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LAYOUT CHANGE & SKILL CENTER
SUBMITTED BY:RAJKUMAR
ME(Auto) 7th Sem.
ROLL NO. – 13MEBLAO18
SHOOLINI UNIVERSITY

Contents

1.Decleration……………………………………………………………………………………3
2.Acknowledgement…………………………………………………………………………….4
3. Abrastract…………………………………………………………………………………….5
4.Company overview…………………………………………………………………………6-14
5.Project Detail
6. Project-01................................................................................................................................................
7. Project-02................................................................................................................................................
8. Project-03................................................................................................................................................
9. Project-04................................................................................................................................................
10. References……………………………………………………………………………..

DECLARATION
I

hereby

declare

that

TRANSFORMATION

the
&

project

MADE

work

entitled

DEXTERITY

SHOP

FLOOR

CENTER

(SKILL

CENTER) it is record of my own work carried out at MAHLE FILTERS
SYSTEMS INDIA LIMITED as requirements of two months project semester
for the award of degree of B-tech. (ME, Automobile), Shoolini University, Solan,
under the guidance of Mr. KAMAL PANDA during 8th June 2015 To 8th Aug
2015.

DATE:- ______________

RAJKUMAR
13MEBLA018

Certified that the above statement made by the student is correct to the best of our
knowledge and belief.

Mr. Munish Sethi
(Mechanical department)

Mr. KAMAL PANDA
(PRODUCTION DEPTT.)

Company Overview Mahle filter system is the largest manufacturer and exporter of Automotive and filtration solution for the automotive filtration. . India. railways and aviation of India a joint venture between MAHLE Filter System Gmbh Germany Globe leader in Engine Systems and Filtration Solutions and Anand.

These include the area of large engines. The industry business unit bundles the MAHLE Group’s industrial activities. the aerospace industry. valve train systems . Detroit .000 employees work at over 100 production plants and 7 research and development centers in Stuttgart. rank amongst the top three system suppliers worldwide system for piston systems. industrial filtration as well as cooling and air conditioning systems for Railway and special vehicles.400 development engineers’ technicians are working forward-looking concepts. Approximately 48. construction and agriculture machinery. MAHLE has local presence in all major world market. The aftermarket business unit serves the independent spare part market with MAHLE products in OE quality . ships.Mahle Filter System GMBH:The Mahle unit with its two business unit Engine System and component as well as and Filtration and Engine peripherals . and liquid management systems. product and system for the ongoing development of vehicle power trains.Tokyo and Shanghai. buses. Northampton. and stationary large engine for power generation. Around the world.cylender components. approximately 2.air management system.

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Anand Group: Anand group has been operating in India since 1961. has made Anand the large conglomerate that it is today. The Anand group is present almost in every part of the world. Anand is a group of 19 companies that have been set up over a period spanning five decades. . It is no mean achievement that ever Anand Company is either a market leader or rank among the top three in the country in its field of operation. Integrating this multifarious units an operation with a drive world force spread across 50 locations into a power full unified entity.

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The product range is highlighted below.The khandsa plants manufacture air filters. . fuel filters and oil filters.

. OEM and After Market Supplier: With the widest range of automotive and industrial filters in the country. Pune (Maharashtra). MAHLE is the principal supplier to both the OEM segment and the Aftermarket with a sizeable presence in overseas markets as well. new filter geometries. as the leading Automotive Filter supplier in the country has consistently invested in research & development to develop filtration media. constructions and systems.Leading Automotive Filter Supplier: MAHLE Filter Systems India. The company has four state-of-art filter plants. the largest of its kind in the country. The Khandsa facility is equipped with an ultramodern filter paper impregnation plant. Khandsa (Haryana) and Chennai (Tamil Nadu). Market Leading Brands in the After Market: ‘Purolator’ & ‘MAHLE’: The company is the largest in its segment in the Aftermarket as well and its products are marketed under the brands – ‘MAHLE’ and ‘Purolator’. USA and Anand. set up as Joint Venture in 1964 between Purolator. Originally known as ‘Purolator India Limited: The company was originally known as Purolator India Limited. located at Parwanoo (Himachal Pradesh). India’s Leading Exporter. MAHLE Filter Systems India was established in 2005.

