ACE DESIGNERS LTD.

INTERNSHIP REPORT 2018-19

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CONTENTS
Sl. No. Topic Page no.
1. Introduction About company 2

2. Component Manufacturing
4
Department
3. Metrology 7
4. Sheet Metal Department 8

5. Customer Service Group 12

6. Hydraulics 13

7. Paint Shop 14

8. Assembly Department 16

9. Electrical Department 18

10. Central Stores 20

11. Quality Assurance 21

12. Tool Room 22
13. Marketing 23
14. Human Resource 25
15. Gratitude 26

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INTRODUCTION ABOUT THE COMPANY

Ace Designers, was founded in 1979 as a design-consulting firm. It is led by three experienced
design engineers and powered by a dynamic team of more than 900 members is one of India’s
largest machine tool manufacturing companies. With a spread of over 50000 square meters, its
manufacturing plants, located in Bangalore, India, are equipped with state of the art technology
to deliver large scale high quality products.

Initially, the team developed product designs for various machine tools including special purpose
machines. Three years hence, in 1982, Ace stepped into the world of manufacturing with a range
of special purpose import substitution machines for the I.C. Engine valve Industry.
Since then, Ace has rapidly grown to become India’s largest manufacturer of CNC turning
centers and has remained the undisputed leader for nearly two decades.

With a strategic focus on manufacturing of CNC turning centers, Ace has developed a wide
range of indigenous cost effective products to meet the changing needs of its customers. Ace has
ensured product excellence through quality driven manufacturing processes supported by
meticulously planned world class infrastructure.

Having played a vital role in the Indian industrial renaissance, Ace machines have established
their footprint in the global arena too. They have found acceptance in Europe, USA, South
America, UK, Middle East, China, South East Asia, Japan and Australia.

Over the years, Ace co-founded several companies & collaborated with a few others to form the
Ace Micrometric group, India’s largest machine tool manufacturing conglomerate.

In the late 90s, Ace introduced its top selling machine, the Jobber. This product was a result of a
strategy to create demand for a competitively priced standardized CNC turning Centre at a time
when mainly customized products were being developed.

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This resulted in a three-fold increase in demand, from 50 machines to 150 machines per annum
in just two years. Over the years, this model has transformed into an entire series & the numbers
have grown to over 1000 machines per annum.

Ace designers plant unit at Bangalore consist of following main departments

➢ Marketing
➢ Purchase and Vendor
➢ Plant Engineering
➢ Component Manufacturing Department
➢ Sheet Metal Department
➢ Electrical
➢ Hydraulics
➢ Painting
➢ Central Stores and Warehouse
➢ Assembly
➢ Quality
➢ Customer Service Group
➢ Tool room/Information System group

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COMPONENT MANUFACTURING DEPARTMENT

The process of converting raw, components, or parts into finished goods that meet a customer’s
expectations or specifications. Manufacturing commonly employs a man-machine setup with
division of labor in a large scale production.
In this department all the components required for the assembly of the CNC Machining Centers
are manufactured with help of different kinds of conventional and nonconventional machines

Here the raw materials form the input to the machine whereas; the finished sub products form an
output from the system.

Different types of operations had carried out in different kinds of Machines used at
Component Manufacturing Department are as follows

 MCY Machine
 AMC Machine
 Horizontal Grinding Machine
 LT-20C Machine
 Vertical Turret Lathe
 Mastic Machine
 Starragheckert Machine

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 MCY Machine

M stands for Axial Direction

C Stands for Horizontal Direction

Y Stands for Linear Direction

In MCY Machine the Axis of the Spindle is placed in vertical Direction. This is used for
machining of predrilled component that is the rough finishing of inner and outer diameter of
component can be done.

 AMC Machine

This Machine is used to perform milling Operation on the component

 Horizontal Grinding Machine

This is the most preferred Machining tool use at CMD; this machine is used to machine the
horizontal Surface of the component.

 Sub Spindle Machine

As the name indicates it contains two Spindles, this machine is specially used for continuous
machining process.

 LT-20C

Working operation of this is same as the other machines, the only advantage of this machine is
the machine speed of the spindle can be altered based on the operation carried on.

 Mazatech Machine

This is one of the horizontal milling machine which is having four axis (X-axis, Y-axis, Z-axis
and B-axis) and this machine is also having six pallets, one is inside the machine and the rest of
them outside the machine ready for indexing.

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The specialty of this machine is it can run continuously for hours together without the aid of
human power. Mazatech has 120 tools with automatic tool changer, which uses different tools
for various operations automatically.

