industrial training report in rane madras mysore

Industrial Training At M/s Rane (Madras) Limited, Mysore.

CHAPTER 1 INTRODUCTION 1.1 Objective of Industrial Training: The main objective of the Industrial Training is to experience and understand real life situations in industrial organizations and their related environments and accelerating the learning process of how student’s knowledge could be used in a realistic way. In addition to that, industrial training also makes one understand the formal and informal relationships in an industrial organization so as to promote favorable human relations and teamwork.Industrial training also provides a systematic introduction to the ways of industry and developing talent and attitudes, so that one can understand how Human Resource Development works. Moreover, students can gain hands-on experience that is related to the students majoring so that the student can relate to and widen the skills that have been learnt while being in university. Industrial training also exposes the students to the real career world and accustoms them to an organizational structure, business operation and administrative functions. In conclusion, there is strong evidence that industrial training is highly beneficial to students’ development, and it is highly valued. The students are well equipped to manage the period of industrial training successfully and undoubtedly gain useful experience of applying their specialist and technical skills, as well as developing their personal and communications skills. This internship also help student to prepare for the work environment and also teach the ergonomics of organizations in the real world. In brief: 

To understand the organization structure of an industry.



To understand Management skills.



To understand the functions and responsibilities of different departments.

1.2 Methods of Industrial Training There are many methods used to assist me in gathering sufficient information for my report. The main source of information was gathered through interviews with particular employees and managers. They were very approachable and assisted me in providing information and knowledge. Next, I also used discussion method to gather information. I discussed with the staffs on certain task that I was not sure and they helped me by explanation briefly about their job description and also about the organization. Dept of Mechanical engineering, PESCE, Mandya

1

Industrial Training At M/s Rane (Madras) Limited, Mysore.

Apart from that, I also used observation method to gather information for my project. I observed how the operations are carried out, how the employees interact among themselves, how the working culture is practiced, how the relationship between the manager and the sub ordinates is and the how the working environment is.

1.3 Scope of Industrial Training: Industrial Training is very important for student learning process in order to understand the theory that already learned and relate it with practical which have been done in practical work at sites, labs, workshops and much more. Therefore, the trainee should be able: 

To train at real working situation at industries before applied the real job.



T o e xpose to a new technology and applications in engineering.



T o respect and follow the company’s rules.



To involve in the real working environment.



To improve student’s confidence and develop responsibility.



To know how to solve a problem that occurs in a real work.



To increase the creativity and innovative during the work.



To improve working skill.

Dept of Mechanical engineering, PESCE, Mandya

2

Industrial Training At M/s Rane (Madras) Limited, Mysore.

CHAPTER 2 COMPANY PROFILE 2.1 Company profile:

Fig. 2.1 Rane (Madras) Ltd., Front View RANE (MADRAS) LIMITED – PLANT II 79/84, HOOTAGALLI INDUSTRIAL AREA, MYSORE – 570018.

Rane (Madras) Ltd is one of the top auto ancillary company and is a part of the Rs. 2709 crore Rane group, engaged in the manufacture and distribution of steering and suspension systems.

Dept of Mechanical engineering, PESCE, Mandya

3

Industrial Training At M/s Rane (Madras) Limited, Mysore.

2.2 RANE’S MISSION : 

Provide superior products and services to their customers and to maintain market leadership.



Evolve as an institution that serves the best interests of all stakeholders.



Pursue excellence through total quality management.



Ensure the highest standards of ethics and integrity in all their actions.

2.3 RANE’S VISION : Rane has been an integral part of the Indian Automotive Industry since 1929. Founded by Mr. T.R.Ganapathy Iyer, Rane started as a Trading House for automobiles and parts. The history of Rane is growing from this reputed Trading House into a major manufacturer of vital components for the Automotive Industry.Seeking world-class technology and adapting it perfectly to Indian conditions, RANE has been a key support system in the growth of the automotive industry. Today, the Rane group, under the leadership of Mr. L Ganesh, Chairman, has in its fold manpower strength of 4500 people and a sales turnover in excess of Rs.2709 crores. And the RHL vision is to maintain market leadership, to establish global presence and to achieve sales of Rs. 4,300 crores. Rane’s major customers in India are –Ashok Leyland, Hyundai, Fiat, Hindustan Motors, Mahindra and Mahindra, Hero Honda, Maruti Suzuki India Ltd., VOLVO-EICHER Ltd., TATA Motors, Eicher, TAFE, Escorts, New Holland Tractors (India) Ltd., John Deere Equipments Pvt. Ltd., Indian Railways etc.

