A

PRESENTATION
VACATIONAL INPLANT
TRAINING
IN

“PRECISION CAMSHAFT LTD.”

Presented by: SHETE AMAR NAGESH
Roll No.:79
(B.E.Mechanical)
PRECISION CAMSHAFTS LTD.
SOLAPUR.
 PCL EOU
FDY 1 STARTED 2000
FDY 2 STARTED 2008
M/C SHOP – STATING
JUNE’ 08
800 EMPL
440000 CAMSHAFTS/ MTH

PCL 2
PCL 1
FDY 1 STARTED 1995
MACHINE SHOP
FDY 2 STARTED 2005
STARTED – 1989
350 EMPL
350 EMPL
125000 CAMSHAFTS /
50000 CAMSHAFTS /
MTH
MTH
 INTRODUCTION

• Founded in 1992.

• Precision Camshafts Limited is the largest manufacturer of camshafts in

India.

• The company manufactures fully finished camshafts from chilled cast iron
as well as forging and steel bar stock, chilled cast iron being their ‘core
competency’.

• Located in Solapur & headed by Mr.Yatin Shah, Managing director, the

group has come a long way since its inception from manufacturing 7,200
camshafts to 8 million camshafts per year.

•
 FLASHBACK
IN-
1992
Established Precision Camshafts with a capacity to manufacture 7200 “semi
machined” camshafts per annum.
1994
Expanded this facility to manufacture 120,000 “fully machined” camshafts per
annum.
1995
Precision Camshafts certified to ISO 9002 by BVQI .
Established Precision Shell Cast – a foundry dedicated for manufacturing
360,000 camshafts per annum.

1997
Enhanced machining capacity from 120,000 to 360,000 per annum.
1999

All units in PCL certified to QS 9000 by BVQI.

2000

Clancy Precision Components Private Limited approved by GM Europe. Started

supplying about 90,000 camshafts per month.

2006

PCL expands its foundry division to 3,000,000 camshafts per annum and its
machine shop division to 600,000 camshafts per annum.

2007

. PVPL bagged prestigious orders from BMW & PORSCHE.

2009

PCL foundry awarded Q1 certificate by FORD.

2011

Construction of third foundry in 80,000 sq.capacity of 3 lakh camshafts.

 OVERVIEW

1999-00 2006-07 2010-11

Turnover 129 752 +3500

( in Millions)

No of sheds 2 4 7

Land area 4 acres 20+15 acres 35 acres

Shed area 50,000 Sq Ft 2,00,000 Sq Ft 4,00,000 Sq Ft

Employees 400 700 +1200

Capacity p.a 0.5 million 3.3 million 12 million

  PRODUCTS:

Fully machined, semimachined

camshafts as per customer
requirement.

Chilled Cast Iron

Camshaft

Straight hollow (Through or Blind) for

oil gallery application by using sand &
or glass core.

Straight Hollow
Camshaft
 Profiled hollow (Through or Blind) for
weight reduction application by using
sand core.

Profiled Hollow Camshaft

Next generation camshafts like trilobe

for VVTI engine application.

Tri-Lobe Camshaft

Fully machined camshafts as per the

customer requirement for locomotive
application made out of rolled steel bar
route. Single source supplier to Indian
Railway’s, Patiala Loco Shed.

Locomotive Camshaft
 VISION & MISSION

VISION
 The Precision Group which comprises of Precision Camshafts Limited and Precision
Camshafts Limited (100% EOU Division) has emerged as a Global player and intends
to supply 20% of the Global passenger car market by 2009-10.
 In this endeavor, Precision Group will aim at- Supplying 12 million camshafts per
annum.

MISSION
 To maximize shareholder returns.
 To aim for total customer satisfaction.
 To create a sustainable supply base.
 To create a motivated workforce.
 To create transparent working environment.
 Contribution to Society in which it operates .
 SET UP

Industry is mainly divided in two shops with no. of units

 Foundry shop.

 Machine shop.
• FOUNDRY SHOP

 Foundry shop includes:

1. Medium Frequency Induction Furnaces.

2. Brinell Hardness Testing equipment and Rockwell Hardness
Testing equipment
3. Sand testing equipment
4. Profile Projector
5. Electronic Pyrometer.
6. 4 Station Shell Molding Machines,
7. Metallurgical and Chemical Laboratory.
• MACHINE SHOP

 Machine shop includes:

1. CNC Landis Cam Grinding machines.

2. CNC Lathes and Machining Centers.
3. CNC Super Finishing Machines
4. Variety of drilling machines
5. Various Special Purpose Machines.
6. Magnaflux crack detection unit.
7. Variety of special purpose custom built gauges and standard
inspection equipments.
 DEPARTMENTS

Basically company has five major department.Each department

is headed by asst. general manager. Whereas Manager, Deputy
Manager, Asst. Manager, Supervisor follow the hierarchy.

