A

INPLANT TRAINING REPORT

completed at

Sharda Motors Industries Pvt. Ltd.

Chakan, Pune.

By

Mr. Sarode Shubham Raosaheb

Enrollment No: 1900340595 Roll No: 20

Under The Guidance of

Mr. S. M. Kadam. Mr. M. R. Bagal.
(Institute Mentor) (Industry Mentor)

DEPARTMENT OF MECHATRONICS
SANJIVANI K. B. P. POLYTECHNIC, KOPARGAON 423 603
MSBTE
2021-2022
 SANJIVANI RURAL EDUCATION SOCIETY’S
SANJIVANI K. B. P. POLYTECHNIC, KOPARGAON
Department of Mechatronics

CERTIFICATE
This is to certify that,
Mr. Sarode Shubham Raosaheb
has satisfactorily carried out and completed the inplant training at,

Sharda Motors Industries Pvt. Ltd.

This work is being submitted for the award of diploma of
Mechatronics
It is submitted in the partial fulfillment of the prescribed syllabus of
MSBTE, Mumbai
For the academic year 2021-2022

Mr. S. M. Kadam Prof. P. B. Khatkale

(Guide) (H. O. D.)

Prof. A. R. Mirikar
(Principal)
 INPLANT TRANING APPROVAL SHEET

MSBTE, MUMBAI

“Inplant Training Report”

Completed At
Sharda Motors Industries Pvt. Ltd.

Submitted By

Mr. Sarode Shubham Raosaheb

Is approved for the Diploma in Mechatronics

Prof. S. M. Kadam

Project Co-Ordinator External Examiner

Date:

Place:
INPLANT TRAINING CERTIFICATE
 ABSTRACT

This “Inplant Traning Report” is related to Sharda Motors Industries LTD.

In the report below, I first mentioned the complete information about the
industry. He then mentioned all that was happening in the industry. And then
included information about the materials, methods, and equipment used in the
industry. The machines and methods required for the finished product are
given below. Information on the equipment used to access the material is
included in the report.

The complete information about the materials required for the exhaust
system and suspension system manufactured in the industry is mentioned. The
advantages of exhaust system and suspension system are shown. And most
importantly, the methods are used for security in industry are included in
report.
 ACKNOWLEDGEMENT

I would like to express my special thanks of gratitude to our HOD. Mr. P. B.

Khatkale, who gave me the golden opportunity to do Inplant Training. Now I must thank
my Institute mentor Mr. S. M. Kadam, and my Industry mentor Mr. M. R. Bagal ,
whose valuable guidance has been once that has helped me in this training to make it a
full proof success, their suggestions and their instructions has served me the major
contribution towards the completion of the training. Now, secondly I would like to thank
Mr. A. A. Dhakane, who helped me a lot in finalizing this project and report within the
limited time frame.
I also extend my deepest gratitude to Principal, Prof. A. R. Mirikar, Sanjivani
K. B. P. Polytechnic, Kopargaon for providing all the necessary facilities and true
encouraging environment to bring out the best of my endeavors. At last I must thank our
Mechatronics Department and Institute Management of Sanjivani Group Of Institute
for arranging us a unforgatable Inplant Training.

Sarode Shubham Raosaheb

TYMK
 INDEX

Sr.No Title Page No.

1) Title Sheet -
2) Certificate -
3) Examiner’s Certificate -
4) Inplant Training Certificate -
5) Abstract -
6) Acknowledgement -
7) Index -
8) List of Figures -
9) Organization Structure of Industry 1
10) Introduction to Industry / Organization 2-6
11) Types of Raw Materials, Test Methods, Instruments / 7-14
Gauges, Quality Assurance / Quality control activities
12) Machines and Equipments 15
13) Techniques and Methodologies 16
14) Major Material Handling Products 17-19
15) Safety Precautions Followed by Industry 20-22
16) Personal Experiences in Industry 23-24
17) Project Work Report during the Inplant Training 25
18) Special / Challenging Experiences Encountered During 26
Internship

