INDUSTRIAL TRAINING

An INTERNSHIP REPORT

Submitted by

NAIMISH ARVINDBHAI PIPROTAR

210190119511
In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING

in

Mechanical Department

Government Engineering College Valsad

Faculty Guide Head of the Department

Prof. B. K. Patel Prof. V. D. Dhiman

Gujarat

Technological
University,
Ahmadabad,
Jan-Apr ,2024
I
 Government Engineering College Valsad

CERTIFICATE

This is to certify that the project report submitted along with the project entitled
INTERNSHIP at WINSTEEL ENGINEERING WORKS Pvt. Ltd.(SURAT)
been carried out by NAIMISH PIPROTAR under my guidance in partial
fulfillment for the degree of Bachelor of Engineering in Mechanical Engineering,
8th semester of Gujarat Technological University, Ahmadabad during the academic
year 2024.
.

Internal Guide Head of

Department Prof. B. K. Patel Prof. V. D. Dhima

II
 CHAPTER 1

OVERVIEW OF THE COMPANY

1.1 Introduction :

Winsteel Engineering Works Pvt. Ltp.. Established by Bhupendra Shah in 1972, have
acquired high reputation and earned experience in the field of structural fabrication. The
company is involved in Design & manufacturing of various type of frameworks and
equipments with drawing which are use in bridge construction, road construction,
elevated metro, river span, special bridges & flyovers and precast construction project.

Winsteel is pioneer and leading formworks and falsework manufacturing in india The
company have rich experience of more then five decades. Company provide Innovative,
Safe and Smart Solutions to Construction industry.

Winsteel Involvement is from the Inception to the Completion of the Project. The
company provide the complete Services right from understanding the project and client's
requirement. Design, Manufacturing, Installation and Commissioning of Equipments,
Site Support, Staff training.

The company has expertise in Design, Manufacturing, Supply & Commissioning of

Bridge Construction Equipments such as Custom made Formwork & Falsework
Systems. Launching Gantries, Accropode Moulds for Breakwater System, Rock
Grapples and RMC Batching Plant Equipments such as Cement Silos, Flyash Silos,
Aggregate Bins, Aggregate Conveyors and so on.

Winsteel to add more value to the products and increase the range of products have

2
made a Technical Collaboration with the International Company-M/S ALPI South East
Asia Co. Ltd. With this Collaboration, company increased it’s product ranges from
Formworks to Launching Gantry. From Travellers, Beam Launchers, Movable
Scaffolding Systems etc, and also added the services like Designing complex moulds,
Formworks, Design of Casting Yard Layout .

2.1 Valuation of Company :

From the year of 1972, turnover was 35000 Rupees to its Recent year 2022 turnover of
more than 107 cr. The company grown up and still Drives to Break it’s own milestone
and target towards 150 cr.

Basic Information About Company

Category of Business Manufacturing/Fabrication

Company CEO Mr. Jaydeep shah

Address Plot no. I68, GIDC Sachin, surat

Class of Organization Private limited

Total Number of Employees 500+

Annual Turnover 128 crore

Top Export Country Canada, Qatar

Clients of company M/S L&T construction Ltd., Afcons,

National Highspeed Rail corporation

3
 Limited, JMC, J Kumar, KEC ect.

2.2 Organization Hierarchy Chart :

Owner/CEO

Jaydeep shah

Operation Head

G. Jayprakash

Production Quality Design Finance H.R Maintenance

Department Department Department Department Department Department

Vinod Niraj Karshan Vishal Shailesh Shailesh

(H.O.D) (H.O.D) (H.O.D) (Accountant) (H.R) (H.O.D)

Hiren Nikunj Jayesh Hemant Pankaj

(Engineer) (Engineer) (Engineer) (Accountant) (H.R)

Pritesh Rinkesh Pratik Harish

(Engineer) (Engineer) (Engineer) (Accountant)

Darshan Shivam Ujjaval

(Engineer) (Engineer) (Accountant)

Bhavik Smit. A

(Engineer) (Engineer)

Akhilesh Smit. B

(Engineer) (Engineer)

4
1.3 Departments of Company :

1. Planning Department :

Planning Department Ensures that all preparations are complete before a

production cycle begins. This includes allocating resources efficiently, ensuring
that materials, equipment, and labor are ready when needed, and organizing the
factory floor.

2. Purchase Department :

Purchase department looks for and buys Raw material like sheet, plates, RHS,
SHS, CHS, C channel , I section, L angel, H section ect. and services at the
lowest possible price and value. Also has to be in Quality product. This might
include decisions about whether the products or components are manufactured
in-house or purchased from external suppliers.

3. Design Department :

The design department in company’s role is to develop a blueprint of required

mould or project for the production process. This is done by sharing ideas and
concepts with other team members and other partners of company (Apli South
East ltd. The design department manager then submits the blueprint to executive
clients for approval.

4. Production Department :

In the company, production department’s role is to convert raw materials and

other inputs into finished products. The primary goal of this department is to
make structure or moulds according to the Design specifications and standards
and minimize production costs and ensure the efficient use of all available
resources.

5
5. Quality Department :

Quality control Involves testing units and determining if they are within the
specifications for the final structure. The purpose of the testing is to determine
any need for corrective actions in the manufacturing process. In the company
Quality Department is also responsible for Certification process of Welders, calls
Welder Qualification Test Certificate according to Welding procedure
Specification.

