A

PROJECT REPORT ON

INDUSTRIAL TRAINING
At
G.N.A Axle Ltd, Mehtiana near
Hoshiarpur

A Project report submitted Sant Baba Bhag Singh

Institute of engineering and technology
, Jalandhar. In partial fulfillment for the
degree of: -
Bachelor of Mechanical
Engineering

Supervised by: - Submitted by: -

Navdeep singh
B.tech/M.E

Roll no. 1421221

G.N.A IMT, Phagwara

INTRODUCTION TO THE COMPANY

1.1 Profile of the company: -

Company Name GNA Duraparts

Contact Person Mr. Gurdeep Singh Sihra.
V.P.O. Mehtiana, Distt. Hoshiarpur -
Address 146001
Punjab (India)
Phone: +91-1882-262273 (7 Lines)
Fax : +91-1882-262280
Email : gnamht@jla.vsnl.net.in
Established in 1994
Covered Area (Sq. Mtr.) 20000
Products Spur Bevel & Pinions, Bull Gears & Pinion
Shafts, Internet Ring Gears, Planet Carrier,
Gear Boxes for Agriculture Equipments,
Flanges

GNA group is on a fast moving track towards growth and globalization. GNA is a group of auto
& transmission component manufacturing companies catering to wide requirements of
Automobiles, Tractors, Off-Highway equipment worldwide. A professionally managed group
Founded by Chairman Sardar Amar Singh ji, whose vision of world class quality manufacturing
& global market made GNA most sought after name in its product range. The

company has a large customer base covering different sectors of the automotive industry
with a diversified product range. GNA manufactures quality automobile components which
meet the highest international standards. The products include Rear Axle Shafts and U. J.
Crosses, Propeller Shaft Assemblies, Hydraulic Lift Shafts, Steering components, Wheel
Spanners, Brake S -cam Shafts, P. T. O. Shafts and Forgings for the automobile industry,
for use in all types of light, medium and heavy vehicles.

INTRODUCTION
GNA group is on a fast moving track towards growth and globalization. The company has a
large customer base covering different sectors of the automotive industry with diversified
product range. Along with this the company shows steady growth profile even during the time
when there is demand fluctuations in the automotive sector.
GNA is an Original Equipment manufacturer (OEM) of various Automobile Majors besides
having a strong presence in the replacement market.GNA has been accredited with ISO 9002 and
QS 9000 certifications for its quality systems, holds a reliable name in the world of automotive
components. Quality Management at GNA is a timeless concept wherein, a change in customer
expectations is a driving force to go beyond conformance to standards.
It is situated at village BINDALA, DISTT.JALANDHAR. It was come into existence in 1946 by
S.AMAR SINGH.
It is spread in 27 acres. Its annual turnover is 60-70 crore.
The production run in three shifts 8:00am to 4:00 pm (first shift), 4:00pm to 12:00
midnight (second shift), 12:00 midnight to 8:00 am (third shift).

GNA Udyog (propeller shaft) comes under GNA group. There are two more units also come in it
i.e. GNA (axle ltd.), GNA (duraparts).
It is one leading industry amongst them which involved in manufacturing
of automobile component. The first component produced by them was axle. Growing from
strength to strength the GNA brand image has today reached the zenith. High quality auto
components, machining in international standard are produced using hi-tech state of art
technology developed indigenously. GNA manufacture original equipment for supply to OEMS,
spares and export market. The GNA ranges of products have a wide spectrum of application in
heavy, medium and light commercial vehicles, passenger cars, jeeps, tractors and trailers. The
GNA range of products can be categorized at the macro level as transmission system, hydraulic
lift system, hand tool and steel forging.

COMPANY PROFILE
The existence of GNA came into being in 1946, in a small village called
Bundala in District Jalandhar of Punjab. GNA has made its presence
prominent not only in India but also across the world. Today, more than
6000 families are proud to be associated with this giant colossal tree that
bloomed from a seedling sown 55 years ago. Founded with a modest
beginning by Late Mr. Amar Singh Ji and nourished by his sons Mr.
Rachhpal Singh and Mr. Gursaran Singh, with the artistic creativity that
was gifted to the next generation by tradition, GNA is now boosted and
taken care by the third generation Mr. Jasvinder Singh, Mr. Maninder
Singh, Mr. Ranbir Singh and Mr. Gurdeep Singh. Today GNA group has
created an important place for itself in Indian as well as Global
Automotive Industry.
GNA group is on a fast moving track towards growth and globalization. The company has a
large customer base covering different sectors of the automotive industry with a diversified
product range. GNA manufactures quality automobile components which meet the highest
international standards. The products include Rear Axle Shafts and U. J. Crosses, Propeller Shaft
Assemblies, Hydraulic Lift Shafts, Steering components, Wheel Spanners, Brake S-cam Shafts,
P. T. O. Shafts and Forgings for the automobile industry, for use in all types of light, medium
and heavy vehicles.
GNA sincerely believes in technology up-gradation for keeping a competitive edge. Indeed, this
explains the continuous replacement of conventional manufacturing equipment with modernized
transfer lines resulting in increased productivity and efficiency at low cost. GNA is core
competency lies in its strong knowledge base of engineering and over 55 years of experience in
manufacturing. GNA has come a long way yet journey toward excellence is never ending.
Expanding the vision & keeping pace with the evolving technology GNA has successfully
extended its product line to serve the rising needs of the auto component market.

