REPORT ON

INDUSTRIAL TRAINING IN
NOAH GROUP OF INDUSTRIES LTD.
SAIDPUR

REPORT ON INDUSTRIAL TRAINING IN NOAH GROUP OF INDUSTRIES LTD. SAIDPUR

Period Covering the Practice: From December 02, 2019 to December 29, 2019
In fulfillment of the requirement for the grading of IPE 3270 (Industrial Training)

Submitted to-

Dr. Muhammad Ahasan Habib

Asst. Professor & Head, Dept. of IPE, BAUST

Submitted by

Nafisa Anjum

ID: 160204004

Department of Industrial & Production Engineering¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬

Bangladesh Army University of Science and Technology

Date of Submission: January 12, 2020

Certification of Approval

The report titled “INDUSTRIAL TRAINING IN NOAH GROUP OF INDUSTRIES LTD. SAIDPUR”
Submitted by Mohammad Tooneer (ID:160204021) has been accepted as satisfactory
under the course “Industrial Training” (Course No. IPE3270).

Approved by-
_________________________________
Dr. Muhammad Ahasan Habib
Asst. Professor & Head, Dept. of IPE, BAUST

Certification of Approval

The report titled “INDUSTRIAL TRAINING IN NOAH GROUP OF INDUSTRIES LTD. SAIDPUR”
and the projects Submitted by Nafisa Anjum (160204004), Md. Hasin Ishrak
(160204017), Nabila Nurul (160204020), and Mohammad Tooneer (160204021) has been
accepted as satisfactory under the course “Industrial Training” (Course No. IPE
3270).

Approved by-

_________________________________
Md. Anwar Hossain (Mamun)
General Manager, NOAH Group of Industries Ltd.

Declaration
I, the undersigned, hereby declare that this report on “Industrial Training in NOAH
Group of Industries Ltd.” has been prepared by myself and neither this report nor
any part of it has been submitted to anywhere. I have no intention to make profit
from this report by utilizing it for business purpose.

Author-

_________________________________
Nafisa Anjum (160204004)
Dept. of IPE, BAUST

Forwarding Letter

Date: January 12, 2020

Dr. Muhammad Ahasan Habib

Asst. Professor & Head, Dept. of IPE

Bangladesh Army University of Science and Technology,

Saidpur, Nilphamari.

Subject: Submission of the report titled “Industrial Training in NOAH Group of

Industries Ltd.”.

Dear Sir,

It is my great pleasure to present you the report titled “Industrial Training in

NOAH Group of Industries Ltd.”. During this industrial attachment program, we
applied our theoretical knowledge as well as some innovative ideas to solve some
practical problems, which we believe may benefit this company. In this report I
have listed our observations, findings, and recommendations.

I would like to express my humble gratitude for giving us the opportunity to work
in a cordial environment. We have tried our best to follow the guidelines properly
and performed the assignment given in this report. I therefore, hope you will
appreciate our wholehearted effort put forth hereby.

Sincerely Yours,

Nafisa Anjum
ID- 160204004
Level- 3, Term-II
Department of IPE, BAUST
Preface

Industrial practice, where a student undertakes a period of training with an

organization, plays an important role in preparing the student for a professional
career. Our industrial practice at NOAH Group of Industries Limited was a great
opportunity to develop our personal and collaborative skills, technical and design
competency and appreciate the importance of human relationships and work attitude.
Participating in internship programs allows the staffs of an organization to
develop leadership and mentoring skills, create exposure for the company, bring new
perspectives and fresh ideas into the work environment. It is also a convenient
pathway for the companies to recruit human resource as some of them absorb trainees
into their workforce after they graduate. For these above mentioned
mutual benefits, the Department of Industrial and Production Engineering of BAUST
arranges industrial training for its final year students during the term break of
level 3, term 2. We, being four of the students of the final year, were assigned to
NOAH Group of Industries Limited for our industrial training.
 
Acknowledgement

I express my sincere and cordial gratitude to the Almighty as we have completed our
industrial training successfully. The development of this report took the effort,
support and guidance of a number of people whom I wish to thank.
I am grateful to Dr. Muhammad Ahasan Habib (Asst. Professor & Head, Dept. of IPE,
BAUST) for allowing and creating the opportunity to execute the industrial training
at NOAH Group of Industries Limited.
I am also grateful to Md. Hasan Ali (Lecturer, Dept. of IPE, BAUST), Sanjeeb Roy
(Lecturer, Dept. of IPE, BAUST) and our course teacher Md. Abubakar Siddique
(Lecturer, Dept. of IPE, BAUST) for their guidance throughout the whole training
and projects.
I also wish to pay tribute to our attachment field supervisor, Md. Anwar Hossain
(Mamun), (General Manager, NOAH Group of Industries Ltd.) who guided us on ways of
improving our skills in gathering practical field knowledge about Industrial and
Production Engineering.
I also thank the authority, executives, supervisors and workers of NOAH Group of
Industries Ltd. for their tremendous support in all aspects of our training.
I cannot end this list without paying tribute to the entire Bangladesh Army
University of Science and Technology, (BAUST teachers particularly those from the
department of Industrial and Production Engineering, for their constructive
training and the knowledge they have imparted in us throughout the three years. 
ABSTRACT

