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COMPANY PROFILE

Shriram piston & Ltd. (Sprl) is one of the largest and most sophisticated
manufacturers of precision automobile components i.e. pistons,piston
Rings,piston pins and engine valves in india.
The products are sold under brand name USHA/SPR in the markets.
The plant has been recognized as one of the most modern and
sophisticated plants in north india in the field of automobile.
Export sales are of 170cr. The year 2013-2014.
Total area covered by the factory is 27 acres.
The factory has manufacturing facilities for piston,ring,pins and engine
valves.
Total strength of the company is 5230nos.consisting of officers,staff, and
workers.
The turnover/sales for the year 2013-2014 is Rs.1200cr.
The company is exporting to more than 35 countries.



PROUCTION CAPCITY OF PLANT

Piston : 14.0 million per year actual production in2013-2014
Pin : 11.3 million per year -do-
Rings : 70.7 million per year -do-
Engine Valves : 27.02 million per year -do-

ACHIEVEMENT IN TERMS OF QUALITY



SPR received the ISO -9001 certificate from RWTUV,Germany in
1994.Technology from the collaborators was supplemented with in-
house efforts and by implementing world-class practices.
The company received QS-9000 certificate from TUV ,Germany in the
year 1999.
The company received ISO-14001 certificate in the year 2001.
SPR received the the TS-16949 Certificate in the year 2003.
The company received OHSAS-18001 certificate in the year 2003.
Best foundry awards from institute of Indian Foundrymen in the year
2003.
Green rating award by Cll,U.P.Pollution board & World bank in 2004.
The company received TPM Excellence award in the year 2004.
The company received recognition award by Government of india for
in House R.&D.
RECEIVED Star Performer (IC Piston Engine & parts ) award from
Engineering export promotion council (EEPC)india.
Received silver award-Quality & Bronze Award-spares from HONDA
Siel Card (I)Ltd. In 2007.
SPRL has received the best Vender Awards from Maruti Suzuki for 4
consecutive times ,best supplier performance awards from Tata
Cummins Ltd for 3 consecutive years.And has self certified ststus
with most of the OEMs.
Excellence award in productivity by ACMA in 2007-08.
Excellence award in Quality by Honda Scooters and Moter Cycles
Limited.
Excellence award in Quality by ACMA in 2007-08.
Excellence award in Manufaturing Excellence award by ACMA in
2007-08.




TECHNICAL COLLABORATION

.M/S. Kolbenschmidt,Germany to produce piston
M/S. Riken Corporation,Japan for piston rings
M/S. Fuji Oozx,japan for the manufacture of Engine valves
M/S. Honda Foundry,Japan for Technical support
The company supplies its products to several Original
Equipment Manufactures(OEMs)
Such as Defense vehicle factories like Ashok Leyland,Tata
Cummins ,Tata Motors Maruti Suzuki, Mahindr
&Mahindra,Tafe Tractors,,SML(Swaraj),kirloskar oil
Engines,Bajaj Auto,Honda Siel Cars, Sundram Claylon,Honda
Scooter.
Shriram Piston and Rings Ltd. Quality is an integral part of
whatever we do, which is reflected in the companys Quality
policy.










TPM:-TOTAL PRODUCTIVITY
MANAGEMENT

T.P.M MEANS

T:-TOTAL (INCLUDINGE OF ALL EMPLOYEES)
P:-PRODUCTIVE (RUNING THE M/C WITH FULL EFFICENCY)
M:-MAINTENCE

T:-TOTAL
Maximization of Total efficiency.
Entire life cycle of production system.
Cover all departments.
Participation of all Employees.

P:-PRODUCTIVE
Pursue the maximization of efficiency of the
production system by making all losses zero.
Zero Accidents, Zero defects, Zero Breakdowns are
real meaning of maximization of efficiency.
M:-MAINTENANCE
Maintenance Cover the entire life cycle of the
production system. IT refers to maintenance of
individual process, plant& Production management
systems.
TPM-POLICY
Zero failure , ZERO DEEFECT, ZERO ACCIDENT,
Through introduction of TPM with participation.
Maximum profit through improvement of overall
equipment efficiency, production in cost & increase in
customer satisfaction.


T.P.M.PILLERS

1:-AUTONOMOUS MAINTENANCE (JISHU HOZEN)
2 :-FOCUSSED IMPROVEMENT (KOBETSU KAIZEN)
3 :-PLANNED MAINTENANCE
4 :-INTEGRATED OFFICE T.P.M
5:-EDUCATION & TRANING
6:-INITIAL CONTROL (NEW EQUIPMENTS)
7:-SAFETY, HEALTH & ENVIORNMENT
8:-R&D NEW PRODUCT
9:-INFORMATION MANAGEMENT
10:-LOGISTIC
11:-MARKETING NETWORK



OPTIMIZATION OF RETURN ON
TINVESTIMENT BY.
Continous improvement.
Technology development.
Organizational and Personnel development.
Cost reduction efforts.
Effective use of all resources.