Diesel water separation media. Pressure sensors for air filtration. Development and Installation of Fuel rig.Major R&D Achievements at MAHLE Filter Systems India:               Involved in several research projects like the development of a high efficiency multi-layered filter media using nano fibers for use in fuel filters of commercial diesel vehicles. Innovative design of a heavy duty air filter element with minimum metal parts New non-woven air filter media for passenger cars with increased service life Design. Oil Filter Systems for turbo-charged engines Eco-friendly Metal-Free Fuel Filters Oil Filters Turbo-fan Dry type Air Filters New Pleating technology to reduce spin-on filter sizes New dual-layered filtration medias for fuel and oil application . China. Involved in the development of all-plastic Air Intake systems for HCV applications for improved aesthetics and noise control. and Fly ash test rig for Mahle. Collapse rig. Development of air filter rig (Life & Efficiency) for Guard filter. Pakistan. Software development for the prediction of permeability in filter media and efficiency / DHC in a oil filter test rig.

street test bench to aid correlation of field performance of the air filter. optimize Air Intake Systems and Resonator performance. generate accurate results of air borne noise in front of orifices. Advanced Testing Infrastructure & Facilities MAHLE’S advanced testing Infrastructure includes test facilities for advanced product lines with the latest environmental control equipment like Salt spray testing and a Thermal chamber. OMS testing apparatus for testing separation efficiency of the Oil Mist Separator. Integrated Head Covers with Oil Mist Separators & complete Plastic Air Intake Systems with snorkels. Design & Simulation capabilities with a range of advanced software Design & Simulation capabilities with a range of advanced software to produce 3d acoustic calculation. dust feeder in the air test rig which helps controlled feeding of test dust. obtain an accurate result of structure borne noise in a defined point above the surface of interest. comprising of Plastic Air Intake Manifolds.R&D CAPABILITIES: Designing of new generation portfolios validated by CAE: The designing of new generation portfolios validated by CAE. pre-cleaners and plastic air cleaners with polyurethane elements. analysis. and evaluation of sound and vibration signals. validation of the simulated acoustic results with a NVH facility. using special filter media with respect to change over lifetime and efficiency as required by the new generation engines. . all-round solution for measurement.

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This continuous improvement can occurs for machinery. and production methods through applications and ideas of company teams.KAIZEN ‘Kai’ means continuous and ‘Zen’ means improvement so Kaizen is Continuous improvement over current processes. labor utilization. . materials.

8:00 7 5:35 20:35 6.5 to 5.OBSERVATIONS MPFI Line 1.no Loading Time Machine Time Unloading Time 1.8  Hot melt Weight = 3. COILING MACHINE Coiling machine make element coil for the filter. 8:00 7 5:05 20:05 3.5 gm. 7:50 7 4:49 18:99 2.  Number of Coil = 12+/-1  Coil Height = 40+/-0. 7:43 7 5:25 19:68 4. 7:56 7 4:20 18:78 7. The main parts are :. 8:05 7 5:10 20:15 Average time required by 1 piece = 20sec (approx) Total cycle Time .centre tube and filter paper. 8:00 7 5:20 20:20 5.  Fold Height = 8 mm+/-1  Paper gap = 3 mm max  Hot melt Distance = 6 mm+/-1  Hot melt width = 4 mm+/-1 Temperature of hot melt = 250 to 260C Total time required per piece = 20 sec Time required by the machine = 7 sec Time per Piece Table:S.

3. Vaccum gauge pressure = 2-3 bar Pressing gauge = 2-3 bar Machine inlet pressure = 6-7 bar Dispensing time = 1000-2000 ms Shot weight = 3-3. HEAT OVEN Heat oven is used for the hardness of ‘Ana bond’ by providing a high temperature. It has three heating coils to provide heat. 4. Pin holes or improper hardness of the adhesive is considered under rejection. 2. Pin holes are also checked. 5. 1. Temperature = 150 +/-10 degree C 2.2. . EPOXY MACHINE Epoxy machine is used up to fill the gap between the coil and the bowl by using an Adhesive like structure “Ana bond ’’.4 grams Coil insertion in the bowl till the dead centre is also done in the epoxy machine. Time = 10-15 min Inspection of adhesive hardness is manual. 1.

Seeming O. 2.0 +/-1 Sean Width = 4.D = 67. 3. 2 to roll up and 2 to seem. Time = 2 – 3 sec SEEMING Seeming machine is used to join the bowl and the upper covering.69 bar 2. 4. .3 – 0. 5.cm Poka yoka in it is hand body detecting sensors. 6. SEEMING MACHINE(AUTO-3) LOCTITE DISPENSING The process of this machine is to dispense a sticky substance which we call as loctite.5 Total ht = 60 +/-0. Pressure = 0.3.5 +/-0. Loctite is used to cover up the gaps and prevent the leakage after the bowl and covering is seemed. If any part of body is inside the working area than the machine stop working and save that person from any harm. 1. It has four rollers. 1.8 Pressure = 3-5 kg/sq.8 Seam hook overlap = 1 mm Min Pipe height = 28 +/-0.