2.4 Down the memory lane… 

Founded as Rane Private Limited in 1929, started as a trading house, trading in automobiles and parts. Represented General Motors, Renault, American Motors etc



As first diversification from trading, in 1959 Engine Valves Limited was established for manufacturing IC engine valves.



In 1960 Rane (Madras) limited commenced manufacture of Steering Linkages (Tie rod ends).



Rane Brake Linings Limited was established in 1964 for manufacturing friction materials.



In 1965 Rane Madras Limited discontinued with its trading activities.



In 1975 Rane (Madras) Limited started manufacturing of Steering Gears.



RML Mysore division was started in the year 1985.

Dept of Mechanical engineering, PESCE, Mandya

4

Industrial Training At M/s Rane (Madras) Limited, Mysore.

2.5 Rane Group Companies and Product Range:

Fig. 2.2 Rane Group Companies and Product Range

2.6 About M/s Rane (Madras) Limited: 2.6.1 Background: 

Inception of manufacturing facilities in the year 1960



Manufacturer of steering and suspension systems for every segment of automobile industry, viz Passenger cars, Multi utility vehicles, Light commercial vehicles, Heavy commercial vehicles and Farm tractors



Branched in Hydraulic products in anticipation of shift in customer requirements



Strategic Technical partnerships with M/s TRW Inc, USA for Steering Gear Products and TRW Ehrenreich GmbH and Co., Germany for Steering Linkage Products



Holds 39% market share in Steering Gear Products (SGP) and 72% market share in Suspension and Steering Linkage Products (SSLP) in India.

Dept of Mechanical engineering, PESCE, Mandya

5

Industrial Training At M/s Rane (Madras) Limited, Mysore.

2.6.2 Plant Locations:

Fig.2.3 RML Plant locations

The 5 manufacturing facilities location and the product range following locations Location Mysore plant Puducherry plant Uttarakhand (Pantnagar) plant Velachery (Chennai) plant Varanavasi (Chennai) plant

Product

Costumer Segment

SSLP, SGP, Hydraulic

Tractor and Commercial vehicle segments,

products

and Hydraulic products

SSLP,SGP

Passenger Car segment

SSLP,SGP

SSLP

Tractors and small commercial vehicles catering to customers in North India Passenger Car, utility vehicle mainly caters to exports market Light Commercial vehicle, Heavy

SSLP,SGP

Commercial vehicle and Utility vehicles segments

Table 2.1 Manufacturing facilities location and the product range Dept of Mechanical engineering, PESCE, Mandya

6

Industrial Training At M/s Rane (Madras) Limited, Mysore.

2.6.3 Product range and Customer base:

Fig. 2.4 RML Product range.

Fig. 2.5 RML customer wise product range

Dept of Mechanical engineering, PESCE, Mandya

7

Industrial Training At M/s Rane (Madras) Limited, Mysore.

2.6.4 List of customers: Sl no Customer 1 MandM- TD Mumbai 2 3 4 5 6

7 8 9 10

11

12 13 14 15 16 17 18

Products 1.Linkage assembly 2.Steering gear assembly MandM-AD Mumbai 1.Suspension ball joint 2.AXLE BJA MandM(Swaraj Division) 1.Steering gear assembly TATA MOTORS Ltd. 1.Suspension ball joint assembly Escorts limited farm 1.Linkage assembly Equipment division 2.Steering gear assembly TAFE Ltd. 1.Linkage assembly 2.Steering gear assembly 3.Cylinders TMTL 1.Linkage assembly 2.Steering gear assembly New Holland Tractors(I) Pvt. Ltd. 1.Linkage assembly 2.Steering gear assembly JDEPL 1.Linkage assembly 2.Steering gear assembly Inter National Tractors 1.Steering gear assembly 2.HSU 3.Cylinders 4.Steering columns Force Motors 1.Linkage assembly 2.Steering gear assembly 3.Lower control arms SIAM Kubota 1.Steering gear assembly Indo Farm 1.Linkage assembly 2.Steering gear assembly Same Greaves 1.Linkage assembly 2.Steering gear assembly Maruti Suzuki India Ltd. 1.Lower control arms DANA India Pvt. Ltd. 1.Linkage assembly Piaggio Ltd. 1.Lower control arms Ashok Leyland 1.Gear shift lever BJA 2.Cylinders

19

HMT Ltd.