The purpose of this report is to provide the details of the institution of

attachment, a description of all the activities undertaken during the attachment
period, the lessons learnt and challenges faced during the same period. In this
report we have try to enlarge our training knowledge and enlisted the keynote
point. This document reports on the 15 days long industrial attachment program that
we underwent in “Noah Group of Industry Ltd”. The training program was the first
ever training we as students received. The program is a 1.00 credit course which is
to be completed satisfactorily to complete our graduation as Industrial and
Production Engineers. The training was organized by IPE Department of BAUST. We
started the program on 02 December 2019 and ended on 29 December 2019. During our
stay, we visited all the plants and facilities. We were introduced to different
machineries and processes. The supporting utility plants were also introduced to us
in a very descriptive way. We were also asked to perform analysis of some of the
different process machineries. We worked for the line balancing in manufacturing
department. We worked on the layout design, ergonomics issues and maintenance in
different departments. We tried to provide some innovative and effective probable
solutions to substantially improve the prevailing situation. I hope that our effort
will help to improve machine utilization, worker efficiency, skill and safety,
value addition of products and reduce production costs and factory hazards to a
tolerable level. This document includes the description of all the plants and the
assignments that we have completed over the time of our stay. This report is
prepared in partial fulfilment of the requirements of B.Sc. Engineering Degree in
Industrial and Production Engineering. It will highlight our work related learning
experiences. The report will outline the work roles, responsibilities,
achievements, activities and challenges faced by a student. Its operations and the
resulting products and services it offers, giving an overview of how the theory we
learnt at the university managed to simplify the assignments and duties we
performed during our attachment period. 
Table of Contents

Certification of
Approval...........................................................................
...................3
Declaration........................................................................
...........................................5
Forwarding
Letter.............................................................................
...........................6
Preface ...........................................................................
.............................................7
Acknowledgemen.....................................................................
...................................8
Abstract ..........................................................................
.............................................9
Introduction.......................................................................
........................................11
Factories & Sections……………………………………………………………………………………………..12
Royalex Metal Industry…………………………………………………………………………………..…….13
Warehouse…………………………………………………………………………………………………………..17
Aluminum Section………………………………………………………………………………………………..24
Pressure Cooker Section…………………………………………………………..………………………….30
Non Sticky Section………………………………………………………………………………………………..38
Assembly Production Section……………………………………………………………………………….41
NOAH Hygiene Care Industry……………………………………………………………………………….43
Project………………………………………………………………………………………………………………….48
Conclusion……………………………………………………………………………………………………………55
References……………………………………………………………………………………………………………56
 
Chapter-1

INTRODUCTION

NOAH, a household and trusted name today started its journey back in 1998 with the
establishment of Royalex Metal Industry (Pvt.) Limited by its founding chairman Mr.
Rahul Kumar Agarwal. With an aim to pioneer in the cookware and steel industry,
NOAH set its journey with the principle of quality and customer at the core. NOAH
has become a respected name through quality products, innovative solutions and
humble service. Later it has grown by introduction NOAH & Aaron China Joint Venture
Industry, NOAH Jute Mill and NOAH Hygiene Industry.

NOAH is one of the largest cookware manufactures of the country today with leading
market share in the Cookware, and segment. Apart from Cookware sector, NOAH has
spread its wing in other sectors like One time usable utensils, Non-stick coated
Aluminum & Stainless still cookware, Jute Bags, and household steel products. The
same core values of NOAH have enable the group to grow from a small venture from a
Northern part of the country to a renowned conglomerate of the country contributing
to the growth of the robust economy. 
Chapter-2

Factories & Sections

NOAH Group is a pioneer Group of Industries at North zone of Bangladesh. A large

contribution of driving economic growth in Bangladesh. Today’s era NOAH Group
produced export quality product that filled Local market demand within very fast
its covered most of the South Asian Countries.
2.1 The number of factories under NOAH group of Industries:
 Royalex Metal Industries

 NOAH Jute Mill

 NOAH Hygiene Care Industry

 NOAH & Aaron China Joint Venture Industry

2.2 Sections in Royalex Metal Industry:

2.2.1 Warehouse
2.2.2 Aluminum Section
2.2.3 Pressure Cooker Section
2.2.4 Non-Stick Cookware Section
2.2.5 Mug & Bucket Section
2.2.6 Kettle, Rice Cooker & Gas Stove Assemble Section

Chapter-03

Royalex Metal Industry

In this factory we had noticed that each and every workstation are automated by
Computer controlled Machine and personnel used to operate the machine and Loading
and Unloading operation. Here Raw materials are provided by China as Supplier.
Products details are given below:

Figure 3.1: Steel Dishware.