Water leak testing is performed by putting the filter inside the water and passing a high pressure gas inside the filter.cm Operator coding properly visible Poka yoka = Hutter for blocked piece = bubbles for leaked piece . Screening is done to provide names. MAGNIFYNG. sharper edges etc. SCREENING Magnifying is done check the cracks.4. If bubble formation is there then we get the rejection piece. if there than the part is reworked and then sent to next station for next process. WATER LEAK TESTING . dates or as per the company requirement. If cracks or something that may have damaged the filters are found than that piece is sent to rejection. 5. There should be no smudges. Time = 30 sec Pressure = 5-6 kg/sq. This is a must required process because it is possible that we can see outer cracks through magnification but the leaks can’t be seen through magnifying glass that’s why we perform water leak testing operation.1 Water leak testing is done to check out leakages in seemed part.

 Degreasing is done to remove the oily surface that is there on the filter bowl so that the paint can be easily got on it.  Solid powder paint is used instead of liquid paint because liquid paint starts flowing down and form an uneven layer of paint on the bowl and we can’t get the desired result.5 hours. .PAINT SHOP LOADING OF BOWLS ON CONVEYER BELT BOWLS PASSES BLOW OF MACHINE TO BLOW OFF WATER IR(PAINT STARTS MELTING IN THIS AREA) DEGREASING OF BOWL BY CHEMICAL MIXTURE BOWLS NEXT PASSES FROM WATER DRY OVEN PCO(PAINT CURE OVEN) PROVIDE A SHINING FINISH TO BOWL WASHING OF BOWLS TO REMOVE CHEMICALS FROM IT PAINT SPRAY BOOTH(SOLID PAINT SPRAYED ON BOWL) UNLOADING (INSPECTION)  The loading to unloading process of one bowl take approximate 1.

After taking the area of the shop floor. DRAW LAYOUT CLICK .1ST PROJECT SHOP FLOOR LAYOUT CHANGE:The project is provided to me by Mr. For changing the layout we measure the shop floor area and AUTO1 is taken as the reference for the layout arrangement. Kamal Panda sir and I thank him for giving me this opportunity. In the shop floor layout change. all the machine area is also noticed so as to arrange the machines in the desired area. the main purpose is to get the extra space out from the shop floor area so as to increase WIP and 5’S.

After making the layout it is checked by Kamal Panda sir and then after the approval it is applied. but is an interesting and learning project.After taking all the dimensions a layout is made on the paper sheet. The toughest job was of shifting of packing line. LAYOUT CHANGING WORK:- . Machines are shifted as per the reference line is provide.

.Reference line Unadjusted trolleys during layout change.

Not only this but it also help in increasing my knowledge and made me to learn some new thing.After the change of layout WIP and 5’S is improved. . Now the uneven lying of material is no more there and we also have space to keep the desired material at desired machine so the movement is also decreased. Conjunction of line decrease. Its teaches me that nothing is perfect so once we should also try ourselves to make things perfect so as to get a benefit from them. Manpower movement decrease. Space for WIP increase. The extra space we have for keeping our bins and trolley without disturbing our 5’S. KEY LEARNINGS:        Safety measures How to behave with your team mates Working procedure in a company About kaizen Time wastage study Quick solution of some common occurring problem How to improve 5’S in a company and what’s the importance of 5’S How to increase productivity Benefits:     5’S of plant improve very well. Plant looks neat & clean.

AFTER LAYOUT CHANGED:- SHOP FLOOR APPEARING VERY WELL .

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PROJECT NO. Here employees learn about company’s goals. machine. process. product. safety & maintenance etc. where we give same working condition as at work floor to the new employees. PICTURES OF SKILL CENTER DOCUMENTS BOARD . equipments. vision.-2 DEXTERITY CENTER:Dexterity center means skill center. mission.

workers and my co-trainees at MAHLE FILTERS SYSTEM INDIA LTD. The “learn while you work” attitude is a very practical touch in the complete tenure of a personal life. Training bridges the gap between the learnt and the happening. KAMAL PANDA (PRODUCTION HEAD) who cared to give out an ample amount of time to me. loving and always ready to help. I would like to put forth my regardful thanks to all those who have and are making it a remarkable attempt in guiding me and making me learn the most during my training at MAHLE FILTERS SYSTEM INDIA LTD. During this phase the trainer or guide or the supervisor is the one who can help make the most of this golden opportunity. KHANDSA GURGAON who have always been so supporting. KHANDSA GURGAON. Ahead I put my special regards to the management.ACKNOWLEDGEMENT Training as teaching is an essential part of an individual’s future career. KHANDSA GURGAON I also pay my special thanks to Mr. regardless of being extremely busy at their work. I have been in close touch with them since the beginning of my training at MAHLE FILTERS SYSTEM INDIA LTD. And I appreciate the relationship they all have developed with me .