20

AMW

1.HSU 2.Steering column 3.Reservoir 4.Cylinders 1.Cylinders 2.GSL ball joint assembly Table 2.2: Rane products and customers

Dept of Mechanical engineering, PESCE, Mandya

8

Industrial Training At M/s Rane (Madras) Limited, Mysore.

2.6.5 DEMING Prize: The DEMING PRIZE is a prize instituted by the JUSE {Union of Japanese Scientists and Engineers} in the 1950s. It is awarded annually to those individuals and companies showing the most important in Quality control. The prize itself is named after Dr. W. Edward Deming Father of Quality. Rane (Madras) Ltd received the Japanese Deming Grand Prize in 2012. The company also won the Deming Application Prize in 2007. Rane (Madras) Ltd. is the only steering and suspension manufacturing company globally to win the Deming Prize and Deming Grand Prize.

2.6.6 The Key initiatives for the future are: 

Expanding Rack and Pinion business through new customer acquisition.



Establishing stronger position in suspension ball joints.



Expanding export business through current and new customers in different geographies.



Enhancing the Company’s position significantly in hydraulic products.



Expanding scope and reach in after market segment



Company plans Capex of Rs. 160 crore, achieve CAGR of 21% in Sales and ROCE of 30% by 2015-16

Dept of Mechanical engineering, PESCE, Mandya

9

Industrial Training At M/s Rane (Madras) Limited, Mysore.

CHAPTER 3 AREA OF TRAINING

3.1 Imparts/Insights obtained: Industrial training is an exposure to the industry at the right time. It helps in learning the details of company such as the organization structure, functions and responsibilities of different departments, management skills, technology, the product and services, maintenance procedure, various tools used etc. Through the training one will know the hierarchy of departments and also it helps to closely watch the happenings in an industry. Through the industrial training program one can prepare himself for the further project work and will provide a strong base for his career. The industrial training helped me to get a deep insight about the structure of the organization, and various departments. It also helped me to gain the knowledge of how departments perform individually and co-ordinate with each other to service the customer needs.

3.2 ORGANIZATION STRUCTURE: Chart below shows the organization chart with different levels of hierarchy.

Fig 3.1 Organization structures - RML, Mysore

Dept of Mechanical engineering, PESCE, Mandya

10

Industrial Training At M/s Rane (Madras) Limited, Mysore.

3.3 Plant Maintenance Engineering Department (PLE):

Fig 3.2: Organization structure – PLE - RML, Mysore 3.3.1 Purpose: 

The purpose is to sustain and enhance availability of plant and machinery to it's maximum level and to improve quality and maintainability of equipments.

3.3.2 Role: 

Upgrade equipment availability



Control maintenance cost



Reduce power cost

3.3.3 Functions: Plant consists of around 320 production machines, H.T furnaces, utilities and facilities including buildings. Caters to the technical service requirement of manufacturing and calibration requirement of testing and measuring instruments. It takes care of company statutory and legal requirements.

Dept of Mechanical engineering, PESCE, Mandya

11

Industrial Training At M/s Rane (Madras) Limited, Mysore.

3.4 Manufacturing Engineering Department (MED) :

Fig 3.3: Organization structure – MED - RML, Mysore 3.4.1 Purpose: 

The purpose is to support the manufacturing function through optimizing the process through modern and innovative tooling, Reduction in cycle time and setup time, Establish manufacturing process for New Product, to meet market demand and quality

3.4.2 Role: 

Improve manufacturing Processes



Productivity Improvement Projects



Special initiative on Tool Cost



Saving Projects

3.4.3 Functions: 

Manufacturing cost competitiveness.



Manufacturing system inability to meet fluctuating demand



Lead time of New product productionization



Process Quality improvement



Inadequate use of Statistical tools

Dept of Mechanical engineering, PESCE, Mandya

12

Industrial Training At M/s Rane (Madras) Limited, Mysore.

3.5 Quality Assurance (Q.A.):

Fig 3.4: Organization structure – Q.A. - RML, Mysore 3.5.1 Purpose: 

To achieve quality to meet customer expectation.

3.5.2 Role: 

Improve incoming material quality



Improve in-process quality



Improve out going product quality

3.5.2 Functions: 

Customer Quality Assurance (CQA) - To improve out going product quality.