AUTHORIZATION OF THE UNIT

 GNA group is on a fast moving track towards growth and globalization. The company
has a large customer base covering different sectors of the automotive industry with a
diversified product range. GNA manufactures quality automobile components, which meet
the highest international standards. The products include Rear Axle Shafts and U. J. Crosses,
Propeller Shaft Assemblies, Hydraulic Lift Shafts, Steering components, Wheel Spanners,
Brake S-cam Shafts, P. T. O. Shafts and Forgings for the automobile industry, for use in all
types of light, medium and heavy vehicles.

Click here for a larger view
HEAD OFFICE
Mehtiana 146 001, Distt. Hoshiarpur
Punjab (India)
Phone : +91 (1882) 262273 (7 Lines)
Fax : +91 (1882) 262302/262280
Email : gnamht@jla.vsnl.net.in

KENTUCKY EXPOSITION CENTRE 60th IAA Show, Hanover, Germany

LOUISVILLE, KENTUCKY, USA. 23-30 September, 2004
Friday, Saturday, Sunday Hall No.H11 Stand No.F48
September 24-25-26, 2004 at Fairgrounds of Deutsche Messe AG-
STAND NO:4711 Hanover, Germany

CUSTOMERS OF GNA UDYOG

Valued Customers Prop Shaft Assy & Components
Ashok Leyland
Nissan
Ashok Leyland
Limited (Heavy
Commercial
Vehicles

Asia Motor Works

Case New Holland

Tata Motors Ltd (
Medium & Heavy
Commercial
Vehicles)
Swaraj Mazda
Limited (Light
Commercial
Vehicles)
Maruti Udyog
Limited ( Passenger
Vans/MUVs)
Mahindra &
Mahindra Limited

New Holland Fiat

India Pvt. Ltd.

JCB

ITL (Tractors)

Caterpillar

Preet Tractors

Action Construction
Equipments Limited
(Tractor Division)
 Piaggio
Commercial
Vehicles

Valued Customers off Highway Vehicles

Mahindra & Mahindra Limited
New Holland Tractors India Pvt.Limited
Preet Tractors Limited
Indo Farm Tractors Limited
International Tractors Limited
Group Customers
John Deere

Renault

CLAAS
JCB

Graziano Transmissions

TMA, USA

Arvin Meritor
Case New Holland
Carraro
Automotive Axles Limited

(Tier I Supplier)
TAFE (Tractors)
GROUP COMPANIES

GNA Udyog Limited GNA-IMT

GNA Axles Limited GNA Duraparts

1.4 Products Range-

 Spur, Bevel & Hypoid Gear
Bull Gears & Bull Pinion Shafts
Internal Ring Gears
Sun Gears & Planetary Gear
Transmission Shafts
Companion Flanges
Axles

MANUFACTURING FACILITIES

Forging
Heat Treatment and Induction
Process Of Pivot Pins
Machining
Assembly
Tool Room

VARIOUS DEPARTMENTS IN GNA

DURAPARTS

Forging shop

(i) Forging I

(ii) Forging II
 Heat treatment cell

Product planning control (PPC)

Metallurgical lab

Engineering cell

Computer network control (CNC)

Die shop

MACHINES USED IN VARIOUS

DEPARTMENTS

PRODUCTS MADE IN GNA GROUP

 General description

Brief notes on production procedure of some

main products

Various departments in GNA Duraparts

1). FORGING SHOP:

Forging involves heating of a metal stock to a desired temperature; enable it

to acquire sufficient plasticity followed by the operations like hammering, bending
& piecering etc. to give it the desired shape. The forging process is very
important and has indispensable position among the various manufacturing
processes generally adopted in the workshops due to some reasons i.e. it refines
the structures of metal, it renders the metal stronger by setting the direction of
the grains & it effects considerable saving in time the labour and material as
compaired to the production of same by cutting from a solid stock and then
shaping it.

Forging department is one of the most important as every production is

started from here it self. There are two types of forging sections. The
 categorization can be done on the base of the mechanism of the various
machinery present i.e. in forging I we can say upsetting forging/closed die
forging and similarly in forging II we can say it as drop forging/open die
forging. These two sections consist of under mentioned machines:

Forging I: It consists of following machines:

(i) Horizontal bandsaws having capacity of working upon maximum diameter jobs of
245mm, power3HP or 2.2 KW, efficiency of 82% & RPM of 1430. The diameter
of job varies from 75 to 125mm.