Pressing, Thermoforming, Bending, Cutting, Elastin, Polishing, Packaging

From this figure we have seen all of wares are steel ware. Here steel is the main
raw material come from china as Steel Roll. By CNC Cutting Machine, which are more
flexible with different types of Dies according to different type products.

Figure 3.2: CNC Sheet Coil Punching Line for Thick Strips
When raw materials ready then it moves in to Mounting Press sections where a large
number of Mounting press machines are available with process or functional layout.
In this section pressure are variable with product. Pressure are change depends on
the distance between ram and dies. From this pressing machine regular production
rate 2000 pieces used base soap water as coolant for pressing operation. Special
attachment used to count the product, this mechanism involved at the ram movement.
Fork Lift conveyor used to convey the material from one workstation to another.

Figure 3.3: Hydraulic Press

3.1 Die
Enriched Machine Shop are available to provide efficient and defect less dies
according to steel ware. All of the dies which used here made by these machine
shop. More experienced worker is involved in this machine Shop. More precious jobs
are happened here.

3.2 Thermoforming
Ovens are used to thermoformed the pressing work piece. Here noticed a problem that
is bottleneck, proper utilization of 5S tool can improve the situation. 200˚
Celsius heat generated by this oven.

3.3 Bending and Cutting

This operation is done by lathe machine. Experienced operator is always busy with
Lathe machines. A special operation had been done here that is embossing, which
provide identities the of steel ware capacity. After those operations all of work
pieces are move on to Buff section where busy and experienced operator are waited
to polish those work pieces by rolling machine with chalk powder.
Then final product entered into packaging section where brand, price tag is
attached to the product and packaging operation done with plastic protection.

3.4 Wastes
At the cutting section scrap materials are performed here, a special operation
collect those scrap and convert those scrap into a roll. This roll are sells by
high value market.

Figure 3.4: Industrial Wastes 

Chapter-4

Warehouse

Warehouse is the commercial building for storing goods complying GMP. It is the
appointed place where the raw materials are stored after arriving and the finished
goods are stored after production.
There are two warehouses:

•Raw material warehouse

•Finished goods warehouse.

Warehouse
↓

4.1 Raw Materials Warehouse:

Figure 4.1: Raw materials warehouse
4.1.1 Segments of raw material ware house:

Unloading Chamber
Sampling booth
 Material entry
 Personnel entry
Ware house (Temperature: 25˚C)
o Racks for raw materials
o Racks for packaging materials
o Racks for QIR (Quality Incident Record)
o Racks for damaged materials

4.1.2 Equipment used:

• Pallet

Figure 4.2: Pallet

• Forklift

Figure 4.3: Forklift

• Rack

Figure 4.4: Rack

• Trolley

Figure 4.5: Trolley

• Bridge Crane

Figure 4.6 Bridge Crane

4.1.3 Procedure performed by warehouse personnel:

 Receiving RM according to lot, unloading materials in pallets, checking
containers & labeling them, discarding defected containers.
 Cleaning of container, issuing GRN (Goods Receiver Note), then labeling as
QUARANTINED.
 Supplying of raw materials according to the FIFO to production area.

Incoming raw material

↓
Unloading (In loading & unloading bay)
↓
Documentation in SAP (System application products)
↓
Separation according to Batch wise or product wise
↓
Keep it in the waiting area
↓
Prepare GRN (Goods Received Note)
↓
Keep the RM into Quarantine area attaching Quarantined Label
↓
Use as per requirement

Figure 4.7: Material Processing in Warehouse

4.1.4 Labels used:

QUARANTINED

SAMPLED

PASSED

REJECTED

Figure 4.8: Different type of labels

4.2 Finished Goods Warehouse:

Raw materials are dispensed into the production unit and after the completion of
production; the finished products are supplied to FGW. Then the finished goods are
arranged as the same of Raw Materials Warehouse (Quarantined, Sampled and Passed).

Figure 4.9: Finished Goods Warehouse

The rejected materials are stored fully in a separate area and the printed
packaging materials are stored in a locked area where only authorized personnel can
be accessed.
 
Chapter-5

Aluminum Section
This is aluminum based section where only aluminum based products are produced. The
scraps or wastes are recycled by melting it again making this section 100% scrap or
waste material free section.

