INTRODUCTION

 NAME : LOKESH
 ROLL NO. : 221901565
 BRANCH : MECHANICAL ENGINEERING
 SEMESTER : 5th
 INSTITUTE : CHOUDHARY RANBIR SINGH STATE INSTITUTE OF
ENGINEERING & TECHNOLOGY.
 TOPIC : SUMMER TRAINING PROJECT REPORT ON PRODUCTION
FROM MARK EXHAUST SYSTEMS LIMITED UNIT - 2,
BINOLA ,GURUGRAM ,HARYANA.
 MARK EXHAUST SYSTEM
LTD

 Owner :- ROHAN KAPOOR

 It is situated in village:- Binola,Gurugram,
Haryana. It Deals with Maruti Suzuki India
Limited, Honda Car India Ltd, Honda Motor Cycle
and Scooter India Ltd.

 Turnover
Approx 150-200 crore per annum
It’s working service is too good . This is a well
disciplined and rule regulated company. Their
employees have good behavior & friendly nature.
They follow safety rule before working.
 Acknowledgment

I would like to thank our gratitude to my teacher as

well as H.O.D Satyapal Yadav who gave me the
golden opportunity to do wonderful project on the
topic (4/6 WEEK INDUSTRIAL TRAINING),
which also helped me in doing a lot of research and
I come to know so many new things I am really
thankful to them; Secondly I would also like to
thank my parents and friends who helped me a lot
in finalizing this project with in the limited time
frame.
 ABSTRACT
It was a great opportunity for me to do four weeks
internship in MARK EXHAUST SYSTEMS
LIMITED UNIT - 2, Binola, Gurugram, Haryana . It
internship was concentrated on the small skills .

The different technologies used in MESL Unit-2

and what skills are needed in organization. During my
internship several queries are cleared by doing some
activities.

In the Company , I have learnt the rules and safety

instruction which helps me in understanding while
working. So, this internship was a great experience.

I met many new people. I achieved many of my

learning goals. I got insight into the work of an
organization
 CONTENTS

Chapter Page No.

1 Company Overview 08-17

1.1 Basic Information
1.2 Products
1.3 Machines
1.4 Department

2 Manufacturing Process 18-37

2.1 Exhaust (Suzuki)
2.2 Bike Handle (Honda Motor Cycle)
2.3 Door Sash (Maruti Suzuki)
2.4 Engine Part (Case oil Pump)

3 Machines List and Information 38-51

MARK EXHAUST SYSTEM LIMITED
UNIT-2
 Chapter-01
COMPANY OVERVIEW

1.1 Basic Information :-

The MARK EXHAUST
SYSTEM LTD UNIT-2 is a Manufacturing
Company that Manufacture the some part for the
many vehicle such as Scooty Exhaust, Bike Handle,
Engine Part, Door Visor. It’s Owner is Rohan Kapoor.
It Established in 2000 . The MARK EXHAUST
SYSTEM LTD UNIT-2 is located in the Vill:-
Binola,Gurugram, Haryana. Mark Exhaust is a
leading manufacturing and global supplier of
automobile component.
1.2 Products:-

Exhaust (Suzuki) Door Sash

(Maruti Suzuki)

Engine Part
(Case Oil Pump Casting) Honda Bike Handle
1.3 Machines :-

 Special Purpose Machine (SPM)

 YLM CNC Machine (Tube Bender Machine)
 Robotic MIG Welding Machine
 Leakage Testing Machine
 Die Casting Machine
 Robotic Spot Welding (Model - YMD)
 Manual Tack Machine
 Bending Machine
 Rolling, Forming, Punching Machine
 Robotic Cell Machine
 Knurling Machine
 1.4 Department:-

 Production Department

 Quality Department

 Maintenance Department
 Chapter-02
Manufacturing Process

2.1 Exhaust (Suzuki):-

The Suzuki Scooty exhaust system plays a crucial role

in managing the emission of exhaust gases produced
by the engine. It helps to reduce noise, direct exhaust
fumes away from the rider, and contribute to the
overall performance of the scooter.
The main work of this company is assemble the part
of exhaust . First of all its parts come from outside .
The main parts of exhaust are following:-
Upper Muffler
All Internal Parts of Exhaust:-
Assembling process of the Parts of Exhaust:-

