(AFFILLIATED TO

NEW DELHI)
28/1, KNOWLEDGE
NOIDA 201306

INDUSTRIAL
REPORT

DELHI
TECHNIC
AL
CAMPUS

GGSIP UNIVERSITY,
PARK-III, GREATER

TRAINING

(JUNE-JULY 2016)
ON

AUTOMOTIVE COMPONENTS & ASSEMBLIES

BACHELOR OF TECHNOLOGY
(MECHANICAL AND AUTOMATION ENGINEERING)
AT

RICO AUTO INDUSTRIES

(Delhi - Jaipur Expressway, Gurgaon, Haryana 122001)

SUBMITTED BY

SUBMITTED TO

DEEPAK KUMAR

Mr. NITESH KR AGRHARI

40218007415

(HEAD OF DEPT.)

B.TECH (MAE 2nd yr.)

BATCH 2015-2018

Under the guidance of

Academic Tutor

Industrial Tutor

..

(Designation)

(Designation)

ACKNOWLEDGEMENT
It is always a pleasure to remind the fine people in the Engineering Workshops for their
Sincere guidance I received to uphold my practical as well as theoretical skills in engineering.
It is indeed a great pleasure for me present this Summer Training Report on RICO AUTO
INDUSTRIES as a part of the curriculum of B.Tech. Course MAE (Mechanical and
Automation Engineering).
D.G.M- HR Mr. PRATAP SINGH of the Industrial Training Unit of the Faculty are very
much thanked for allowing me to have my training in Engineering Workshops
First and foremost I would like to extend my sincere thanks to my Guide,
Mr. Rajeev Yadav Dept. of HPDC - Prod. DIE CASTING
Mr. Amrish Bhardwaj Dept. of HPDC - Prod. MACHINE SHOP
Mr. RB Yadav Dept. of HPDC Maintenance
Mr. Pawan Andhana of HPDC Quality
I was privileged to experience a sustained enthusiastic and involved interest from their side.
This fuelled my enthusiasm even further and encouraged me to boldly step into what was
totally dark and unexplored expanse before me.
Finally I apologize all other unnamed who helped me in various ways to have a good
training.

DEEPAK KUMAR
2nd Year Student
DTC, Greater Noida.

PREFACE
Training is important phase of student life. During this the student gets the knowledge of both
theoretical of the subject. Training also impresses students overall approach to life and
enhances his/her confidence to undertake takes which have been done or guided.
My training was at RICO AUTO INDUSTRIES LTD, GURGAON. My training was from
13 June 2016 to 30 July 2016.
RICO is an establishment which supplies components and sub-system assemblies to OEMs.
The following report discusses all the activities, problems and solutions undertaken to
provide high quality casting production at the cheapest rates.
The report rotates about a general process followed to manufacture a component.

TABLE OF CONTENTS

1. Company Profile
1.1
1.2
1.3
1.4
1.5
1.6

History and Milestones

Manufacturing Locations
Customers and theirs Contribution
Product Range
Gauge for Inspection
Vision and Strategies

2. General Process Flow Diagram to manufacture a components

2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8

Storage
Inspection of Aluminum Alloy
Melting of the Aluminum Alloy
Casting Process
Inspection of Casting
Fettling
Machining and Assembly
Packaging and Labelling

Department of MAE (Mechanical and Automation Engineering) Faculty

Members
S No.

Faculty Name

Rank

Mr. Nitesh Kumar Agrhari

Assistant Professor

Mr. Sumit Chawla

Assistant Professor

Mr. Tarun Kandpal

Assistant Professor

Mr. Radha Kant

Assistant Professor

Dr. Dwesh

Assistant Professor

Mr. Sangram Singh

Assistant Professor

Ms. Renu Singh

Assistant Professor

Mr. Sangram Singh

Assistant Professor

1. COMPANY PROFILE

Signature

Rico is a world-class engineering company supplying a wide range of high precision

fully machined aluminum and ferrous components and assemblies to automotive OEMs
across the globe.
Ricos consolidated group total turnover is over US$ 245 Million
Ricos integrated services include design, development, tooling, casting, machining
and assembly across ferrous and aluminum products.