Figure 5.1: Aluminum Cookware

5.0 Procedures followed in this section:

→ →
→
↓

← ←
←

Figure 5.2: Block diagram of the procedures of aluminum cookware

5.1 Casting:
An object made by pouring molten metal or other material into a mould. Casting is a
manufacturing process in which a liquid material is usually poured into a mould,
which contains a hollow cavity of the desired shape, and then allowed to solidify.
The solidified part is also known as a casting, which is ejected or broken out of
the mould to complete the process. Casting materials are usually metals or various
time setting materials that cure after mixing two or more components together;
examples are epoxy, concrete, plaster and clay. Casting is most often used for
making complex shapes that would be otherwise difficult or uneconomical to make by
other methods. Heavy equipment like machine tool beds, ship's propeller etc. can be
cast easily in the required size rather than fabricating them by joining several
small pieces. Here before furnace operation prepared an aluminum mixture where 600
kg of scrap material with 160 kg virgin Aluminum Bar. For this reason, this factory
is called more efficient factory in NOAH group Industries limited.

Figure 5.3: Casting of Aluminum Bars

5.2 Rolling:

In metalworking, rolling is a metal forming process in which metal stock is passed

through one or more pairs of rolls to reduce the thickness and to make the
thickness uniform. The concept is similar to the rolling of dough. Rolling is
classified according to the temperature of the metal rolled. If the temperature of
the metal is above its recrystallization temperature, then the process is known as
hot rolling. If the temperature of the metal is below its recrystallization
temperature, the process is known as cold rolling. In terms of usage, hot rolling
processes more tonnage than any other manufacturing process, and cold rolling
processes the most tonnage out of all cold working processes. Roll stands holding
pairs of rolls are grouped together into rolling mills that can quickly process
metal, typically steel, into products such as structural steel (I-beams, angle
stock, channel stock), bar stock, and rails. Most steel mills have rolling mill
divisions that convert the semi-finished casting products into finished products.

Figure 5.4: Rolling Machine

 
5.3 Cutting:

The cutting blades fitted are carefully and accurately ground to give easy, clean
quick cuts, and free of burrs. These special features help the operators save a
great deal of their energy. But some shearing machines can cut sheet bar and flat
bar up to 10mm. It is electrically welded together to make it a sturdy stable unit
capable to withstand highest stresses due to heavy duty usage. The footplates are
reinforced with bracing angles so that they give firm stability to the shear. The
machine is provided with section knives with sliding blades which can be adjusted
by hand to make 90 cuts on angles and T-sections of different sizes as well as with
openings for cutting round and square bars. Two types of cutting machines are used.
Straight line or vertical cutting machine and Circular cutting machine.

Figure 5.5: Cutting Machine

 
5.4 Heat Treatment:

Heat treating (or heat treatment) is a group of industrial and metalworking

processes used to alter the physical, and sometimes chemical, properties of a
material. The most common application is metallurgical. Heat treatments are also
used in the manufacture of many other materials, such as glass. Heat treatment
involves the use of heating or chilling, normally to extreme temperatures, to
achieve a desired result such as hardening or softening of a material. Heat
treatment techniques include annealing, case hardening, precipitation
strengthening, tempering, carburizing, normalizing and quenching. It is noteworthy
that while the term heat treatment applies only to processes where the heating and
cooling are done for the specific purpose of altering properties intentionally,
heating and cooling often occur incidentally during other manufacturing processes
such as hot forming or welding.

Figure 5.6: Heat Treatment Machine

5.5 Spinning:

After Heat treatment when sheet metal is relaxed then sheets are moved on in
section. There are two stages are performed in Spinning Section.

Figure 5.7: Spinning Machine Operations

5.6 Washing & Polishing

After spinning section cookware are get dirt by coolant in spring machine. The
solution used for polishing are Sulphuric Acid and Nitric Acid. The ratio of
sulphuric acid and nitric acid is 1:4 in the solution. And to finish it off caustic
soda is being used. For this reason, need to be wash by clean water and then it
will be polishing at buff section. Final Products are available after washing and
Polishing. Then Packaging, labeling operation made this Product for market.

Chapter-6

Pressure Cooker Section

Pressure cooking is the process of cooking food at high pressure, employing water
or a water-based cooking liquid, in a sealed vessel known as a pressure cooker.
High pressure limits boiling, and permits cooking temperatures well above 100 °C
(212 °F) to be reached. Pressure cookers work by expelling air from the vessel, and
trapping the steam produced from the boiling liquid inside. This raises the
internal pressures and permits high cooking temperatures. This, together with high
thermal heat transfer from the steam, cook’s food far more quickly, often cooking
in between half and a quarter the time for conventional boiling. After cooking the
steam is released so that the vessel can be opened safely.

Figure 6.1: Pressure Cooker

6.1.0 Materials Used for Manufacturing

Pressure cooker are mainly made up of stainless steel and Aluminum

Properties Stainless Steel Aluminum Alloy

Composition 18%Cr,10%Ni,Fe Al 3003 Or 3004
Thermal Conductivity 16 W/M K 162 W/M K
Tensile Strength 515 Mpa 130 Mpa
Yield Strength 205 Mpa 125 Mpa
Shear Strength 190 MPa 83 Mpa
Brinell Hardness Number 201 Mpa 160-550 Mpa
% Elongation 40% 10%

6.1.1 Materials used for manufacturing

Aluminum pressure cookers are cheaper but aluminum reacts with acidic
materials there by changing the flavor of cooked items. They are less durable than
stainless steel cookers.
Stainless steel cookers are costlier and are provided with three layer or
copper clad bottoms for uniform heating because stainless steel has a lower thermal
conductivity.
Some pressure cookers are also provided with a non-stick interior.
Gaskets are made up of rubber or silicone.