In process Quality Assurance (IQA) - To support in-process material quality to meet internal customer requirements.



Supplier Quality Assurance (SQA)

- To improve incoming material quality to meet internal

customer requirement.

Dept of Mechanical engineering, PESCE, Mandya

13

Industrial Training At M/s Rane (Madras) Limited, Mysore.

CHAPTER 4 MY OBSERVATIONS AND TASK As a CIM student I studied the plant layout, cell layout and the process flow of a product of a particular variety (Customer Company)

Fig 4.1 Layout of SSLP (Not to scale)

4.1 CASE STUDY (ISHIKAWA PRODUCT MODULE): In this cell the final part obtained is the drag link for cars like MARUTI 800 and OMNI. This final part is obtained by assembling ball pin and socket which are manufactured in this cell and then finally assembling them. A drag link converts rotary motion from a crank to a second crank or link in a different plane or axis. The term is commonly used in automotive technology for the link in a four bar steering linkage that converts rotation of a steering arm to a center link and eventually to tie Dept of Mechanical engineering, PESCE, Mandya

14

Industrial Training At M/s Rane (Madras) Limited, Mysore.

rod links which pivot the wheels to be steered. A drag link is used when the steering arm operates in a plane above the other links. The drag link converts the sweeping arc of the steering arm to linear motion in the plane of the other steering links. Typically, one end of the drag link is connected via the Pitman arm and steering gearbox to the steering wheel (providing the connection between the driver and the steering system); the other end is attached to the vehicle frame by the idler arm.

Fig 4.2 Drag link assembly Ishikawa product module(Integrated cell) is as shown in the figure

Fig 4.3 Process Flow of Integrated Cell

Dept of Mechanical engineering, PESCE, Mandya

15

Industrial Training At M/s Rane (Madras) Limited, Mysore.

Process Flow in Integrated cell: 1.

Raw materials from supplier to stores

2.

Raw materials (Forged part) to the Integrated cell

3.

Machining Process I.

Machining of Ball pin a. Turning b. Pin hole drilling c. Pin hole chamfering d. Turning and Burnishing e. Thread rolling

II.

Machining of Socket a. Piercing b. Bore machining c. Garter grooving d. Stem centering e. Stem turning f. Thread rolling

4.

Heat Treatment

5.

Inspection – magnetic inspection for crack detection and other faults

6.

Assembly Line a. Pre assembly b. Roller peening c. Boot greasing d. Boot assembly e. Boot clip assembly f. 90 deg correction and Packing

Dept of Mechanical engineering, PESCE, Mandya

16

Industrial Training At M/s Rane (Madras) Limited, Mysore.

4.2 Machining process: 4.2.1 Machining of Ball pin: 1 Turning:

Fig 4.4 Ball pin turning Mount the ball pin between the tail stock center and the face drive and clamp the component. Switch on the machine, after completion check visually and if found ok proceed to first off inspection check with appropriate gauges and continue. Machine Used: C.N.C. TURNING MACHINE Process parameters: PARAMETER

SPECIFICATIONS

CHECK METHOD

Speed

3150-2000 rpm

Visual

Feed

0.28-0.22 mm/rev

Visual

Tail stock pr.

16-20 Kg/cm2

Visual pressure gage

Cutting medium

Soluble oil

Visual

Tooling details: TOOL NO

DESCRIPTION

TOOL LIFE Per Edge No of Edges Total

MTJNL 2020

Holder

TNMG 150608

Insert

Dept of Mechanical engineering, PESCE, Mandya

200

6

1200

17

Industrial Training At M/s Rane (Madras) Limited, Mysore.

2 Pin hole drilling:

Fig 4.5 Ball pin hole drilling Mount the ball pin in the guide bush and lock the Pneumatic cylinder. Switch on the cycle. After completion visually check and if found ok proceed to first off inspection and check with appropriate gauges and continue. Machine Used: DRILLING MACHINE (AURAM) Process parameters: PARAMETER

SPECIFICATIONS

CHECK METHOD

Speed

1000-1750 rpm

Visual

Feed

Auto

Visual

Cutting medium

Soluble oil

Visual

Tooling details: TOOL NO

DESCRIPTION

RJF 0314

Fixture

MJF 0151

Drill jig 3.2 s.s drill

TOOL LIFE Per Edge

No of Edges

Total

100

10

1000

3 Pin hole chamfering:

Fig 4.6 Ball pin hole chamfering Hold the component in the vice and switch on the cycle. After completion check & if found ok continue. Machine Used: DRILLING MACHINE (AURAM) Dept of Mechanical engineering, PESCE, Mandya

18

Industrial Training At M/s Rane (Madras) Limited, Mysore.

