INDUSTRIAL TRAINING REPORT

DRONACHARYA COLLEGE OF
ENGINEERING SUBMITTED BY:
KSHITIJ KUMAR
ME ( 20331)
 ABOUT THE
COMPANY
Multi unit,multi product group that deals in broad range
of sheet metal assemblies,die casting components and
forging for the domestic and export markets.
Jbm group began its engg. Activity in 1983 with the
establishment of gurera gas cylinder ltd and entered the
auto component industries with the inception of
SUZUKI AUTO INDIA.
Four plants in NCR.
 OUTLOOK OF PLANT
OUTLOOK OF
THE PLANT J1
MAJOR LEARNINGS IN ENGINEERING
DEPARTMENT
• Types of Welding and guns used.

• Study of poka yoke.

• Study of laser cutting machine.

 TYPES OF WELDING AND GUNS USED

Resistance welding

• Spot welding
• Multi spot welding
• Stationary spot welding
• Portable spot welding

Projection welding

• Nut projection welding

• Stud projection welding
 RESISTANCE SPOT WELDING
• Resistance welding is a welding process which join the metals with the heat
obtained from resistance offered by the work to the flow of electrical
current through the parts being joined.

• A pair of copper alloy electrodes conducts

electrical current through the two sheets
pressed between the interface. The two sheets
offer maximum resistance to the flow of
current, this generates heat, the interface melts
and consequently solidifies under the
pressures of the two electrodes, thereby
joining the two sheets at the spot that was
under the two electrodes.
TYPES OF GUN USED IN SPOT WELDING
• X- TYPE GUN

Also known as "scissors" or "pinch"

• C-TYPE GUN

C guns are generally the cheapest

and the most commonly used.
 PROJECTION WELDING
Nut projection welding
• Projection Welding Is A Type OfResistance
Welding.

• High current in less time is the main

feature of this welding.

Stud projection welding

• Stud is a form of spot welding where a bolt or

nut is welded on another metal sheet.
 STUDY OF POKA
YOKE
Poka Yoke = Zero Defect
• Basically the poke yoke is the Japanese technology. It is used to reduce the
manufacturing defects in the parts to zero.

• Poka Yoke sense that bolt then that process will occur otherwise that processwill not
occur.
 Type of Defects for which Poka- Yoke can be
used

• Part Miss, Nut Miss, Spot, Miss Hole miss.

• Part Shift.

• Nut Welded at wrong place.

• Color Difference.

SIGNALS
PANEL
 LASER CUTTING
MACHINE
• Six axis robotic machine worth rs I crore(abb
company).
• Yetteribium laser is used.
• Yetteribium crystal produces light by photoelectric
effect.
• Laser light get passed to robotic head through
optical fibre cable(TIR).
• Yetteribium crystal contained in box which is placed
in room maintained at 22degree c.
• Chiller cools laser head using distilled water.
• FRL removes moisture of air
• Working temp.of robotic head is 3000-4000 degree celsius.
• Used to cut elliptical cross section of axle to spiral.
• Oxygen helps in burning.
• Nitogen takes care so that burr do not cover the laser head.
• Dot test performed once in six months to centralize the
laser beam.
• There is ups which can run the laser machine for half an
hour after electricity is cut.
• Spiral profile gas 21 control points
• Nitrogen pressure= 7 bar approx.
• Oxygen pressure= 3.7 bar approx.
• Air pressure= 5.40 bar approx.
• Avg operating power= 1000W.
 MISSION

TO MAKE JBM A SYNONYM FOR WORLD CLASS

ORGNISATION EXCELLENCE IN SHEET
METAL TECHNOLOGIES
VISION
EXPANDING LEADERSHIP IN OUR BUSINESS
THROUGH PEOPLE, KEEPING PACE WITH
MARKET TRENDS AND TECHNOLOGY
 PRODUCT
MANUFACTURED
SKIN PANEL
BODY IN WHITE PARTS
CHASSIS & SUSPENSION PARTS
WELDED ASSEMBLIES
EXHAUST SYSTEMS
SEAT BELTS
FRONT/ REAR AXIS
WHEEL RIM
 PROJECT UNDERTAKEN

TO INCREASE THE PRODUCTION OF PRESS SHOP

WITH THE HELP OF GANGING OF DIES.
 INTRODUCTION OF
PROJECT
• Here in this project we are concentrating
on only on factor i.e. Increase in
productivity. Here we are using a method
of ganging of dies in which two similar dies
are mounted on a press machine. This help
us reduction of productivity time. Which will
enhance the productivity. So this method is
very much effective in increase the
productivity of the material. This is cost and
time saving method which will help in the
betterment of the industry.
EXPLAINING PROJECT WITH AN EXAMPLE
PART NO.-DZ161013
PART NAME : GUSSET HEAD

Gusset head is generally a BAJAJ part which are used in platina bikes.
These parts gives the support to the engine.
 TABLE
Process Description Incoming source of Product Expected/actual
variation characterstics strokes (per
hour)
Receiving Inspection Wrong size 1.5+/-0.1
Wrong grade 260*1250 +/-2mm
Visual defects
Blanking Improper profile Free from
Dent/scratch Burr
Dent 250/150
Crack
Forming Incomplete bend Free from
Scratch Burr
Crack Crack 250/160
Dislocation Scratches
Piercing Dim us/os Free from
Hole/slot size Burr 250/170
Location Crack
Visual defects
Bending-trimming No thinning Free from
Incomplete profile Burr
Scratch Crack 250/180
burr Thinning
NOW IFAPPLY 2 DIES IN SAME PRESS THEN THE OPERATION CAN
BE PERFORMED AT FASTER RATE

TO USE GANGING OF DIES THE FOLLOWING THINGS SHOULD BE

TAKEN INTO CONSENDERATION

Power of the press.

Size of the bluster bed.
Size of the dies.
Shut height of the die.
Shut height of the press.
Tonnage required for the die.
 CALCULATION :- (COST
ESTIMATION)
Procurement for the metal sheet- 45 rupees per kg
Dimensions of sheet -1230x260mm
Weight of on sheet- 1.020 kg
Thickness of the sheets- 1.5mm
Scraps cost -25 rupees per kg
 Now according to table
Cost estimated for blanking- 2x150=Rs300
Cost estimated for forming-
2x160=Rs320 Cost estimated
for percing-2x170=Rs340
Cost estimated for bending-trimming- 2x180=Rs360

Total cost-Rs1320
This is a rough calculated cost in this hidden cost are not involved like maintainace, worker availability
etc. are not included.
Now if re plan our process and mount 2 dies in one press
For example
Blanking and forming at a time in a single press having different dies. This will save time as well as
machine cost.
And similarly at the same time piercing and bending trimming operation can be done.
Now the calculation of cost
Cost for blanking and forming-2x150=Rs300
Cost for piercing and bending-2x170=Rs340
Total cost=Rs640
This is a rough calculated cost in this hidden cost are not involved like maintainace, worker availability
etc. are not included.
 ADVANTAGES OF
GANGING OF DIES
Cost saving
Time saving
Man power saving
Less press machine required
Utility of press machine increases
Pace of work is fast
Production is high
 DISADVANTAGES

Require bigger bluster bed

May require a dummy cushion when one die require cushion
and other’s didn’t so dummy cushion is given to the second
die in order to balance it.
Tonnage of press should be greater or equal to the die required.
Shut height of both the dies should be same and should be in
press shut height range.
 CONCLUTION

This method is very much effective in increasing the

production rate. This works quite efficiently. By
using this method we can cover some parameter
which is very much important for every industry.
THANK YOU