(ii) Forging furnace can be gas or oil fired and are widely used for heating the
jobs for hammer forging. They prove quiet economical and facilitate better
temperature and atmosphere control. Here in this shop oil fired is mostly used in
which furnace oil is used as a fuel. There are brick arrangements provided in
these furnaces Forging furnaces having working temperatures of 1123-1200
degree Celsius, mounted with 10hp powered motor & have capacity of work to be
done of 1.25 ton/hr.

(iii)Up set forging machine here are of two types and can be differentiated with
the help of its working load capacity i.e 500 ton and 800 ton. The diameter of the
job that can be worked upon these machines are 115 and 150 mm respectively.
The power used

for running of these machines is pneumatic type i.e. air

pressure.
 (iv)Compressors for producing air pressure for working the pneumatic machines.
These are of reciprocating type. The oil used in the is of type AWS 100. he
capacity of oil tank is of 10 litres. Working pressure is of 7kg/cm2g and
hydraulic test pressure is
11.55 kg/cm2g.

In forging I two types of products are being made. One is axle. The total

production of the axle per day is 650 to 700. similarly

the product made is shaft & the total production per day is 200 to 300.

Forging II : There are following machines in this shop:

(i)Forging furnaces are used to heat the raw material up to 1100
degree Celsius with the help of rough furnace oil, which is used as fuel.
The feed of rough material are given in batch type feed and in continuous
way. A pusher is provided to push the rectangular work pieces, which are
brought, from the band saws. This pusher is operated by an electric motor.
There is a pump to control the amount of oil to the furnace.

(ii)Power hammers here are of two types are of two types i.e. capacity wise
one is of 6.5 ton and 2.5 ton. These hammers are used to hit on to the die
to form several shapes of products e.g. crown etc. These machine are
working on the principle of pneumatic type i.e. power used is of air
pressure. Pneumatic hammer is operated by a rotary air compressor of
single stage type of two in quantity. Air is compressed to pressure of 7 bars
and temperature of 120 degree F. the maximum pressure can be produced
up to 20 bar. A foot operated lever controls the air supply and required
blows of the hammer is obtained. This hammer is used for forging of ring
gear, drive gear, tail pinion, star gear and bevel gears etc.

(iii)Power presses are kept in adjacent side of these power hammers so that they

can be used for piercing and blanking operations just after hammering. These

presses are of mechanical

type and have capacity of 400 and 200 tones. These presses work on
the crank mechanism.

(iv)Normalizing furnace is used to normalize the product, which is to cover the

cracks produced after hammering and other machines. The normalizing
temperature is kept at the constant value of 880 to 920 degree Celsius with
the help of setting of thermocouple. The type of structure obtained will depend
upon thickness of the cross section and rate of cooling. Thin section will give
much finer grain than that of thick section. Furnace oil is used as fuel in the
normalizing furnace. There are 3 heat zones while this process. For example
when material is 20MnCr5 zone I is of 880 degree C, zone II is of 900 degree
C & zone III is of 920 degree C. time taken for all these is only 20 minutes.
The purposes of normalizing are to produce a uniform structure, grain
 refinement, reduce internal stresses, improve mach inability & improve
hardness, strength & other mechanical properties.

(v)Short blasting machine is used for removing scaling produced due to

past processes. This is done by throwing small size balls on the work
material in batch way. This also produces somewhat good surface finish.
The common material of metal shorts is malleable iron & cast steel.

(vi)Brinell hardness tester is used to know the hardness in brinell scale before

sending the product to next procedure.

In forging II there are also two main products i.e. crown and bull gear. The

total production per shift of these two products are 250

and 300 respectively. The total number of workers in both forging I

and forging II are 100.

Forging Furnaces:-
The furnaces used in the unit are oil-fired furnaces. In these furnaces, first of all
from the main tank the supply of oil is provided to the furnace. A pumping unit is
provided to all the furnaces used and this pumping unit consists of a heater
which heats the oil to a temperature of 90-100 degrees and then the oil is
supplied to the furnace. A blower is present which moves the air into the re-
cubature. Its function is to heat the air to a temperature of about 250 degrees ant
 then move the air into the furnace. The furnace temperature which is used for
forging is 1250-1300 degrees. A regulating valve is present and it is used to
regulate the supply of oil and a butterfly valve is present to regulate the supply of
air.

Following are its two types:-

1. Pusher-type furnace: - In the pusher-type a pushing system is provided which is

used to push the work-pieces into the furnace. The pusher mechanism which is
used is hydraulic and it is controlled by oil pressure. The temperature inside the
furnace is 95-105 degrees and the pressure is 12-15 pound per square inch (psi).
2. Batch-type furnace: - In the batch-type furnace, a batch of the work

pieces is made & that batch of work pieces is heated at the required
temperature & afterwards the work pieces are moved one by one to the
forging machines.