1 Exhaust Pipe
Line:- Exhaust pipe
and flange, catalytic
converter are added
to this line. Three
type of machines are
used to connect all
these. Such as :-

i. Robotic MIG
Welding
Machine :-
Robotic MIG
Welding Machine
is used to connect
flange, exhaust
pipe, upper
muffler.
ii. Leakage Testing Machine:-The Leakage Testing
Machine is used to check any leakage in the
exhaust pipe.

iii. Visual Inspection:-In this, a worker does the

finishing of the exhaust pipe.

After the entire process is completed, the exhaust pipe

is sent to the Muffler Line.
2 Muffler Line:-
Muffler are made in this line, to
make a muffler, many parts are required which come
from outside such as catalytic converter, exhaust
pipe, muffler (cover), upper lower, plate muffler,
extension pipe. To connect all these parts, use this
line. Many machine are used in this line to assemble
these parts. Such as:-

1 Manual Tack Welding Machine

2 SPM Machine
3 Robotic Cell Machine
4 Leakage Testing Machine
a) Manual Tack
Welding
Machine:- The
Plate Muffler is
connected to
the upper lower
part, with the
help of Manual
Tech Welding .

b) Special Purpose
Machine:-
The small
exhaust pipe
are connected
to the upper
lower part, with
the help of
SPM.
c) Robotic Cell:- The inner part of the exhaust is
fixed inside the muffler (cover) and the muffler is
welded from outside, and then the exhaust flange
is connected to the muffler through a pipe.

d) Leakage Testing Machine:- The Leakage Testing

Machine is used to check any leakage in the exhaust,
if any leakage is found then it is welded again and
finishing and sent to the next worker.
3 Suzuki Muffler Line:-

In this
line, the upper part of the
exhaust is connected so
that the exhaust can be
connected with the
vehicle. After this, the
exhaust is put in the
cleaning machine and
then after being cleaned,
primer is applied on it and
then painted. After all
these processes are done,
it is sent to the quality
department so that no
defect is carried forward.
If any defect in found then
it is checked again and
again rectified and sent to
Dispatch room.
 Manufacturing Process

 2.2 Bike Handle (Honda

Motor Cycle):-
The work of this
line is simply that the pipe is bent
with the help of YLM CNC Tube
Bending Machine and then
threading is done on it with a
Knurling Machine.

Why is threading on handle

important:- It is very important to
do threading on the handle. If we
do not do threading on the handle,
then the handle will not be fixed
well in the bike and when the
driver hits the brake, the handle Threads
can slide forward or backward due
to which an accident can happen.
 Manufacturing Process

 2.3 Engine Part (Case Oil Pump Casting):-

Process explain step by step:-

1. Design and Mold Preparation:- Begin with a

detailed design of the engine part, including its
dimensions, features, and specifications. - Create
a mold (die) for the part, typically made of
hardened steel, with two halves: the "die" and the
"core" that form the desired shape.
2. Melting the Metal:- Heat the selected metal alloy
(commonly alluminium, zinc, or magnesium) in a
furnace until it reaches its melting point.
3. Injection: - Inject the molten metal into the mold
cavity under high pressure. This step is known as
the "shot. The high pressure ensures that the metal
fills all the intricacies of the mold, creating a
precise replica of the part.
4 Cooling and Solidification:- Allow the molten
metal to cool and solidify within the mold. Cooling
channels in the mold help control the cooling rate,
ensuring even solidification and preventing defects.

6 Ejection:-After the metal has solidified, open the

die casting machine. Eject the newly formed
engine part from the mold. This part is often
referred to as the "casting.

7 Trimming and Finishing:-Trim any excess

material (flash) from the casting using cutting or
machining processes. Surface finishing processes
like polishing or shot blasting may be applied to
improve the part's appearance and performance.