Process parameters: PARAMETER

SPECIFICATIONS

CHECK METHOD

Speed

475-750 rpm

Visual

Feed

Manual

Visual

Cutting medium

Dry

Visual

4 Turning and Burnishing:

Fig 4.7 Ball pin head turning & burnishing Mount the ball pin in the spindle, and switch on the cycle .After completion of the process visually check and if found ok proceed to first off inspection check with appropriate gauges and continue. Machine Used: BALL PIN TURNING & BURNISHING MACHINE Process parameters: PARAMETER

SPECIFICATIONS

CHECK METHOD

Speed

Fixed

Visual

Feed

Hydraulic

Visual

Cutting medium

Dry

Visual

Hydraulic Pr.

30-40 Kg/cm2

Visual

Tooling details: Dept of Mechanical engineering, PESCE, Mandya

19

Industrial Training At M/s Rane (Madras) Limited, Mysore.

TOOL NO

DESCRIPTION

TOOL LIFE Per Edge

ZZ 473

Parent collet

ZZ 363

Burnishing roller

No of Edges

Total

1 in 2 month

DSDNN 25 25 Holder SNMG

Seco make

250

8

2000

5 Thread rolling:

Fig 4.8 Ball pin thread rolling Place the ball pin on the ball head rest (Nylon), and stem on the rolling blade, switch on the cycle. After completion visually check and if found ok proceed to first off inspection and also check for any flat threads and also any over ride of the thread. Machine Used: THREAD ROLLING MACHINE (PRAGA) Process parameters: PARAMETER

SPECIFICATIONS

CHECK METHOD

Hydraulic pressure

8-12 Kg/cm2

Visual

Dwell Time

2.0-4.0 sec

Timer

Cutting Medium

Servo cut 945 Oil

Visual

Tooling details: TOOL NO

DESCRIPTION

TOOL LIFE Per Edge

M12x1.25 RH Thread Rolls

1

No of Edges

Total

10000

10000

4.2.2 Machining of Socket: Dept of Mechanical engineering, PESCE, Mandya

20

Industrial Training At M/s Rane (Madras) Limited, Mysore.

1 Piercing:

Fig 4.9 Piercing blank Load the socket in between the Fixture jaws & Tighten the jaws, Switch on the cycle. After completion of the cycle, Check visually and if found ok move on to first off inspection. Check with appropriate gauges for the critical dimensions as in check list and continue the operation. Machine Used: COLUMN DRILLING MACHINE Process parameters: PARAMETER

SPECIFICATIONS

CHECK METHOD

Speed

315 rpm

Rotary switch

Feed

0.315-0.5 mm/rev

Needle

Cutting medium

Soluble oil

Visual

Tooling details: TOOL NO

DESCRIPTION

TOOL LIFE Per Edge

RJF2002

Pneumatic Vice

MJF 141

26.50mm T S 2F drill within house made step

No of Edges

Total

500

2 Bore machining:

Dept of Mechanical engineering, PESCE, Mandya

21

Industrial Training At M/s Rane (Madras) Limited, Mysore.

Fig 4.10 Bore machining of socket Clamp the socket in the Spindle and switch on the cycle. After completion, check visually and if found ok move on to first off inspection. Check with appropriate gauges. If found ok continue the process. Machine Used: MURATA CNC CENTER Process parameters: PARAMETER

SPECIFICATIONS

CHECK METHOD

Speed

2500 rpm

Visual

Feed

0.22-0.28 mm/rev

visual

Cutting medium

Soluble oil

Visual

Chuck pressure

16-20 kg/cm2

Pr. gage

Tooling details: TOOL NO

DESCRIPTION

TOOL LIFE Per Edge

PCLNR 2020

Tool Holder

CNMG 120408

Insert

S16SCLCR

Boring Bar

CCMT09T308

Special boring bar 500 cutting Insert

Dia 165 mm

3 Jaw Chuck

800

No of Edges

Total

04

3200

2+2

2000 4months

3 Garter grooving: Dept of Mechanical engineering, PESCE, Mandya

22

Industrial Training At M/s Rane (Madras) Limited, Mysore.