Working procedure in forging shop: -

1. Material cutting: - This is the first step which is involved in forging. After

the material is received & inspected it is sent for the material cutting. In
material cutting operation the material is cut in accordance with the required
dimensions. The material cutting is done on band saw machines which are
 fully automatic in operation. After the material cutting is done the material is
sent into the forging shop.
1. Heating: - This is the second step which is involved. In this step the material is

heated to the forging temperature in the furnace. The forging temperature is

1250-1300 degrees. The furnaces which are used are oil-fired furnaces & they
can be either pusher type or batch type. After the material is heated it is sent to
the forging machines. The process of heating the stock can be divided into two
stages: -

First stage (Preheating zone): - In this stage the temperature to which

the stock is heated is 500-700 degrees.

Second stage (Full heating zone): - In this stage the temperature is

1260-1300 degrees.

3. Forging: - In this step the material is forged on either a drop hammer or a

forging press or on the up-setter. The type of the machine which is to be

used depends upon the shape & size of the component to be forged.
4. Trimming: - In this operation the excess & unwanted material is removed

from the forged component. After forging operation is done then the forged
component is passed to the trimming press for the material removal.

1. Heat treatment: - After the trimming operation is done then the forged

component is ready for heat treatment. In this operation the forged

 components are placed in trays made of mild steel & are placed in the
furnace for a suitable period of time. The heat treatment processes which
are done at GNAU are normalizing, hardening & tempering. The type of the
heat treatment process which is to be done depends upon the type of the
steel. After heating, quenching of the heated components is done in a
quenching bath for a suitable period of time. The heat treatment process is
done to improve the mechanical properties of steel & to relieve the internal
stresses which are set up due to forging.
6. Shot-blasting: - This process is done to remove the scales & impurities which

are caused during heat treatment. After the heat treatment the components
are put in the shot-blasting machine & thus the scales are removed & the
components are polished.
7. Grinding: - This is the final step involved. In this step the unwanted

material is removed from the components to provide them a smooth

surface finish. The grinding process is done on the grinding machines
which comprises of the grinding wheel.

After the grinding process is completed the hardness checking of

the components is done & afterwards these forged components are sent
to the machine shop for further machining.

Measuring instruments used in forging shop: -

The measuring instruments which are used in the forging shop are: -

1. Vernier caliper

2. Measuring scale
1. Measuring tape

4. External & internal calipers

Temperature measurement instruments used in forging shop: -

1. Thermocouple

2. Optical pyrometer

The thermocouples are located at suitable heating zones inside the

furnace & they measure the temperature of the heating zone & this
temperature is represented on the digital temperature indicator to the
operator.

Furnace oil used in forging shop: -

The furnace oil which is used in the furnaces is the residual furnace oil
(RFO).

Fuel consumption in the furnaces is 100 liters.

4). HEAT TREATMENT:

Heat treatment is defined as an operation involving heating and cooling of a

metal or alloy in a solid state to obtain desirable conditions. There are many
causes of the heat treatment to be done to the product to be done. It is
 done to cause relief of internal stresses developed during cold working

processes. It is done to harden and strengthen materials, improve machine ability,

change grain size, improve ductility and toughness, increase heat wear and

corrosion resistance of materials & to homogenize the structure.

product to give it required hardness. This is done with the help of following
mentioned processes & various machines:

I. Carburizing: Carburizing is a method of introducing carbon into solid iron-base

alloys in order to produce a hard case. Carburizing may be pack carburizing, gas
carburizing and liquid carburizing. But here only gas carburizing is being done. In
this process components are heated at 920 degree Celsius for four hours in an
atmosphere of gases of [CO+H2+N2]. The main motive of this process is to
diffuse into the outer surface of the
components. It is the process by which the increasing of
percentage of carbon is being done to gain good surface

hardness. This can be only possible with the help of following

apparatus:

(i)EOT crane is used to carry the fixtures on which batches of items

are carried. This crane has capacity to load 2 ton.
 (ii)Washing bay is filled with casting soda in which is the products which
are covered with layer of oil & coolants are being washed. This process is
being done for 10 to 15 minutes.

(iii)Carburizing furnace is the apparatus used for carburizing process.

In this apparatus the temperature is maintained at 920 degree
Celsius. In this after washing the crane lifts the fixture of the products
and put into this apparatus. This process is carried for long period of
15 to 16 hours. The fluid used in this process is carburizing fluid 440.

(iv)Super quenching apparatus is the area where the fixture from the
last process is put into. In this process the super quenching oil is the
quenching medium. There is heat exchanger arrangement which
does not allow the temperature of oil to raise more than 75 degree
Celsius.