19) References 27
 LIST OF FIGURES

Figure No. Title of Figures

1.1 General Layout
2.2 Location Of Industry
3.3 Vernier Calliper
3.4 Plunger Dial Gauge
3.5 Micrometer
3.6 Feeler Gauge
3.7 Rockwell Hardness Test
3.8 Press Maschine
3.9 Lock seaming Machine
3.10 Flange up Machine
3.11 Double End Spinning Machine
3.12 Yashkawa Spot Weld Robot
6.13 Forklift
6.14 Elevator
6.15 Pully
6.16 Hand Pallet Truck
7.17 Safety Shoes
7.18 Safety Gloves
7.19 Safety Glass
7.20 Earplug
7.21 Systematic Arrangement
8.22 Muffler P425
8.23 Muffler W150
 CHAPTER 1: ORGANIZATION STRUCTURE OF INDUSTRY:

About Sharda Motors Industries,

History,

SHARDA MOTOR Founded in 1986, Sharda Motor Industries Ltd (SMIL) has scaled
to numerous highs in the automotive industry. The latest techniques, design, equipment and
modern manufacturing which is highly efficient, organized and structured in India, we are
making new grooves in this area, adding excellence and technological expertise.

About Company,

Sharda Motor is the market leader in manufacturing of Exhaust System, Catalytic

Converter, Independent Suspension, Seat Frames, Seat Covers (Two Wheelers & Four
Wheelers), Soft Top Canopies, and Pressed part- White goods products.
Sharda Motor believes to satisfy all their customers and those who use their products and
services by meeting their needs promptly and accurately by maintaining the highest quality
standards. They provide equal opportunity for development, advancement and growth.
Sharda Motor has state-of-the-art manufacturing facilities with continuous focus on new
product, innovation and technology upgradation, research and development.

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CHAPTER 2: ORGANIZATION STRUCTURE OF INDUSTRY AND
GENERAL LAYOUT:

2.1. Organization Structure,

Plant Head

Senior Manager

Assistant Manager

Senior Engineer

Engineer

Trainee

Worker

2
2.2. Genaral Layout

Fig. 1.1 General Layout

3
 Vision

To be among the Top 100 Companies in India. We will achieve this by focusing on
Innovative Products+ Services & globally expanding our presence."

Mission

We strive to provide a world class value proposition to all customers we serve & give
long term growth opportunities to our employees, shareholders & all other stakeholders.

4
2.3. Location Of Sharda Motors Industries Around The World :

Fig. 2.2 Location Of Industry

5
 Company Details

Company Name : Sharda Motors Industries PVT. LTD (SMIL)

Company Status : Active

Company Category : Non-Government Company

Nature Of Industry : Automobile

Employees : 999

Date Of Incorporation : 29 Jan 1986

Activity : Manufacturing Exhaust System & Suspension System

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CHAPTER NO 03: TYPES OF RAW MATERIALS, TEST METHODS
INSTRUMENTS/ GAUGES , QUALITY ASSURANCE / QUALITY
CONTROL ACTIVITIES.
Depending upon requirement the various material used to make wheels ,
3.1. Muffler:
Steels is used manufacture muffler Different type of grades are used of steel Like SA-276,
SAPH440, SUS304, SUS409

3.1.1. SA-276: Grade-304.

Chemical Component:
Carbon (C) – Max 0.080
Sulphur (S) – Max 0.030
Phosphorus (P) – Max 0.045
Silicon (Si) – Max 1.00
Nickle (Ni) – Max 11.00

3.1.2. SAPH440:
SAPH440(Steel Automotive Pickled Hot-rolled & 440Mpa)

Chemical Composition:-
Phosphorous (P) maximum percentage is 0.040%
Sulphur (S) maximum percentage is 0.040%
Carbon (C) is not identified in the standard
Manganese (Mn) is not identified in the standard & iron (Fe)

Mechanical Property: -
Tensile strength at least 440Mpa
yield strength is min 270 to 305 Mpa Depend on thickness elongation
property min percentage range is 29 to 34mm

3.1.3. SUS 304:

Chemical Component:
7
Carbon (C) – Max 0.07
Manganese (Mn) - Max 2
Phosphorus (P) – Max 0.045
Sulphur (S) – Max 0.03
Silicon (Si) – Max 0.75

