POORNIMA COLLEGE OF ENGINEERING

A REPORT ON
INDUSTRIAL VISIT

Submitted in Partial Fulfillment for the department of

Non syllabus subject
Bachelor of Technology Degree
Of
Rajasthan Technical University, KOTA

2012-2013

Guided By: Submitted By:

Miss. Soni vijayvergia TARANG GUPTA
(tutor ) SOMANSHU DUDEJA
SUSHANT KUMAR
Me(II) , O

DEPARTMENT OF MECHANICAL ENGINEERING

POORNIMA COLLEGE OF ENGINEERING
ISI-6, RIICO INSTITUTIONAL AREA
SITAPURA, JAIPUR-302022

(RAJASTHAN)
 Certificate
This is to certify that Mr. TARANG
GUPTA
Roll no.58 of first year B.E. mechanical
Engineering has completed industrial visit,

TO

CENTRAL INSTITUTE OF PLASTICS ENGINEERING AND

TECHNOLOGY,
2012-2013

Miss. SONI VIJAYVRGIA MR. PRASHANT KALRA

Visit Incharge Visit Incharge

MR. G.K PANDA

H.O.D.

Poornima COLLEGE OF ENGINEERING

Jaipur.
POORNIMA COLLEGE OF ENGINEERING

CONTENT
 INTRODUCTION
 QUALITY POLICY
 OBJECTIVE
 MANPOWER
 COURSES
 SHORT TERM
 LONG TERM
 PLACEMENT SERVICE
 TECHNICAL SERVICE
 PRACTICAL KNOWLEDGE

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CENTRAL INSTITUTE OF PLASTICS ENGINEERING AND

TECHNOLOGY

Corporate Office

RIICO INDUSTRIAL AREA,SITAPURA,

JAIPUR, RAJASTHAN -302022

Email: cipethq@vsnl.com

PROFILE

1. General Profile:

Central Institute of Plastics Engineering and Technology (CIPET) is an

autonomous Institute under the Department of Chemicals and Petrochemicals, Ministry
of Chemicals and Fertilizers, Government of India. CIPET Head Quarters was
established at Madras in 1968 with UNDP assistance. This is the only institute of its kind
in India where all the facilities like design, tooling, processing and testing of plastics are
available under one roof. CIPET caters to the needs of plastic industries through
manpower training, processing, design and CAD/CAM/CAE, testing, consultancy,
advisory and developmental services.

To meet the growing needs of plastics conversion industry, CIPET has

established extension centres in various States of the country. Each centre of CIPET
has been equipped with state-of-the-art machinery in the area of mould/product design
and development, CAD, plastics processing and testing/quality control. Apart from
developing training manpower and technical services for plastics industries, each centre
has been entrusted with a specific thrust area for development.

The thrust area of each centre is given below:-

1. Madras (HQ): Standardization, Quality control & testing of plastics materials and
products.
2. Ahmedabad : Development of plastics processing machinery & testing equipments
3. Amritsar : Substitution of plastics for conventional materials
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4. Bhubaneswar : Application of plastics in housing and packaging

5. Bhopal : Application of plastics in agriculture
6. Hyderabad : Application & development of engineering plastics
7. Imphal : Application of plastics in water management and household
appliances
8. Mysore : Application of plastics in precision engineering
9. Lucknow : Application of plastics in teletronics and automobiles.

2. Corporate Profile

CIPET Corporate office (H.Q.) is located at Chennai (Madras) in order to

monitor, control and general superintendence of all the CIPET Centres spread over in
11 States of the country. The Corporate office includes the Corporate Training &
Planning, CAD/CAM/CAE for plastics, Project Monitoring & Advisory Cell, Business
Development Cell etc. Besides monitoring and administering the routine training and
technical activities of the CIPET Centres, the corporate office mainly concentrates on :

 International standard training for students in the state-of-the-art machinery like

Microprocessor Controlled Injection Moulding Machines.
 International Journal on "Plastics Engineering & Technology"
 Preparation, Evaluation and In-depth study on Technical/Feasibility Reports in the
area of plastics
 Setting up of Small Scale Plastics Industries and Testing Laboratories for Plastics
 Information & Documentation in all the areas of plastics
 Placement of CIPET Trained students in the managerial/supervisory and operator
level.