Fig 4.11 Garter grooving of socket Clamp the socket in the grooving collet and tight the collet with the help of handle. Switch on the cycle, after completion of the cycle visually check for any damage and if found ok move on to first off inspection. Check with appropriate gauges and also check manually for any burr fold and after inspection continue the process. Machine Used: COLUMN DRILL MACHINE Process parameters: PARAMETER

SPECIFICATIONS

CHECK METHOD

Speed

315 rpm

Rotary switch

Feed

0.125 mm/rev

Needle

Cutting medium

Soluble oil

Visual

Tooling details: TOOL NO

DESCRIPTION

RJF 0216

Fixture

MT 0023

In house made garter grooving

TOOL LIFE Per

No of

Edge

Edges

600

2

Total

1200

tool 8mm x 8mm HSS Sq.bar of constant length 47.5 mm to be used

4 Stem centering: Dept of Mechanical engineering, PESCE, Mandya

23

Industrial Training At M/s Rane (Madras) Limited, Mysore.

Fig 4.12 Stem centering of socket handle Locate the socket in the bunk and clamp pneumatically. Switch on the cycle, after completion of the cycle visually check and if found ok move on to first off inspection. Machine Used: DRILLING MACHINE (AURAM ) Process parameters: PARAMETER

SPECIFICATIONS

CHECK METHOD

Speed

450-1750 rpm

Visual

Feed

Auto feed

Timer

Cutting medium

Dry

Visual

Tooling details: TOOL

DESCRIPTION

NO

RJF 0148

TOOL LIFE Per

No of

Edge

Edges

1200

2

Total

Centering fixture 3/16” x7/16” Center Drill

2400

MT2 Taper shank adapter .

5 Stem turning: Dept of Mechanical engineering, PESCE, Mandya

24

Industrial Training At M/s Rane (Madras) Limited, Mysore.

Fig 4.13 Stem turning of socket handle Locate the groove I.D of socket in the plate provided in headstock fixture. Clamp the socket in between the Spindle & Tail stock center. Switch on the cycle, after completion of the cycle check visually and move on to first off inspection and check with appropriate gauges and continue. Machine Used: TAKISAWA Process parameters: PARAMETER

SPECIFICATIONS

CHECK METHOD

Speed

2000-2500 rpm

Visual

Feed

0.2-0.3 mm/rev

Timer

Cutting medium

Coolant

Visual

Tooling details: TOOL NO

DESCRIPTION

PDJNN

TOOL HOLDER

DNMH12

INSERT

TOOL LIFE Per Edge

No of Edges

Total

200

4

800

6 Thread rolling:

Dept of Mechanical engineering, PESCE, Mandya

25

Industrial Training At M/s Rane (Madras) Limited, Mysore.

Fig 4.14 Thread rolling on the socket handle Load the dummy component on the work rest blade, Switch on the cycle. After completion check visually and if found ok move for first off inspection and continue the process with socket. Machine Used: THREAD ROLLING MACHINE (PRAGA) Process parameters: PARAMETER

SPECIFICATIONS

CHECK METHOD

Hydraulic pressure

25-40 kg/cm2

Pr. gage

Dwell Time

25-60 sec

Timer

Cutting Medium

Servo cut 945 oil

Visual

Tooling details: TOOL NO

RZZ 2111

DESCRIPTION

M12x1.25 6g RH Thread

TOOL LIFE Per

No of

Edge

Edges

Total

50000

Rolls for(M12) M14x1.25x90 LH/

50000

RH thread Rolls for (M14)

4.3 Drag link assembly line: 1 Pre assembly:

Dept of Mechanical engineering, PESCE, Mandya

26

Industrial Training At M/s Rane (Madras) Limited, Mysore.

Fig 4.15 Pre assembly of Drag link Press the bottom cup into the socket, apply a thin layer of AP2 INDROL grease on the ball pin head, then Insert ball pin & top cup on the ball pin head .Press the grease smeared ball pin ,top cup into the socket by operating the switch. After completion of the operation check visually and if found ok continue. Machine Used: PNEUMATIC PRESS Process parameters: PARAMETER

SPECIFICATIONS

CHECK METHOD

Pneumatic pr.