1.1 HISTORY & MILESTONES

1984-86
Rico Auto Incorporated (1984-85) and Commercial Production Started (1986)
First Aluminum High Pressure Die Casting Plant set up in Dharuhera (50 Kms from
IGI Airport
Delhi)
Preferred relationship with Hero Moto Corp and Maruti Suzuki
1990-92
Ferrous Casting & Machining Plant set up in Gurgaon (20 Kms from Delhi, India)
Entered International Market as OEM Supplier to MEC Japan.
1994-96
FCC RICO (50:50) JV formed
Started supplying globally to USA & UK (Eaton, Cummins, GM etc.)
1998-00
Second Aluminum HPDC & Machining Plant set up in Gurgaon
2000-02
Set up full service Engineering, Design & Development function.
Added Customers: Ford, Jaguar, Land Rover
Certified TS 16949, ISO 140001, OHSAS 18001
2002-04
Enhanced Ferrous & Aluminum Capacity
Added Customers: Caterpillar, Honeywell, Detroit Diesel, Volvo
2004-06
R&D Center started
Added Customers: Nissan, Tata, Perkins
2007-09
JV (50:50) with CONTINENTAL GERMANY (Hydraulic Brakes)
JV (50:50) with MAGNA INTERNATIONAL (Oil and water pump)
JV (92.5:7.5) with JINFEI CHINA (Aluminum Alloy Wheels - 2 Wheelers)
Added Customers : Renault, BMW, JATCO, Magna
2010-14
Added new facilities/plant at Bawal, Bhiwadi, Sanand, Chennai & Haridwar

Added Customers : GKN, Toyota, Allison Transmissions, Volkswagen India, Musashi,

Kohler,
Avtec, Bentley
AAN Engineering setup as a Defense Vertical.

1.2 MANUFACTURAING LOCATIONS

7

Gurgaon
Bhiwadi
Haridawar
Chennai
Sanand
Manesar
Dharuhera
Bawal

RICO AUTO INDUSTRIES

Main Entrance

BASIC LAYOUT:

RAW MATERIAL
MATERIAL STORAGE
STORAGE
RAW

FURNACE
(MELTING)
FURNACE
(MELTING)

FOUNDARY SHOP

PAINT SHOP

HPDC SHOP ( HIGH PRESSURE DIE CASTING )

MACHING ROWS
(TURNING, BROACHING
FACING, DRILLING Etc)
ASSEMBLY ROWS
1. WHEEL HUB ASSEMBLY
2. BRAKE PANEL ASSEMBLY
3. CLUTCH ASSEMBLY

QUALITY UNIT
FINAL PRODUCT

ADMINISTRATION
BLOCK

STORAGE

1.3 COUSTOMERS AND CONTRIBUTION

10

1.4 PRODUCT RANG

11

GROUP REVENUE- PRODUCT SEGMENT WISE

PRODUCT RANGE

12

13

1.5 VISION: To be preferred Suppliers to OEMs across the globe.

STRATEGIES
14

 World Class Quality

ISO TS 16949, ISO 14001, OHSAS 18001
Total Productive Maintenance (TPM) & 6 Sigma

Integrated Services
Design, Development & Engineering Services
R&D, Testing & Validation
Tooling & Prototyping
Casting (Aluminum & Ferrous)
Machining & Assembly
Packaging & Logistics

Preferred Supplier
Customer Focused Enterprise
Efficient Account, Program & Launch Management

People
Regular Training & Skill Building
Empowerment & Leadership

Globalization
Global Presence & Scale
Global Teams

Shareholder Value
Focus on Return on Capital Employed

Consistent Dividend Distribution

2. GENERAL PRODESS FLOW DIAGRAM TO

MANUFACTURE A COMPONENT

15

RECEIPT THE
ALUIMIUM ALLOY

INPECTION OF THE
ALUMINIUM ALLOY

STORAGE OF ALUMINIUM
ALLOY

MELTING OF ALUMINIUM
ALLOY

INSPECTION OF THE
MOLTEN METAL

STORAGE OF THE
MOLTEN METAL

HOLD THE MOLTEN

METAL FOR CASTING

CASTING PROCESS

INSPECTION OF CASTING
16

FETTLING OF CASTING

MACHINING

FINAL INSPECTION OF
CASTING

PAINT SHOP

ASSEMBLY

PACKAGING AND
LABELLING

2.1 STORAGE

17

DESPATCH

Storage Facility
The raw material is categorized and stored as depicted above depending on their
grade.