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QUALITY POLICY

3. Objectives

TECHNICAL MANPOWER TRAINING (Managerial & Supervisory)

TECHNICAL/DEVELOPMENTAL SERVICES
* Long Term Training * Testing and Quality Control services
* Short Term Training * Mould/Product Design and Fabrication
* Modular/Tailor-made Training * Job orders in processing and mould
Programme proving
* Entrepreneur Development Programmes * Applications Development
* Training for Foreign Nationals * Consultancy & Advisory Services
  * Information & Documentation
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MANPOWER TRAINING
Worldwide, plastics manufacturing and processing industries have grown
tremendously in the last decade. The plastics industry in India is predominantly in the
small-scale sector employing mostly unskilled and untrained manpower. Besides the
increased consumption of plastics for various consumer applications, use of plastics in
the field of automobiles, agriculture, water management, plasticulture etc., is also
increasing rapidly. Due to globalisation of Indian economy and joint ventures with
leading industries from the developed countries, there is a growing demand for
improving the quality of products on par with the international standards. The demand
for quality improvement and economic production can be met through
development/induction of trained manpower. CIPET has complete infrastructural
facilities to provide training in the areas of Design, Tool Room, Processing, Testing and
CAD/CAM/CAE to develop technically trained manpower through long-term and short-
term training programmes.

 Long Term Courses

 Short Term Courses
 Modular / Tailor-made Training Programmes
 Entrepreneur Development Programmes
 Placement Services

SHORT TERM COURSES

( 3 DAYS TO 3 MONTHS )

FOR ENTREPRENEURS, MANAGERS, ENGINEERS, FOREMEN, SUPERVISORS AND

TECHNICIANS IN PLASTIC INDUSTRIES IN THE AREAS OF (EXAMPLES)

 IDENTIFICATION & SELECTION OF PLASTICS MATERIALS

 QUALITY CONTROL & TESTING OF PLASTICS MATERIALS & PRODUCTS
 DEVELOPMENT OF NEW PLASTIC MATERIALS AND THEIR FORMULATION
 ADVANCED TECHNIQUES OF PLASTICS PROCESSING
 PLASTICS PRODUCT DESIGN
 DESIGNING OF DIES AND MOULDS

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 MOULD MAKING TECHNOLOGY

 CAD/CAM/CAE FOR PLASTICS

ENTREPRENEURAL DEVELOPMENT PROGRAMME (EDP)

 AWARENESS PROGRAMME ON PLASTICS AMONG THE PUBLIC FOR BECOMING

ENTREPRENEURS

 CONDUCTED EXCLUSIVELY FOR THE BENEFIT OF SC/STs AND WEAKER SECTIONS OF

THE SOCIETY
 ORGANISED FOR WOMEN ENTREPRENEURS

PLACEMENT SERVICES

CIPET courses are designed to meet the industry requirement in a

particular specialized area e.g.. Tooling / Mould Manufacturing / Design & CAD /
Plastics Processing / Plastics Testing & Quality control / Machine Maintenance /
Plastics Composites etc. The details of CIPET courses and the positions generally
offered to CIPET trainees are given in the following table.

S.No Name of Course Position/Level of Employment

Plastic Engineer/Prodn. Engineer/
Post Graduate Diploma in Plastics
1 Executive Shift Engineer/ Plastics
Engineering
Technologists
Prodn. Officer/ Process Engineer/Shift
Post Graduate Diploma in Plastic
2 Supervisor/ Prodn. Supervisor/Senior
Processing Technology
Process. Technicians
Post Graduate Diploma in Plastic Quality Supervisor/Testing Engineer/
3
Testing & Conversion Technology Supervisor/Lab Technicians
Post Diploma in Machine Maintenance Supervisor/ Engineer
4
Maintenance /Plant Maintenance Engineer
Diploma in Plastics Mould Mould/Die maker CNC machine
5
Technology ( DPMT) technicians/supervisor
Diploma in Plastics Mould making Mould/Die maker CNC machine
6
Technology (DPMM-T) technicians/supervisor
7 Post Diploma in Plastics Mould Mould/Die

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Designers/Engineers/CAD/CAM
Design (PD-PMD)
Engineers.

TECHNICAL SERVICES  

The Plastics Testing Centre (PTC) in CIPET is well equipped with all
modern plastics testing facilities. These facilities are being utilized effectively to improve
the standard and quality of plastics materials / products. The PTC has been providing
very useful services to the plastic conversion industries by testing of raw materials and
finished products like pipes, containers, squatting pans, films etc. The testing services
also include identification and characterization, composition of materials, grade
selection, property evaluation formulation and supplementing standards etc. The centre
is closely associated with Bureau of Indian Standards (BIS) for establishing standards
and to issue certificates for various plastic materials and products. The institute is
appointed as an agency for testing of pipes and other materials supplied for Water and
drainage departments. The PTC also has interaction with International Standards
Organization (ISO) in the formulation of standards.

The PTC in CIPET is recognized by the following institutions

organisation.