6. Marketing Department :

A marketing department’s role is to promote a company’s products and services

and maintain the image of company. Marketing is important to manufacturing
because its job is to gain and keep Clients. This role could include messaging or
social media Handling and making sure that it's consistent across all marketing
channels. Oversees the company side of marketing, including budgeting and
market research.

7. Safety Department :

The role of safety department in company is to protect employees, customers,

and the community from potential harm. The department’s primary goal is to
reduce the risk of injury, illness, or death to workers. For that the winsteel
arrange the safety awareness seminar, every Tuesday.

8. Maintenance Department :

The maintenance department's main purpose is to ensure optimal asset reliability

and performance. The team of maintenance Regularly Maintain the working
condition of moulds and on-site inspection of mould. Maintenance can also
include: measures, problem solving skill, Repair, Improvement.

9. Store Department :

One of the basic functions of stores is to account for every material received in
Stores by maintaining proper records of all the incoming, stored and outgoing
materials so that proper accounting is maintained. Hence , record keeping is a
vital function of stores .

6
10. Account Department :

The accounting department’s responsibilities include, Preparing financial

statements, Paying bills, Preparing customer bills, paying wages of workers &
employees, Recording and reporting cash flow transactions. Manufacturing
accounting is a form of accounting that focuses on tracking and recording
financial data associated with the production process.

11. HR Department :

The functions of an HR Department, which include: Talent acquisition,

recruitments of workers & employees, selection, and onboarding. Also Employee
engagement and performance management, Training and development. Human
resources (HR) is responsible for finding, recruiting, screening, and training job
applicants.

12. Dispatch Department :

The purpose of Dispatch Department is to improve the operability by properly

controlling over the capacity of delivery & date management. A Dispatch
Department 's responsibilities include receiving emergency and non-emergency
calls, monitoring driver logs, keeping records, and dispatching appropriate team
members on-site. Their duties can also include monitoring weather reports or
notifying authorities if necessary.

7
Plants Layout :

Plant no. I-68 Plant no. I-99

Plant no. I-150 Plant no. I-182

8
3.1 Products of Company :

• Formwork and Moulds

Winsteel designs and Supplies the Formworks, Falseworks and Moulds for various
Precast Elements and Cast in Situ Elements. Range of products includes Pilecap
Formworks, Pier Formworks (Self Supporting/with or without Tie rods), Cast in Situ
Piercap Formworks, Precast Piercap Moulds, Moulds for I-Girder, U-Girder, Pi-Girder,
T-Girder, Box Girder, Parapet Moulds, Guideway Beams etc. Box Girder Moulds or
Segment Moulds for Full Span, Long line Method or Short line method for casting

9
Single, Double or Triple Box Girder.

• Movable scaffolding systems

Winsteel with their partners and specialized consultants designs and manufactures
Movable Scaffolding Systems (MSS) used for span-by-span in situ construction of
Bridges.

• Launching Gantry

Launching Gantry or Launchers is Used to Install or erect the precast Box Girders Full
span or Segment. The Launching Gantry (LG) are designed as per the project
requirement. The System is designed with Safety as paramount criteria along with
efficient and easy operation.

• Tetrapod & Accropode Moulds

Winsteel manufactures Moulds for tetrapod and Accropode concrete units which are

10
used for Breakwater system during the construction of ports and Jetties .

• Custom Made Moulds • Tunnel

• Residential and commercial projects

It consists standard size of Floor Forms and Wall Forms. These can be configured in
various sizes and shapes. Winsteel also manufactures moulds for precast Walls, Slabs,
Columns, Footings, Ladders, Roof elements etc

• RMC Batching plant Equipments

Cement silos/ Flyash silos : Cement silo is the on-site storage container that allows for
the storage and distribution of different cement mixes. Cement silos can come in a range
of sizes to fit the needs of construction sites.

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Aggregate Bins : Aggregate bins, also known as aggregate batchers, are automated
devices that weigh and distribute materials. They are used in places where space is
limited but high capacity and speed are required.

Aggregate Conveyors : Winsteel also designs and manufactures the Swiveling Type
Aggregate Conveyers for Star Type Bins as well as In-Line.

• Special/Custom Made Equipments

Rock Grapple : Winsteel designs and manufactures Grapple of various types and
capacities. Our grapples are made from special alloy steels.

Chisel : Chisel is used for rock breaking for various hardness and capacities. It is
manufactured from alloy steel and the cutting edge is hardened to break the rock and
sustain the continuous impact and wear.

CHAPTER 2

PROJECTS OF THE COMPANY

2.1 Projects During 51 years of timeline :

12
Project : 2nd Narmada Bridge, Bharuch, Gujarat

Items : Long line Segment Mould

Client : M/S L&T Constructions Ltd.

Year : 1998

Project : Second Vivekanand Bridge,Kolkata,WB

Items : Short Line Segment Mould

Client : M/S L&T Costructions Ltd.

Year : 2004

Project : Wadi Abdoun Bridge, Abdoun, Jordan

Items : Trestle / Short line Segment Mould

13
Client : M/S L&T Constructions Ltd.

Year : 2004

Project : Bangalore International Airport, Bangalore, Karnataka

Items : Precast Roof Element Mould

Client : M/S L&T Constructions Ltd.

Year : 2005-06

Project : Gangapath Bridge, Patna, Bihar

Items : Pier Shutter/Short line Segment Mould

Client : M/S VSL India Ltd.

