`

PROJECT REPORT ON
TIME STUDY AND WORK CONTENT
OF CAPTAIN LINE

MADE BY –DEEPAK TIWARI

COLLEGE –DEHRADUN INSTIYUTE OF
PROJECT HEAD-
TECHNOLOGY
MR.PANKAJ
CHANDEL GUIDED BY- MR. VIPIN SINGH NEGI
`

CONTENTS

 INTRODUCTION
 HISTORY
 PANTHNAGAR PLANT
 EARLY PRODUCT
 PRODUCT RANGE
 CURRENT PRODUCT
 DEFENCE PRODUCT
 TECHNOLOGY
 FUTURE PLANS
 WELDING
 METAL FINISING
 SEALANT OPERATION
 FIXTURES
 ROBOTS
 TYPES OF LINES
 CAPTAIN VARIENT
 CAPTAIN PROCESS FLOW
 TIME STUDY
 WORK CONTENT
 REPORT
 TOTAL TIME
 CONCLUSION
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INTRODUCTION

ASHOK LEYLAND:
Is an Indian automobile manufacturing company based in Chennai, India. Founded in 1948, it is the 2nd
largest commercial vehicle manufacturer in India, 4th largest manufacturer of buses in the world and 16th
largest manufacturer of trucks globally. Operating six plants, Ashok Leyland also makes spare parts and
engines for industrial and marine applications. It sells about 60,000 vehicles and about 7,000 engines
annually. It is the second largest commercial vehicle company in India in the medium and heavy commercial
vehicle (M&HCV) segment with a market share of 28% (2007–08). With passenger transportation options
ranging from 19 seaters to 80 seaters, Ashok Leyland is a market leader in the bus segment. The company
claims to carry more than 60 million passengers a day, more people than the entire Indian rail network. In the
trucks segment Ashok Leyland primarily concentrates on the 16 ton to 25 ton range of trucks. However
Ashok Leyland has presence in the entire truck range starting from 7.5 tons to 49 tons. With a joint venture
with Nissan Motors of Japan the company made its presence in the Light Commercial Vehicle (LCV)
segment (<7.5 tons) Ashok Leyland’s UK subsidiary Optare has shut down its bus factory in Blackburn,
Lancashire.[3] This subsidiary’s traditional home in Leeds has also been vacated in favour of a purpose
built plant at Sherburn-in-Elmet. The company later under Madras State Government and other shareholders
finalized for an investment and technology partner and thus the British based joined in 1954, changing the
name to Ashok Leyland.

Ashok Leyland is the 2nd largest manufacturer of commercial vehicles in India, the 4th largest manufacturer
of buses in the world and 16th largest manufacturer of trucks globally. With a turnover of 2.3 billion and a
footmark extends across 50 countries they are one of the most fully integrated manufacturing companies this
side of globe.

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HISTORY

Ashok Leyland was founded in 1948 by Raghunandan Saran, a freedom fighter from Punjab. After
Independence he was persuaded by India’s first Prime Minister Nehru, to invest in modern industrial
venture. Thus Ashok Motors was incorporated in 1948 as a company to assemble and manufacture Austin
cars from England, and the company was named after the founder’s only son Ashok Saran. The company
had its headquarters in Rajaji Saalai, Chennai (then Madras) with the plant in Ennore, a small fishing hamlet
in the North of Chennai. The Company was engaged in assembly and distribution of Austin A40 passenger
cars in India. The company later under Madras State Government and other shareholders finalized for an
investment and technology partner and thus the British based joined in 1954, changing the name to Ashok
Leyland.

Sometime later, Raghunandan Saran died in an air crash, prior to that he had been negotiating with Leyland
Motors of England for assembly of commercial vehicles as he envisioned commercial vehicle were more in
need at that time than were passenger cars. The company later under Madras State Government and other
shareholders finalized for an investment and technology partner and thus Leyland Motors joined in 1954
with equity participation, changing the name of the company to Ashok Leyland. Ashok Leyland then started
manufacturing commercial vehicles. Under Leyland’s management with British expatriate and Indian
executives the company grew in strength to become one of India’s foremost commercial vehicle
manufacturers. The collaboration ended sometime in 1975 but the holding of British Leyland, now a major
British Auto Conglomerates a result of several mergers agreed to assist in technology which continued until
the 1980s. Post1975, changes in management structures saw the company launch various advanced vehicles
and pioneering innovations in the Indian market, with many of these models continuing to this day with
numerous upgrades over the years.