 HMC Machine

The performance of this machine resembles Mazatech. The only difference in this machine is it
has two pallets, one is inside the machine and the other is outside the machine waiting for
indexing.

 Starragheckert Machine

This is one of the biggest machines in ACE designers. It has got 20 pallets. It has two working
machines, each machine having one pallet inside the machine frame and rest of 18 are outside
the machine waiting for indexing one after another.

This machine is mainly used for day and work continuously. Generally tools used in these cnc
machines have carbide tips; where in the actual cutting action is done by carbide tip tools.

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METROLOGY

Metrology is the science of measurement. All measurement activities in ACE are carried out at
the Metrology Lab. It is the standards lab at ACE. Calibration of measuring instruments and
other high-precision measurements are the specialization of this department.

Constructional Features of the Metrology Lab.

● Vibration isolated floor for stable measurement. Standard flooring is 20” thick concrete
base
● Temperature is controlled between 19-21 C
● Humidity is maintained between 40% RH – 60%RH
● ISO Class-8 Clean room
● Light Intensity is 300 lux to 500 lux
The various machines and their specifications:

● Ballbar-QC20
● Roundness Tester
● Co-Ordinate Measuring Machine (CMM)
● Laser Interferometer
● Profile Projector
● Roundness Tester (Taylor Hobson)
● Smart Balancer
● Electronic Level \ Blue Level
● Surface Roughness Testing Machine

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SHEET METAL DEPARTMENT

Sheet metal is metal formed by an industrial process into thin, flat pieces. It is one of the
fundamental forms used in metalworking and it can be cut and bent into a variety of shapes.

Type of sheets:

● Hot rolled condition

● Cold rolled condition

Hot rolled:

Hot rolling is a mill process which involves rolling the steel at a high temperature (typically at a
temperature over 1700° F), which is above the steel’s recrystallization temperature. When steel is
above the recrystallization temperature, it can be shaped and formed easily, and the steel can be
made in much larger sizes. Hot rolled steel is typically cheaper than cold rolled steel due to the
fact that it is often manufactured without any delays in the process, and therefore the reheating of
the steel is not required (as it is with cold rolled). When the steel cools off it will shrink slightly
thus giving less control on the size and shape of the finished product when compared to cold
rolled.

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Cold rolled:

Cold rolled steel is essentially hot rolled steel that has had further processing. The steel is
processed further in cold reduction mills, where the material is cooled (at room temperature)
followed by annealing and/or tempers rolling. This process will produce steel with closer
dimensional tolerances and a wider range of surface finishes. The term Cold Rolled is mistakenly
used on all products, when actually the product name refers to the rolling of flat rolled sheet and
coil products.

Sheet metal is basically used for to produce the outer structure or frame to the machine to protect
the machine. At the outer structure the MS sheet metal is used. And at the sliding section the
stainless steel sheet is used avoid the scratches and to provide smooth sliding and efficient
sliding.

Basically the development of sheet metal can be produced based on the dimensions of 3D model
of the frame will be produced in some prescribed software package in computer. This
development will be transferred to the AF2000E system and that development will be
automatically transformed into some suitable program for laser cutting operation.

The laser cutting operation will be carried out in the AF2000E machine.

A -- AMDA

F – FANUC

The formation of laser will be carried/ produced in fanuc.

The cutting operation will be taken on amda machine.

The composition of laser beam is

● Carbon dioxide = 5%
● Helium = 40%
● Nitrogen = 55%
The nitrogen is generally used for cooling purpose in the machine.

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BENDING:

This is the most important operation after the cutting operation of the sheet metal the bending
operation will be carried out in AMDA machine which is having the capacity from 8 ton to 13
ton load.

In this machine the bending operation will be done as per the dimension and the angle of bending
will be done according to the dimensions.

The stopper on machine is moves automatically as per the dimensions .For each part individual
code is given to the computer. During bending operation, the code is selected and the bending
operation is done according to the dimension.

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WELDING:

Welding is the process of joining two similar materials by producing the heat between the plates
and it is permanent joining process.

Here we are using METAL INERT GAS WELDING (MIG WELDING).Welding can be done
by manually or by using robot.

In manual welding process finishing will not be in proper manner and time consumption will be
more. And temperature hazardous and high intensity of flash light hazardous to eyes. To
overcome these difficulties the robot is used for welding which is having six degrees of freedom,
which improves the productivity, finishing accuracy, less time consumption and complex parts
are welded by robot without intermission of human. The welding operation has done by batch
wise.

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CUSTOMER SERVICE GROUP (CSG)

CSG acts as an interface between the Micromatics (MMT) throughout India and the technical
part of ACE itself.