Year : 2015

14
Project : Mumbai Monorail Project, Mumbai, Maharastra

Items : Guideway Beam Moulds /Pier Shutter

Client : M/S L&T Constructions Ltd.

Year : 2009-10

Project : Motera International Stadium, Ahmedabad, Gujarat

Items : Precast Column Mould/Precast

Client : M/S L&T Constructions Ltd.

Year : 2017-18

Project : Kudankullam Nucleur Power Plant,TN

Items : Tetrapod Moulds

Client : M/S L&T Constructions Ltd.

Year : 2017-18

15
Project : Chisel

Items : Chisel

Client : M/S L&T Constructions Ltd.

Year : 2012-13

Project : Rack Grapple, Vishakhapatnam

Items : Rock Grapple

Client : M/S L&T Constructions Ltd.

Year : 2019-20

Project :Mumbai – Ahmedabad High Speed Rail Project, NHSRCL, India – 3

Items : Pier & Piercap formworks

Client : M/S. L&T Construction

Year : 2021~24

16
Project : Kanpur Metro Rail Project (UPMRC), Uttar Pradesh

Items : U Girder Mould

Client :- M/S. JMC Projects (India) Ltd.

Year :- 2022-23

Project : Mumbai – Ahmedabad High Speed Rail Project, NHSRCL, India – 1

Items : Full Span Mould for Box Girder

Client : M/S. L&T Construction

17
Project : Brahmaputra SCB Between Guwahati & North Guwahati (GSCB), Assam

Items : Short Line Segment Mould

Client :- M/S. VSL India Pvt Ltd.

Year :- 2020-21

18
 CHAPTER 3
THE MACHINES USED IN COMPANY

3.1 Laser Cutting Machine :

Laser Cutting is a non-contact process which utilizes a laser to cut materials,

resulting in high quality, dimensionally accurate cuts. The process works by directing
the laser beam through a nozzle to the workpiece. A combination of heat and pressure or
inert gas (oxygen, air) creates the cutting action.

The principal is that, laser beam hits the surface of the material and heats it so strongly
that it melts or completely vaporizes. Once the laser beam has completely penetrated the
material at one point, the actual cutting process begins. The CNC system follows the
selected geometry and separates the material in the process.

Vertical laser cutting machine is Used to cut 2D geometry on sheet metal and channels.
While Horizontal type laser cutting in typically used to cut 3D geometry on RHS, SHS,
CHS, C channel, H & I section and anything that can be held in Grip of machine.

3.2 Belt Saw Machine :

A belt saw machine is a power saw that cuts material by drawing a Endless metal
band across it. The band is a flexible steel band with teeth on one edge that is
stretched between two or more wheels. Band saws are used for a variety of materials,
including wood, metal, and plastic.

Band saws are faster and easier than hand sawing. The hydraulic transmission
system of a band saw machine consists of a hydraulic circuit composed of pumps,
valves, cylinders, tanks, pipelines, and other auxiliary parts, hence saw beam is lifted
and lowered.

3.3 Rolling Machine :

Rolling machines use three or more rollers to compress sheet metal or plate into a
thinner, more uniform shape. The top roller applies downward pressure on the metal

19
plate, causing it to undergo a plastic bending deformation process.

Sheet rolling machines are used to produce a variety of cylindrical products. In company
it’s major use is to make cone for pearcap, and straightening of plate.

3.4 Shearing Machine :

Shearing machines are multipurpose devices used in the cutting of alloys and other sheet
metal. Some shearing machines use a scissor-like, angular shear action to cut metal into
sheets or strips. Other, larger machines use a straight shear action with the blade fixed at
an angle as opposed to the angular movement.

3.5 Bending Machine :

Sheet bending machine is used to make big right angles as well as curved folds. It is also
used to shape metals in the required shape and size. High pressure exerted on the metal
part causes it to deform and take the desired shape or the bend.

V-bending is the most common sheet metal bending method. As its name, the v-bending
method employs a v-shaped die and a punch to bend metals at desired angles.

3.6 Hydraulic Press :

A hydraulic press machine is a mechanical device that uses hydraulic fluid to generate
compressive force. It’s made up of double acting cylinders, filled with hydraulic fluid.
A hydraulic press uses Pascal’s law, which states that pressure is transmitted evenly
throughout a fluid, to work. Press is a tool used in the manufacturing industry to
deform/shape a work-piece under high pressure.

3.7 Punching Machine :

A metal punching machine, also known as a punch press, is a machine tool that punches
and embows flat sheet materials. It works by applying pressure between punch tool and
die in which a workpiece is held, which changes the size or shape of the material. The
form and construction of the die determines the shape produced on the workpiece.

Punching machines operate on the principle of shearing and deformation of the material.

20
They use a punch tool, also known as a punch, to apply a force on the material and cut
out a desired shape.

3.8 Mig Welding :

MIG (metal inert gas welding) welding uses a constant voltage power supply to create
an electric arc that fuses the base metal with a filler wire (generally coated with thin film
of copper) that is continuously fed through the welding torch. At the same time, an inert
shielding gas is also fed through the gun, to protect the weld pool from atmospheric
contamination.

3.9 SWA Welding :

Shielded metal arc welding (SMAW), also known as manual metal arc welding, is a
manual arc welding process that uses a consumable and protected electrode. As the
electrode melts, a cover that protects the electrode melts and protects the weld area from
oxygen and other atmospheric gases.