4-6 kg/cm2

Visual

2 Roller peening:

Dept of Mechanical engineering, PESCE, Mandya

27

Industrial Training At M/s Rane (Madras) Limited, Mysore.

Laser sensor to ensure Internals.

Pokayoke fixture to detect wrong ballpin.

Fig 4.16 Roller peening machine Assemble spring, spring seat & end plug into the socket, place them in the fixture & Peen it. After completion of the cycle check visually& if found ok move to first off inspection & continue. Machine Used: ROLL PEENING MACHINE Process parameters: PARAMETER

SPECIFICATIONS

CHECK METHOD

Roller gap

1.25±0.1 mm

plate gage

Pneumatic pr.

4-6 kg/cm2

indicator

Dwell time

110-130 sec

indicator

3 Boot grease filling:

Fig 4.17 Boot greasing Set for approximately 5gms AP2 (Yellow colour) & fill uniformly on inside groove of Dept of Mechanical engineering, PESCE, Mandya

28

Industrial Training At M/s Rane (Madras) Limited, Mysore.

the boot by operating the switch. After completion check visually for proper filling of grease inside the groove portion & if found ok continue. Machine Used: GREASE DISPENSING UNIT (CENLUB) Process parameters: PARAMETER

SPECIFICATIONS

CHECK METHOD

Pneumatic pr.

4-6 kg/cm2

Visual

4 Boot assembly:

Fig 4.18 Boot assembly Manually fit the larger dia of the grease filled boot on the back opening of the peeened end through ballpin after completion check visually & if found ok continue. Boot after assembly should be in free condition & not to be in squeezed condition. 5 Boot clip assembly:

Fig 4.19 Boot clip assembly

Dept of Mechanical engineering, PESCE, Mandya

29

Industrial Training At M/s Rane (Madras) Limited, Mysore.

Insert the boot assembled end on the taper cone through the ball pin end. Place the clip on the clip seat & position the taper cone, operate the air valve. After completion of the cycle check visually 100%. Machine Used: BOOT CLIPPING MACHINE Process parameters: PARAMETER

SPECIFICATIONS

CHECK METHOD

Pneumatic pr.

4-6 kg/cm2

Visual

6 90 deg correction and Packing:

Fig 4.20 90deg correction and packing of drag link assembly Insert ø3mm pin into the ball pin hole & turn such a way that the ball pin hole axis is approximately90deg (±15deg ) to the axis of the socket stem center. 1. Apply rust off oil. 2. Fix the protective cap to the ball pin. 3. Place the assembly into the cartoon box (16 Nos. in each box). 4. Check for the presence of batch code.

Dept of Mechanical engineering, PESCE, Mandya

30

Industrial Training At M/s Rane (Madras) Limited, Mysore.

CHAPTER 5 CONCLUSION As a postgraduate student I would like to say that a training program like an industrial training is an excellent opportunity for me to get to the ground level and experience the things that we would have never gained through going straight into a job. I am grateful to my college PESCE and Dept of Mechanical Engineering, for including training like this in the curriculum. The industrial exposure and learning is the best way to get the knowledge about the manufacturing world. It gives clear picture of the organization. The main objective of the industrial training is to provide an opportunity to postgraduates to identify, observe and practice how engineering is applicable in the real industry. It is not only to get experience on technical practices but also to observe management practices and to interact with fellow workers. During my stay at RML, I got hat experience and the feeling of responsibility. It was a great experience. Engineering personnel of the RML are people that have a lot of experience. All of them were willing to help in my training. They have a vast knowledge about the fields they are work with. So it was easy to learn from them. The 2 months training that I received at Rane (Madras) Ltd., was great experience for me not only on technical terms but also in terms of interaction with other workers. I learnt a great deal on applying the knowledge I have gained at the college. Learning something from books and lectures is nothing like having firsthand experience. At Rane I got to apply my knowledge. The company gives the full freedom for the trainee. The trainees are allowed to ask and do anything relevant to the training. Engineers are always very enthusiastic on giving us the best training experience.

Dept of Mechanical engineering, PESCE, Mandya

31

Industrial Training At M/s Rane (Madras) Limited, Mysore.

CHAPTER 6 BIBLIOGRAPHY

Bibliography: 

Information from departments.



RML library.



Company Literature.



Annual reports.



Internet 

www.rane.co.in



http://en.wikipedia.org/wiki/Rane_(Madras)_Ltd

Dept of Mechanical engineering, PESCE, Mandya

32