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Report on Industrial Orientation
Ruby Iron Workshop
Satyan Shrestha 067 / DME / 621 10 Mar 2013
THAPATHALI ENGINEERING CAMPUS Department of Mechanical Engineering Kathmandu, Nepal
Table of Content
1. Profile of Industry a. Introduction of Ruby Iron Workshop. b. General information. c. Plant layout of Ruby Iron Workshop. d. Organizational structure and administrative set up. e. Working time schedule. f. List of Machineries. 2. Basic features of industry 3. Nature of business 4. Process flow chart 5. Specific technological aspects 6. General problems of the Workshop 7. Suggestions 8. Conclusions
Going through the Syllabus of Mechanical Engineering III/I. We ,the students of Diploma in Mechanical Engineering, Thapathali Campus were provided to visit the Industrial area whose main motto is to be familiar with the various industrial features, to gain various knowledge about different mechanical industrial aspects. This report is based on the orientation at the Ruby Iron Workshop of Patan after observing it and its operation for 8 days i.e. every Wednesday for two months. From this report we can find out the profile of industry including machine layout, profile of the industry personnel, organizational structure and administrative setup of the industry, general problem of the industry and suggestion for the improvement of selected aspect of the problem. It also describes about the service provided by the work shop. The main objective of the industrial orientation is to make the student feel the working difference between the lab environment and that of industry, develop the communication skill and the different aspects of the management and production. This really helps to increase the practical skills, information of technology and meaningful procedure to learn the skills.
This orientation was possible thanks to the cooperation and support of people, who have enabled the student to gain much more than what the scholastic or industrial aspects of the program could have given. The student is grateful to them all, and would like to express his appreciation to the following people: Er. Munshi Pd. Shah, he is an owner and managing director of Ruby Iron workshop, for sharing enthusiastically with his experience in engineering. The student is sincerely, indebted to him for his support and assistance contributing the success of the orientation. Mr. Deepak Pradhan, the student’s supervisor, who has helped in coordinating with the administration stuffs and provide valuable assistance in his logbook and report writing. Department of Mechanical Engineering, Thapathali Engineering Campus for providing references, ideas and support to complete the work.
The student will also like to express his appreciation to the IOE T.U., for assigning Industrial Orientation as a part of the syllabus.
PROFILE OF THE INDUSTRY
Introduction of Ruby Iron Workshop Established in 22nd Bhadra of 2039, Ruby Iron Workshop is located at Patan Industrial Estate, Lagankhel, Lalitpur. Patan Industrial Estate helps for the establishment of Ruby Iron Workshop. Whereas Patan Industrial Estate was established in 12 th mangsir 2020. The total area of Patan Industrial Estate is 124351 square foot for 49 blocks. With the help of Government of India, Patan Industrial Estate was established. So the establishment of Patan Industrial Estate gives the establishment of Ruby Iron Workshop. Ruby Iron Workshop has serviced for 30 years from the date of establishment. This workshop has been able to provide technical service for both national and international clients. This workshop has sufficient assembly shop, machineries, fabrication shop and design facilities for its work. This workshop successfully completes the projects according to the order of clients. The Ruby Iron Workshop selects most of the mechanical works to fulfill the necessities of the clients. This workshop starts the work by using it’s own technology , machineries and its own design. This workshop is small but does the effective works under the guidance of it’s MD. The workers use their technical skills and experience to complete the work. Talking about the success of the industry since the establishment, the workshop has been able to gain national and international clients regularly, under its portfolio. General information Name of company: Ruby Iron Workshop Address: Patan Industrial Estate, Lalitpur, Nepal Establishment date: 2039-05-22 Capital Investment for establishmen: Rs. 2,07,658 (in 2039 B.S.) Total no. of manpower: 6 Telephone no.: 01-5536559 Name of shareholder: Munshi Pd. Shah Name of proprietor: Krishna shah Name of M.D.: Munshi Pd. Shah Name of the Supervisor: Gyan Kumar Maharjan Name of manager: Deepak Pradhan
Plant layout of Ruby Iron Workshop
Assembly Area Store Room
c f e
a - Shearing Machine b - Color Spraying Machine c, g - Arc Welding Machine d - Sheet metal Roller e - Metal Cutter f - Grinder h - Gas Welding Machine i - Drilling Machine j – Pipe bending machine Power Supply
Managing Director’s Office
Organizational Structure & Administrative Setup
Er. Munshi Pd. Shah Managing Director
Gyan Kr. Maharjan Supervisor
Deepak Pradhan Accountant/Manager r
Raj Kapoor Sunwar Helper Surya Lama Helper
Ganesh K.C. Helper Helper
Working Time Schedule Days Sunday – Friday Saturday Office Time 9:00 – 5:00 Holiday
List of Machineries
S.N. 1. 2.