3.10 Plasma Cutting Machine :

A Plasma Cutting Machine operates by using ionized gas (plasma) to cut through
conductive materials. It involves a power supply, gas flow, plasma generation, a plasma
torch, and the cutting process. The intense heat of the plasma melts the material, while
the gas stream blows away the molten metal, creating the cut. In company there is only
compressed air is use to generate plasma.

3.11 Oxy-Fuel cutting Machine :

Oxyfuel cutting is a combustion process using oxygen or a fuel gas flame. The heating
flame warms up the material to its ignition temperature. Next, an oxygen jet of at least
99.5 percent purity is blown onto the heated spot, oxidizing the metal. Burning metal
immediately turns to liquid iron oxide. CNC flame cutting machine, is a tool used to cut
thick metal plates and sheets. In company, LPG is use as fuel gas with oxygen.

3.12 Drill machine :

21
A drilling machine works by rapidly rotating a tool bit and lowering it into the desired
area at a predefined tool speed and feed rate to create cylindrical holes in a workpiece.
The workpiece must be securely held in place on the drill table during drilling operations
using vises and clamps.

3.13 Overhead Hydraulic Crane :

An overhead crane, commonly called a bridge crane, is a type of crane found in

industrial environments. An overhead crane consists of two parallel rails seated on
longitudinal I-beams attached to opposite steel columns by means of brackets. The
traveling bridge spans the gap. A hoist, the lifting component of a crane, travels along
the bridge. If the bridge is rigidly supported on two or more legs running on two fixed
rails at ground level, the crane is called a gantry crane. A double girder crane has a much
larger functional area and lifting capacity than a single girder crane. In company there is
mostly 10T & 20T of capacitive crane is present.

3.14 Hoist :

The two main types of hoists for an overhead crane are chain and wire. A chain hoist is
held in place by a chain holder and is designed for lifting loads of less than ten tons.
They provide true vertical lift and rise straight up.

3.15 Air Compressor :

An air compressor is a mechanical device that increases the pressure of air above
atmospheric pressure. It works by putting atmospheric air under high pressure, which
converts its potential energy into kinetic energy. This energy is then stored in an air tank
for use Defferent purpose like in paint sprayer and clean of parts.

3.15 Hydraulic Jack :

Hydraulic jacks are extremely useful mechanical devices which are employed to lift
heavy loads up. Using hydraulics, these jacks are able to afford greater lift over larger
distances. Hydraulic jacks are commonly utilized in the automotive, industrial and
construction industries. In company jack is mostly use in adjustment of heavy structure.

22
3.16 CNC Lathe Machine :

A CNC lathe machine is normally used to perform / produce precise round shapes with
both an Outer Diameter (OD), and an Inner Diameter (ID). Practically all kinds of
structures could be machined with this machine tool, depending on their needs in
different industries. In company, there is mostly screw&nut of screw jack, shaft, pin,
wheels are manufactured. Manual Lathe machine also are there, in which is tool path is
operated my person him self, instead of computer numeric control.

3.17 Pedestal Grinder :

A pedestal grinder is a larger version of a grinder that is mounted on a pedestal. The

pedestal can be bolted to the floor or sit on rubber feet. Pedestal grinders are used to
sharpen high-speed steel cutting tools used on the lathes and milling machines, debur, or
used to remove surface imperfections and to work extremely hard materials.

Also there is An angle grinder, also known as a side grinder or disc grinder, is a
handheld power tool used for grinding (abrasive cutting) and polishing.

3.18 Diesel Generator :

A diesel generator (DG) (also known as a diesel genset) is the combination of a diesel
engine with an electric generator (often an alternator) to generate electrical energy. This
is a specific case of engine generator. A diesel compression-ignition engine is usually
designed to run on diesel fuel, but some types are adapted for other liquid fuels or
natural gas (CNG). Generally it use During shorteg of electricity.

3.19 Water cooling :

Water chillers for laser cutters are designed to handle high-temperature waste heat
through the use of a closed-loop, recirculating system that constantly removes excess
heat from targeting optics and conducts this heat into an external source such as a
standard refrigerator or another chiller device.

3.20 Air Dryer :

An air dryer for a plasma cutter removes moisture, oil, and particulates from the
compressed air supply. This helps improve cut quality and extend the life of the plasma

23
cutter.

3.21 Pneumatic Paint sprayer :

In contrast, air spray systems inject compressed air into the fluid stream of paint to
achieve atomization. All coatings contain solids which are abrasive. Through normal use
the spray tip and parts of the pump will show wear.

3.22 Magnetic Drilling machine :

Magnetic drills were initially designed for construction companies to drill a large
quantity of holes in structural steel already in place, such as i-beams. They offer
increased stability and are easier to use than a hand held drill and also provide better
accuracy and cut large diameter holes faster.

3.23 Tapping Machine :

A tapping machine is a mechanical device used to create internal threads in materials

such as metal. It features a spindle that rotates a tap, a cutting tool designed for
threading. The machine is mounted securely to a workpiece, ensuring stability during the
tapping process.

3.24 PUG cutting machine :

A Pug Cutting Machine is a portable, lightweight gas cutting machine that can be used
for straight line and circle cutting. It has a motorized flame cutting technology and can
use fuel gas like acetylene or LPG. The machine has a track for straight line cutting and
an optional circle cutting attachment.