In 1987, the overseas holding by Land Rover Leyland International Holdings Limited (LRLIH) was taken
over by a joint venture between the Hinduja Group, the Non-Resident Indian transnational group and
IVECO, part of the Fiat Group. Ashok Leyland’s long-term plan to be-come a global player by
benchmarking global standards of technology and quality was soon firmed up. Accession international
technology and a US$200 million investment programme created a state-of-the-art manufacturing base to
roll out international class products.

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PANTNAGAR PLANT

 Ashok Leyland’s Pantnagar manufacturing facility Located in Dev Bhoomi, Uttarakhand, this is now
our largest manufacturing unit, spread across 190 acres of land. The plant is capable of churning out
trucks at the rate of 75,000 vehicles a year; built with an investment of 1500 crores.

 Pantnagar state-of-the-art shop floor equipment has been sourced from Japan, USA, as well as India.
Lean manufacturing principles, process control for high quality output and flexibility to manage
quick changeovers are all built into machine and process selection.

 Work on separate sections, such as chassis, engine and gearbox, suspension and cab are divided into
designated business units to maximize efficiency. Here the CNC flexible roll forming technology has
been introduced for frame manufacture; a first in India.

 Ashok Leyland Ltd flagship of the Hinduja Group rolled out the 100,000th vehicle from the state of
art facility at Pantnagar, Uttarakhand.

 Hosing the latest technology and processes, this is fully integrated plant manufactures all future
grazing product across trucks and buses, spread over 200 acres of land and with an annual capacity of
700,000 vehicles the plant also produces aggregates such as engine, gear boxes and axle.

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EARLY PRODUCT

TITAN:
In 1968, production of the Leyland Titan ceased in Britain, but was restarted by Ashok Leyland in India. The
Titan PD3 chassis was modified and a five speed heavy duty constant-mesh gear box was used together with
the Ashok Leyland version of the O.680 engine. The Ashok Leyland Titan was very successful and
continued in production for many years.

.
HINO ENGINE:
During early 80’s Ashok Leyland entered into collaboration with Japanese company Hino Motor from
whom technology for the H-series engines was sourced. Many indigenous versions of H-series engine were
developed with 4 and 6 cylinders and also conforming to BS2 and BS3 emission standards in India. These
engines proved to be extremely popular with the customers primarily for their excellent fuel efficiency. Most
current models of Ashok Leyland come with H-series engines.

IVECO PARTNERSHIP:
In late 1980’s Iveco investment and partnership resulted in Ashok Leyland launching the'Cargo' range of
trucks based on European Ford Cargo trucks. The Cargo entered production in 1994, at Ashok Leyland’s
new plant in Hosur, southeast of Bangalore.[5]These vehicles used Iveco engines and for the first time had
factory-fitted cabs. Though the Cargo trucks are no longer in production and the use of Iveco engine was
discontinued, the cab continues to be used on the Ecome trange of trucks as well as for several of Ashok
Leyland’s. Military vehicles.
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PRODUCTS RANGE

MINING AND CONSTURCTION

TRUCKS

LONG HAUL DISTRIBUTION TRUCK

STALLION

DEFENCE SUPER
LRV
VEHICLES STALLION

GUN
TOWER
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CURRENT PRODUCT

U-TRUCK:
Ashok Leyland, announced sale of vehicles on the new U-Truck platform from November, 2010 with the
rolling out of the first set of 10 models of tippers and tractor trailers in the 16 – 49-tonne segments. Further,
another 15 models are set to enter the market in the next12 months.

STILE:
STiLE was Multi-purpose vehicle manufactured by Ashok Leyland. The vehicle was unveiled during 2012
Auto Expo and was launched in Jul 2013. STiLE was produced as a “Multi-purpose vehicle” to be used as
commercial vehicle (hotel shuttles, taxi, ambulances, panel van, courier service, inter-city and for intra-city
travel. In May 2015, Ashok Leyland stopped production of the vehicle due low demand for the mode.