NAME OF MACHINE LATHE MACHINE SHAPING MACHINE GRINDING MACHINE BENCH GRINDER PORTABLE GRINDER DRILLING MACHINE BENCH DRILLING MACHINE PORTABLE DRILLING MACHINE METAL CUTTING MACHINE COLD BITUMEN SPRAYING MACHINE WELDING MACHINE ARC WELDING GAS WELDING
MANUFACTURED IN INDIAN INDIAN
INDIAN CHINESE INDIAN CHINESE INDIAN NEPAL
4. 5. 6.
Explanation 1. Welding Machine 2. Shaper Machine 3. Drill Machine 4. Lathe Machine 5. Grinding Machine
1. WELDING MACHINE : Welding technology is gaining importance in the filed of fabrication, reconditioning of worn parts, and has become principal joining process of numerous metal products of different sizes and shapes. The welded joints gives the strength equal to that of original metal. Welding simply is the process of joining two or more metal pieces by heating them up to the desired temperature with or without the application of pressure and with or without use of filler metal. In Ruby Iron Workshop, there are two types of welding machines as follows : 1) Gas Welding :It is the process of joining two similar types of metal sheet with the help of gas flame. It is generally done with the help of oxyacetylene gas flame. Here welding torch is used to weld metals. The welding metal results when two pieces are heats to a temperature that produces a shared pool of molten metal. The molten pool is generally supplied with additional metal called filler. Filler material depends upon the metal to be welded. In case of gas welding following two welding techniques are to be cares in practice. Gas welding is practiced with LPG gas in the Ruby Iron Workshop. 2) Arc Welding : It is also the process of joining similar metal pieces with the help of fusion of metal as the arc mutually passed over the joint to be welded at certain temperature. Arc welding accomplish with the bare or coated metal electrode that consumed in molten puddle and become parts of the weld metal. Since welding with coated electrode is slow procedure, more rapid welding process is good. 2. SHAPER MACHINE : A shaper machine is a machine tool used for shaping or surfacing metal and other material. Shapers have been largely superseded by milling machines or grinding machines in modern industrial practice. The basic function of a shaper machine is still sound and tooling for them is minimal and very cheap to reproduce. They can be invaluable for jobbing or repair shop where on one or a few pieces are required to be produced and the alternative
methods are costly and too expensive. The mechanically operated machines are simple and robust in construction, making their repair and upkeep easily achievable. The most common use is to machine straight, flat surfaces but with originality and some accessories a wide range of work can be done. Other examples of it’s use are : Keyways in the boss of a pulley or gear can be machined without resorting to a dedicated broaching setup Dovetail slides Internal splines Keyway cutting in blind holes 3. DRILLING MACHINE: It is one of the most important machine tools in a workshop. Although it wa primarily designed to originate a hole, it can perform a number of similar operations. In drilling machine, holes may be drilled quickly and at low cost. The hole is produced by the rotating edge of a cutting tool called as drill that exerts large force on the w/p clamped on the table. Today drilling machine is needed everywhere that to to produce hole in an object. There s one drilling machine in the industry. 4. LATHE MACHINE : Lathe machine is the machine which specially works on cylindrical objects. It is usually used to make machine parts. But we can also do different operation like drilling, threading, facing, turning, etc. in the lathe machine. We can also use different tools for doing different operation like turning, chamfering, grooving, threading, etc. Some lathe may be automatic and some may not. There is one lathe in the workshop. 5. GRINDER MACHINE : Grinding is metal cutting operation performed by means of a rotating abrasive wheel that acts as a tool. This is used to finish workpieces which must show a high surface quality, accuracy of shape and dimension. Most grinding is a finishing operation because it removes comparatively little metal, 0.25 to 0.50mm in the most operations and the accuracy in dimensions is in the order of 0.000025m . Grinding is also done to machine materials which are too hard for other machining method that use
cutting tools. Many different types of grinding machine have now been developed for handling various kinds of work to which the grinding machine have now been developed for handling various kinds of work to which the grinding process is applicable. Grinding is done on surface of almost all shapes and of all kinds. The grinding machines used in the Ruby Iron Workshop are as given below : 1) Portable Grinder : The usual form of portable grinder resembles a portable or electric hand drill with a grinding wheel mounted on the spindle.