3.24 Total Number of Machines Plant vise :

I – 68

Drilling machine3. Pneumatic paint sprayer1 compressor3

Tapping machine 1 Hydraulic Press2 Air Dryer2

Shearing Machine4. Belt saw machine2. Water cooling2

24
Punching machine4. Overhead crane(rope)3. Diesel Generator1

Sheet Bending Machine4. Overhead Hoist12

Leaser cutting machine (H) – 1. Grinder (pedestal)1

Leaser cutting machine(v)1. Rolling machine1

Plasma cutting machine1. Rolling machine (bench)2

Oxy-Fuel cutting machine1. Magnetic Drilling machine1

I – 99. I – 150

Hydraulic Press – 2. Hydraulic press – 1 press machine (manual 19s) -

1 Compressor – 4 Drilling machine – 1 Generator - 1

Drilling machine – 4 Overhead Hoist – 4

Overhead crane (rope) – 8. Overhead Crane (rope) - 1

Generator – 1 Belt saw - 1

I – 182

CNC lathe – 6. Compressor - 1

Manual Lathe – 4. Metal cutting machine (19s) - 1

Grinder (pedestal) -1 Grinder (19s) - 1

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 CHAPTER 4
PROJECT DURING INTERSHIP

4.1 Piercap :

Introduction :
A pier cap, also known as a headstock, is a horizontal structural member that transfers
loads from a bridge’s deck to its piers. Pier caps are pyramid-shaped concrete or stone
blocks that sit on top of piers, which are vertical supports at the end of a wall.

Procedure of Manufacturing :
The first step is to analyze the drawing provided by design development. Then ,
according to detail drawing of structure, all the nessory material are arranged according

26
to Bill of material. cutting and shaping also involves in this process. Rolling or bending
of cone (inner core of Piercap) is one of shaping process. It is Done by rolling machine,
as mentioned in 3.19. The figure mantion below is sample of Design configuration;

In simultaneously, there is jig is prepared for Piercap in plant no.99. A jig is a type of
tool used to control the location of seam plate. A jig’s primary purpose is to provide
repeatability, accuracy, and interchangeability in the manufacturing of products. The
place is selected as per dimensions of structure. Under the supervision of an engineer,
workers start to fabricate the Piercap. The whole Piercap made in 3 segment, 2 side & 1
middle one, including core (cone). The plates needed for fabrication is already been
brought from plant no.68. then as figure mentioned below, the process is going on ;

Raw material cutting process

Jig preparation Rolling process of Cone

27

Skin plate fitting on jig

 Stifnner Fitting

Cage pressure by SHS welding

Stifnner in cone

Piercap support frame attaching

Complete fabrication of piercap

Welding of inner core panel (cone)

Disassembled middle segment

Disassembly of Piercap (in 3 segment)

28 Working platform fitting

[Tie rod , screw jack fitting]
After assembly of Piercap and approved by production supervisor, there where role of
quality control inspector is begin. QC supervisor visit the place of assembly and visual
inspection in done first. In this type of inspection, defects in welding, sputter particles,
dimensional accuracy as per drawing (including tolerance), geometrical deformity, parts
fitting, operability of screw jack ect are under consideration.

In next phase , the defferent types of measurement are to be performed like , dimensions
measurement by measure tape, water level measure of entire structure, neseccory centre
matching ( cone’s centre), spirit Level testing, flatness Checking, welding size
measurement by welding Gauge, gap measure by filler Gauge ect are considered.

In further next phase, non destructive testing is performed like , ultrasonic thickness
testing, LPT (lequid penetrant testing) for assuring the crack free welding joints and
DFT testing in order to measure the thickness of paint and primer coating (has to be
equal or above 120 micron). After performing these test , if structure fullfill the quality
criteria then it approved to dispatch.

Before painting the Piercap , surface preparation is must be needed by sandblasting. It is

acensial for make rough surface for better adhesion. Then first layer of primer is applied
on part around range of 40 to 60 micron. Then on the top of primer, second layer of
paint is applied around 60 micron. The total coating must be greater than
120micron.after painting, stenciling is done in order to named defferent parts.

29
 CHAPTER 5
QUALITY CONTROL

Introduction :

Quality control Involves testing units and determining if they are within the
specifications for the final structure. The purpose of the testing is to determine any need
for corrective actions in the manufacturing process. In the company Quality Department
is also responsible for Certification process of Welders, calls Welder Qualification Test
Certificate according to Welding procedure Specification.

Process of quality control :

1 Dimensions measurements :

30
It is mostly done my measuring tape. Common Dimensions like length, width, diagonal,
Centre distance ect are measured by this method. The tape use in measurement is
indicates dimensions in mm, Inch, centemeter, meter and feet. This method is manual,
therefore there is possibility of error in measured reading.

2. Flatness Checking :

The seam plate fixed on structure is must be flatten in the tolerance range of 3mm.
Welding and temperature gradient is reason of uneven flatness. This inspection in done
by flat rectangular hollow section made of steel, which is precisely flat. This RHS is put
on seam plate, if the gape between two surfaces is not visible then it’s consider to be flat
surface of seam plate. If the gape is equal to 3 mm then it’s not allowable and by
hammering, the things can fixed.