Two important jobs of MMT:

● Install the machines in the customer factories

● In case of malfunction, the customer contact the MMT’s and they act as the customer
care center.
Operation Strategies

● Make to Order
● Make to Stock
● Assemble to Order
● Engineer to Order

Organization Structure of CSG

General manager

Executive Engineers

Technical Assistants

Processes under CSG:

● Service Support
● Repair Services
● Customer Complaint Analysis
● Customer Training
● Free Replacement Item Control

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HYDRAULICS

Hydraulic engineering is concerned with the flow and conveyance of fluids, principally water.
However, the fluid used in mechanical application is oil.

The primary components of basic hydraulic assembly are:

1. Power Pack: It is the power unit driving a hydraulic system. Its main function is to
pressurize the oil in the system using a pump and other control accessories and collect it
on return.
The parts of the power pack are as follows:

● Tank
● Pump
● Filter
● Air breather
● Accumulator
● Check Valve
● Fluid Level Gauge

2. Hydraulic Elements: It consists of all the elements that directly or indirectly help in the
control of flow of fluid and hence, transfer of energy.
The different parts in hydraulic elements are:
 Direction control valve
 Pressure reducer
 Pressure switch
 Gauge isolator
 Distribution box
The basic principle on which hydraulics works is:
The motor converts electrical energy into mechanical energy.
This is the first energy conversion that takes place. The pump converts the mechanical energy
into pressure energy of the oil.

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PAINT SHOP

The primary concern of this department is cleaning of castings and sheet metal works and
painting them to prevent rust and also to give the machine aesthetic looks.

For sheet metal works the material used are:

 CRCA Sheet: Cold rolled closed annealed
 HRCA Sheet: Hot rolled closed annealed

The process of painting is as follows:

1. The dust settled on the component is cleaned and the grease is removed using suitable
cleansing agents.
2. The component is then rinsed with soft water
3. De-rusting – there are two ways of doing this:
a. Using phosphoric acid base- this cannot remove black scales
b. Using hydrochloric acid base- this removes the black scales
4. Activation: the metal surface is activated i.e. it is given a charge so as to aid phosphating such
that it adheres to the metal surface.
5. Phosphating: Phosphate coatings are used on steel parts for corrosion resistance, lubricity, or
as a foundation for subsequent coatings or painting. The main types of phosphate
coatings are manganese, iron and zinc.

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Most phosphate coatings serve as a surface preparation for other coating and/or painting.
It has many features like electric isolation, excellent adhesion, porosity, dielectric
nature etc. The whole process is carried out in phosphating tanks.
6. The work is then double rinsed using de-mineralized water.
7. It is then taken to a water drier oven which dries the component.
8. Powder Coating: It is applied as a free-flowing, dry powder. It does not require a solvent to
keep the binder and filler parts in a liquid suspension form. The coating is typically
applied electrostatically and is then cured under heat to allow it to flow and form a
“skin”.
The powder may be a thermoplastic or a thermoset polymer. For this process, the metal is
placed on a conveyor which is earthed. The most common way of applying the powder
coating is to spray the powder using an electrostatic gun, or Corona gun.
The gun imparts a positive electric charge on the powder, which is then sprayed towards
the grounded object by mechanical or compressed air spraying and then accelerated
towards the work piece by the powerful electrostatic charge.
The object is then heated, and the powder melts into a uniform film, and is then cooled to
form a hard coating.

For castings the method of liquid painting is used.

1. Blasting the casting so as to remove oil and other contaminants.

2. Primer is applied onto the casting
3. Putty is applied to fill deep holes which give the casting a smooth finish.
4. An epoxy primer is again applied onto the surface
5. Sandering is now done.
It is the process wherein the roughening of surface is carried out using emery paper so as
to help the paint adhere to the casting surface.
6. A masking tape is used to cover machine areas which are not to be painted from paint
deposition.
7. Paint is now applied onto the casting

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ASSEMBLY DEPARTMENT

Assembly is a process of joining or combing the various components in order to get the
finished product.

There are certain tests carried out in assembly department:

▪ Geometrical test
▪ Axis running test
▪ Spindle Vibration test
▪ Continues running test
▪ Circulatory test
▪ Standard profile test
▪ Load test

Geometrical test

This test is made in order to achieve all the geometrical accuracy. The measurements are made at
the positions equally distributed throughout the length of the bed. The levels are placed on the
traverse slide. When slide ways are not horizontal then the use of fixture is recommended.
Readings on the levels shall not exceed the permissible value at any positions along the length of
the sideways.

