SUMMER TRAINING REPORT

ON
TO INCREASE THE YIELD
In Metallic division

Submitted to: Submitted by:

Mr. James Kunjwal SAHIB MERAJ
Astt. Professor M.E dept.
 CONTENTS
Part 1- COMPANY OVERVIEW
 Acknowledgement
 About varroc
 Mission
 Vision
 Core values
 QMS ,EHS & TPM Policy
 Historical background of a company
 Product
 Awards & Appreciation
 Clients
Part 2- Report
 Metallic division
 Layout of metallic division
 Manufacturing of input and ouput shafts/gears
 Yield improvement report
 Implements
conclusion
 ACKNOWLEDGEMENT

“Expression of feeling by words makes them less significant

when it comes to make statement of gratitude.
There are few moments in life when you really feel like
expressing gratitude and sincere thanks. I take this opportunity
to express my deep gratitude to person who has helped me.
The summer training project would not have been a success
without the timely guidance of Mr. R.P.Chauhan (head of
metallic division) and Mr. Ramesh Singh (H.O.D Forging
Division).
I enjoyed full freedom to move in the organization and collect
the required information from the order department as well.
And lastly i am also thankful to our honoured faculties for their
constant support and for granting the opportunity to gain
practical knowledge through the summer training programme.
VARROC ENGINEERING Pvt. Ltd. PANTNAGAR

• Plant Name : Varroc Engineering Pvt. Ltd.- Plant –

VEPL-PN
• Location : Plot No.20,Sector 9,IIE SIDCUL
Pantnagar, Udham Singh Nagar-263153
• Plant Production Started : April 2007
• Total No of Employees : 922 Nos.
• Plot Area : 101171 Sq.mt
• Turnover [FY 13-14] : 369 Cr

• Major Customer : Bajaj Auto Ltd.

 ABOUT VARROC
 Varroc group is private group.
 The varroc group manufactures and markets a highly diversified portfolio
of automotive components and subassembles for two wheelers, three
wheelers, four wheelers for sale in domestice and as well overseas.
 In the four wheelers space the group has ventured only into plastic
mounded component, engine valves and forged component.
 The Varroc group structured into two separate entities:
Varroc polymers private limited (VPPL) and Varroc engineering private
limited (VEPL).
Varroc polymer manufacture polymer based components and varroc
engineering manufacturing electrical, electronic and mechanical components.
 MISSION
Varroc aims to become global player in the business of component supplies to
automobile and white goods industry across india and select foreign markets like
USA, Europe and ASIAN countries, growing at 25% CAGR with 15% of the
value of products being exported by the year 2010.

VISION
We are committed to serve the society by adding value to the customers,
employees, suppliers, shareholders and the community at large in terms of:
 Providing customer satisfaction by offering reliable product and service at
competitive price
 providing an environment conducive to the development, growth and
satisfaction of employees while fulfilling their reasonable aspiration.
 Providing adequate returns to the shareholders while nurturing business
growth.
 Contributing to the well-being of the society and conducting ourselves as a
responsible corporate citizen known for integrity and ethics.
CORE VALUES
QUALITY POLICY
ENVIRONMENT, HEALTH & SAFETY
POLICY
TPM POLICY
HISTORYCAL BACKGROUND OF
COMPANY
 AWARDS & APPRECIATION-Varroc
Group
 The varroc-IMES transaction was awarded the best acquisition by a foreign
company in Italy for a year 2007.
 Kaizen championship trophy for year 2007 , which was conferred upon by
the tpm club of India. (kaizen award has been constituted for promotion of
kaizen culture amongst India industry by TPM club of INDIA.
 Varroc wins ACMA gold trophy for excellence in quality and productivity.
 VEPL-1, VEPL-4, VEPL-6 plants got Awards from Bajaj auto ltd. For
outstanding quality performance in this year (20.10.2007).
 BAL TPM AWARD was presented to VEPL-6.
 VEPL-3 received the Bajaj Silvar Award for quality supplier.
 The Appreciation Award was given to VPPL-4 at kaizen competition in
nasik.
 Varroc group won accolades in the form of appreciation from clients like
bajaj auto, lg, honda and caterpillar.
 Honda Award for best quality supplier for yesr 2007-2008.
CLIENTS
 PART 2- REPORT
METALLIC DIVISION