3. Water level testing :

It is used to determine the apparent inclination of an structure or surface and for

matching water level elevations at locations that are too far apart for a spirit level to
span. A water level device showing both ends at the same height. The simplest water
level is a section of clear tubing, partially filled with water.

4. Visual inspection :

By this inspection the person or quality inspector checked the parts or structure by his
own necked eyes. In this process th defects in welding, sputter particles, need of
grinding,needs of welding ,structural deformation ect. Are included.

5. DFT Testing :

Dry film thickness (DFT) testing measures the thickness of a coating or multiple layers
of coating (primer & paint). It is a measurement of the dry and cured material after all
liquid has evaporated. DFT is important for product quality, process control, and cost
control. The thickness of paint must be 60 micron and thickness of primer must be 60
micron.

31
6. UT Testing :

Ultrasonic thickness testing (UT) is a non-destructive testing (NDT) technique that uses
sound waves to detect defects and measure the thickness of materials. It is use for
checking raw material like seam plate, or the parts which is already fixed in structure.

7. LPT testing :

It is non-destructive testing method that uses capillary forces to make surface flaws
more visible. The test uses a liquid called a penetrant that is applied to the sample during
testing. LPT can detect surface-breaking flaws such as cracks, laps, and porosity. It can
be used on nonporous and fairly smooth materials. In plant it is mostly use in welding
cracks finding.

8. Lab test :

It is not done by company at it’s own but company send specimen towards lab where UT
of welding, Radiography, and different chemical and mechanical destructive testing is
performed.

Instruments Use in Quality Control :

1. Measuring tape/Rulers

Measuring tape is a type of hand tool typically used to measure distance or size.
It is like a much longer flexible ruler consisting of a case, thumb lock,
blade/tape, hook, and sometimes a belt clip. A tape measure will have imperial
readings, metric readings or both.

2. Vernier caliper/ micron meter :

A vernier caliper is a tool used to precisely measure linear dimensions. It has two
scales, a main scale and a vernier scale, that allow for readings to the nearest
0.02 mm. The vernier scale slides parallel to the main scale and allows readings

32
 to be made to a fraction of a division on the main scale.

A micrometer is an instrument used for making precise linear measurements of

dimensions such as diameter, thickness, and lengths of solid bodies. It is made of
a C-shaped frame with a movable jaw operated by an integral screw.

3. DFT Testing Device :

These electronic instruments measure the change in magnetic flux density at the
surface of a magnetic probe as it nears a steel surface. The magnitude of the flux
density at the probe surface is directly related to the distance from the steel
substrate. By measuring flux density the paint thickness can be determined.

4. UTG (ultrasonic thickness gauge) :

In this ultrasonic thickness gauge working principle, sound waves or pulses are
reflected by the probe when they are in contact with an object’s material through
its surface. Once the pulses are reflected, the thickness of an object can be
measured.

5. Filler Gauge :

Feeler gauges are made up of a series of steel plates or blades that are precisely
calibrated in thickness. Each blade is marked with its thickness and is often
joined at one end with a pin or rivet and fold back like a fan into a handle. The
thickest blade that can be inserted into a gap or crack shows its width.

6. Welding Gauge :

Welding gauges are inspection gauges used for checking alignment, checking
dimensions before welding, verifying weld dimensions, and checking porosity of
welds.

7. Spirit Level :

A Spirit Level is a tool used to indicate how parallel (level) or perpendicular

(plumb) a surface is relative to the earth or other surface.

33
 8. Telescopeing Inspection mirror :

One of the most widely used types is the popular telescopic inspection mirror,
which utilises an extendable telescopic arm. Telescopic inspection mirrors have a
long telescopic arm which can be extended and locked off, using a twist action,
at any desired length. It is also use with veriable focal length torch.

CHAPTER – 6

DESPATCH
The purpose of despatch is to improve the operability and properly controlling over the
capacity of delivery & date of delivery management. Despatch responsible for receiving
emergency and non-emergency calls, monitoring drivers log, keeping records ect. It also

34
includes employees warfare on site or company office to site & site to company.

The process of despatch is simple but handling of vehicle which contains multiple
structure, having tons of weight, is critical things. It must needed skilled driver, to drive
these goods at the site with safety.

When the assembly of any product is completed and it’s operability is green marked by
QC person, then it started to disassemble again. According to numbers of parts &
dimensions of part , the truck is chosen. The length of truck is specified in ‘Feet’. The
list of despatch is already been made , where name of Driver, length of truck, time of
dispatch, place of dispatch, no. Of items, name of items, date, vehicle number ect
mentioned. The despatch vehicles are provided by client (L&T).

Thought that I would like to implement in company :

Pr.1 :- Difficulty in water level testing.

35
In water level testing, there is some visual errors might be possible cause of capillary
effect inside the tube. Also cause of uneven cross-section of tube, there were some
difference in reducing is possible to occur. Also bending or buckling of steel scale is
result to change in reading.

Alternative :- it is possible to use Arduino along with GY-87 10DOF a MEMS device (
3-axis gyro + 3-axis Accelerometer + 3-axis megnetometer) . This combination might be
provide higher accuracy as compared to conventional method.

Procedure & working :

As a micro controller use ‘ESP 32’ which is able to wireless communication. Joint it
with 9axis motion capture sensor which is contain 3-axis of gyro for angular
displacement measure , 3-axis Accelerometer for linear displacement and 3-axis
megnetometer for accurate determination of motion tracking.