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DOST:
The Dost is a 1.25 ton light commercial vehicle(LCV) that is the first product to be launched by the Indian-
Japanese commercial vehicle joint venture Ashok Leyland Nissan Vehicles. Dost is powered by a 58hp high-
torque, 3-cylinder, turbo-charged Common Rail Diesel engine and has a payload capacity of 1.25 Tonnes. It
is available in both BS3 and BS4 versions. The body work and some of the underpinnings relate to
Nissan’sC22 Vanette of the 1980s; this is most visible in the door design. The LCV is being produced in
Ashok Leyland’s Hosur plant in Tamil Nadu. The LCV is available in three versions with the top-end
version featuring air conditioning, power steering, dual-color of a beige-grayt rim and fabric seats. With the
launch of Dost Ashok Leyland has now entered the Light Commercial Vehicle segment in India.

BOSS:
Boss is an Intermediate Commercial Vehicle launched by Ashok Leyland. This is available in the range of
8T to 14T. This is available with two engine options120IL (LE) and 130CRS (LX) engines and both are
first-time such an engines are offered in this range of trucks. The LX variant is available with Air condition
and Leymatic AMT which are again the industry first.

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DEFENCE PRODUCT

ASHOK LEYLAND DEFENCE SYSTEM:

Ashok Leyland De fence Systems (ALDS) is a newly floated company by the flagship company of Hinduja
group, holds 26 percent in the newly formed Ashok Leyland Defence Systems (ALDS). The newly floated
company has a mandateto design and develop de fence logistics and tactical vehicles, Defence
communication and other systems.Ashok Leyland is the largest supplier of logistics vehicles to the Indian
Army. It has supplied over 60,000 of its Stallion vehicle.

LRV:

In October 2006, Ashok Leyland bought a large stake in the Czech-based- LRV, later renaming as LRV
Ashok Leyland Motors servo, to gain entry into the competitive European market. But prolonged recession
in Europe forced to shut down the Czech operations in 2013.

SUPER STALLON:

In 2010 Ashok Leyland acquired a 26% stake in the manufacturer SUPER STALLION, a company based on the premises of a
former British Leyland subsidiary C.H.Roe. In December 2011 Ashok Leyland increased its stake in Optare to 75.1%.s which
form the Army’s logistics he Hinduja Group. Ashok Leyland.

8
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TECHNOLOGY

HYTHANE ENGINES:
Ashok Leyland has also developed Hythane engines in association with the Australian company Eden
Energy. Ashok Leyland successfully developed a 6-cylinder, 6-litre (370 cu in) 92 kW (123 hp) BS-4 engine
which uses Hythane (H-CNG,) which is a blend of natural gas and around 20% of hydrogen. Hydrogen helps
improve the efficiency of the engine but the CNG aspect makes sure that emissions are at a controlled level.
A 4-cylinder 4-litre(240 cu in) 63 kW (84 hp) engine is also being developed for H-CNG blend in a joint
R&D program with MNRE (Ministry of New and Renewable Energy) and Indian Oil Corporation.

CNG ENGINES:
The CNG concept is now in full swing, with more than5,500 of the technology’s vehicles running around
Delhi. The company is also already discussing the wide-scale use of Hythane engines with the Indian
government. Hythane engines may be expected in the near future.

NISSAN PARTNERSHIP:
Ashok Leyland’s partnership with Nissan is also focusing on vehicle, powertrain, and technology
development listed under three joint ventures. With impressive investment, the joint ventures will focus on
producing trucks with diesel engines that meet Euro 3 and Euro 4 emission standards.

HYBRID TECHNOLOGY:

The buses and trucks are set to feature a new electronic shift-by-wire transmission technology as well as
electronic controlled engine management for greater fuel efficiency. Ashok Leyland focuses on improving
fuel efficiency without affecting automotive power, and the vehicles will have a 5% improvement on fuel
efficiency. Ashok Leyland is also developing electric batteries and bio-fuel modes.

IBUS:
Ashok Leyland announced iBUS in the beginning of2008, as part of the future for the country’s increasingly
traffic- clogged major cities. Its Rs 60-lakh, iBus,a feature-filled, low-floor concept bus for the metros
revealed during the Auto Expo 2008 in India this low floored iBus will have the first of its kind features,
including anti-lock braking system, electronic engine management and passenger infotainment. The
executive class has an airline like ambience with wide LCD screens.