8 Quality Control:- Inspect the casting for any

defects or imperfections. Conduct measurements
and tests to ensure it meets the required
specifications and quality standards.
8 Additional Processes (Optional):- Some engine
parts may undergo additional processes like heat
treatment, plating, or painting for enhanced
performance and corrosion resistance.

9 Packaging and Shipping:-Once the part passes

quality control checks, it's packaged and prepared
for shipment to the assembly plant or customer.

10 Reusing the Mold:-The mold can be reused for

multiple casting cycles, making die casting a cost-
effective and efficient manufacturing methode.
This process is highly automated and efficient,
making it suitable for producing high volumes of
engine components with consistent quality.
 Manufacturing Process

 2.4 Door Sash (Maruti Suzuki):-

In the context of
a car, a door sash typically refers to the vertical or
horizontal trim piece that runs along the perimeter of
the door frame. It serves both functional and aesthetic
purposes. Functionally, it helps seal the door to
prevent water, dust, and noise from entering the
vehicle's interior. Aesthetically, it can add a decorative
element to the door's design. The specific design and
placement of the door sash can vary between different
car models and manufacturers.
1 Roll Forming:-Roll
Forming is a metalworking
process that shapes a
continuous strip of metal
into a specific profile by
passing it through a series
of rollers. This process is
often used to create long,
consistent, and precise
metal parts or components
used in various industries
like construction and
manufacturing.
2 Angle
Cutting:-: Cutting
angles with a
pressing machine
involves
positioning a
metal sheet under
a cutting tool and
using the machine
to press and shear
the metal, forming
the desired angle
shape.
3 Notching:-
Notching is a
metalworking process
where a machine
removes a portion of
material from the
edge or corner of a
metal sheet or plate
to create a V-shaped
groove or cutout. It's
often used for joining
or assembly purposes
in various industries,
including construction
and manufacturing.
4 Cap Fitment &
Final Inspection:-
The cap fitment
process involves
selecting the right
cap, placing it onto
a container, sealing
it securely, and
ensuring quality
before further
packaging or
distribution
 Chapter -03
MACHINES INFORMATION

3.1 Special Purpose Machine (SPM):-

The SPM are those

machine which are not
available off the shelf.
These are not convert in
standard manufacturing
programs. Therefore those
have to be designed & tailr
made as per the customer
specific requirement. They
are also called as bespoke
machines.
3.2 YLM CNC Tube Bending Machine:-

YLM CNC machine are

well-known for their
precision and reliability.
They are commonly used
in various industries,
including manufacturing.
Tube bending is any metal
forming processes used to
permanently from pipes or
tubing. Tube bending may
be form-bound or use
freeform-bending
procedures, and it may
use heat supported or
could forming procedures.
Working of CNC Tube Bending Machine:-
Here's
a step-by-step process for bending a pipe using a CNC
tube bending machine:-

1. Material Preparation:-Start with a straight pipe

or tube made of materials like steel, aluminum, or
copper. Ensure the pipe's diameter, wall thickness,
and length are within the machine's specifications.

2 Machine Setup:- Choose the appropriate CNC

tube bending
machine with the necessary tooling and
capabilities for your specific job. Install the
required tooling, which includes the bending die
and clamp die, onto the machine. Program the
CNC machine with the desired bending
parameters, including the bend angle, bend radius,
and the distance between bends (if multiple bends
are required).
3 Loading the Pipe:-Place one end of the pipe into
the machine's clamp or chuck, ensuring it's
securely held in place.

4 Positioning:-Use the CNC controls to move the

pipe into the correct position for the first bend.
The machine may have a mandrel that is inserted
into the pipe to prevent it from collapsing during
the bending process.

5 Bending:-Initiate the bending process using the

CNC controls. The machine will precisely bend
the pipe to the programmed specifications,
typically through a combination of rotary and
linear motions. Monitor the bending process for
any issues and make adjustments if necessary.
6 Measurement and Inspection:-After the first
bend is completed, use measurement tools such as
calipers or a coordinate measuring machine
(CMM) to verify that the bend meets the required
specifications.