DOCUMENTS BOARD .

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OUR PRODUCT (OIL FILTER) INLET HOLES OUTLET HOLE 15 FACETS TO TIGHTEN THE FILTER WITH TOOL .

Function: Act as support to filter element and ensure no mixing of clean and dirty oil .CHILD PART OF OIL FILTER WITH FUNCTION Gasket retainer Sealing gasket Function: Hold the gasket and join with Function: Provide sealing between filter and engine block housing through seaming process CV gasket Cover plate Function: Act as sealing between clean and dirty oil. Function: Provide threads to assemble with mating part and able to sustain under vibration and pressure Center tube Function: Act as support to filter media and allow End plates Function: Act as support the filter and provide sealing from both ends with the help of bonding adhesive oil to flow through holes Housing (Bowl) Function: Act as canister and join with cover assy. Adhesive Function: Bonding of paper from both ends with end plated Relief valve Bottom spring Function: Act as safety valve when filter is chocked and allow oil to pass through to avoid any Engine seizer or damage.

FUNCTION FLOW DIAGRAM OF OIL FILTER OIL INLET THROUGH HOLE OIL FLOW OIL OUTLET THROUGH CENTER HOLE .

PICTURES OF SKILL CENTER SAMPLES OF PRODUC .

WATER LEAK TESTING M/C SAFETY MAN WITH PROPER PPE’S .

 To provide knowledge about safety equipments.  To provide working environment on skill center as at shop floor.  Practical knowledge about how to make the filter at seaming machine. assembly tables and moulding fixture etc. in the skill center we used machines.  To provide practical during induction training. process flow charts. how to use & benefits of safety equipments. company process.  To provide knowledge about our product. how to perform water leak testing & then what is the procedure of packing & how it will? . As show in above pictures. measuring instruments. machines & measuring equipments. safety man with proper equipments.OBJECTIVE OF SKILL CENTER:Objective of skill center is to provide working environment to the new employees of the company.  To be friendly with machines & equipments.

 They know very well about the quality concern.  They can differentiate the good & reject piece.  During induction new employees learn through the practical which they will perform.BENEFITS OF SKILL CENTER: During seven days induction training new employees know more effectively about the company.  Surprise about machine mechanism & operation almost hide. .  They awake about safety & safety equipments.  They perform & learn about the machine.  They get practical knowledge about product & machines before come to the shop floor.  New employees try to learn very effectively.

we prevent problem that could be expensive later on.Quality at Mahle:Our professional project management system identifies possible source of defects already during the initial phases of development. Consistent control procedures during the development process monitor timing and achievement of the project targets. . All Mahle plants are certified according to the international quality standard of the automotive industry. In this way.

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we prevent problem that could be expensive later on. In this way. Consistent control procedures during the development process monitor timing and achievement of the project targets. All Mahle plants are certified according to the international quality standard of the automotive industry. .Quality at Mahle:Our professional project management system identifies possible source of defects already during the initial phases of development.

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And I appreciate the relationship they all have developed with me. regardless of being extremely busy at their work. Ahead I put my special regards to the management. KAMAL PANDA (PRODUCTION HEAD) who cared to give out an ample amount of time to me. During this phase the trainer or guide or the supervisor is the one who can help make the most of this golden opportunity. workers and my co-trainees at MAHLE FILTERS SYSTEM INDIA LTD. I express my indebtedness to all who have directly or indirectly contributed to the successful completion of my industrial training. loving and always ready to help. that I could utilize every single minute in the company. KHANDSA GURGAON. KHANDSA GURGAON who have always been so supporting. I have been in close touch with them since the beginning of my training at MAHLE FILTERS SYSTEM INDIA LTD. Finally. KHANDSA GURGAON I also pay my special thanks to Mr.Training as teaching is an essential part of an individual’s future career. I would like to put forth my regardful thanks to all those who have and are making it a remarkable attempt in guiding me and making me learn the most during my training at MAHLE FILTERS SYSTEM INDIA LTD. . so. The “learn while you wthe gap between the learnt and the happening. I would also like to appreciate that they gave me experience of almost every cell of the company.