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FUTURE PLANS

A new flagship bus named Solo, described as a low-floor minibus, will soon be launched in
Indianmarket.AL is planning to introduce the JanBus, a single step, front engine, fully-flat floor bus.AL is
looking at bringing Hybrid version of Optare’s electric buses. AL upcoming products are Falcon 56-seater
AC school bus, Partner (6 ton GVW) and Boss (9 to 12 tons GVW) range of vehicles. From all accounts,
Ashok Leyland (AL), one of India’s leading bus makers, is in cruise control. It has an oversized share of the
market at 41.78 per cent, and, along with Tata, which has 41.94 per cent, rules the universe of buses in India.
Moreover, Ashok Leyland has a considerable advantage over the smaller players — especially from abroad,
like Volvo or Isuzu — with its strong distribution network of 420 nationwide dealers, enviable brand
identity, good relations with state transport corporations as well as local sourcing partners.

Yet, AL has decided it needs to push the envelope in products and technology. It has done so by buying a 75
per cent stake in British bus manufacturer Optare, in December 2011, with the intention of bringing its
flagship bus, Solo, described as a low-floor midibus, to the Indian market. The bus will hit Indian roads in
the next few months. This could turn out to be a savvy move. Sometimes, proactive policies while in a
position of strength can do wonders to check problem spots that often germinate into full-fledged disasters.
And, it is not as if Ashok Leyland hasn’t had its share of problems. For instance, amidst the 2008 recession,
the company’s bus sales took a dip from FY07 to FY09 in arguably one of the fastest growing markets for
buses in the world. Recently, it was unable to win important bids for contracts with two state transport
corporations.

The bus market in India — which saw 98,673 units (including big buses and small ones) sold in 2011-12
versus 92,754 in the previous year — is undergoing a significant transformation. Earlier, travellers in India
primarily considered cost as the fundamental determining factor in the decision-making process of which bus
to board. Now, comfort, along with safety and reliability is a priority, says Abdul Majeed, analyst with PwC
India, which explains Volvo’s rise to prominence in the luxury end of the spectrum. The key driver for all of
these is technology, something that industry observers say both AL and as its competitor Tata are not up to
speed with, at least their global competitors.

10
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A new flagship bus named Solo, described as a low-floor minibus, will soon be launched in
Indianmarket.AL is planning to introduce the JanBus, a single step, front engine, fully-flat floor bus.AL is
looking at bringing Hybrid version of Optare’s electric buses. AL upcoming products are Falcon 56-seater
AC school bus, Partner (6 ton GVW) and Boss (9 to 12 tons GVW) range of vehicles. From all accounts,
Ashok Leyland (AL), one of India’s leading bus makers, is in cruise control. It has an oversized share of the
market at 41.78 per cent, and, along with Tata, which has 41.94 per cent, rules the universe of buses in India.
Moreover, Ashok Leyland has a considerable advantage over the smaller players — especially from abroad,
like Volvo or Isuzu — with its strong distribution network of 420 nationwide dealers, enviable brand
identity, good relations with state transport corporations as well as local sourcing partners.

Yet, AL has decided it needs to push the envelope in products and technology. It has done so by buying a 75
per cent stake in British bus manufacturer Optare, in December 2011, with the intention of bringing its
flagship bus, Solo, described as a low-floor midibus, to the Indian market. The bus will hit Indian roads in
the next few months. This could turn out to be a savvy move. Sometimes, proactive policies while in a
position of strength can do wonders to check problem spots that often germinate into full-fledged disasters.
And, it is not as if Ashok Leyland hasn’t had its share of problems. For instance, amidst the 2008 recession,
the company’s bus sales took a dip from FY07 to FY09 in arguably one of the fastest growing markets for
buses in the world. Recently, it was unable to win important bids for contracts with two state transport
corporations.

The bus market in India — which saw 98,673 units (including big buses and small ones) sold in 2011-12
versus 92,754 in the previous year — is undergoing a significant transformation. Earlier, travellers in India
primarily considered cost as the fundamental determining factor in the decision-making process of which bus
to board. Now, comfort, along with safety and reliability is a priority, says Abdul Majeed, analyst with PwC
India, which explains Volvo’s rise to prominence in the luxury end of the spectrum. The key driver for all of
these is technology, something that industry observers say both AL and as its competitor Tata are not up to
speed with, at least their global competitors.