Mechanical Properties:
Yield strength:205
Tensile strength: 515
Elongation: 40
Hardness:195

3.1.4. SUS 409:

Chemical Component:
Carbon (C) – Max 0.08
Manganese (Mn) - Max 1
Phosphorus (P) – Max 0.04
Sulphur (S) – Max 0.03
Silicon (Si) – Max 1

Mechanical Properties:
Yield strength: 175
Tensile strength: 360
Elongation: 22
Hardness: 175

3.1.5. Mig Welding:

In Mig (Metal inert gas) welding wire used is copper. And gas used is
Argon (90%) + CO2(10%).
Paint:- PPG ashien .Berger.

8
3.3. Measuring Instrument used in Industry :

3.3.1. Vernier Caliper :

Fig. 3.3 Vernier Caliper

We know the core uses of Vernier Calipers is for measuring the distance between two
opposite side of a surface. We can measure the internal and external dimensions and even
the height of an object with accuracy. It can measure up to one-hundredth of a millimeter.

3.3.2. Plunger Dial Gauge :

Fig. 3.4 Plunger Dial Gauge

Application :

1. To Check Run Out.

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2. To Check Parallelism.
3.3.3. Micrometer :

Fig. 3.5 Micrometer

A micrometer is a measuring device used to measure flat surfaces or different geometries.

3.3.4. Feeler Gauge :

Fig. 3.6 Feeler Gauge

A feeler gauge is a hand-held tool used for measuring gap widths between two objects
that are close together.

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 3.3.5. Rockwell Hardness Test :

Fig. 3.7 Rockwell

The Rockwell hardness test is often used as a 'quick test' on the production floor or in
the laboratory, mainly for metallic materials.

3.4. Quality Assurance \ Quality Control Activity:

1. Raw Material Checking Physically Width & Thickness With The Help Of Vernier
Caliper .
2. Muffler Inspection.
3. Suspension System Inspection.
4. Exhaust System Inspection.

3.5. Machine Used In Industry:

1. Cutter Machine
2. Deburring Machine
3. Spotting Machine
4. Lock Seaming Machine
5. Flange Up Machine
6. Stuffing Machine
7. Double Spinning Machine
8. Leackage Checking Machine
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9. Shrinker Machine
10. Press Machine
11. End form
12. GBD Measurement
13. Leasure Machine
14. Nash Spot Weld Robot
15. Welding Robot
16. TST Spot weld Robot

Fig. 3.8 Press Machine

Fig. 3.9 Lock Seaming Machine

12
Fig. 3.10 Flange up Machine.

Fig. 3.11 Double End Spinning Machine.

13
Fig. 3.12 Yashkawa Spot Weld Robot.

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 CHAPTER NO : 04 MANUFACTURING ACTIVITY

In industry different types of manufacturing activities to manufacture the Exhaust

System , Suspension System & Assembly Process.

1. Manufacturing of Exhaust System

2. Manufacturing of Suspension System
3. Assembly Process

4.1. Manufacturing of Exhaust System :

1. First pipes and metal sheets come in as raw material as purchase inward as per
requirement.
2. Pipes are sent to the pipe bending section where pipes are cut and bent to form the
shape required by the type of exhaust.
3. Metal sheets are notched by process called notching sent to the lock seaming
machine where the metal sheet is folded and seamed to form the outer body of the
muffler.
4. Then various parts of the muffler are stuffed inside the muffler body and are such as
glass wool by process called stuffing and packed with the end plates.
5. Then the bended pipes and mufflers are stored as WIP in between the Muffler
section and Exhaust Assembly line.
6. After this as per requirement the bended pipes, mufflers and catalytic convertor are
welded together and hangers are attached to them to form the complete Exhaust
assembly.
7. At last the assembled exhaust systems are loaded in trolleys and dispatched to the
respective OEM.

4.2. Manufacturing of Suspension System:

1. First all the parts needed for the assembly of the suspension is supplied as FOC parts

15
 by Mahindra & Mahindra.
2. SMIL (CHAKAN) stores all the parts like struts, coils, control arms in its stores as
inventory and sends them on the assembly line whenever required.
3. The suspension system assembly takes place at two lines:
4. MPV Axle line and
5. LTV Axle line.
6. After the assembly is done these are stored as finished products in the inventory and
dispatched as per M&M requires.

