which are not production or not machine but repaired by
tool room are known as miscellaneous jobs.











MODEL PLATES


The model is made of cast iron. It is hard and heavy in handling. In
construction of model plate first of all thickness is maintained
according to the drawing. The model plate is kept firstly on shaper
machine. After getting the desired thickness that is from 20mm to
25mm the plate is kept on boring machine to make plate right angled
from all sides.
Next step is to do marking of model plates, this marking is done so
that no air gaps should remain in model plates. Marking is done by
using 90 degree V- shaped cutter and it is done with more efficiency
and has good surface finish. When rings are made with model plates
there is a pressure exerted air gaps can be formed. This marking
prevents the formation of air gaps from the ring and can reduce the
life of ring.










SAMPLE PISTON DIES

Pistons are made in piston foundry of die-casting. Die-casting is a metal casting
process that is characterized by forcing molten metal under high pressure into
a mold cavity. The mold cavity is created using two hardened tool steel dies
which have been machined into shape and work similarly to an infection mold
during the process. Most die castings are made from ferrous metals specially
zinc, copper, aluminium, magnesium, lead, pewter, and tin based alloys.
Depending on the type of metal being cast, a hot or cold chamfer machine is
used.
The casting equipment and the metal dies represent large capital costs and this
tends to limit the processes to high volume production manufacture of parts
using die casting is relatively simple, involving only four main steps , which
keeps the medium sized casting, which is why die casting produces more
casting than other casting process . Die casting are characterized by a very
good surface finish (by casting standard) and dimensional accuracy.
Two variants are pore-free die casting which is used to eliminate gas porosity
defects and direct injection die casting, which is used with zinc casting to
reduce scrap and increase yield.










PROCESS FLOW CHART









RECEIVE JOB
CARD
STUDY DRAWING/
REQUIRINMENT
ASSES MAETRIAL
AND TOOLING
PLAN PROCESS

*TURNING
*MILLING
*GRINDING
*FITTING
INSPECTION
DELIVERY TO
SHOPS



TOOL ROOM SERVICE PROVIDE TO SHOP

DEPARTMENTS

Piston Machine Shop (Domestic).

Piston Machine Shop (Exports).

Piston Machine Shop New (LVD plant).

Piston Foundry.

Piston Foundry(Export)

Pin Plant.

Heat Treatment Shop.

Ring Packing.

Piston Packing.

Ring Machine Shop.







MEASURING INSTRUMENTS

Vernier calliper

Dial gauge.

Dial vernier calliper

Digital vernier calliper.

Lever dial gauge.

Micrometer.

Pitch gauge.

Tri-scale

Steel scale.








CUTTING TOOLS


Module cutter

DP cutter

Slitting cutter

Drilling cutter

Dove tail cutter

Right hand tool

Boring tool

Knurling tool

Filling tool

End mill







VARIOUS SECTIONS IN TOOL ROOM

(1) DIE SECTION


(2) CNC SECTION


(3) MILLING SECTION


(4) DIE SECTION


(5) TOOL AND CUTTER GRINDING SECTION


(6) FITTING SECTION








VARIOUS MACHINE IN TOOL ROOM


(1) DIE SECTION: Core and Outer mold etc


(2) CNC SECTION: Milling M/C 2 HMT FN2U,Filling, Tapping,
Rimming, Pedestal grinder, Tool Sharpening, Lapping etc

(3) MILLING SECTION: Milling FN3 Vertical, Milling FN2
Horizontal, Copying milling, EDM etc

(4) TURNING SECTION: Centre lathe, CAM turning etc

(5) TOOL AND CUTTER GRINDING SECTION: Tool & cutter,
sharping machine, bench grinding tool and lapping
machine etc


(6) FITTING SECTION: Drill machine etc







BIBLOGRAPHY


I. Daily Diary

II. Notes

III. Machine Manual

IV. Drawing

V. Shop Floor

Technical guidance by:
MR. SILAS SINGH