11
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WELDING

TYPES OF WELDING

SPOT
WELDING

MAG MIG
WELDING WELDING WELDING

STUD
WELDING

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WELDING

WELDING:
Is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing
fusion, which is distinct from lower temperature metal joining techniques such as brazing and soldering,
which do not melt the base metal. In addition to melting the base metal, a filler material is often added to the
joint to form a pool of molten material (the weld pool) that cools to form a joint that can be as strong as the
base material .Pressure may also be used in conjunction with heat, or by itself, to produce a weld. Some of
the best known welding methods include:

GAS METAL ARC WELDING (GMAW):

Sometimes referred to by its subtypes metal inert gas (MIG) welding or metal active gas (MAG) welding,
is a welding process in which an electric arc forms between a consumable wire electrode and the work piece
metal(s), which heats the work piece metal(s), causing them to melt, and join. Along with the wire electrode,
a shielding gas feeds through the welding gun, which shields the process from contaminants in the air. The
process can be semi-automatic or automatic. A constant voltage, direct current power source is most
commonly used with GMAW, but constant current systems, as well as alternating current, can be used.
There are four primary methods of metal transfer in GMAW, called globular, short-circuiting, spray, and
pulsed-spray, each of which has distinct properties and corresponding advantages and limitations.

Originally developed for welding aluminum and other non-ferrous materials in the 1940s, GMAW was soon
applied to steels because it provided faster welding time compared to other welding processes. The cost of
inert gas limited its use in steels until several years later, when the use of semi-inert gases such as carbon
dioxide became common. Further developments during the 1950s and 1960s gave the process more
versatility and as a result, it became a highly used industrial process. Today, GMAW is the most common
industrial welding process, preferred for its versatility, speed and the relative ease of adapting the process to
robotic automation. Unlike welding processes that do not employ a shielding gas, such as shielded metal arc
welding, it is rarely used outdoors or in other areas of air volatility. A related process, flux cored arc
welding, often does not use a shielding gas, but instead employs an electrode wire that is hollow and filled
with flux.

STUD WELDING:
Is a technique similar to flash welding where a fastener or specially formed is nut welded onto another metal
part, typically a base metal or substrate. The fastener can take different forms, but typically fall under
threaded, unthreaded or tapped. The bolts may be automatically fed into the spot welder. Weld nuts generally
have a flange with small nubs that melt to form the weld. Weld studs are used in stud welding systems.

Capacitor discharge weld studs range from 14 gauge to 3/8" diameter. They can come in many different
lengths ranging from 1/4" to 5" and larger. The tip on the weld end of the stud serves a twofold purpose It
acts as a timing device to keep the stud off the base material. It disintegrates when the trigger is pulled on the
gun. 13
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When the tip disintegrates, it melts and helps solidify the weld to the base material. Arc studs range from a #
8 to 11⁄4" diameter. The lengths are variable from 3/8" to 60" (for deformed bars). Arc studs are typically
loaded with an aluminum flux ball on the weld end which aids in the welding process.

Stud welding, also known as "drawn arc stud welding", joins a stud and another piece of metal together by
heating both parts with an arc. The stud is usually joined to a flat plate by using the stud as one of the
electrodes the polarity used in stud welding depends on the type of metal being used. Welding aluminum,
for example, would usually require direct-current electrode positive (DCEP). Welding steel would require
direct-current electrode negative (DCEN).Stud welding uses a type of flux called a ferrule, a ceramic ring
which concentrates the heat generated, prevents oxidation and retains the molten metal in the weld zone. The
ferrule is broken off of the fastener after the weld is completed. This lack of marring on the side opposite the
fastener is what differentiates stud welding from other fastening processes

Portable stud welding machines are available. Welders can also be automated, with controls for arcing and
applying pressure. Stud welding is very versatile. Typical applications include automobile bodies, electrical
panels, shipbuilding and building construction. Shipbuilding is one of the oldest uses of stud welding. Stud
welding revolutionized the shipbuilding industry. All other manufacturing industries can also use stud
welding for a variety of purposes.

A type of stud welding called capacitor-discharge (CD) stud welding differs from regular stud welding in
that capacitor-discharge welding does not require flux. The weld time is shorter, enabling the weld to bond
with little oxidation and no need for heat concentration. It also allows for small-diameter studs to be welded
to thin, lightweight materials. This process uses a direct-current arc from a capacitor. The weld time in this
process is between 1 and 6 milliseconds. Capacitor discharge stud welding with the latest equipment can
create a weld without burn through showing on the opposite side of very thin metals. CD stud welding is
often used for smaller diameter studs and pins, as well as on non-standard materials and for accuracy. On the
other hand, arc stud welding is primarily for structural purposes and larger diameter weld studs.