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 CHAPTER NO : 05 MANUFACTURING TECNIQUES AND
METHODOLOGIES :

Operations of SMIL is integrated among all its plants in India in order to make optimal
use of its resources Hence its operations are highly complex. The Raw material, WIP,
Components of SMIL are shared among its plants in India so as to make optimal use of its
resources.
At Gate Numbers 1, 2 and 3 Raw Materials, Components, WIP enter in the form of:
5.1. JOB WORK (JW);
Job Work are those parts which are which are made by various automotive companies in
Pune for which the raw material is provided by SMIL (Chakan).

5.2. FREE OF COST MATERIALS (FOC'S):

Free of Cost materials comprises of all raw materials, WIP, Sub assemblies and components
that are provided free of cost by Mahindra and Mahindra and SMIL(Chennai and Nashik).

5.3. BOUGHT OUT PARTS (BOP'S):

Bought out Parts are all raw materials, WIP, Sub assemblies and components that are
bought by SMIL (Chakan).

After this the Job Work and Bought Out Parts are sent for quality check and Free
of Cost Materials are directly sent to the stores.

After the quality check is over the OK material is sent to the stores and the rest are sent to
the rejected materials area to be sent back to the supplier.

MPV-multi purpose vehicle and LTV-light transport vehicle W201 means SUV.

Unlike Exhaust systems the Suspension Systems are only assembled in SMIL(Chakan).

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CHAPTER NO 06 : MAJOR MATERIAL HANDLING PRODUCT

1. Cranes
2. Pulleys
3. ForKlift
4. JCB Crain
5. Sling

6.1. Forklift :

It is small industrial vehicle, having a power operated forked platform attached at the
front that can be raised and lowered for insertion under a cargo to lift or move it. Forklifts
serve the needs of various industries including warehouses and other large storage fac

Fig. 6.13 Forklift

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6.2. Elevators :

Type of craines that lift materials usually in Industry.

Fig. 6.14 Elevator

6.3. JCB Crain :

Device Mounted on overhead rail or ground wheels or rails, they lift swing and transport
large and heavy material.

6.4. Pulley:

Fig. 6.15 Pulley

A pulley is a wheel on an axle or shaft that is designed to support movement and change
of directio of a taut cable or belt, or transfer of power between the shaft and cable or belt

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6.5. Hand Pallet Truck:

Fig. 6.16 Hand Pallet Truck

A pallet truck (also known as a pump truck or pallet jack) is a wheeled trolley designed
to lift and transport pallets. The truck's tapered forks slot underneath the pallet and the
pump handle can then be used to raise and lower the load.

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CHAPTER NO 07 : SAFETY PROCEDURE FOLLOW BY INDUSTRY

7.1. Safety Shoes:

Fig. 7.17 Safety Shoes

Benefits of Wearing Safety Shoes at Workplace

1. Prevention from Slips and Falls
2. Protection against burns
3. Keeping feet warm in extreme weather
4. Resist Fatigue.
5. Saviour against electrical hazards.

7.2. Safety Gloves:

Fig. 7.18 Safety Gloves

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 Safety Gloves are the type of hand protection equipment made up of plastic,
rubber, or synthetic material. It is usually used while cleaning or working with oils,
solvent, or chemicals. Also, it is used during the welding process to protect from cuts and
abrasion.

7.3. Safety Glass:

Fig. 7.19 Safety Glass

Welding goggles provide a degree of eye protection while some forms of welding and
cutting are being done. They are intended to protect the eyes not only from the heat and
optical radiation produced by the welding, such as the intense ultraviolet light produced by
an electric arc, but also from sparks or debris.

7.4. Earplug:

Fig. 7.20 Hand Pallet Truck

A pallet truck (also known as a pump truck or pallet jack) is a wheeled trolley designed
to lift and transport pallets. The truck's tapered forks slot underneath the pallet and the
pump handle can then be used to raise and lower the load.

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7.5. Systematic Arrangement:

The goal of this step is to organize the work area. Each item should be easy to find, use,
and return: a place for everything, and everything in its place.