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Axis Running Test

This is mainly used for measuring of run out of the spindle nose. The instrument used in this
operation is Dial gauge indicator.

Spindle Vibration Test

This method is mainly used to check the parallelism of the spindle axis. In this process the
deflection of the axis of the spindle should be towards the planes, this is because to prevent the
spindle axis movement along with the movement of the tool or forces acting on the working
surface by the tool that causes the irregular dimensions of the work piece, to overcome this
difficulty the spindle axis should be tilted towards the planes.

Run-out test

When the spindle is rotating at very high speed the axis of the spindle gets deflected in the
circular manner. In order to overcome this difficulty proper mechanism chuck is used and the
speed is reduced or the speed of the spindle is altered depending on the diameter of the spindle.

Steps involved in checking Process

● Start the machine in cold condition

● Reset the backlash of X and Z to O
● Fix Dial gauge on the rigid part of the machine indicating slide and set the dial to
zero.
● Run the program to check the back lash value
● Compensate the back lash value in the system
● Run the program and note down the variation in backlash value of every 30min until
is runs continuously for minimum of 4hrs.
The most commonly used turret is BTP-63, i.e. Distance between base of the turret and axis of
spindle is 63mm.

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ELECTRICAL ASSEMBLY

In electrical assembly the two process models are adopted those are.

1. Electrical interface
2. Outsourcing of sub-assembly
Electrical interface:

This is the one of the electrical assembly sections in this the electrical connections will be made
in the company itself.

Out Sourcing of sub-Assembly:

In this some of the assemblies will be bought from the vendors. Different type of parts can be
bought from the vendors.

Switch gears:

MPCB (Motor Protective Circuit Breaker)

MCB (Miniature Circuit breaker)

Contactors

AC (Alternating Circuit)

DC (Direct Circuit)

SSR (Solid State relays)

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Different types of input Devices

➢ Put Switches
➢ Pressure Switches
➢ Load Switches
➢ Limit Switches
➢ Proximity Switches

Different types of output Devices

➢ Solenoid Coil
➢ Contactors
➢ Relays

Control Systems:
Packages used in Electrical Assembly
➢ Fanuc
OIMATTD (unique drive)
➢ Simance
OITD (Separate Drive)

Types of wires used

0.18 to 0.58 these wires are used for control circuit wires

0.75 to 35 these wires are used based on application.

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CENTRAL STORES

A store refers to raw materials, work-in-progress and finished goods remaining in stock. Store-
keeping means the activities relating to purchasing, issuing, protecting, storing and recording of
the materials. Store-keeping includes the receipts and issues of materials, their recording,
movements in and out of the store and safeguarding of materials. The store is a service
department headed by a store-keeper who is responsible for a proper storage, protection and
issue of all kinds of materials. Central Stores is the department of storing of the parts required for
the manufacturing of the CNC machining centers.
Central Stores has two sections they are:

➢ Receipt Section : Concerned with the inputs to the Stores

➢ Issue Section : Concerned with details pertaining to the output from the stores

There are numerous divisions in the stores to facilitate the storage of the products like AG, AM,
BG and BM. There are numbers of racks with several sub divisions.
Each product that enters the stores either in-house or bought from vendor has a unique code of
representation which makes worker to recognize easily and can figure out where it is placed in
stores. Whole central stores are computerized where in the storage and address of Each and
every product in the stores is updated regularly. If the number of products of a particular type is
less than computer automatically recognizes the shortage and necessary measures are taken.
Central Stores is used for the storage of small parts like fasteners, chucks, Spindles etc.
Bulky parts like conveyors, beds and large miscellaneous castings of the CNC machining centers
are stored in Warehouse.

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QUALITY ASSURANCE (QA)

It exists to measure, evolve, analyze and feed in the data to facilitate process improvements in
the department.
This department deals with:
● Inspection of incoming items
● Performing tests on machines such as Ball bar test and Laser test
● Metrology and calibration of measuring instruments

In-House Manufacturing QA
This is involving the inspection of those components that are manufactured in-house.
After the manufacture of the first component, the operator inspects it himself and the
dimensions are recorded. Depending on the complexity, there is a secondary inspection
conducted.
Inspection is conducted by the operator at every stage of the manufacture of the component.
Upon the completion of all these processes, the results are entered into SAP. After the complete
manufacture of the component, the component is stored in stores.
Items/Components are classified into 3 categories:
1. Most critical items
2. Less critical items
3. Least critical items
For most critical items, almost all components are inspected. For other categories batch
inspection is carried out. The department has a chart stating how many components are to be
inspected per 1000 components and depending on the number of components complying with
the quality standards the whole lot is either accepted or rejected.
In case of continuous supply of faulty items corrective and preventive action (CAPA) is carried
out.