• Production Department.
• Human Resource Department.
• Sales Department.
• Quality Assurance Department.
• Maintainance Department.
ORGANIZATION AND SECTION DEPARTMENT
1. Production Department: In production department the camshafts are manufactured
2. Purchasing Department: They purchase forged camshafts and the design is as per
customers demand and sends to machine shop.

3. Inspection department: In case on lathe machine operation they use Inprocess gauge it is
very useful it not only show how correct the job is made but also indicate how well tool is
performing, it also saves time and readily tells the error

4. Maintenance Department: Company having old lathe machines and CNC machine also, to
having smooth operation Maintenance Department maintain machines time to time.

5. Stored Department: The made camshaft is stored in store department until the total lot is
not completed.
Other departments:

VI. Marketing Department.

VII. Sale Department.

VIII. Account And Finance Department.

IX. Human Resource And Development Department.

Variety of camshafts with sectional views.
LIST OF RAW MATERIAL FOR FOUNDRY
1. Pig Iron
2. M S Scrap
3. C I Scrap
4. Ferro Chromium Carbon
5. Ferro Silicon Carbon
6. Ferro Molybdenum Carbon
7. Ferro Manganese Carbon
8. Resin Coated Sand
9. Calcium Silicate
10.Copper
11.Nickel Shot or Plates
12.Non Calcined Petroleum Coke(RawCoke)
13.Copper – Plates or Scrap
14.Ramming Mass
15.Core fix
16.Steel Shots
17.Slag Bar
18.Ferro Prosperous
19.Slag Powder
20.Grinding Wheels
21.Calcined Petroleum Coke
 PROCESS
1. Company runs in 3 shifts per day i.e. 8 hours per shift.
2. The pig iron, wrought iron, mild steel, rejected camshafts etc are used as raw
material. Composition is decided and accordingly quantity of raw material is
lifted using heavy electromagnetic crane.
3. Material is weighed and heated beyond re-crystallization temperature upto
1400°C.
4. Moulding followed is shell moulding as it has many advantages w.r.t surface
finish.
5. In shell moulding pattern used is metallic. All type of allowance are provided on
pattern. Moulding sand contains some amount of thermosetting resin. When
current is passed through pattern resin act as binder and thin shell are formed.
6. Since castings are chilled casting, small chills are placed in shell. Chills are used
to control the rate of solidification of metals as per required hardness.
7. Now cope and drag boxes are bolted after placing riser and gating system.
8. Each shell weights about 3.5 kg and produces two camshafts.
9. Reusability of shell is not possible.

10. Simultaneously molten liquid is poured in mould.

11. The shells are cooled steadily.
12. Now shells are passed through mechanical vibrator and are broken and
casting is obtained.
13.Now cleaning and fetling process viz mechanical shaking, shot blasting,
removing of sprue, risers, gating system is carried out.
14.These are non-machined camshafts if required they are further moved for
machining in machine shop.
15.As per requirement of customer various machining process are carried, all
tools used in industries are advanced and high-tech.
16.In machine shop various operation carried are turning, hobbing, bearing
grinding, cam grinding, milling, drilling etc.
17.Machining is purely done as per customers need.
 Manufacturing Process Flow Chart Castings (Foundry) -

Ferro Alloys

Steel Scrap FR / MR IG

Melting
Crucible

Laddle
Sand Store

Shell Pouring
Pattern Shell
Moulding
Chills hood
Exhaust

Chill storage

Knockout
Hopper B.E.
Waste Sand IG

Rejection (FR)
Inspection
Sand Unloading
For recycling For Recycling
OK
Shot blasting
FR: Foundry Rejection
MR: Machining Rejection
IG: Internal Generation
BE: Bucket Elevator Fettling

Final
Inspection
To Machine Shop
Dipatch
To As Cast to Customers
Manufacturing Process Flow Chart For Machine Shop –
B) Forged & Bar Stock Camshafts (Railway Camshafts)

Receive Forgings /
Bar

Key Way Milling

Drilling of Oil Hole

& Locating Holes

Rough Grind Cam

Lobes

Remove Bend

Finish Cam Grind

Cam Lobes

Finish Grind
Journals

Polishing

Inspection

Packing

Dispatch To
customer
CLIENTS of PCL
 CONCLUSION

• After completing my training I came to know not only

practical application of various operations but also the
organization of company.

• It gave a good exposure to actual proceedings in industry.

• I was acquainted with various new terms which I was never

herd previously.
 REFERENCES

 Precision camshafts Pvt. Ltd.

 www.pclindia.in

 Manufacturing Process by Hajra Chowdary.

 Manufacturing Process by P N Rao.

 Workshop Technology (Volume II) by Raghuvanshi.

 Production Technology by P.C.Sharma.

 PHOTO GALLERY
Foundry shop :

Elevation Pouring

Inspection & Packing Store