II. Tempering: Tempering involves heating hardening components below the lower
critical temperature i.e. at 180 degree Celsius. In this process this temperature is
being hold for about 2 to 2 hours and the cooling is being done open air. At
this temperature a hexagonal lose packed carbide begin to form and with the
rejection of carbon the crystal structure of martensite changes from tetragonal to
body centered cubic characteristic of ferrite. This process is being carried with
the help of following apparatus:

(i)Tempering furnace is used for this process in which temperature is being

maintained between 200 & 250 degree Celsius. In this furnace the walls
 inside are winded with the element which is being heated and there is a

motor attached to fan to spread the hot air on the fixture on which the

products are being arranged.

III. Scaling removing: It is being done with the help of short blasting machine. This
process is used to clean the components after heat treatment. The metal slides
are thrown on the surface e of the components. The material used as the short
balls are malleable
iron, cast iron or cast steel.
IV. Hardness checking: It is being done with the help of Rockwell
hardness testing machine. The harness is kept between 58 & 61
Rockwell hardness.

Purpose of Heat treatment: -

1. To relieve the internal stresses set-up in the material after hot or cold

working in order to improve the machinability.

2. To improve the mechanical properties like tensile strength, hardness,

ductility, shock resistance etc.

3. To modify the structure of steel.

4. To increase the corrosion & wear resistance.

Furnace specifications: -

Type of furnace Oil fired

Fuel used Residual Furnace Oil (RFO)

Maximum loading capacity of trays - 150-200 kg at a time

Capacity of hardening furnace 15 ton

 Maximum loading capacity of furnace 12 trays at a time

Capacity of tempering furnace 15 ton

Fuel consumption Approximately 100 liters per day

Measuring instruments used in heat treatment: -

1. To check heat treatment furnace temperature, Temperature controller /

Indicator thermocouple are used.
2. To check hardness, BHN Testing Machine / Micro-measure are used.

3. To quench oil temperature checking, temperature indicator is used.

Heat treatment of machined components: -

The first stage of the heat treatment was concerned with the heat
treatment of the components after forging. Now in the second stage comes
the heat treatment of the components after machining. These heat
treatment processes mainly comprises of the case hardening techniques of
heat treatment. The case hardening processes which are used in GNAU
are: -

1. Induction hardening: - The Induction hardening is a surface hardening process

in which the surface layers of the metal are hardened but a relatively soft core
is maintained. The induction hardening is achieved by passing a high
frequency alternating current through the work-piece which is placed in an
inductor coil. The alternating current generates a magnetic field of equal
intensity but of reverse polarity. Thus, the current penetrates & the surface of
 the piece is hardened but a soft core remains.
2. Carburizing: - Carburizing is the process of saturating the surface layer of steel

with carbon. The main purpose of carburizing is to

obtain a hard & wear-resistant surface on machine parts by the

enrichment of the surface layer with carbon. The various machined
parts are directly carburized after getting machined & after
carburization they are sent for final grinding. There are various
techniques of carburizing like pack carburizing, gas carburizing &
liquid carburizing. At GNAU gas carburizing in the electrical
carburizing furnace is done.

Heat treatment equipments: -

1. Induction hardening machine (medium frequency)

2. Carburizing furnace (electrical)

3. Tempering furnace (electrical)

4. Magnetic particle tester (MPT)

5. Hardness Testing machine

6. Grinding machine

7. Gas welding machine

Procedure for Induction hardening: -

1. Machining After forging the components are sent to the machine shop for the

subsequent machining which is to be done & after machining the components are
ready for the case hardening.
2. Induction hardening After the subsequent machining is done in the machine

shop the components are ready to be induction hardened & the induction
hardening is done on the induction hardening machines which are of medium
& low frequency. The main tooling of these machines is the induction coil.

1. Hardness testing After the Induction hardening is completed the hardness

testing of the hardened pieces is done. The hardness tester is used for
testing the hardness.
4. Checking case hardness After hardness testing is done the checking of

the case hardness of the components is done to find the depth of the
hardened layer. The micro-measure is used for checking the case
hardness.
5. Magnetic particle testing (MPT) In this step the components are checked for

any cracks which might have been developed during the induction hardening.
First of all the components are sprayed with kerosene oil & then they are
viewed under the ultrasonic light for finding any crack. If any crack might be
present it would be illuminated with green light.
6. Tempering Tempering is done to remove the brittleness which might have been

developed during heat treatment & thus it restores the ductility of the hardened
component. The tempering is done in the tempering furnace which is electrical in its
operation.
7. Grinding Grinding is the final step which is involved. In this step any

unwanted material which is present at the edges is removed & a smooth

finish is provided.

5). PRODUCT PLANNING CONTROL {PPC} :

PPC includes the investigation, co-ordination and it ensures timely production

of products through efficient and optimum use of facilities like man, machine,
material evaluation of manufacturing capabilities and requirements and money.
PPCs function serves as the brain of the organization. Its objective is to provide
a physical system together with a set of operational guidelines to efficiently
convert materials, human skills and other inputs into finished products. The
highest efficiency in production is obtained by manufacturing the required quality,
at the required time by the best and cheapest method. Management employs
production planning and control {PPC} to coordinate all manufacturing activities.