 
6.2 Manufacturing process

→ →
→

← ←
←

→ →
→

← ←
←

Figure 6.2: NOAH pressure cooker manufacturing process

The process starts with a stainless steel or aluminum disc.

o Generally, the thickness of the disc depends on the thermal Conductivity,

internal pressure and capacity of the pot.
o Diameter of the disc depends on capacity of pot.
o The disk dipped in a suitable lubricant to aid the forming Process.
o Common lubricants used are drawing oils (tallow or lard Oil), soap/fat paste
type materials (5% soap, 25% water, 25% oil and 45% Solids).
o The major operation involved is cup drawing. The stainless steel disk is
drawn through an inverted circular shaped die to form a nicely rounded pot.
o A clearance of about 1.1t (thickness) is provided.
o A punch cutter is allowed to make notches in the pot’s rim.
o These notches help in interlocking with lid helping it to hold High pressure.

o Then an aluminum disk is dipped in an aluminum silicon solution for a uniform

coat.
o This disk is placed at the bottom of the pot on which a stainless steel disk
is placed.
o The thickness of bottom disc can be up to 4.5mm.
o Then the bottom of the pot is heated to a temperature of 1100ºf.
o This activates the aluminum silicon solution to fuse the disk to the bottom
of the pot.
o The pot is then cooled by dipping in water.
o The ragged edges are trimmed off. Then the pressure cooker pots are sent to a
special chamber where the grinding tools polish the surfaces of the pot.
o Then the pots are washed thoroughly to remove any residues.

6.2.1 Hydraulic Press

Figure 6.3: Hydraulic Press Machine 

6.3 Manufacturing of lid
o Three pressing operations are required to make the lid.
o Two holes are punched on the lid for two valves.

Figure 6.4: Manufacturing of Lid

6.4 Fixing other accessories

 To install the main valve, the main hole is aligned with a retaining ring.
 The spring loaded valve is tightly screwed by an automated device.
 Similarly, a backup valve is fixed in the smaller hole.
 These valves help in preventing explosion.
 A plastic cooking guide is fixed around the main valve.
 A rubber gasket is used to have an air tight sealing.
 Holes are drilled on either sides of the pots.
 Handles are fixed with the help of screws and nuts.

Figure 6.5: Fixing other accessories

6.5 Production capacity and quality control

Production Capacity 50%

No. of Working Days in a month 26 days
No. of Working Days in a Year 312 days
No. of Shifts per day 1
No. of Working hours per shift 8
Production Capacity per year 36,000

6.6 Pollution control and energy conservation

6.6.1 Pollution control

 The entrepreneur is advice to contact concerned state pollution control board

for detailed guidance in the matter.
 However, the water in this industry is generated during cleaning, washing,
and pre- treatment blanching of raw material. It is advisable to test the water
discharge as per specification laid down by such treatment has been made in the
profit.
 “NOAH pressure cooker” not any high conical and raw materials which spread
pollution. They follow government rules of pollution high walls in production
department to reduce the noise pollution.

6.6.2 Energy consumption

 Although the energy requirement, it’s small yet some important point for
conservation of energy are given below.
 In electronically installation appropriate electric machinery should be &
properly installed.
 There should be no fault in machinery.

6.7 Quality Control

“Quality is near an accident; it is always the result of high intention, sincere

effort intelligent direction and skilful execution”. Above all, quality means
setting the highest standards for their selves.” In industrial context quality is
defined in much more functional fashion thus we can say that quality means,
“Fitness for use” whether for a product or service. It is also considered as the
sum total of the attributes or properties that describe the product. Today the
existence of any manufacturing unit depends on the quality of product or services
it manufactures or supplies. The image or goodwill of any unit is closely related
to the quality of product made or supplied by that unit; In the NOAH PRESSURE
COOKERS Industry are too much conscious about its product. Industry will have
latest equipment for the checking of raw-materials and finished product. So that
Industry can maintain quality of their product and build image in the market.
Industry will first check finishing of cooker, then test visuals test and at last
pressure.

Chapter-07

Non Sticky Cookware section

A non-stick surface is a surface engineered to reduce the ability of other

materials to stick to it. Non-stick cookware is a common application, where the
non-stick coating allows food to brown without sticking to the pan. Non-stick is
often used to refer to surfaces coated with polytetrafluoroethylene (PTFE), a well-
known brand of which is "Teflon." In the twenty first century other coatings have
been marketed as non-stick, such as anodized aluminium, ceramics, silicone,
enamelled, and seasoned cookware. Super hydrophobic coating is the newest non-stick
coating for sale.