5-S POLICY

THE 5-S PRACTICE IS A TECHNIQUE USED TO ESTABLISH AND MAINTAIN QUALITY
& ENVIRONMENT IN AN ORGANIZATION
1. S (SERI) :- SORTING /SEGREGATION
2. S (SEITON) :- SYSTEMATIC ARRANGEMENT
3. S (SEISO) :- CLEANING/CLEANLINESS/NEATNESS
4. S (SEIKETSU) :-STANDADRDISATION
5. S (SHITSUKE) :- SELF DISCIPLINE / HABIT FORMATION

TOTAL CUTOMER SATISFACTION THROUG
QUALITYMANAGEMENT AND CONTINUOUS IMPROVEMENT

Organization which is sensitive & interactive to needs of costomer.
Work to international norms of quality & Management.
The company has successfully practiced the best work ethics &
technology along with the TPM& kaizen approach &harmony
through teamwork.
Continuous upgrading of quality &process to meet changing of
customer.


PROJECT:-Implementation of Gap
alignment M/c before heat treatment

INTRODUCTION

PISTON RING:- A PISTON RING is a split ring that fits into a groove on the
outer diameter of a piston in a reciprocating engine such as an internal
combustion engine or steam engine.

FUNCTION OF PISTON RING:-The three main function of piston ring
in reciprocating engines are:
1: Sealing the combustion chamber so that there is no transfer of gases from the
combustion chamber to the crank.
2: Supporting heat transfer from the piston to the cylinder wall.
3: Regulating engine oil consumption.
The gap in the piston ring compreses to a few thousandths of an inch when inside
the cylinder bore.

RING NOMENCLATURE:-There are two nomenclature of piston
ring:

1:- RING NOMENCLATURE(COMPRESSOR RING)


2:-RING NOMENCLATURE(OIL RING)





PISTON RING CLASSIFICATION

PISTON RING
1:-COMPRESSION :- (A) PLAIN COMP.
(B) CHROME COMP.

2:-OIL:-(A) PLAIN OIL
(B)OIL CROME


PLAIN COMP. CROME COMP
Taper comp 1: Taper crome
Plain comp 2:Chrome comp
Plain Napier 3:Crome comp(Sharpe edge)
KS comp 4: Reverse torsion
Taper Napier 5: KS crome
Interupted cut


PLAIN OIL OIL CROME
Plain oil 1: High tension crome ring
Parallel bevel oil 2: I.D plated high tension crome ring
Cross bevel oil 3:twin crome
Plain high tension



-








RING PROCESS SEQUENCE:-Ring in foundry shop the ring first
produce in the foundary shop from the melton cast iron in the from of rough
ring.which dia and finish is very far from the actual ring.

1.SEMI FINISH SIDE FACE GRINDING
When the ring comes in the ring plant the first process which does on the ring
is semi finish side face grinding in the process in grinding machine the face of
the ring is ground upto axial height 0.83(+.015,-.015)
2.WASH IN SOLVENT
After grinding of ring, ring is washed in solvent , for the remove rust and dirt.
3.HEAT TREATMENT PROCESS
This is the process which follow after second step.this is very important process
because in this process we change the molecular structure of the rings and
improve the needed quality of the ring such as reduce the brittleness and increase
strength also in heat treatment process the ring become totally flate due to heat.
This process held on 530 centigate temperature half hour and then leave for cool
in air.
4.FINISH SIDE FACE GRINDING
After heat treatment the ring sends to disckas machine ,in this machine the side
face of the ring is get final finish upto axial height.8(-.01,-.2)
5.WASH SOLVENT
Again the rings are washed in the solvent as the after first process
6.DEMAGNETISETION
When the rings passed through the grinding machine due to friction it get
magnetic properties due to which rust and dirt of the iron are stuck of its
surface.which creates problem,like destroy the finish of surface . therefore its is
necessary to remove this properties.so for remove this process the ring are held
on demagnetize machine for few minutes under which counter magnetic force
apply on its and remove magnetize properties.
7.CAM TURNING
The shape of the ring in not totally circular instead of it is oval shape which is
produce in cam turning machine where we produce the value of
Cam% :14
E-Value :67.54
T-So-Dia :94.32
D-150-Dia :93.97
Its is the most important process of the ring making because the next step
depend on it ,if the ovality on the ring not produce then it will not suitable for
piston.
8.GAP CUTTING
In this process the ring cut from the one side ,which is known as gap. The gap is
cut in the ring for make it flexible ,because when the ring is fit in the piston and
piston move the due to flexibility it make contact with linear. And the close gap
cut is equal to D+.05(+.1,-.1)



9.WASH IN SOLVENT
10.Demagnetization upto 15 gauss max
11.TAPER TURNING




In this process we work on the parameter of the ring like tool pitch,spacer
width,taper angle, radial thickness and closed gap. This is done on the CNC
machine and an important process because it reduce the surface of contact b/w
the ring and linear due to which the friction recdue.and save the work energy.
Mostly in this process the space width tolerance as +.1 to -.1 and taper angle is
1deg55, closegap is equally to (d+.2).