Lakshmi Precision Screws Ltd.

Lakshmi Precision Screws Ltd.

Summer Training
Welcome to IMEA Team

At LPS from

rd 3

July 2008

Vision 2010
MISSION
Be a globally competitive organization providing the best fastening solutions.

VISION 2010
Make LPS a ‘Most Sought After’ Brand.
Achieve US $110 Million in Sales. Become a Deming Organization Expand Manufacturing to 2 more locations

‘Most Sought After’ means:
1. Fastest New Product Development time. 2. Fastest Customer Response Time. 3. Customer PPM < 100 consistently.

O

U

R

V

A

L

U

E

S Respect For People

Customer Obsession

Continuous Improvement

History & Milestones .

Established by Mr. B P Jain as LPS .History & Milestones 1972 .

Continuously received Regional Export Award from EEPC 1993 .Registered as Public Limited Company 1988 .History & Milestones 1984 .A2LA and NABL Accreditations .Established as Exporter 1991 to 93 .Established LPS Plant-II 1995 .

.ISO 9002 Certification 1996 . S. Productivity & Development of Automotive Parts 1998 .History & Milestones … 1996 .Korea for Quality. Switzerland .Joint venture with BOSSARD-AG.Technical tie-up with Sunil Machinery Corp.Marketing tie-up with RECOIL Pty. Australia 1998 .

SAP R/3 implemented .License to manufacture & market Torx® brand of proprietary products from Textron Inc.History & Milestones … 1999 .ISO 14001 Certification 2002 .ISO/TS 16949:1999 Certification 2001 .QS-9000:1998 Certification 2001 . USA 2000 .

License to manufacture fasteners with Doerken® Proprietary Delta-Seal® & Delta-Tone® Finishing Technology .Golden Peacock Environment Management Award 2003 .VOLVO Global Supplier Certification 2003 .ISO/TS16949 (Version 2002) Certification 2004 .Recommended for OHSAS 18001 Certification 2005 .History & Milestones … 2002 .

Marketing tie up with Wiha Werkzeuge GmbH. Germany for their Quality Tools 2006 – Quality Software – Sapphire implemented to integrate plant-wide Quality data and institute online traceability 2006 – Winner of Silver Award for Manufacturing Excellence in the Engineering – Emerging category during ‘Indian Manufacturing Excellence Awards 2006’ conducted by Frost and Sullivan .History & Milestones … 2005 .License to manufacture & market EJOT® brand of proprietary products Delta-PT® & Altracs® from EJOT GMBH. Germany 2005 .

9 and above to Volkswagen globally 2006 – Winner of 1st runner up award in North West Qualtech awards 2006 2006 – Winner of 2007 – Winner of 3rd prize in Kaizen Competition conducted by CII in 2007 .History & Milestones … 2006 – Certified to supply high tensile fasteners of grade 10.

Our Key Customers .

Our Product Range • Standard Products • Special Products • Components .

Our Product Range … • STANDARD PRODUCTS • • • • • • • • • • • Socket Head Cap Screw Socket Counter Sunk Head Screw Socket Set Screw Knurled Cup Point Flange Bolts/ Screws Dowel pins Stainless steel Fasteners Socket Low Head Cap Screws Socket Button Head Cap Screw Hex Head Bolts/ Screws Hex Nuts Friction grip bolts .

Our Product Range … • SPECIAL PRODUCTS • • • • • • • • • • • • Torx and Clamp Compressor Bolt Wheel Bolts Collar Bolts and Axles Axles Studs Pivot Pin Transmission Bolt C. Bolt.R. Hub Bolt Durlock Screw Wheel Bolt and Stud Hex Bolts .

Our Products … • COMPONENTS • • • • • • • Piston Pins Shafts Ball Pins Ball Rods Plunger Sockets Spine Shafts .

• Grade: JIS. Above M30 by Hot Forging. ISO. ANSI. DIN. • Length: 6 mm to 300 mm by Cold Forging. BIS.Manufacturing Capabilities • Diameter Range: M3 to M30 by Cold Forging. IS. . Above 300 mm by Hot Forging.

White.Manufacturing Capabilities … • Variety of Finishes: • Dacro Coating. Green. Bleach Yellow & Yellow) • Thermal & Chemical Blackening . • Zn Plating with Chrome Passivation (Black.

Transmission / Engine Fasteners .

In the symbol. the circle represents the co -process. it symbolized craftsmanship and unending productivity. . the workers and the people related to LPS are represented by the view of a Hexagon nut. When interpreted as a nut. understanding Dedicating towards the workers work or duties in a quality circle. LPS is the name itself (LAKSHMI PRECION SCREW) in self explanatory or explaining the keenness every worker or employee to produce a precise product.Description of Symbol The hexagon is a symbol of precision.

internal stress etc. Heat treatment. 4. Production of die and punch according to the bolt Forging operation. zinc iron and phosphate plating is generally done.Different Process of Making Bolt 1. Final inspection and packaging . 2. And is used for making Head. Plating. 5.thread cutting is done on thread rolling machine.done for improving strength. Thread rolling. 6.plating is done by electroplating mechanism and zinc. 3.done in forging machine.