Figure 15: Non sticky cookware

7.1 Production Process:
All NOAH Group products are manufactured exclusively in Bangladesh, using a
technologically advanced process:

7.1.1. Aluminium sheet is supplied from China and is then forming into
suitable forms under very high pressure. The pressure-cast aluminium process used
for NOAH cookware prevents warping for the lifetime of the product, unlike other
cookware brands using spun or stamped aluminium. Cast aluminium also distributes
heat evenly.

7.1.2. The molten aluminium is pressurized to remove bubbles and ensure proper
filling of the moulds. Each NOAH Group product is covered with a Limited Lifetime
Warranty covering manufacturing defects.

7.1.3. To prepare the aluminium body for the coating and to ensure improved
adhesion, the interior is sandblasted.

7.1.4. After sandblasting, a steel surface layer is steel- deposited on the

interior of the cookware. This prevents contact of the aluminium with food even if
the non-stick coating is damaged, and protects the cookware and coating from
oxidation, ensuring the longest possible usage lifetime for the products.

7.1.5. The actual coating process utilizes a specially developed specialized

coating machine to give each NOAH product three solid layers of non-stick coating.

7.1.6. The pan’s bottom is accurately trimmed. Combined with the cast
aluminium construction that prevents warping, the perfectly flat base ensures that
your cookware will never spin or become unstable on the cooktop.

7.1.7. In a final step, the handles are attached. Our unique method uses
threaded handles on exterior bolsters rather than rivets, to prevent food build-up
inside the pan that leads to bacterial growth.

7.1.8. The finished NOAH cookware is now ready to be shipped to home chefs
around the world!
7.2 Manufacturing process
 → →
→

← ←
←

→ →
→

← ←
←

Figure 6.2: NOAH nonstick cooker manufacturing process

Chapter-08

Assembly Production Section

Assembly Product:
8.1. Rice Cooker

Figure 8.1: Rice Cooker

8.2. Gas Stove

Figure 8.2: Gas Stove

8.3. Kettle

Figure 8.3: Kettle

8.3.1 Assembly of Kettle:

 Bending
 Stamping
 Coil Joint
 Cable Joint
 LED Joint
 Inner Handle Joint
 Base Joint
 Switch Joint
 Outer Handle Joint
 Lid Joint
 Polishing Inner
 Polishing Out
 Sticker & Check
 Packing Poly
 Base Cable Joint
 Packaging Poly of Base Cable & Cartooning
 Base LED Joint
 Wire Cup Joint

Chapter-09

NOAH Hygiene Care Industry

9.1 Polymer Plastic Product

NOAH Group recently started a new business that Polymer Plastic made Plate, Glass
and Parcel Box. Now a days these are very essential products in the market. Easily
NOAH Group caught up this business condition at Agile Market. Polymer Plastic
Product This section is 100% recyclable and fully automated machine controlled
workstation.

Figure 9.1: Polymer Plastic Process

9.2 Raw Material

PVC (Polyvinyl chloride) PVC comes in two basic forms: rigid (sometime abbreviated
as RPVC) and flexible. The rigid form of PVC is used in construction for pipe and
in profile applications such as doors and windows. It is also used in making
bottles, non-food packaging, food-covering sheets, and cards (such as bank or
membership cards). It can be made softer and more flexible by the addition of
plasticizers, the most widely used being phthalates. In this form, it is also used
in plumbing, electrical cable insulation, imitation leather, flooring, signage,
phonograph records, inflatable products, and many applications where it replaces
rubber. With cotton or linen, it is used to make canvas.

Figure 9.2: Raw Material

9.3 Injection Moulding

Injection moulding is a manufacturing process for producing parts by injecting
molten material into a mould. Injection moulding can be performed with a host of
materials mainly including metals (for which the process is called die-casting),
glasses, elastomers, confections, and most commonly thermoplastic and thermosetting
polymers. Material for the part is fed into a heated barrel, mixed (Using a helical
shaped screw), and injected (Forced) into a mould cavity, where it cools and
hardens to the configuration of the cavity. After a product is designed, usually by
an industrial designer or an engineer, moulds are made by a mould-maker (or
toolmaker) from metal, usually either steel or aluminium, and precision-machined to
form the features of the desired part. Injection moulding is widely used for
manufacturing a variety of parts, from the smallest components to entire body
panels of cars. Advances in 3D printing technology, using photopolymers which do
not melt during the injection moulding of some lower temperature thermoplastics,
can be used for some simple injection moulds.
Figure 9.3: Injection Moulding