1. Bureau of Indian Standards.

2. Department of Family Welfare, Govt. of India.

3. Department of Science & Technology, Govt. of India.

4. Various State Government departments for quality assurance

5. Underwriters Laboratories Inc., USA (under consideration)

6. American Association for Laboratory Accreditation on behalf of Asia Pacific

laboratory

Accreditation and Co-operation (APLAC).

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The PTC is presently in the process of getting  NABL accreditation.

The PTC provides basic service to the industries and Government Agencies for quality
through:

 Identification and characterization of plastics and composites.

 Testing and quality assessment of plastic materials and products as per national and
international standards.
 Formulation and supplementation of test standards.
 Design and development of testing equipment's as per the testing requirements.
 Undertakes developmental projects and special assignments sponsored by
Universities endures industries/organisations leading to indigenisation, newer
application of plastics and helping for effective absorption of imported technology.

The major areas are

 Development of product concepts and application ideas through testing and

characterization
 Development and evaluation of materials and products for newer applications
 Development of innovative applications in the field of Electronics and
Telecommunications, Transport Engineering Components, Housing and Packaging,
Agriculture and Water management.

2. Design and CAD / CAM / CAE

  The design department with CAD has the latest software for imparting effective
training on product and mould design. The department provides following services to
the plastic Industries:

 3 - Dimensional solid modeling

 Product design and mould validation of

 Injection Moulding

 Gas assisted injection Moulding

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 Compression moulding and

 Transfer moulding process.

 Process simulation and mould design validation of blow moulding and

thermoforming.

 Extrusion Die Design : Pipe Die, Sheet Die & Co- Extrusion Dies

 3 D Digitizing and 2D Digitizing (CAD drawing conversion)

 A - A plotting services using inkjet/Laser Plotters

 Generation of CNC part programming.

 Scanning of Drawings/Profiles

 Short Term training programme for skill upgradation.

FACILITIES AVAILABLE

SOFTWARE
INTEGRATED CAD SOFTWARE PLASTICS ANALYSIS SOFTWARE

Pro - Engineer MOLDFLOW

Unigraphics C- Mold

I – DEAS POLY CAD

HARDWARE

SERVER : Silicon Graphics - Indigo 2 512 MB RAM,

20 GB Hard Disk.

NODES Silicon Graphics - O2 128 MB, RAM 4GB

Hard Disk

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PLOTTER AO Deskjet and Laser Plotters

PRINTER Deskjet and Laser Printers

SCANNER 3 - Dimensional Digitiser.

Many new applications of plastics are identified in specialized areas like

electronics, automobiles, aerospace etc. This has necessitated the use of expertise in
the design and tooling facility. To develop product designs and fabricate moulds, orders
from various industries are received. Many of the fabrication works undertaken by
CIPET are in the nature of import substitution. These design and fabrication works are
done by trainees, which subject them to rigorous training. Many Govt. undertakings and
institutions are approaching CIPET to manufacture intricate moulds. Besides fabrication
of moulds, the tool room also undertakes job orders of varying magnitude such as repair
of moulds & dies, grinding, drilling, designing, development of jigs & fixtures, tool parts
etc.

3. Plastics Processing Division

Plastic Processing division has broad range of practical training facilities in

the form of conventional processing machines. In addition to the training activities the
Processing division is also competent enough to undertake mould providing and
moulding job works in different processing machines.

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The following customer services are provided by

theprocessing division :

 Job - work on moulding of plastics products and providing of moulds.

 To conduct tailormade/ modular training programmes on the specific topics as per
the requirement of Plastics Industry.

 To organise Awareness / Orientation & Entrepreneurship Development Programme

(EDPs) on " Plastic Processing Techniques".

 Consultancy & Advisory services to the plastic Industries on "troubleshooting" of

processing defects " and " improvement in productivity".

 To provide consultancy services to the new entrepreneurs on " Setting up of a

Plastic Industry".

FACILITIES AVAILABLE       

 Modern Injection Moulding Machines of following manufacturers : -

JSW - Japan

ELECTRONICA - India

ENGEL - Austria

WINDSOR - India

 Multilayer Blow Film Plant of Dr. Collin, Germany

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 Pipe & Blown Film Extruders - Kolsite, India.