Joint with power supply and tiny screen and packed it in small case. Programing of
esp32 also easy, can find code from library.

Working :- when we run the code in esp32 it starts to communicate with gyro sensor.
put the whole assembly at any place and calibrate as zero or define as origin point.

Now if we move this device from that point gyro sensor, gives thousand of reading
because change in it’s cordinates. This cordinate are on the laptop or mobile screen. If
want to check level , than put at multiple place and see the reading of displacement. This
is might be more accurate and faster than tube method.

Pr.2 :- Gaping in cone (core of Piercap)

In rolling machine, there were top roller which is provide pressure, is maintain its

36
displacement or pressure by adjusting screw having both side of roller. There is no
arrangement for this two screw adjustment so both can turn simultaneously & equal
pressure applay on surface of plate.

After cone welding, there were often sees that upper side of cone’s plate end touch but at
bottom side still gap is remaining. It’s because of uneven rolling.

The area at which plateside touch might be passed through higher pressure (more turned
screw) & the area at which gap is remaining is might be passed through low pressure
(less turned screw) so the curvature remains by greater radius compered to upper side of
the cone.

Sol. : - just take off the screw and send it to laser marking and mark every thread as
sequence number . Also by some calculation, this number provides value of pressure.

Pr. 3 :- centre marking on various channels and sections (I,H,C) for drilling.

The marking with measuring tape is might be enough for requirements, only at one digit
ahead than point like 4.5,5.5 mm only . How can human mark 4.2, 4.3 by usng measure
tape ? Also there are uncertainty in measurement and marking because of skills and
defferent nature of defferent workers.

Alternative:- it is possible to design laser base vernier caliper along with micro
controller ‘ ESP 32 c3’ ( compact in size) + tiny 4mm stepper motor + sonar sensor +
screen.

Working :- held the I-section between two jaws. Run the code and stepper motor is runs
on rack gear.it move extrime forward and backward. At jaw of Vanier, there is sonar
sensor , which is sense motor’s doby , how much it far. The reading of sonar is send to
the micro controller where by combination of both reading, the total distance traveled by
motor between two jaws are calculate. And just enter the value, where we wanna make

37
the laser pointed and stepper motor move at that point.

Adv. :- The is not depend on workers, it always remain same , on matter who use.
Possible to mark fraction of millimetre (eg. 4.2, 4.3, 4.5). Possible to get accuracy upto 3
digits after point (eg. 4.291, 5.002). Improve quality, good impression on clients &
helpful for QC profile.

Pr.4 :- Material Handling

The catted material from laser cutting, Plasma Cutting ect. Are stored in hoard
condition. Workers have to pickup every piece and transport it other places, over & over
. It might time consuming and streshfull for workers.

Alt. :- can be arrange the rail all across the plant, with special designed carriage or
trolley running on it. Trolley are able to reach position next to the workers hand, or at
particular machine. So that cutted parts directly stored on it and send to the gate or
wherever needed.

Also there were bunch of empty place available inside the plant, were this trolley can be
stored.

Adv. :- it reduces time to transport. Define material handling, reduces scrap at site of
machine. Improve ergonomics of workers. Set good impression to visitors/clients &
improve organization’s image.

Pr. 5 :- Noice pollution (conditionally at particular place)

There were to much Noice when material load and unload inkart & at the place of
horizontal laser machine.

Sol. :- it might be resolve by fitting ‘Teflon sheet’ at required. Even it can be fixed on

38
hammer during, hammering of the skin plate.

Others :

- A projection marking Device (laser base). Help to draw projection of bulkhead

on platform.

- Flatness testing device for skin plate. The device is similar to other , only
difference is that this device contains 4 wheel. It is apears like toy car but enough
to destroy expectations of production supervisor.

Experience with work force :

Umang patel (mentor) Help me to clear all questions , always friendly & like
to share his experience and knowledge much as
possible

Sejal patel (QC supervisor) Help to clear all Drawing related and some strange
question, always friendly. Allowed me to use all QC
equipments for learning purpose

Pankaj patel (HR manager) Allowed me to get in company for internship

Staff (Engineers) Like to share their knowledge

Workers (I-68) Cooperative, help to understand the things, kind

behaviour

Workers (I-99) Less interaction with them but also cooperative

Workers (I-150) Less interaction but cooperative

CNC operator (I-182) Had good time with them, cooperative & always
friendly. Share the knowledge what they had , also I
share the knowledge what I have.

39
 Government Engineering College Valsad

DECLARATION

I hereby declare that the Internship report submitted along with the Internship entitled Internship
at Winsteel Engineering Works pvt. ltd.(surat) submitted in partial fulfillment for the degree of
Bachelor of Engineering in Mechanical Engineering to Gujarat Technological University,
Ahmadabad, is a bonafide record of original project work carried out by me at Winsteel
Engineering Works pvt. Ltd. under the supervision of prof. B. K. Patel and that no part of this
report has been directly copied from any student’ report or take from any other source, without
providing due reference.

Naimish Arvindbhai Piprotar

Name of student Sign of Student

III
 ACKONWLEDGEMENT

I am very thankful to our guide, Prof. B. K. Patel Government Engineering College Valsad.
Whose guidance and support have helped me for completing this internship work. His belief
in me has helped us to perform better than I have could. They have been great motivator and
have encouraged us in our work.
I am also thankful to Prof. V. D. Dhiman, Head of Mechanical Engineering Department, and
all other faculty members of Government Engineering College Valsad for providing
necessary permission for completing our work.
Special regards to our engineers uman patel & Sejal and all technician, workers for helping
and supporting us during the internship. I am very thankful to my parents and myself for
supporting me financially and mentally.
Lastly, I thank who helped me in some or other way for carrying out this work.