Fig. 7.21 Systematic Arrangement

7.6. Self Descipline:

The solution is to apply the ideas of 5S over and over, all above four points are combined
in this same as a routine part of normal work. Assign responsibility, track progresses, and
continue the cycle. That's why Descipline is so important.

23
 CHAPTER NO : 08 PRACTICAL EXPERIENCE IN INDUSTRY

We measure these diamension of Muffler

8.1. Muffler Diamension:

Muffler Part: P425 & P426 Muffler Assembely

Part no: 0901AAA04301N

Sr. No Parameter Speciffication Method Of

Inspection
1 Total height 324.4 ±2mm Height gauge

2 Perforator tube height 1.5 ±0.5mm Vernier

3 Tube ID inlet \ outlet ∅41.7±0.25 Vernier

4 Embossing details Should be visible and correct Visual

0901AAA04301N part no.
5 Inlet \ outlet pipe ID Damage \ Dent Visual

6 Assimbely Free from noise, weak tack Visual & shaking of

welding, Dent & Damage muffler

Fig.8.22 Muffler P425

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8.2. Muffler Diamension:

Muffler Part: W150 / U350 Muffler Assembely

Part no: 0901BAA00451N

Sr. No Parameter Speciffication Method Of

Inspection
1 Total height 237.8 ± 1mm Height gauge

2 Perforator tube height 1.5 ±0.5mm Vernier

3 Tube ID inlet \ outlet ∅49.1±0.25 Vernier

4 Embossing details Should be visible and Visual

0901BAA00451N correct part no.
5 Inlet \ outlet pipe ID Damage \ Dent Visual

6 Leak test Free from noise, weak tack Visual & shaking of
welding, Dent & Damage muffler

Fig. 8.23 Muffler W150

25
 CHAPTER NO 09 : PROJECT WORK REPORT DURING THE
INPLANT TRAINING.

The topic “study of industrial robotic welding” is related how many type of welding are
used in industrial the main purpose of given information about robot why should to robot
used in industry . Also I‟ve included points to benefit of robot and it application.
There are many type of welding used in industry. Like as spot welding. Mig welding. Tig
welding. Arc welding. Electric resistance welding.
It's simple definition of welding is “joining metals through heating them to a
molten state and fusing them together.” With increasing progress in welding processes and
techniques, the definition has had to change. It is quite true to say that the weld is stronger
than the base metal. Beside the classic application areas of welding such as shipbuilding,
automobile manufacturing, building construction, and pipelines, currently welding
techniques are being used in more complex application fields including aircraft, space
vehicles, and nuclear reactors.
A basic typical robot has a movable physical structure, a motor of some sort, a sensor
system, a power supply and a computer "brain" that controls all of these elements.
Essentially, robots are human-made versions of animal life — they are machines that
replicate human and animal behavior.

26
 CHAPTER NO 10 : SPECIAL / CHALLENGING EXPERIENCES
ENCOUNTERED DURING INTERNSHIP

The company "Sharda Motors Industry Pvt. Ltd". When I joined company as a trainee
technician at production department, I have experienced many things over there, same as
other technicians I have practiced all the work they were doing, as like operating the
machine which is a periodic maintenance of the machine, in that the work which I've done
is mentioned above as like observing the job. Side by side I have completed my implant
training manual which includes all the weekly work I have performed or practiced in the
company, as the training was scheduled for 16 weeks. Also I have made a Project Report
which includes all detailed information about Exhaust System . My institute mentor and
industry mentor had guided me a lot about the work and also helped in completing project
work and inplant training report.
By this training I have got many things to learn in the company. I also came to know
about importance of time and hard work, and we were given targets to complete in given
time. Company's senior employes have given us more knowledge about job. As the days
were passing we have learn many things about real life and work knowledge..

27
 CHAPTER NO 11 : REFERENCES

1. Work Shop Manual.

2. Training Session.
3. Self Work & Experience.
4. Internet.
5. Internet Videos.
6. Flowchart.
7. Industry Manual.
8. Industry Management.
9. Quality Department.
10. www.shardamotor.com.

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