Products are manufactured by the transformation of raw materials.

Planning looks ahead, anticipates possible difficulties and decide that in
advance as how to production and how it can be carried out in best way. A
production planning control system has main function to perform some before
arrival of raw material and tools and other while the raw material process
undergoes processing. The main function of this section is to plan about
production of the product. This includes many things such as raw material
ordering, processing time management etc. This department calculates the
total production time of each product and thinks it advance process working
period. The main motive of this department is to reduce the inventory of raw
 material. So there fore the planning is done such that the total amount of steel
kept in unit is under control. Following mentioned are step by step calculations
which are planned for raw material planning by PPC department:

1) Number of components in

(i). Cutting section

(ii). Forging

(iii). Forging vendor department

(iv). Vendor

(v). Machine shop

1. Total

3) Target of the month(say February)

4) Steel stock

5) Peaces that can be made from stock

6) Due steel
7) Pieces that can be made from the due steel
8) Total
9) Balance for next month(say march)
10) Weight of piece
11) Net steel required
 From above all steps we can see that the main motive of PPC
department in raw material planning is that overhaul process will start 2
st
months before the need so that forging takes place in 1 month and rest
work in last month. Thus by all this planning the department decides the
need of net steel as raw material.

Objectives of PPC:

1. To maintain adequate but not excessive stocks of raw materials, work in

process and of finished goods to meet production requirements and
delivery schedules.
2. To coordinate the production activities of different departments.

3. To ensure effective utilization of production facilities.

4. To prepare production schedules advertisements to meet delivery

schedules.
5. To operate the plant at optimum level of efficiency.

6. To ensure production of right product in right quality at the right time.

 Importance of PPC:

1. PPC acts as factorys nervous system as it regulates all plant operations just as

nervous system regulates muscular movements.

2. PPC acts as an effective instrument for cost control.

3. PPC is helpful in accelerating industrial productivity.

4. PPC rationalizes plant operations.

5. PPC benefits the society.

Functions of PPC: Following are the main functions of PPC:-

1. Planning: It is necessary to plan things properly for getting best results.

Similarly for production planning in advance, it is very necessary that how

planning should be done and controlled. It is the department which decides
about each element of the job, what should be done, where, how & when?

Functions of Planning:

To investigate about the complete details and requirements of the product

to be manufactured.
 Predetermination of future achievements.

Planning about quality and quantity of material.

Planning the design of the product to be manufactured.

Planning about the sequence of the operations.

Planning about interval transportation.

2. Routing: Routing may be defined as the selection of path, which each part

of the product will follow being transferred from raw material to finished
products. Path of the product will also give sequence of the operations to
be adopted.

In other words routing means determination of most advantageous path to

be followed from department to department and machine to machine till raw
material gets its final shape.

Routing in industry depends upon the nature and the type of industry:

Continuous industry As such these industries are also automatic. Therefore the

problem of routing in these industries is very simple. Once the route is decided in
the beginning, generally no further control over the route is needed.

6). METALLURGICAL LAB:

 This labs main purpose is of do inspection f raw material do
acceptance or rejection of the material. This also helps to now various
contents of material in the made specimen after forging processes. So
there fore this department is an essential part of the industry. This lab
performs the following functions:

(i) Macro Etch test in which HCl is being used to clean structure of given
metal.
(ii) Jominy hardenabily test is performed in which we do heating and then end
quenching and then check the hardness of the specimen.

(iii) Step down test is the test in which magnaflux on step down sample is being
done.
(iv) Cracks detection is the test in which magnaflux powder and kerosene
mixture is used to clean the surface and the checking of cracks is done in
microscope.
(v) Grain size checking test is a test in which the grain size is being checked
with the help of microscope.
(vi) Microstructure checkup up is being done after normalizing, tempering,
hardening, carburizing etc.

The main frequently performed work in this lab is estimation of

percentage of carbon in the specimen in between the production
processes. In this the chips of the material is being produced using the
 drilling machine. Then their chips are heated in the furnace with cupric
oxide (CuO) in presence of dry oxygen free from carbon dioxide. The
reaction took place is as below:

C + 2CuO = CO2 + 2Cu

Other gases and carbon dioxide are absorved in U tubes

containing anhydrous (CaCl2) and solution of K(OH) respectively. The
volumes of containers are noted before and after the combustion. These
volumes are compaired with the charts and thus percentage of carbon is
estimated.

