Acknowledgement

It is a great pleasure and privilege for me to present this practical training report carried out
at “RANE NSK STEERING SYSTEM PVT LTD." and submitted in partial fulfillment
of the requirement for the award of the degree of the Bachelor of Technology in Electrical
Engineering to Rajasthan Technical University, Kota.

We express our sincere thanks to H.O.D. Mr. Pramil Sinha, Electrical Engineering
Department of our college for his kind cooperation and valuable suggestions.

We are very much thankful to Mr. Abhishek Mishra (Deputy Manager) at RANE NSK
STEERING SYSTEMS PVT LTD and inspiration at every step to an extent. This training
would not have been possible without her support and able guidance. She was very
supportive throughout the period in sharing their knowledge and technical aspects.

Finally, we express earnest and sincere thanks to the whole “RANE NSK STEERING
SYSTEMS PVT LTD.” for the generous help and co-operation in every possible manner.

Ankit Kumar Gauttam

College ID: 19EE002

i
 Candidate’s Declaration

I hereby declare that the work, which is being presented in the practical training report
carried out at “Rane NSK Steering System Pvt Ltd.” and submitted in partial fulfillment
of the requirement for the award of the degree of the Bachelor of Technology in Electrical
Engineering to Rajasthan Technical University, Kota is a record of my training carried
under the Guidance of Mr. Abhishek Mishra, Deputy Manager (EHS) at Rane NSK
Steering System Pvt Ltd., Bawal, Haryana.

Ankit Kumar Gauttam

Signature: -

College ID: 19EE002

Mr. Abhishek Mishra

Deputy Manager (EHS)

Rane NSK Steering System Pvt Ltd. Bawal, Haryana.

ii
Training Certificate

iii
 Abstract

Rane NSK steering system group is the joint organization of Indian (RANE) and Japanese
(NSK) companies which is in BAWAL, HARYANA. This company has taken contract to
manufacture and design steering column for HONDA and MARUTI companies.

RANE NSK incepted in 1997& RANE (INDIA) and NSK (JAPAN) with joint venture of
49:51. And this joint venture manufactures and produces column of electric power steering.

This company is possessing its working in three different department in which it offers
internship opportunity as MED (manufacturing engineering development), PLE
(production line engineering) & safety department. Although there are several different
departments also like PPC (production planning and control) and HR (human resources).

This company has two major areas one is SHED-2 area is for manufacturing and machining
processes of child parts of the steering column. And another area is SHED-1 which is
separated to assemble each child part with its testing and convert it into final product.

MED & PLE department are authorized to have concern about manufacturing and
production for the product which is being designed on machine shop floor. These
department play vital role in order decide a perfect design and various parameter which are
needed to fulfil the requirement of desired product. These all referred parameter are very
useful to obtain desired product by using various production and manufacturing
machineries on shop floor of the plant.

The program which is mandatory to complete before joining this company for new jonnies
and provide a basic knowledge is known as DOJO TRAINING in which “DOJO” is a
Japanese word. This training program of almost four days provide a basic knowledge about
quality and safety as well as documentation.

It also provides overview of the tools that are used duuring the manufacturing and
processing.

iv
 Contents

Acknowledgement I

Candidate Declaration II

Certificate III

Abstract IV

List of Figures VII

List of Table VIII

Chapter 1: INTRODUCTION

1.1 About Company 1

1.2 Department &Their Role 1

1.3Safety DOJO 2

1.4Quality DOJO 3

Chapter 2: Electric Power Steering

2.1 Introduction to EPS 5

2.2 Working of EPS 6

2.3 HPS V/s EPS 6

Chapter 3: EHS at RANE NSK

3.1 Environment 8

3.2 Health 8

3.3 Safety 9

3.4 Role of EHS 9

Chapter 4: Fire and its prevention

4.1 Fire and its type 11

4.2 Fire Extinguishers 12

4.3 Clean Agent Fire Suppression System 13

4.4 Flame Proof Lighting 14

v
4.5 Oil Level Indicator 14

Chapter 5: Unsafe Act and Conditions

5.1 Unsafe Act 16

5.2 Unsafe Conditions 16

5.3 NEAR MISS Condition 17

5.4 LUKKO SAFETY System 18

5.5. Implementation of Safety Curtain 18

5.6 5S Rule 19

Chapter 6: Machine Level Upgradation

6.1 Machine Level Identification 20

6.2 Upgradation Process 21

6.3 Machine Safety Risk Matrix 21

Chapter 7: Look-Across Activity

7.1 Introduction 22

7.2 Steps to Accomplish Look-Across Activity 23

Chapter 8: Problems in RAIN HARVESTING SYSTEM

8.1 Introduction 24

8.2 Overflow of Coolant Tank 25

8.3 Overflow of Trolley 25

8.4 Coolant Oil from Scrap Area 25

Chapter 9: CONCLUSION 26

Reference 27

vi
 List of Figures

Fig.1.1:Safety Rules 3

Fig.2.1: Electric Power Steering 5

Fig.2.2: Working of EPS 6

Fig.2.3: HPS V/s EPS 7

Fig. 3.1: Occupational Health 8

Fig.3.2: Accidents 9

Fig.4.1: Types of Fire Extinguisher 13

Fig.4.2: Clean Agent fire Supression System 14

Fig.4.3:Flame Proof Lighting 14

Fig.4.4: Ball Connected at Both Ends 15

Fig.4.5: Oil Level Indicator 15

Fig.5.1: Unsafe act, Condition and Near miss 18

Fig.5.2: Safety Curtain 18

Fig.7.1: Machine with Safetty Guards 23

vii
 List of Tables

Table-1.1: Customers of Company 1

Table-1.2: Various Departments and their role 2

Table-1.3: CAR and Their EPS model 3

Table-2.1: Comparison between HPS and EPS 7

Table-6.1: Machine Safety Risk Matrix 21

viii