SPOT WELDING (RSW):

Is a process in which contacting metal surfaces are joined by the heat obtained from resistance to electric
current Work-pieces are held together under pressure exerted by electrodes. Typically the sheets are in
the0.5to 3 mm (0.020 to 0.118 in) thickness range. The process uses two shaped copper alloy electrodes to
concentrate welding current into a small "spot" and to simultaneously clamp the sheets together. Forcing a
large current through the spot will melt the metal and form the weld. The attractive feature of spot welding is
that a lot of energy can be delivered to the spot in a very short time (approximately 10–100 milliseconds).
That permits the welding to occur without excessive heating of the remainder of the sheet. The amount of
heat (energy) delivered to the spot is determined by the resistance between the electrodes and the magnitude
and duration of the current.] The amount of energy is chosen to match the sheet's material properties, its
thickness, and type of electrodes. Applying too little energy will not melt the metal or will make a poor weld.
Applying too much energy will melt too much metal, eject molten material, and make a hole rather the weld.
Another feature of spot welding is that the energy delivered to the spot can be controlled to produce liable
welds. 14

14

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METAL FINISHING

OPERATION IN METAL FINISHING

 BUFFING
 SANDING
 GRINDING
 BOLT ON
 MAG WELDING
 DOOR FITMENT
 REWORK
 DISPATCH

POLISHING AND BUFFING:

Are finishing processes for smoothing a work piece’s surface using an abrasive and a work wheel or a
leather strop. Technically polishing refers to processes that use an abrasive that is glued to the work wheel,
while buffing uses a loose abrasive applied to the work wheel. Polishing is a more aggressive process while
buffing is less harsh, which leads to a smoother, brighter finish. A common misconception is that a polished
surface has a mirror bright finish, however most mirror bright finishes are actually buffed. Polishing is often
used to enhance the looks of an item, prevent contamination of instruments, remove oxidation, create a
reflective surface, or prevent corrosion in pipes. In metallography and metallurgy, polishing is used to create
a flat, defect-free surface for examination of a metal's microstructure under a microscope. Silicon-based
polishing pads or a diamond solution can be used in the polishing process. Polishing stainless steel can also
increase the sanitary benefits of stainless steel. The removal of oxidization (tarnish) from metal objects is
accomplished using a metal polish or tarnish remover; this is also called polishing. To prevent further
unwanted oxidization, polished metal surfaces may be coated with wax, oil, or lacquer. This is of particular
concern for copper alloy products such as brass and bronze. The term chem -mechanical was coined to
describe action of corrosive slurry on silicon in a polishing process. Multiple rotating heads, each studded
with silicon wafers, get forced against a large rotating buffing pad, which is bathed in corrosive slurry.
Material removal at elevated temperature progresses first through oxidation, then through oxide removal by
abrasion. This cycle repeats with each rotation of a head. Potassium Hydroxide and Silox (white paint-base)
can be combined with deionized water to form such slurry.

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GRINDING:

Is a subset of cutting, as grinding is a true metal-cutting process. Each grain of abrasive functions as a
microscopic single-point cutting edge (although of high negative rake angle), and shears a tiny chip that is
analogous to what would conventionally be called a "cut" chip (turning, milling, drilling, tapping, etc.).
However, among people who work in the machining fields, the term cutting is often understood to refer to
the macroscopic cutting operations, and grinding is often mentally categorized as a "separate" process. This
is why the terms are usually used in contradistinction in shop-floor practice.

GAS METAL ARC WELDING (GMAW):

Sometimes referred to by its subtypes metal inert gas (MIG) welding or metal active gas (MAG) welding, is a welding
process in which an electric arc forms between a consumable wire electrode and the work piece metal(s), which
heats the work piece metal(s), causing them to melt, and join. Along with the wire electrode, a shielding gas
feeds through the welding gun, which shields the process from contaminants in the air. The process can be
semi-automatic or automatic. A constant voltage, direct current power source is most commonly used with
GMAW, but constant current systems, as well as alternating current, can be used. There are four primary
methods of metal transfer in GMAW, called globular, short-circuiting, spray, and pulsed-spray, each of
which has distinct properties and corresponding advantages and limitations.

Originally developed for welding aluminum and other non-ferrous materials in the 1940s, GMAW was soon
applied to steels because it provided faster welding time compared to other welding processes. The cost of
inert gas limited its use in steels until several years later, when the use of semi-inert gases such as carbon
dioxide became common. Further developments during the 1950s and 1960s gave the process more
versatility and as a result, it became a highly used industrial process. Today, GMAW is the most common
industrial welding process, preferred for its versatility, speed and the relative ease of adapting the process to
robotic automation. Unlike welding processes that do not employ a shielding gas, such as shielded metal arc
welding, it is rarely used outdoors or in other areas of air volatility. A related process, flux cored arc
welding, often does not use a shielding gas, but instead employs an electrode wire that is hollow and filled
with flux.