 LAYOUT OF METALLIC DIVISION

 PROCESS FLOW CHART

MATELLIC INWARD BROACHING

STORE INSPECTION

THREADING HOBBING HEAT

TREATMENT

SHORT THREAD ROLLING

BLASTING SOFTENING

HONING GRINDING WASHING

F.I.D
 YIELD REPORT

Gross
S. Gear Part Net Billet Forging Finish Forging
Model Steel Grade Billet Yield
No. Name No. Weight Weight Weight Yield
Weight
1st.
1 JZ 372 SCM415HM 327 365 321
Driven 126 88% 35%
2nd.
2 JZ 872 SCM415HM 214 239 207
Driven 76 87% 32%
3rd. 16MnCr5
3 JZ 873 214 239 209
Driven LSI 94 88% 40%
4th. 16MnCr5
4 JZ 874 224 250 221
Driven LSI 126 88% 50%
5th. 16MnCr5
5 JZ 437 226 252 224
Driven LSI 113 89% 45%
2nd. 16MnCr5
6 JZ 867 105 117 104
Drive LSI 40 89% 34%
3rd. 16MnCr5
7 JZ 868 186 207 183
Drive LSI 101 88% 49%
4th. 16MnCr5
8 JZ 869 178 198 172
Drive LSI 70 87% 35%
16MnCr5
9 JZ 870 214 239 208
5th.Drive LSI 89 87% 37%
3rd. 16MnCr5
10 PLT 106 176 196 172
Drive LSI 91 88% 46%
4th. 16MnCr5
11 PLT 107 202 225 198
Driven LSI 116 88% 51%
2nd. 16MnCr5
12 BM 914 106 118 104
Drive LSI 56 88% 47%
2nd. 16MnCr5
12 BM 914 122 136 119
Drive LSI 56 87% 41%
3rd. 16MnCr5
13 BM 915 184 205 182
Drive LSI 101 89% 49%
4th. 16MnCr5
14 BM 916 176 196 171
Drive LSI 74 87% 38%
2nd.
15 BM 918 SCM415HM 228 254 221
Driven 116 87% 45%
3rd. 16MnCr5
16 BM 919 214 239 209
Driven LSI 98 88% 41%
We understood the Yield loss tree, and observed that we can actually work on
three areas primarily like - Less transfer efficiency, Process Parameters
optimization and Wastage during colour change. IN FIRST FACE WE ARE
WORKING ON THREE STAGE WHICH ARE INDICATED BY RED RING .

Yield Loss Analysis

Step 1 - Understand the situation
 Step 2 - Expose and eliminate abnormalities

Yield loss analysis stage wise . Forging to turning 41.63 % & turning to Teeth
cutting 4.56 % . We have taken improvement projects forging to turning.

Present Situation(Gear wise)

 Case Study -1
Step 3 - Plan Improvement

Step 4 – Action Plan Improvement

For that we have made a improvement plan parts wise for 3dr pl , 4dr dn
pl & both model of GPH through die design change .
 Case Study -2
Step 5 - Implement Improvement

We have modified the die & producing the flash less parts. Through this
modification material saved 5 gram /part.
 After improvement

Yield Improvement Trend

Step 6 - Check & Monitor Results
400
336330
350
300
Value(in Gm)

250 234 228

214204 214 204
198 188
200
150 122 112
100
50
0
1st Driven 5th Driven 5th Drive 3rd Driven 4th drive Jz GPH for all
for all jz Jz jz/bm /bm model
models
Before Cut weight After Cut weight
 60
58.56
57.09
50

40

%
Yield
30

20

10

0
Before After
This is result parts wise in spur gears we have saved 5 gram & in GPH 6
gram / part.
 CONCLUSION
At the end of the project I come to the conclusion that this
project successfully saved a man power to the company and
also increased the productivity of the current workers.
Also this Project Suggest the improvement of Environmental
condition and also saved the electrical energy.