9.4 Roll-Fed Thermoforming

The in-line thermoforming process is designed to take advantage of the hot sheet
coming off the extruder. The sheet is mechanically conveyed directly from the
extruder through the oven to maintain the sheet at a forming temperature and then
to the forming station. The forming step must be synchronized with the extruder
take-off speed. This type of thermoforming is usually limited to sheet 0.125" or
thinner and applications that do not require critical thermoforming (optimum
material distribution and close tolerances). This process is more difficult to
control than other thermoforming processes. The major disadvantage is that with the
extruder and former being tied directly together an upset in one causes a shutdown
in both. The majority of roll-fed machines or in-line machines are commonly used
for the production of thin-walled products such as cups, trays, lids, internal
packaging, and other finished products with a finished wall thickness of 0.003" to
0.060". Because of the speed of these machines secondary operations are
incorporated within the unit. These may consist of printing, filling, sealing, die
cutting, scrap cutting, or automated removal and stacking of finished product. The
normal roll-fed machines consist of the roll station, upper and lower heating
banks, form station, cooling station, and trim station.

Figure 9.4: Roll-Fed Thermoforming

9.5 Recycling Machine
After finishing product rest of scrap materials are recycling by the recycling
machine. After this type of machining again receive the raw materials (GPPS).

Figure 9.5: Recycling Machine

 
Chapter-10

Project
10.1 Project-1

Project Name: Improvement of production capacity for an Assembly Line in Assembly

of Kettle.

Project Description: Time Study of Secondary Packaging Unit of a Production Line

and analyze the result with proper reasons why the value of kettle production is
lower than standard value and provide logical recommendations so that the value of
production can be increased.

Time Study:

We ran a time study on the manually done activities by the worker in the secondary
packaging station in search of any bottleneck situation that may have hampering the
productivity. But fortunately we found the ‘bottleneck’ to be absent. As we all
know a bottleneck situation is that state when a process rate that is significantly
lower than the other rates it slow down the process to its rate.

Details of the Production Line:

Product: Kettle
Packs/min: 12 Trade Price: N/A
Target time (min): 180 Run Time: 165
Target (in packs): 1000 Output (in packs): 700

The process flow of secondary packaging of Kettle is drawn below:

→ →
→

← ←
←

→ →
→

← ←
←

Figure 10.1: Process flow of a kettle assemble line

 
Number of cycles to be observed: The number of cycles that must be timed is given
by the following formula:
n = (𝑧𝑠/𝑎𝑥̅ ) 2

Where,
z = Number of normal standard deviations needed for desired confidence
s = Sample standard deviation
a = Desired accuracy percentage
x = Sample mean

There was no previous data concerning work measurement. As a result, sample mean
and standard deviation was not known. That is why we decided to take 5 observations
for each of the tasks to be studied.

Observed time (OT): The observed time is the average of the recorded times.
OT = 𝛴𝑥i/𝑛
Where,
Σxi= Sum of recorded times
n = Number of observations

Performance Rating (PR): Performance rating is given to a worker based on how

efficient he is compared to standard worker (100 BSI) . Generally it is based on
nature and type of work. For standard purpose, 95% rating is taken in this report.

Normal Time (NT): The normal time is the observed time adjusted for worker
performance. It is computed by multiplying the observed time by a performance
rating (PR).
NT =OT X PR

The reason for including the adjustment factor is that the worker being observed
may be working at a rate different from a normal rate, either to deliberately slow
the pace or because his or her natural abilities differ from the norm. That is why,
the observer must assign a performance rating, to adjust the observed times to an
average pace.

A normal performance rating is 1. A performance rating of 0.9 indicates a pace that

is 90 percent of normal, whereas a performance rating of 1.05 indicates a pace that
is slightly (105 percent) faster than normal. For long jobs, each element may be
rated; for short jobs, a single rating may be made for an entire cycle.

Standard Time (ST): The normal time does not take into account such factors as:

 Personal delays: Getting a drink of water or going to the washroom

 Unavoidable delays: Machine adjustments, repairs, breakdowns etc.
 Rest breaks
 Bad light
 Atmospheric conditions (heat and humidity)
 Mental strain
 Monotony

The standard time for a job is the normal time multiplied by an allowance factor
(AF) for these delays.

ST X NT X AF

Where,
AF =1+A
A = Allowance percentage based on job time

Table 10.1: Observed Time to unpackage Items

Calculation:

No. Of Observations should be taken for desired accuracy percentage = 42

observations
But for practical reasons we have taken 10 observations.