16
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SEALANT OPERATION

SEALANT:
Is a substance used to block the passage of fluids through the surface or joints or openings in materials, a
type of mechanical seal. In building construction sealant is sometimes synonymous with caulking and also
serve the purposes of blocking dust, sound and heat transmission. Sealants may be weak or strong, flexible
or rigid, permanent or temporary. Sealants are not adhesives but some have adhesive qualities and are called
adhesive-sealants or structural sealants.

FUNCTION:

Sealants, despite not having great strength, convey a number of properties. They seal top structures to the
substrate, and are particularly effective in waterproofing processes by keeping moisture out (or in) the
components in which they are used. They can provide thermal and acoustical insulation, and may serve as
fire barriers. They may have electrical properties, as well. Sealants can also be used for simple smoothing or
filling. They are often called upon to perform several of these functions at once.

SEALANT USED IN PLANT

 SPOT WELDING SEALANT

 DOOR SEALANT
 THUMB SEALANT
 TERAKOL
 STRUCTURE SEALANT
 GLASS BEAT SEALANT

17

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FIXTURES

FIXTURE:

Is a work-holding or support device used in the manufacturing industry. Fixtures are used to securely locate
(position in a specific location or orientation) and support the work, ensuring that all parts produced using
the fixture will maintain conformity and interchangeability. Using a fixture improves the economy of
production by allowing smooth operation and quick transition from part to part, reducing the requirement for
skilled labor by simplifying how work pieces are mounted, and increasing conformity across a production
run. A fixture differs from jig in that when a fixture is used, the tool must move relative to the work piece; a
jig moves the piece while the tool remains stationary.

PURPOSE:
A fixture’s primary purpose is to create a secure mounting point for a work piece, allowing for support
during operation and increased accuracy, precision, reliability, and interchangeability in the finished parts. It
also serves to reduce working time by allowing quick set-up, and by smoothing the transition from part to
part. It frequently reduces the complexity of a process, allowing for unskilled workers to perform it and
effectively transferring the skill of the tool maker to the unskilled worker.[2]Fixtures also allow for a higher
degree of operator safety by reducing the concentration and effort required to hold piece
steady.[3]Economically speaking the most valuable function of a fixture is to reduce labor costs. Without a
fixture, operating a machine or process may require two or more operators.

FIXTURE
FFFFIXTURE

 MECHANICAL FIXTURE
 PNEUMATIC FIXTURE
 ELECTRO-PNEUMATIC FIXTURE

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ROBOT

ROBOT:
Is a mechanical or virtual artificial agent, usually an electro-mechanical machine that is guided by a
computer program or electronic circuitry. Robots can be autonomous or semi-autonomous and range from
humanoids such as Honda's Advanced Step in Innovative Mobility (ASIMO) and TOSY's TOSY Ping Pong
Playing Robot (TOPIO) to industrial robots, medical operating robots, patent assist robots, dog therapy
robots, collectively programmed swarm robots, UAV drones such as General Atomics MQ-1 Predator, and
even microscopic Nano robots. By mimicking a lifelike appearance or automating movements, a robot may
convey a sense of intelligence or thought of its own.

KUKA ROBOT:

The KUKA system software is the operating software and the heart of the entire control. In it all basic
functions arestored which are needed for the deployment of the robot system .Robots come with a control
panel that has a displayer solution of 640 x 480 pixels and an integrated 6D mouse, with which the
manipulator is moved, positions are saved(Touchup), or where modules, functions, data lists, etc. Are
created and modified. To manually control the axes, the enabling switch on the back of the control panel (the
KCP, or KUKA Control Panel) must be activated (today only with a panic function). The connection to the
controller is a VGA interface and a CAN-bus .A rugged computer located in the control cabinet
communicates with the robot system via an MFC card. Control signals between the manipulator and the
controls are transferred using the so-called DSE-RDW connection .The DSE card is in the control cabinet,
the RDW card in the robot socket .Controls for the old KRC1 types used Windows 95 to runV x Works-
based software. Peripheral equipment includes a CD-ROM and a disk drive; Ethernet, Profi bus, Interbus,
Device net and ASI sockets are also available. Controls for the newer KRC2 type use the Windows X
Poperating system. Systems contain a CD-ROM drive and USB ports, Ethernet connection and feature
optional connections for Profibus, Interbus, DeviceNet and Profinet.