7 Repositioning and Additional Bends:-If multiple

bends are needed in the pipe, reposition the pipe in
the machine using the CNC controls and repeat
the bending process for each bend.

8 Unloading the Pipe:-Once all bends are

completed and verified, release the pipe from the
machine's clamp or chuck.
9 Quality Control:-Inspect the final bent pipe for
any defects, including dimensional accuracy,
surface finish, and straightness. Conduct any
necessary quality tests to ensure it meets the
required standards.
10 Finishing (if needed):- Depending on the
application, additional processes such as cleaning,
or coating may be required.

11 Packaging and Shipping:- Prepare the bent pipe

for packaging and shipping to its destination.CNC
tube bending machines offer high precision and
repeatability, making them ideal for
manufacturing complex pipe or tube
configurations with tight tolerances. The CNC
controls allow for efficient production and
customization of bent pipes for various industries.
3.3 Robotic MIG Welding
Machine:-

A Robotic MIG Welding

machine is a type of
automated welding system
that uses Metal Inert Gars
(MIG) welding process. It
utilizes a robotic arm equipped
with a MIG welding torch to
perform welding tasks with
precision and efficiency. The
machine is programmed to
follow specific welding paths
and parameters, enabling it to
weld various metal
components consistently. This
technology is commonly used
in industries to improve
welding quality, reduce
productivity.
3.4 Leakage Testing
Machine:-

A leakage testing
machine, also known as
a leak tester or leak
detection system, is a
specialized device used
to detects in sealed
products or
components. It is
commonly employed in
industries where
product integrity and
quality control are
critical, such as
automotive, aerospace,
medical devices, and
packing.
There are various Exhaust Pipe Nozzle
methods for leakage
testing, including:-
1 Pressure Decay Test:-
This method measures
the drop in pressure
within a sealed
container over a specific
period. If there is a leak,
the pressure will
decreases, indicating a
defect.
2 Bubble Testing :- In
this simple method, the
product is immersed in
water, and bubbles will
form at the location of
any leakage.
3.5 Die Casting Machine:-

A die casting machine is

a specialized industrial
machinery used to
produce metal part with
high accuracy,
consistency, and
efficiency through the
die casting process. Die
casting is manufacturing
process where molten
metal is injected under
high pressure into a steel
mold (called a die) to
create complex shapes
with smooth surfaces.
The main component of
die casting machine
include:-
3.6 Robotic Spot Welding (Model - YMD):-

The Robot receives wire

as needed through a
wire feeder, while a
high-heat torch melt
metal to begin the
welding process. These
devices can withstand
the high temperature
around thousands of
degrees and thus keep
human workers safer.
Certified human
operators still need to
remain close to the
robots.
3.7 Rolling and Forming Machine:-

A Rolling and Forming

machine is a mechanical
devices used in
manufacturing processes
to shapes and manipulate
materials such as metal,
plastic, or paper. It
employs rollers or dies to
deform the material into
desired shapes,
dimensions, or profiles.
This technology products
such as sheets, tubes, and
profiles by passing the
material through a series
of rollers or dies. The
process is versatile and
efficient, enabling the
production of consistent
and accurately shaped
components.
3.8 Robotic Cell Machine:-
A robotic cell machine is an
automated manufacturing
setup that incorporates robotic
systems to perform various
tasks within a controlled
environment. These tasks can
include assembly, material
handling, quality control, and
more. The cell typically
consists of one or more robots,
sensors, actuators, and other
equipment working together to
execute specific processes.
Robotic cell machines are used
to enhance efficiency,
accuracy, and productivity in
manufacturing, often reducing
the need for human
intervention and improving the
overall production process.
They find applications in
industries such as automotive,
electronics, pharmaceuticals,
and many others.
3.9 Knurling Machine :-A knurling tool is a
manufacturing and repairing tool used on lathe
machines. A knurling tool is used to give the metal a
cross pattern shape, which helps to human hand to
hold the knurled tool more firmly.