OT = 8.042+5.6+6.66+4+4.4+5+4.6+5.2+3.8+5.2/10 = 5.2502 sec

NT = 5.2502 × .95 = 4.98769 sec
AF = 1+.15 = 1.15
ST = NT × AF = 4.98769 × 1.15 = 5.7358435 sec
Table 10.2: Observed Time in assembly line

SL Work Element Observation time in secs Avg Obs time

1 2 3 4 5 6 7 8 9
1. Bending 15.6 15.7 16.1 15.2 16.2 15.5 15.7 14.9 15.2 15.5
2. Stamping 11.7 11.9 11.5 11.7 11.8 12.1 11.4 11.8 11.7 11.7
3. Coil Joint 15.2 15.1 15.2 15.2 15.3 15.1 15.2 15.2 15.1 15.2
4. Cable Joint 27.6 27.5 27.6 27.1 27.2 27.6 27.5 27.3 27.4 27.5
5. LED Joint 33.6 33.9 33.1 33.6 33.1 33.2 33.5 33.4 32.1 33.4
6. Inner Handle Joint 12.2 11.2 12.1 11.9 11.6 11.4 11.6 11.8 12.3
11.6
7. Base Joint 15.8 14.2 15.2 15.1 15.2 15.6 15.1 14.9 15.2 15.4
8. Switch Joint 23.7 22.1 23.1 22.9 23.1 23.5 23.1 22.9 23.1 23.3
9. Outer Handle Joint 16.5 17.1 16.8 17.2 16.2 16.5 16.6 16.2 16.4
16.4
10. Lid Joint 19.7 18.7 19.2 19.4 18.6 18.5 18.6 19.1 18.4 18.4
11. Polishing Inner 15.9 16.1 15.8 16.2 15.7 16.2 16.3 15.5 16.2 15.6
12. Polishing Out 17.6 17.8 17.6 17.5 17.1 17.9 17.5 17.6 17.2 17.5
13. Sticker & Check 14.1 14.1 14.2 14.1 14.2 14.2 14.2 14.1 14.6 14.2
14. Packing Poly 25.1 26.1 25.2 25.1 25.6 25.1 25.4 25.7 25.2 25.3
15. Base Cable Joint 19.2 19.4 19.1 19.5 19.5 19.2 19.1 19.2 19.5 19.4
16. Packaging Poly of Base Cable & Cartooning 33.1 33.3 33.1 33.5 33.1 33.5
33.4 33.9 33.1 33.4
17. Base LED Joint 9.2 9.1 9.1 9.2 9.4 9.2 9.1 9.2 9.3 9.2
Total 323

Calculation:

No. Of Observations should be taken for desired accuracy percentage = 42

observations
But for practical reasons we have taken 10 observations.

OT = 323 secs = 5.3833 mins

NT = 5.3833 × .95 = 5.115 mins
AF = 1+.15 = 1.15
ST = NT × AF = 5.115 × 1.15 = 5.8812909 min

Table 10.2: Observed Time Final Master Cartoon

No. of Observation Time in secs

1. 40.97
2. 33.60
3. 39.52
4. 39.10
5. 38.90
6. 39.55
7. 38.99
Total 303.72
Calculation:

No. Of Observations should be taken for desired accuracy percentage = 42

observations
But for practical reasons we have taken 10 observations.

OT = 303.7/7 secs = 42.39 secs

NT = 42.39 × .90 = 39.051 secs
AF = 1+.15 = 1.15
ST = NT × AF = 42.39 × 1.15 = 48.81 secs

Summary of Time Study:

Figure 10.2: Standard times for different process in assembly section

Discussion:

From the above flow of rates, we can see the highest time needed for unpackaging of
cartoons is 5.74 second per product. This indicates presence of bottleneck state.
But unfortunately the day we ran the study, the machine in the primary stage showed
frequent shutdown resulting in the shutdown of secondary assembly. As the worker
used to do the clogged work in that idle time so it may appear there is no
bottleneck state here as the work is getting done ultimately. So it appears to be
challenging to identify the reality whether the bottleneck state is hampering the
production as there is no uniform flow.

Conclusion
Our industrial attachment journey has been started with many future ideas to be
accomplished. However, we needed some time for observing the company trends and
deciding in which aspects they lack actually. The prime objective of our attachment
in at NOAH Group of Industries has been to find those gaps and try to solve it with
our existing knowledge and upcoming experiences gathered in this company. The first
two weeks has been spent dedicatedly for knowing ins and outs of this company about
process, water supply, fire safety systems, effluent handling system and the basic
overview of the production procedures. In the third week, we have concentrated on
the productivity unit. We have chosen to submit one project which conveys the
identification of those limitations that has been identified. The project involves
the ways to improve work of a production line of kettle with the help of
mathematical proofs, time study, work study and method. NOAH Group of Industries,
no doubt, a great option for benchmarking by any other companies. But still, they
and we both believe that continuous improve is the key factor for sustainable
business. And, that is why it is the time to think about the existing limitations
and try to eliminate or reduce it.

 
References

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Processes in Manufacturing (9th
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[2] Degarmo, Black & Kohser 2003, p. 384.
[3] Degarmo, Black & Kohser 2003, p. 384.
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[5] "Pressure Cooking Meat Analogues". The Gentle Chef. Retrieved 13 November 2018.
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publications/science
reports/scientific-status-summaries/food-packaging.aspx
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[10] Todd, Robert H.; Allen, Dell K.; Alting, Leo (1994). Manufacturing Processes
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