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APPLICATION AREAS:
The industrial robots are used in a number of application areas, such as material handling, loading and
unloading of machines, palletizing and DE palletizing, spot and arc welding. They are used in number large
companies, predominantly in the automotive industry, but also in other industries such as the aerospace
industry.

Specific applications include:

 Food and beverage industry: for tasks such as loading and unloading of packaging machines, cutting
meat, stacking and palletizing, and quality control.

 Construction industry: e.g. for ensuring an even flow of material.

 Glass industry: used, for instance in the thermal treatment of glass and quartz glass in laboratory
glass production, bending and forming operations.

 Foundry and forging industry: the robots’ heat and dirt resistance enables them to be used directly
before, in and on the casting machines. They can also be used for operations such as deburring,
grinding or drilling, and for quality control.

 Wood industry: for grinding, milling, drilling, sawing, palletizing or sorting applications.

 Metal processing: for operations such as drilling, milling, sawing or bending and punching. Industrial
Robots are used in welding, assembly, loading and unloading processes.

 Stone processing: the ceramic and stone industries use the industrial robots for bridge sawing.

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TYPES OF ROBOTS

ROBOT

KUKA FANUK

TITAN QUANTEK

 Total no of robots in Captain line = 45

 Total no of robots in Boss =5
KUKA

 Total no of robots in G-91 =2

FANUK

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TYPES OF LINES

G-91

CAPTAIN

BOSS

 No of stations in G-91 line = 33

 No of stations in Boss line = 60
 No of stations in Captain line = 92

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CAPTAIN VARIENT

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CAPTAIN PROCESS
FLOW

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TIME STUDY

OBJECTVE OF PROJECT

 Time study of captain line.

 Work content study of captain line.

TIME STUDY:

Is the application of techniques designed to establish the time for a qualified worker to carry out a
specified job at desired level of performance. It is a direct and continuous observation of a task using a
timekeeping device (e.g., decimal minute stopwatch, computer-assisted electronic stopwatch, and video
tape camera) to record the time taken to accomplish a task and it is often used when: there are repetitive
work cycles of short to long duration.

The application of science to business problems, and the use of time-study methods in standard setting and
the planning of work, was pioneered by Frederick Winslow Taylor. Taylor liaised with factory managers and
from the success of these discussions wrote several papers proposing the use of wage-contingent
performance standards based on scientific time study. At its most basic level time studies involved breaking
down each job into component parts, timing each part and rearranging the parts into the most efficient
method of working. By counting and calculating, Taylor wanted to transform management, which was
essentially an oral tradition, into a set of calculated and written techniques.

PROCEDURE OF TIME STUDY:

• Define and document the standard method.

• Divide the task into work elements.

• These first two steps are conducted prior to the actual timing. They familiarize the analyst with the
task and allow the analyst to attempt to improve the work procedure before defining the standard
time.

• Time the work elements to obtain the observed time for the task.

• Evaluate the worker’s pace relative to standard performance (performance rating). 25

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WORK CONTENT

WORK CONTENT:

The Gilbert’s made use of scientific insights to develop a study method based upon the analysis of work
motions', consisting in part of filming the details of a worker’s 'activities and their body posture while
recording the time. The films served two main purposes. One was the visual record of how work had been
done, emphasizing areas for improvement. Secondly, the films also served the purpose of training workers
about the best way to perform their work. This method allowed the Gilbert’s to build on the best elements of
these work flows and to create a standardized best practice.

Total
work Excess
Basic
work
content time
content

Time due
Time due
to Excess
to defects
inefficient Time
in design
methods

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REPORT ON TIME STUDY AND WORK

CONTENT
STUDY OF CAPTAIN LINE

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CONCLUSION OF TIME STUDY AND WORK CONTENT

 Time study of CAPTAIN line leads to conclusion that total cycle taken during the entire cycle is
418min 24 sec (25104 sec).

 Time study of CAPTAIN line leads to conclusion that total work content during the entire cycle is
555 min 18 sec (33318 sec).

 Time study of CAPTAIN line leads to conclusion that total cycle time of robot is equal to the work
content i.e. 120 min 21 sec (7221 sec).

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