2.2. INSPECTION OF ALUMINIUM ALLOY (Considering case of ADC)

Ni : 0.5% max
Ph : 0.1% max
Mg : 0.3% max
Sn : 0.05% max

Inspection Method: Spectrometer

Inspection Frequency: 1 Sample per Heat

2.3. MELTING OF THE ALUMINIUM ALLOY

The ADC-12 and ADC-14 alloys are melted at 650 to 800 degree Celsius. The returns
including the rejections like runners, risers, casting and machining rejection are also
melted for further processing. They are loaded in a trolley using an electromagnet of 5
Ton capacity. A charging vibrator is used to transfer this material in induction furnace.
Alloy Melting for Ready-made Alloy ADC-12
Melting Temp: 720 +/- 30 degree Celsius
Melt Time: 60 +/- 15 minutes
Heat Preparation and Melting (from Pure Aluminium) ADC-12

Melting Temp:

850 +/- 50 degree Celsius

Melt Time: 90 +/- 15 minutes

Hold Material for Cast
Temp of metal: 640 to 690 Degree Celsius The
chemical composition is checked at every step using spectrometer with frequency
remaining the same, 1 sample per heat.
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2.4. CASTING PROCESS

The main category of casting facility in Gurgaon plant is of High Pressure Die Casting
(HPDC). The plant has a total of 35 HPDC machines. Minimum Capacity: 135 Tonne
Maximum Capacity: 1800 Tonne These machines are mainly procured from the following
manufacturers: Toshiba

2.5. QUALITY CONTROL :

Quality control in the production field is defined as the systematic control of various factor
that affect the quality of the product. It depends upon the raw material, tools, type of labor,
working condition , measuring instruments etc.

INSPECTION :
1. INCOMING INSPECTION :
Dimensional inspection
Surface inspection
Material inspection
2.

IN PROCESS INSPECTION :
RPM of the machine
Tool change frequency
Finished good inspection
Process flow diagram of product

3. FINAL INSPECTION :
The number of pieces of the products are checked on CMM (Coordinate Measuring
Machine) and then filled in the pre delivered inspection report.

2.6. FETTLING PROCESS :

1. First take O.K casting and start fettling.
2. Remove all outer flase.
3. After that face of parting line is cleaned with the help of rough file.
4. Clean of flase of ejection pin.
5. Clean slot hole.
6. After that check the casting and put it in trolley.

19

PROCEDURE OF REPAIRING THE DIE :

1.
2.
3.
4.
5.
6.

Reference shot sample of die are checked visually.

Collect the feedback from log book.
All the inserts and parts of the die washed , cleaned , polished and assembled.
Check the cooling system , rubber pipe , mountings like ejector pin , ejector plate etc.
Polishing of inserts or parts perpendicular to parting line.
Lubrication of all moving die parts and centring with the proper lubricant.

2.7. MACHINING SHOP :

Different types of machine used in machine shop are :

COMPUTER NUMERICAL CONTROL MACHINE ( CNC) :

There are 15 CNC machines in the machine shop. These machines are used to perform
different machining operations.
The CNC works a/c to the program written by the operator. CNC have two or more
programmable directions of motion called axis. An axis can be linear or rotary.
Common linear axis names are X ,Y and Z.
Common rotary axis are A , B & C.
The axis of any CNC machine is required for the purpose of causing the motion needed for the
manufacturing process.

LATHE MACHINE :
There are five lathe machines in the tool room shop.
These all have self centred chucks.

GRINDING MACHINE :
Cylindrical grinding machines are used for surface finishing.

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ELECTRO DISCHARGE MACHING:

24

Electric discharge machining provides an effective manufacturing technique that enables the
production of parts made of special materials with complicated geometry which is difficult to
produce by conventional machining processes. Controlling the process parameters to achieve the
required dimensional accuracy and finish placed this machining operation in a prominent position.
From that reason, electric discharge machining has found broad applications in industry. The
absorbing interest for electric discharge machines has resulted great improvements in EDM
technology. Nowadays, sophisticated electric discharge machines are available for most of
machine shop applications

Basically Electric Discharge Machining (EDM) is a process for eroding and removing material by
transient action of electric sparks on electrically conductive materials. This process is achieved by
applying consecutive spark discharges between charged workpiece and electrode immersed in a
dielectric liquid and separated by a small gap. Usually, localized breakdown of the dielectric
liquid occurs where the local electrical field is highest. Each spark melts and even evaporates a
small amount of material from both electrode and workpiece. Part of this material is removed by
the dielectric fluid and the remaining part resolidifies rapidly on the surfaces of the electrodes.
The net result is that each discharge leaves a small crater on both workpiece and electrode.
Application of consecutive pulses with high frequencies together with the forward movement of
the tool electrode towards the workpiece, results with a form of a complementary shape of the
electrode on the work piece..

25

2.8. PACKAGING AND LABELLING

The components/ assemblies are packed and labelled accordind to customer requirement
and are despatched.

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