BASIC FEATURES OF INDUSTRY
Types of work in the workshop Machine section i. Job related to the lathe machine a. Turning b. Facing c. Threading d. Chamfering e. Parting f. Grooving g. Drilling ii. Job related to shaping machine a. Producing flat surface b. Producing inclined or angular surface c. Producing irregular or composed surface of straight line element d. Producing grooves and key ways Job related to drilling machine a. Drilling Job related to grinding a. cutting off b. removing small amount of metal c. tool edge sharping
Welding section i. job related to welding section a. Arc welding b. Gas welding c. Gas cutting Sheet metal section / Fabrication section Job related to sheet metal a. Folding b. Light sheet rolling
NATURE OF BUSINESS
A. Fabrication products a. Roof trusses for school building & factory shed b. Roofing tent c. Auditorium seats d. Steel railing e. Household goods such as gate, doors, windows, tables, etc. f. Solar water heater g. Plastic pipe die B. Erection a. Wrestling ring b. Poles c. Large trusses d. Water treatment filter & filter tank e. Sewage treatment machine C. Repair and maintenance of different types of machineries a. Repairing the shafts, gears used in machine b. Repairing and maintenance of most of the machine components Note: These are some of the works e
SPECIFIC TECHNOLOGICAL ASPECTS
WASTE DECOMPOSING MACHINE Ruby Iron Workshop has done lots of innovative work till date. One of such project is the Waste Decomposing Machine which was supported by European Union for the locals of Kathmandu. This machine was designed by the managing director of Ruby Iron workshop and was well received by the client. It is used to make small particles of decomposable waste material which is then converted into fertilizer.
This project was a technically challenging project because of its new kind in Nepal. Materials used in it are of steel. Inside it, it has got some fan like blades for rotating the waste evenly and at the bottom of the machine there is steel net and from under there the fire is given to burn the waste. This whole machine runs from a 20 H.P. motor which is connected to the fan like blade from the method of pulley and belt. So when this machine runs on it’s full capacity, it is capable to turn the waste into fertilizers or some usable compound. The selling price of this machine was around NRs. 10, 00, 000. More of these machines have been ordered by the client. WRESTLING RING Among the works that the Ruby Iron Workshop boasts about is the making of Wrestling ring. Under the rough design of Mr. Bharat Bahadur Bishural (Nepal’s first international professional wrestler aka The Himalayan Tiger ), the managing director of Ruby Iron Workshop ( engineered in Machine Designing) designed a state of art design for the wrestling ring. The capital investment for the international standard wrestling ring was NRs.8,00,000. Due to the reputation of Ruby Iron Workshop on the technology, the client ordered the making of international sized 20×20 sq.feet wrestling ring. A different types of technical design was used in the fabrication of the ring due to which it was harder to make similar ring by others such that the client ordered for another ring but due to the constraining workload, the workshop was unable to make another wrestling ring.
GENERAL PROBLEMS OF A WORKSHOP
The student has found that the workers of Ruby Iron Workshop are skillful and experienced in their field of work. But the safety of machine and man is found to be in poor condition, it lacks the proper safety equipments, movable parts of machines are not covered, sparks of cutters affects the working of another worker, etc. Though the workers are skillful and experienced in their field, they
lack the capability to complete the whole work on their own, such that most of all are centric towards the managing director of the workshop. Another problem that the student feels is that the workers are ill-paid such that they are not dedicated to the welfare of the workshop. Though the workshop has ample probability to develop ( as it has gained reputation from national and international clients), the lack of willpower to develop is hindering which is also the reason for the lack of changes in infrastructure.
Seeing the ample probability to develop, for the welfare of the workshop and it’s workers , the student will like to suggest some of the applicable suggestions. Workers must be provided with safety equipments like gloves, glasses, etc. To motivate the workers for the wellbeing of the workshop, at least proper overtime payment must done ( if the increment in salary , regular health checkup , insurance , provident fund, etc is not applicable ). Training must be given to the workers such that they do not have to rely on the managing director of the workshop such that the efficiency of the manpower increases. And, at last, optimism is the path of success.
The industrial orientation, which lasted for nearly six weeks, had come to an end. The program had greatly acquainted the student with the prevailing conduction of industry. In many more ways, the Orientation program has enabled the student to understand the wonders/usefulness of mechanical engineering, its nature as an academic endeavor, various applications in reality and the possibilities of mechanical engineering in the development of the individual and the nation.
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