. It gives the length from which they make the given product. They make a drawing for that product in AutoCAD 14 or in solid works. then from these length of wire he make calculation for the dimension of head it goes to the that engineer which make its process sheet and what type of raw material is used in making that product.How the Process For The Bolt Making Initialize By The Company The customer gives a description or drawing to the company as his requirement He Gave description about that product which he wants. In that drawing engineer first equate the volume of the product to the area of the wire. Then it goes for approval that all things and process for that product is right or not. This description firstly goes to the engineering department.

then these dies and punches and ready and goes in the tool store room for checking. drilling machines etc. Where they decide that this product goes to various machines for production and in in what time interval this Product will goes to another machine for next step. Then dies. After that this description goes to the Production department. . hole gauge etc. .How the Process For The Bolt Making Initialize By The Company Then it goes to the production planning and control department. punches are made on different machines. They make dies and punch for that product as in the description and drawing given by the supervisor. wire cut. These checking’s are done in pore gauge.then the die and punch for checking goes to projector profile machine which check the under collar radius in the die and head angle given in the punch and die. drilling. Then this description and design goes to the supervisor of the tool room. Like lathe.

Heat Treatment Heat treatment is an important operation in the manufacturing process of machine parts and tools. It may be defined as an operation of heating and cooling of metals in the solid state to induce certain desired properties into them. To improve magnetic and electrical properties. Heat treatment can alter the properties of steal by changing the size and shape of the grains of which it is composed. heat and corrosion. or by changing its micro constituents. It is generally employed for the following purposes: Advantages: To improve machinability To change or refine grain size To relieve the stresses of the metal induced during cold or hot working. • • • • • . To increase resistance to wear.

Most Commonly Used Operations Of Heat Treatment Are 1) 2) 3) Annealing Hardening Tempering 4) Carburizing (case hardening) .

Annealing It is one of the widely used operations in heat treatment of iron and steel and is defined as the softening process in which iron base alloys are heated above the transformation range in the furnace itself. The success of annealing depends upon controlling the formation of Austenite. and the subsequent transformation of the austenite at high sub critical temp. Various types of any annealing treatments are: . Alternatively. and held there until the austenite has transferred into pearlite (final cooling can be done in still air). the steel may be transferred to another furnace at about 6500°c.

The rate of cooling is controlled by quenching medium. by quenching in water . it is defined as the heat-treatening process in which steel is heated to 200°c above the transformation range. blast by dry air. followed by continuous cooling to room temp.S. . oil or brine solution. These solutions are: • Solution of salt or caustic soda.T.Hardening • According to A. soaking at this temp. high flash point/clean water from grease of soap. inside the components.M. for a considerable period to ensure through penetration of the temp.

It is an operation used to modify the properties of steel hardened by quenching for the purpose of steel hardened by quenching for the purpose of increasing its usefulness.T. .Tempering • According to A. Such a reheating permitting the trapped martensite and relieve the internal stresses. Toughness and ductility are improved at the expense of hardness and strength.S. reheating being carried out under subcritical temp.M. it is defined as the reheat process.

It is the process of carburisation such that saturating the surface layer of steal with carbon to about 0. so that only the surface layer will respond. The carburised steel is then heated and quenched.its carbon content is low.Case Hardening or Carburizing • This process is used to produce a high surface hardness for wear resistance supported by a tough shock resisting core. . and the core remaining soft and tough since.9% or some other process by which case is hardened and core remains soft.

Project on Simulation • Objective: To calculate stresses acting on the tools (die and punch) while cold forging so to prevent tools from failure and to ensure a longer life for a given forging sequence. drafting software (AutoCAD). • Given: Forging sequence for given bolt. . simulation software (Nagsim 2d).

. Here the step by step simulation in Nagsim gives the prevailing stress values at different points of the tool which would be applicable as if the tool were actually operated on the forging machine.Project on Simulation • Simulation: It implies an approach in which a virtual (computational or on computer) but similar to existing system is designed to predict the actual application parameters. Medium can be a computer or a prototype. Thus without any actual operation on the machine we can have an insight of the stresses acting on the tools and can design the tools to withstand those stresses with a longer life.

punch are chosen from among the listed ones. The materials for the blank.Procedure Of Doing Simulation 1. A step by step tooling as per the given forging sequence is drafted with the help of AutoCAD. The simulation software (Nagsim) will automatically transfer the deformed blank step by step. Now the step by step tooling drawing of AutoCAD is imported in the software. • • • . The tooling is drafted such that the cut-off length is inserted once in the first step because the same will be transferred to further steps in deformed shape. die. A new project file is created in the simulation software.

where in each step refers to a tool displacement of . • Material of punch is alloy of HRC 60 or carbide (58-60 HRC). As soon as simulation starts running the punch moves downward thereby deforming the blank material as per the die shape. .Procedure Of Doing Simulation • Here. • Material of the blank is given by the customer and is chosen to have almost same properties with respect of percentage of major elements like carbon. Now the first stage simulation is run by providing tool displacement (usually 200 steps). 5. to ensure good fatigue and wear strength provided by high hardness. The simulation is stopped as the material takes the desired shape. the material of die is tungsten carbide. which also provides good wear strength.01 mm.

Now the stress values acting on the tools in different stages are checked by reading the results. . The results in the form of animation are recorded by the software and can easily be obtained by clicking the result button and selecting the stage. Now the deformed shape will automatically be transferred to second stage. thereby giving the final bolt shape. 7. Again the simulation is run and further deformation of blank material starts. 8. Simulation is stopped as soon as the required shape is achieved. Similarly the final stage simulation is performed.Process Of Doing Simulation 6.

• If not than an alternate solution is found such that changing the material of tool or increasing the diameter of cut-off.3 in to consideration. we can decide whether the tool is capable of withstanding the acting stresses or not. .Result Of Simulation • The results are shown in the form of animated figures with different colors. • Now the recorded value is compared with the yield strength of the material and taking a factor of safety greater than 1. In this way the maximum prevailing stresses in each of the three stages are recorded. A sided scale defining stresses corresponding to different colors is referred to find the point of maximum stress.

Result Of Simulation 1st Station .

Result Of Simulation 2nd Station .

Result Of Simulation 3rd Station .

Thank you .

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