Naimish Piprotar

IV
 ABSTRACT

Kia Motors is a South Korean multinational automotive manufacturer that produces a range of

vehicles, including sedans, SUVs, and electric cars. The company was founded in 1944 and has

since become one of the largest automobile manufacturers in the world.

Kia Motors' success can be attributed to its strong focus on research and development, which

has led to innovative design and technological advancements in their vehicles. In recent years,

Kia Motors has also made significant strides in the field of electric vehicles.

In addition to its impressive lineup of vehicles, Kia Motors is also committed to sustainability

and environmental responsibility. The company has implemented eco-friendly practices

throughout its manufacturing processes and has set ambitious goals for reducing its carbon

footprint.

An internship at Kia Motors provides a unique opportunity to gain hands-on experience in the

automotive industry, as well as exposure to the company's culture of innovation and

commitment to sustainability. Interns can expect to work on projects related to product

development, marketing, or sustainability initiatives, among others. The experience gained

during an internship at Kia Motors can be invaluable for a career in the automotive industry or

related fields.

V
LIST OF FIGURES
VI
Figure 1 outside look of workshop....................................................................................................................................3
Figure 2 workshop layout..................................................................................................................................................4
Figure 4 Ring spanners....................................................................................................................................................10
Figure 5 Fix spanners......................................................................................................................................................10
Figure 6 Combination spanners.......................................................................................................................................11
Figure 7 Box spanner......................................................................................................................................................11
Figure 8 Adjustable spanner............................................................................................................................................11
Figure 9 T-spanner..........................................................................................................................................................12
Figure 10 Allen key.........................................................................................................................................................12
Figure 11 Ratchet............................................................................................................................................................13
Figure 12 Simple pliers...................................................................................................................................................13
Figure 13 Cuter pliers......................................................................................................................................................13
Figure 14 Nose pliers......................................................................................................................................................14
Figure 15 Locking pliers.................................................................................................................................................14
Figure 16 Fuel filter wrench............................................................................................................................................15
Figure 17 Oil filter wrench..............................................................................................................................................15
Figure 18 Screw drivers..................................................................................................................................................15
Figure 19 Hammer..........................................................................................................................................................16
Figure 20 Hydraulic lift...................................................................................................................................................17
Figure 21 Air gun............................................................................................................................................................17
Figure 22 Hydraulic jack.................................................................................................................................................18
Figure 23 Air compressor................................................................................................................................................18
Figure 24 Wheel balancing.............................................................................................................................................19
Figure 25 Wheel alignment.............................................................................................................................................19
Figure 26 Wheel changer................................................................................................................................................20
Figure 27 oil filter...........................................................................................................................................................22
Figure 28 oil filter for petrol...........................................................................................................................................23
Figure 29 Air filter..........................................................................................................................................................23
Figure 30 A/ filter...........................................................................................................................................................23
Figure 31 O2 sensor clean...............................................................................................................................................24
Figure 32 Replace fuel filter............................................................................................................................................24
Figure 33 Engine belt......................................................................................................................................................26
Figure 34 Starter motor...................................................................................................................................................27
Figure 35 Brake pad and disk..........................................................................................................................................28
Figure 36 Worm shaft and steering.................................................................................................................................29

VII
Figure 37 Worm shaft case and steering.........................................................................................................................29
Figure 38 tensioner..........................................................................................................................................................30
Figure 39 Axel oil seal and special remove tool oil seal................................................................................................31
Figure 40 Special tool fit to oil seal................................................................................................................................32
Figure 41 Wheel alignment.............................................................................................................................................32
Figure 42 Clutch plate and pressure plate.......................................................................................................................33
Figure 43 release bearing................................................................................................................................................34
Figure 44 Shock absorber................................................................................................................................................35
Figure 45 Shock absorber bush and mounting................................................................................................................35

VII
 Table Of Content

Certificate.........................................................................................................................................................I
Industry letter..................................................................................................................................................II
Declaration.....................................................................................................................................................III
Acknowledgement.........................................................................................................................................IV
Abstract...........................................................................................................................................................V
LIST OF FIGURES.......................................................................................................................................VI
Table Of Content.........................................................................................................................................VIII
Chapter: 1 INTRODUCTION OF INDUSTRY..............................................................................................1
Introduction..................................................................................................................................................1
company profile of kia................................................................................................................................2
introduction of dealership............................................................................................................................3
workshop introduction.................................................................................................................................3
Workshop Layout.........................................................................................................................................4
SPECIFICATION OF VARIOUS MODELS..............................................................................................5
Chapter: 2 TOOLS &EQUIPMENT..............................................................................................................10
The different types of tools used on workshop..........................................................................................10
The different types of Equipment used in workshop................................................................................17
Chapter: 3 Various maintenance of vehicles.................................................................................................21
Chapter: 4 problems and causes and solution................................................................................................28
Chapter: 5 Conclusion....................................................................................................................................43
Chapter: 6 Reference......................................................................................................................................44

VIII
 Reference

Gujarat Technological University 9 Government Engineering College Valsad