Similarly there are some equipments and apparatus required for performing
various tests which are mentioned as in following:

I. Treatment or experimental zone:

(i) Combustion table furnace
(ii) Control unit for carbon apparatus {used to know about carbon content and
working temperature kept is 1200 degree Celsius}
(iii) Strohlein apparatus {used to know carbon content in steel}
(iv) Weight balancing machine
(v) Barometer {used to know the atmospheric pressure}
(vi) Volumetric section {used to check % of Mn, Cr, Ni, Cu, molebedinum,sulphur,
phosphorus &vanadium}
(vii) Fume chamber
(viii) Distillation plant
(ix) Microscope
(x) Drilling machine
(xi) Phosphating tank
(xii) Surface grinder
(xiii) Muffle furnace{temperature ranges from 0 to 1200 degree Celsius}
(xiv) Jominy apparatus for quenching test

II Sample preparation zone:

(v) Polishing machine

(vi) Belt grinder
(vii) Abrasive machine {used for sample cutting}

7). ENGINEERING CELL:

In this department the main purpose is to make a file/report on the product

to be manufactured. First of all the customer send the intimation of the product
to the purchase department in which there are many things such as bill of
material to be used for manufacturing the product, drawing of the product,
tolerances, mechanical properties of the product etc. This file is being brought
to the engineering department.

The engineering department consists of designers, engineers and drafts men

who helps in performing their work in this department. The engineering
 department first of draws the product lay out. Then the flowchart of the
manufacturing processes are being made. Then in the same serial order the list
of costs incurred for manufacturing of the product is being made. This quotation
may contain various kind of costs such as cost for raw material, machining,
labour, die arrangements etc. So there fore the main function of the engineering
department is of preparation of details of manufacturing information of the
product to be made.

This all work of engineering department is done for the requirements of

good production which are mentioned as following:

1). To ring customer satisfaction that the product will work properly and the
price is reasonable.

2). Adequate profit that it should be easy to manufacture with in the available

resources and should call for minimum number of operations.

According to this department the main part is the drawings of the part. A designer

communicates his ideas to the manufacturing section through the medium of

drawing. Drawing shows the exact size and shape of he product.

An engineering drawing should contain following information for the

manufacturer:

1. Component part number and part description.

2. Dimensions from a common datum face to facilitate setting and ganging.

3. Tolerances and limits allowable.

4. Material details or the specifications.

5. Finishing description.

8). COMPUTER NETWORK CONTROL (CNC):

CNC shop is equipped with various costly machines, which may be

automatic, and computer controlled type. The labour used in this shop is
highly skilled type. The list of various machines used in this shop is as
following:

Gear hobber made by Churchill Company in England. This machine is of

mechanical type and have maximum full load current 15 amps.
Gear hobber made by Lorenz Company having maximum hammering load

capacity of 1.5 kg.

Gear hobber made by Lorenz Company having maximum hammering load

capacity of 1000 kg.

CNC 03 made by Frontor 1856 weisser. It is assembled with a monitor of

simens. This machine is used for rough turning & facing functions.
CNC 03 made by Frontor 1856 weisser. It is assembled with a monitor of

simens. But this machine is used for final turning, boring, step facing etc.

Horizontal machining center made by Rolland, which is a universal

machine. The coolant used is biostable coolant. The machining capacity is

500 L.
Grinder with a tapered wheel made by Fortuna Werke AG.
 CNC Turning machine made by Frontor 1856 Weisser.

Vertical CNC machining center made by Hart Ford. The various functions

that can be performed are drilling, milling, boring, reaming & tapping. This
machine can be worked at higher RPM i.e. 8000 RPM.
Surface broaching machine, which works vertically and is made by

Varinelli.
CNC machine used for turning operation and is made by Duplo Standard.

The control panel is of sinumerilic.

Then there are 5 CNC machines in line. These all are made by Itala.

CNC drilling machine made by Leadwell.

CNC robodrill made by Hanuc.

12). DIE SHOP:

Die is a cavity in which the hot piece is placed in forging & by the
application of force the hot metal is given the required shape. So the die is
the exact shape of the original component.
Dies are of two types: -
1. Rough blocker: - Blocker is the die which has the larger dimensions so that more
metal flow is incorporated in first blows.
2. Finisher: - Finisher is the die which has the exact dimensions including
tolerances used to give the product during forging whole of metal not flows
 in the cavity. Some of it comes out to counter it a hollow portion is
incorporated around die & this portion is called gutter.
Die is the most important tool for closed die forging. Making a die as per
design specifications is most essential work in automobile industry. Die
manufacturing is a completely sequential process, due to this there is a separate
die manufacturing section is
provided in the factory.
Die making machines: -
The machines which are involved are as under: -
1. Lathe machine
2. Milling machine
3. Power hacksaw
4. Grinding machine
5. Drilling machine
6. Electric discharge machining (EDM) machine
7. CNC wire cut (for rimming dies)
8. Shaper
9. Electric arc welding set-up

Die material: -

Composition of the die materials used is as under:-

1. DIN 2713 Carbon 0.55 Silicon 0.30 Manganese 0.66

Phosphorus & sulphur 0.035 Chromium 0.70 Molybdenum 0.30

 Nickel 1.70 Vanadium 0.10

2. DIN 2714
Carbon 0.56
Silicon 0.30
Phosphorus & sulphur 0.035
Molybdenum 0.50
Nickel 1.72
Vanadium 0.10

Die making procedures:-

Block selection: - Here we have to select the size of the die block. For this we
have to check the number of cavities. Approximately 20 mm of gutter is provided
around a cavity of size 100 125 mm. next thing is to check the thickness of the
block for general pieces 70 mm thickness & half the clearances.

