ABOUT THE COMPANY

J.K. Fenner (India) Limited is a member of the  JK Organization which

ranks among the top Industrial houses in India for over 100 years. The
name Fenner has been synonymous with Mechanical Power
Transmission and Sealing Solutions. Fenner commenced operations in
India in 1929 and put up their first manufacturing unit at Madurai in
Tamilnadu in the year 1956. Currently there are 7 manufacturing units
over 5 locations.

Jk Fenner which is located in sriperumbudur unit is mainly manufacturing

oil seals.

Fenner (India) Ltd has been providing Oil Seals to the Auto OEM and
Replacement Markets for close to 50 years.

Fenner Oil Seals, sold under the Brand Name, “Pioneer”, are well accepted in
all segments of Automotive Industry, be it a two wheeler or three wheeler or
Passenger Car or SUV / MUV or Commercial Vehicles or Agriculture
Equipment (Tractors / Tillers / Combines, etc).

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 ABOUT OIL SEALS

The function of the oil seal is to stop whatever fluid is inside from leaking out .
The seal may also be used to prevent outside materials, such as dirt.

Oil seal generally contains Rubber, the metal and the spring.

The purpose of the Rubber is to stop the fluid from leaking from different parts.

The metal will give rigidity and strength to the seal and gives firm gripping.

The spring will help make the Rubber more effective. All materials must be
selected depending on the environment in which the oil seal will function.

Apart from the above, Fenner can also supply seals made of any other specialty
rubber, based on the customer’s requirement. These include, but not restricted
to, the following :
 
 Polychloroprene Rubber (CR)
 Ethylene Propylene Diene
 Rubber (EPDM)
 Butyl Rubber (IIR)
 Poly urethane (PU)

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 PROCESS OF OIL SEALS
OIL SEAL basically involves 3 process:

1. Blanking
 Warming
 Extrusion
 cooling
2. Phosphating
3. Dipping
4. Curing

MANUFACTURING PROCESS FOR OIL SEAL:

 The Rubber is received from the supplier.

 Initially Rubber is given for testing.

1) BLANKING

 WARMING

 Rubber in general will be more stiff and very hard to bend in order
to make it bend we need to send it through a warming mill.

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 Temperature is around 90°C during warming.
 After it is sent through warming mill (mills that
use cylindrical rollers) .It mainly uses 5 compounds

 Nitrile – 3mins warming time

 Polyacrylic – 6mins
 Vition – 6mins
 Silicon
 HNBR(Hydrogenated nitrile butadiene rubber) -6 mins of
warming time

 EXTRUSION

 After warming the material it is sent through the Extruder. It is a

process used to create objects of a fixed cross sectional profile. A
material is pushed through a die of the desired cross-section. In
this process rubber is passed through the die and required shape
is obtained.
 In this Extrusion process, material is loaded onto the machine.
 Inside a extruder, There is a cutter which chops the rubber (which
is loaded into the extruder) into equal parts with specified weight
and dimensions.

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  Different shapes can me made according to the shape of the
die.
 Different shapes of rubber are showed in following figures.

 Since the extrusion is a hot process, Temperature of the rubber

will be around 150 - 200°C.

 VIBROCOOLER

 In order to use the rubber in further stages we need to

use Vibrocooler.
 Rubber from the extruder Goes to the cooler and cools
the rubber.

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 STORAGE

 Finally the rubber is kept in a storage area.

 It must be stored in an AC room.
 Its Maximum shelf life is 3 days and its temperature is 22 ±3 °C.
 Now the rubber part is done.

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 2) PHOSPHATING PROCESS

 This process is used for metal.

 Phosphate used is Zinc phosphate.
 It involves around 6-7 tanks .
 Phosphating is generally done for corrosion protection.
 Now the metal is loaded into the tank.

- Tank 1: Degreasing – to remove excess of grease or dirt, oil, lubricant

from the metal through a chemical process.

-Tank 2: Rinsing- Rinse the metal in water.

- Tank 3: Activation: Activating the metal surface for zinc

phosphate Coating by using activating chemicals, chemicals activate the
metal to obtain fine crystalline structure during zinc phosphate coating
which will increase corrosion resistance and adhesion properties.

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 -Tank 4: Phosphating: For-Smooth & uniform coating of sheet
metal surface with zinc Phosphate. This process makes sure that it is
corrosion free.

Rinsing process is carried out.

- Tank 5: Passivation: It reduces the chemical reactivity of its

surface. In order to make it less reactive.

 Now again rinse the metal

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 After rinsing, dry the material.
 Now unload the material from the tank.

 SHELL STORAGE
 Now we need to store the shell.
 Shell shelf life is around 7 days.
 It is kept at a temperature of 27±5°C.

3) DIPPING PROCESS
 In order to bond rubber to metal, the metal is dissolved in a
solvent. Some common Brands used are chemlok 202.

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 After dissolving in a solvent, the roller rotates in order to dry it.
 The metal is unloaded.

 CURING PROCESS

 It is the process where both metal and rubber are moulded

together.
 When the tools and fixtures are ready, the molding time,
temperature and pressure will be set up for trial. Then the
operator execute first article inspection to make sure that the
dimensions, seal type, marking, colour and appearance are
corresponding to the specification. When the first articles are
considered qualified the molding process for batch
production can be started.
 After curing it ,Deflashing and trimming is being done
 During deflashing, the process used to remove excess
material from the moulding compound.

POST CURE:

A part of seals need to proceed with post cure to strengthen the

adhesive. The setting of temperature and time is different for various

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 rubber compounds. The finished parts have to be removed from the
oven for cooling down after post cure.

INSPECTION OF FINISHED PARTS:

Random measurement and appearance check are necessary before

shipment. The OD, ID, height and dimensions are all measured and
recorded for future tracking.

PACKING:

Product part numbers, types, dimensions must be checked before

packing. The packing way can be based on customers’ requirements.

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 Incoming Raw material
PROCESS FLOW DIAGRAM
Metal Insert - Shell
Incoming Raw material
PR

Rubber

Phosphating
1. Degreasing
2. Rinsing
Warming 3. Activation
4. Phosphating
5. Passivation
6. Drying

Extrusion

Dipping -
Cooling METLOK

Blank storage Shell storage

Deflashing Curing Trimming

SPRING FITMENT

INSPECTION

PACKING

OIL SEALS
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MEASUREMENT DEVICES

VERNIER CALLIPER –

A measuring instrument consisting of an L-shaped frame with a

linear scale or digital scale along its longer arm. Using vernier
calliper we can determine the diameter of the object (inner and
outer), even the length of the object can be determined using this.
Least count of a vernier calliper is 0.01cm
So basically least count is the smallest value measured in the
instrument.

VERNIER HEIGHT GAUGE –

A Vernier height gauge is a measuring device used either for

determining the height of objects.

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 DIAL GAUGE -

Gauge consisting of a circular dial. It is used for measuring height.

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PROJECT ON 5’S

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CLEANING CHECKLIST

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CONCLUSION

I have had a wonderful learning experience at JK fenner india.

The way they follow the 5’s activity and kaizen is great and I had a great
pleasure in helping them in the 5’s project by giving them some
innovative ideas .So I thank everyone for giving me such a opportuinity.

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