 Extruder for Tubing - DGP - Windsor
 Compression Moulding Machine
 Thermoforming Machine.
 Rotational Moulding Machine
 Blow Moulding Machine
 FRP - Demonstration Facility

4. Tool room

CIPET - TOOLROOM at Chennai, Ahmedabad, Amritsar, Bhopal,

Bhubaneswar, Hyderabad, Lucknow and Mysore have excellent CNC machining
facilities for taking up commercial job assignment for mould fabrication, high precision
machining and manufacturing of standard mould bases. The facilities of toolroom are
given below :

CNC MACHINES
* Universal Milling and Boring Machines
UME 600 -MIKRON SWITZERLAND
with SUSACAM Software
ROBO FORM 40 - CHARMILLS
* Die Sinking – EDM
SWITZERLAND
TORNADO 300 -
* Universal Lathe with Hydrobar feeder
COLCHESTER,ENGLAND U.K
ELB SCHLIFF - PERFECT FUTURE
* High Precision Surface & profile Grinder
GERMANY

INSPECTION FACILITIES

* Co-coordinator measuring machine ACCURATE – INDIA

Profile Project – EPO LP10 – JAPAN

* Ultrasonic Flaw Detector USK5 – GERMANY

Surf Test – 3 Mitutoyo – JAPAN

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SPECIAL PURPOSE MACHINES

* Jig Boring Machine with DRO B3- DR-HAUSER SWITZERLAND
* Co- coordinator Drilling & Boring
AD40- DRO ACCUMAX INDIA
machine with DRO
KA 2000 - RORSCHACH
* Rigid Die Sinking Machine
SWITZERLAND
* Center lathe with Hydro Copying
H22 - HMT – INDIA
Attachment
* Rotary Surface Grinding RUSSIA
* Cylindrical Grinder K130U-HMT-INDIA
* Optical Profile Grinding machine GLS 80A WASINO JAPAN

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5. Applications Development  

Development of materials/blends and alloys, additive formulation, plastics

mould ability, equipment development viz., Carbon Black Content Tester, Melt Flow
Indexer, Notch Cutter, and Hot Air Oven etc.

6. Consultancy & Advisory Services

                   Material selection, equipment & machinery, testing and standardization,

product & mould design and fabrication, setting up of tool room, processing units and
laboratories, formulation for materials, troubleshooting, failure analysis of products and
preparation of project reports.

7. Information & Documentation

Collection & Dissemination of information on all the areas of Plastics

Engineering & Technology.

LONG TERM COURSES

CIPET has played a significant role in developing trained Manpower for

the Plastics Industries in INDIA through LONG TERM COURSES in all the disciplines of
Plastics Engineering and Technology. Since inception, CIPET has trained around
20,000 students in the field of Plastics Engineering and Technology.

SHORT DURATION TECHNICAL PROGRAMMES

The Personnel/Executives from Plastics Industries are trained by CIPET

on all technological aspects i.e. Tooling, Design and CAD, Plastics Processing, Testing
& Quality evaluation of Materials and Products by organising short-duration training
courses, modular/tailor-made courses with duration varying from 2 days to 4 weeks.
These programmes are well designed for the upgradation of technical know-how & skill
of the participating personnel. Till date 18,000 executives and personnel from various
organisations have greatly benefited from these programmes.

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CUSTOMER SERVICES

With an Excellent integration and utilisation of Facility in Tooling, CAD &

Design , Plastics Processing, Testing and Quality Assurance, CIPET is competent to
meet the customer requirements in providing qualitative technical services.

ISO 9001 -ACCREDITATION

CIPET has been awarded with ISO-9001 certification by BVQI for "Design,
Development & conduct of specialized training courses in the field of Plastics
Engineering & Technology"

OTHER ACCREDITATIONS

CIPET Testing laboratories are duly recognized by NABL and BIS for
conduct of plastics Material & Products-Testing as per National and International
standards.

Capacity wire dia range – 0.30 – 8mm.

Unit started during the year 1976.
Manufacturing types
Precision metallic coil springs such as
i) Valve Springs.
ii) Variable Pitch Springs.
iii) Conical Springs.
iv) Compression Springs.
v) Tension Springs.
vi) Torsion Springs.
vii) Shaped Springs
Shop floor
(a) Spring coiling machine
Machines Range
(i) Automatic Spring coiling machine (0.4 mm – 1.5 mm)
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(ii) Universal Automatic Spring Coiling machine. (0.5 mm – 4.5 mm)

(iii) Universal automatic spring coiling machine (0 .5 mm – 7.5 mm)
(b) Grinding Machines :- Grinding machines are used to grind the top & bottom
surfaces of the springs, as the springs are made of wires therefore after coiling if we try
to make the spring stand vertically grinding in necessary to get the best parallel tops &
bottom.
(c) Stress Relieving Furnaces :- To reduce the stresses in material ( 200 lts)
Tempering Temp – 3000 – 4500C ( Depending in the wire dim.)
Time – 20 – 60 min ( Depending in the wire dim.)
(d) Manual Mandrel coiling machine – Tension springs.