Block preparation: -
- Automatic hand raw cutters are used to cut the blocks.
- Both sides are given reference
- Dove tail marking & machining is done.
- No tool mark should be there.

- Impression marking & marking of other location is done by choosing

one machined surface as datum surface.
Primary machining: -
- Facing is done on lathe machine
 - Impression turning is done on milling machine
- A hole is machined on both sides which are known as tong hole. Tong bars
are put into these holes & die can be easily lifted.
- Then marking is done. Marking means drawing up the marks where
machining is done. It is done with the help of height gauge & surface plate.
- The cavity can be made by either machining on a milling machine or
by the help of an electrode on the EDM machine.
Pressing & polishing: - By using a hand grinder the grinding is done. Also
the tool marks are removed. Carbide cutter is used. Polishing is done with
iron stone to have better surface finish & also easy withdrawal.
Final inspection: -
- Dove-tail parallelity check
- Dove-tail alignment check
- Top surface level check
- Dove-tail reference check

Shafts
Live
Power Hydraulic Power Drive
Take Hollow Lift Take Tie Rod
Off Shafts
off Shafts Shafts Shafts Shafts Assembly
 (i)Power Take off Shafts for Transmitting power from tractor to implements.

Utility Applicable
Automobile -
Off Highway
Agri
Machinery

(ii)Hollow Shafts for transmitting power in the tractor and off

highway vehicles.

Utility Applicable
Automobile -
Off Highway
Agri
Machinery

(iii)Hydraulic Lift Shafts for transmitting power to lift arms.

Utility Applicable
Automobile -
Off Highway -
Agri
Machinery

SINGH

3). Spur and Helical Gears

 Bull Gears Bull Pinion Shafts Gears for Gear Boxes
(i) Bull Gears for torque transmission in off highway and
tractors.

Utility Applicable
Automobile -
Off
Highway
Agri

Bull Pinion Shafts

(ii) Bull Pinion Shafts for transmitting torque in off highway vehicles.

Utility Applicable
Automobile -
Off Highway
Agri
Machinery

(iii) Gears for Gear Boxes

Utility Applicable
Automobile -
 Off Highway -
Agri
Machinery

4). Epicyclic Reduction Gear

Ring Gears Spur Satellite Gears

Flanges
(x) Ring Gears for Epicyclic Reduction in off highway

vehicles and tractors.

Utility Applicable
Automobile -
Off
Highway
Agri
Machinery

Spur Satellite Gears

(ii) Spur Satellite Gears for Epicyclic Reduction.

Utility Applicable
Automobile -
Off Highway
Agri Machinery

Flanges

(iii) Flanges for off highway transmission.

Utility Applicable
Automobile -
Off
Highway
Agri -
Machinery

5). Hypoid and Bevel Gears

Crown Wheel & HYPERLINK

"http://www.gnagroup.com/prod_hypoid1.htm" Crown Wheel & Pinion for
 HYPERLINK "http://www.gnagroup.com/prod_hypoid2.htm" Crown Wheel &
Pinion for

Pinion for Trucks Off Highway Cars and SUV

(i) Crown Wheel & Pinion for Trucks

Utility Applicable
Automobile
Off
Highway -
Agri -
Machinery

(ii) Crown Wheel & Pinion for Off Highway

Utility Applicable
Automobile -
Off Highway
Agri
Machinery

(iii) Crown Wheel & Pinion for Cars and SUV

Utility Applicable
Automobile
Off
Highway -
Agri -
Machinery
 6).Right Angle Drive Gear Boxes

Right Angle Drives with 1 & 2 outputs in different gear ratio for
various agriculture and other implements.

Utility Applicable
Automobile -
Off Highway -
Agri
Machinery

7). Propeller Shaft Assy & Components

Propeller Shaft Assy. Various components

(xi) Propeller Shaft Assy. Of various sizes suitable for Cars, SUVs, LCV and

heavy trucks upto 20 tonnes.

Utility Applicable
Automobile
Off -
Highway
Agri
Machinery
(xii) Various components like U.J. Cross, Spline

8). Steering Column Assy.

Steering Column Assemblies for LCVs, HCVs. Also available for various
tractors.

Utility Applicable
Automobile
Off
Highway -
Agri
Machinery