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TOOL ROOM

Tool room is where machining of components takes place.

Principles of work holding:
 Wedge action
 Taper
 Helical
 Collets
 Pin arbor chuck
 2 Jaw chuck
 3 Jaw chuck
Chuck
A chuck is a specialized type of clamp used to hold rotating tools or materials. A self-centering
chuck uses jaws, interconnected via a scroll gear, to hold onto a tool or work piece. Because
they most often have three jaws, the term three-jaw chuck without other qualification is
understood by machinists to mean a self-centering three jaw chuck.
The term universal chuck also refers to this type. On an independent jaw chuck, each jaw can be
moved independently. Because they most often have four jaws, the term four-jaw chuck is
understood. The independence of the jaws makes the chuck ideal for gripping non-circular and
circular cross-sections with extreme precision. The non-self-centering action of the independent
jaws makes centering highly controllable.

Collets
A collet is a holding device that forms a collar around the object to be held and exerts a strong
clamping force on the object when it is tightened via a tapered outer collar. It may be used to
hold a work piece or a tool. Each collet generally has only a narrow clamping range, which
means that many collets are required to hold a given range of materials in the chuck, unlike with
many other types of chuck that will generally cover a wide range of sizes. The space clamping
works on the helical principle.

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MARKETING

Marketing department is also known as Technical Service Group (TSG). It acts as a link between
the customer and ACE so as to get all the technical requirements from the customer and to take
the respective course of action. In ACE Designers Sales and Marketing activities are handled by
a separate subsidiary unit called Micromatic Machine Tools Pvt. Ltd., (MMT). MMT acts as the
interface between the customer and all ACE companies. MMT takes care of Indian and non-US
markets.

The main functions of the marketing department are:

Pre-Sales:

● Enquiry
● Lead
● Contact generation
● Opportunity
● Quotation
Post-Sales:

● OA
● PI
● Inspection
● Minutes of Meeting (MoM)
● Dispatch
● Tax Invoice
Generation of Leeds: It involves finding a suitable customer whose application matches ACE
Designers product range and manufacturing abilities. Advertising in different industry based
magazines, participating in exhibitions and trade shows held all over the world, conducting
seminars and workshops are some of the main strategies that ACE Designers use to catch new
opportunities for business.

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Handling Enquiries and Request for Quotation (RFQ): Customer sends an enquiry if he is
interested in buying the product. The marketing team discuss on the feasibility of the enquiry.
Once if proved feasible, Request for Quotation (RFQ) will be generated.

Some of the marketing strategies used by ACE are:

● Tech centers
● Exhibitions
● Road Shows
● Seminars and Workshops
● Industrial trade magazines
ACE Designers has 32 % of the total market share of all the machine tools across India. ACE
Designers marketing team use the concept of Just-In-Time (JIT).

MMT oversees all sales and service activities. They get an enquiry from the customer
which is forwarded to the TSG which then makes a quotation depending on what the
requirements are i.e. if it is a standard model or is customized.

This quote is sent to MMT which then sends it to the customer. Once all negotiations are
done the purchase order is given by the customer and the advance payment is finished, MMT
issues an order forwarding format to start the production of the machine to ACE. In case of
customized models separate component drawings are issued and the work begins.

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HUMAN RESOURCE (HR)

Functions of HR:

● Time office management Entry & exit time, working hours

● Attendance administration
● Salary and wage administration
● Training
● Man power handling
● Employee counseling and guidelines
● Overseas deputation and sponsorship
● Innovative HR practices
● Feedback system management
● Compensation policy

Common H.R activities

Recruitment, training, payroll administration and performance management Welfare and

Safety activities Ace being a heavy machinery manufacturing company takes care about the
safety aspects of each individual. Safety of the working environment is better maintained and the
workers are well trained regarding the essence of usage safety precautionary items. Gangways,
sideboard, emergency equipment, first aid boxes, fire extinguishers were some of the safety
measures observed.

Recreational Activities

Ace organizes annual recreational activities such as sports and cultural activities, bringing
all the employees under one roof. This helps to create a strong social relationship between
employees irrespective of their occupation.

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Apprenticeship training program

In Ace designers, people with requisite qualification undergo apprenticeship training for
one year in line with the Apprenticeship program. During this period, Ace provides all facilities
to the employee.

Employee training

In Ace need for training of every employee is identified by his immediate superior. The
same will be conveyed to the HR department. The HR department organizes the common
training program for all the employees to whom it was suggested by his superior.

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