(e) Testing machines

(1) Hardness tester
(2) Load testing machine
(3) Digital Load testing machine
Raw Material identification Colour code
Colour Raw material description
Yellow - IS 4454/(1981) – Part 1, Grade – 2
Parrot Green - IS 4454/(1981) Part – 2, Grade – 3
White - IS 4454 (1981) Part – 1 Grade – 4
Gray - IS 4454 (1975) Part – II Grade – SW
Purple - IS 4454 (1975) Part – II Grade – VW
Royal blue - IS 4454 (1975) Part – III Grade – 1 D
Violet - IS 4454 (1975) Part III – Grade – 2 D
Sky blue - IS 4454 (2001) Part – IV, Grade – 1
JOB CARD / IDENTIFICATION CARD
CUSTOMER COILCODE
PART NO. M/C NO.
CUMPRESSION SPRING QTY
1 COILING STATUS INITIAL
2 LENGTH CORRECTION
3 DEGREASING

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4 STRESS TEMP
RELIEVING TIME
5 GRINDING/UNGROUND
6 DEBURRING
7 SHOTPEENING TIME
8 STRESS TEMP
RELIEVING TIME
9 COLD SETTING/
SCRAGGING
10 ZINC PLATING THK
DEEMBRITTLE – TEMP
MENT TIME
11 PHOSPHATING / OILING

Steps for finished world class spring

1) Coiling 7) Plating
2) Length correction 8) Wire straighting
3) Tempering 9) Anim Straighting
4) Grinding 10) Looping
5) Deburring 11) Gap cutting
6) Cold setting 12) Final inspection

PRODUCTION IMPROVEMENT POLICY/SYSTEM

5 S Japanese Theory
Snitsuko / self – discipline
Seiketsu (Sanitizing)
Seiso (Stick & Span)
Seiton / Systematizing)
Seirin (Sorting)
5S in not only a matter of house keeping. It is an integrated approach for
productive improvement & insure P Q C D S M to the company which practice 5S
P- 5S increases production.
Q- 5S improves Quality
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C- 5S Reduces Cart
S- 5S improves safety
M- 5S improves morale.
All 5S contribute productive improvement
Quality – (i) Only happens when you care enough to do your best.
(ii) Quality always scores lets keep ours high.
- (Quality Policy)
We are committed to provide best quality product, which consistently meet
or exceed customs expectations & strive for continuous improvement.

KANBAN TABLE – Monthly planning Daily position.

Part No. Schedule Stock To be 1 2 3 4
Quantity on 1st produced coiling Length Tempering Grinding
correction

5 6 7 8 9 10 11 12
1-D Cold Plating Wire Aron Looping Gap Final
Deburrin setting Straight Straightening cutting inspection
g

13
Administrative 14
floor

12

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4 5 6
Up stair Down stair
7
1 2
8
3 Stock
9

11 10
Testing Machine

Entrance
& Exit

1. Spring coiling Machine

2. Automatic coiling machine (04mm – 1 mm)
3. Material handling cenitomeet
4. Automatic spring coiling machine (.4 – 1.5 mm)
5. Universal Automatic spring coiling machine (.5 –4.5 mm)
6. Universal Automatic Spring coiling machine (1.5 – 7.5 mm)
( 7 – 10 ) – Grinding Machines
11. Heat treatment Machine for stron Relieving
12 – 13. Manual hard spring coiling machine a/or special spring
14. World’s first working model of Manual hard Spring coiling Machine.
Accessories from HAL

i) Environmental Control System

ii) Hydraullic System

iii) Wheels and Brakes

iv) Engine fuel control system

v) Instrument and sensors

vi) Electrical System Components

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vii) Avionics

viii) Ejection seat.

Values

i) Customer Satisfaction

ii) Commitment to total quality

iii) Cost and time consciousness

iv) Innovation and creativity

v) Trust and team spirit

vi) Integrity

vii) Respect of the individual

Mission: To become a globally competitive air space industry while working as

instrument for achieving self reliance; in design manufacturing and maintenance of

aerospace defense equipment and diversifying an commercial lines in a climate of

growing professional ……

OBSERVATION: The cipet is a institute deals with study related to plastic, here

students work with passion, attention, with huge interest, .. Here plastic appliance is

also been prepared. They get order and students have helped him to complete the

order. Which leads to direct interactions of problems to students which they face in

factory.. .

RECOMMENDATION: Miss.Soni Vijayvergia (tutor)

REFERENCES: Google. Com, friends, seniors, reference books,etc…

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