JCBL FINAL PROJECT REPORT

Page | 1

SIX MONTH’S INDUSTRIAL TRAINING REPORT

ON

“BUS & BUS BODY MANUFACTURING”

JCBL, MOHALI (PUNJAB, INDIA)

Submitted in partial fulfillment of the requirement for the award of degree of

BACHELOR OF TECHNOLOGY

IN

MECHANICAL ENGINEERING

BY

PRABHAKAR TIWARI

(ROLL NO: - 100041127841)

DEPARTMENT OF MECHANICAL

ARYABHATTA GROUP OF INSTITUTE &TECH., BARNALA

MAY, 2014

Page | 2

Acknowledgement

I here acknowledge that the semester of industrial training in the curriculum of B.Tech at ACET,

Punjab Technical University is an appraisal worthy course part in the four years of engineering in

which a student has given a platform to work and commence with a new career where he learns

a lot from the well trained and highly educated people, the managerial environment.

The period of Internship is a period in which one has to take a push from the ground of his

technical understandings of things and have a jump to the industry where he grasp and learn

things because of the responsibilities he has working with.

I express my heartiest gratitude to my Guide Mr. Vishal Kalyan (HOD PED) JCBL for his sagacious

guidance, excellent supervision and valuable advice during the course of the training.

This report of project is the part of my project which I have submitting at Aryabhatta College of

Engineering Technology, Barnala in Punjab Technical University where I have grown to maturity

and the Lecturers and Professors have kindles me with the best knowledge of Engineering and

Innovations.

The Report is submitted for the Evaluation of me as student for the final semester of B.Tech

Mechanical Engineering.

With this acknowledgement I would like to pay a deep hearty gratitude to my Manager at JCBL

and to my professors at college who make me capable of making this project report.

Prabhakar Tiwari

Page | 3

Industrial Training Marks & Attendance Report

Training Marks:-

Attendance Report:-

Page | 4

Table of Contents

1. Summary of the project work…………………………………………………………………….……….… 5

2. Company profile………………………………………………………………………………………..…….…… 6-7

3. Milestones of the JCBL/MSL………………………………………………………………………….……... 8

4. JCBL group manufacturing activities…………………………………………………………….……..… 9

5. Turnover JCBL…………………………………………………………………………………………………….... 10

6. Current capabilities………………………………………………………………………………………….…… 11

7. JCBL network………………………………………………………………………………………………….…….. 12

8. Building lasting relationship- a snapshot of JCBL customers……………………………....... 13

9. State transport undertakings………………………………………………………………………………… 14

10. Bus building process………………………………………………………………………………………….….. 15

11. R&D (Research and Development) & PED (Production Engineering Dept.)……………….. 16

12. Sections and shops in JCBL……………………………………………………………………...…….……… 17

13. Press shop……………………………………………………………………………………………………………… 18

14. Rolling……………………………………………………………………………………………………….……………. 19

15. Other Shop……………………………………………………………………………………………………….……20-25

16. Project………………………………………………………………………………………………….…………………… 26

17. Project-1………………………………………………………………………………………………….……………… 27-31

18. Suggestions on the basis of the time study………………………………….……………………………….. 32

19. Preventive maintenance check list for Rolling Machine…………………………………………….. 33

20. Project-2…………………………………………………………………………………………….…………………… 34-35

21. Project-3………………………………………………………………………………………………….……………… 36-39

22. Project-4………………………………………………………………………………………………….……………… 40-43

23. Bibliography ……………………………………………………………………………………………….……………….44

Page | 5

Summary of the Project work

The training project report comprises of following sections:

- Company Portfolio which in brief tells about company profile, about Manufacturing

activities, about clients,

- Basics of Plant visit which was our 1 week training in the company in which we are

acquainted with the different shops and details of Bus manufacturing.

- Products- JCBL Offers; the various products in brief the JCBL offers to the clients.

- Conceptualization about the various Terms used in the field

- My profile- The Internee which limelight my job, my experience in company and the

various projects I have handled.

Besides the training of handling of Industrial Engineering and the various projects we are

equipped with the knowledge of Microsoft office which is used in making the deliverable

reports and the use of various tools we use during the project work.

In last but not the least I have mentioned in the report the various key skills some of which

develops within me while working under an organization which is greatly managed, reputed

among its competitors and clients and which is rapidly growing and some of which is enkindled

in me automatically while diving in the patents. So as whole the report limelight of growing and

developing industry and highlights the advantage of my decision of taking into the automotive

company especially into JCBL.

Page | 6

Company Profile

JCBL

Built with passion

JCBL- A name synonymous high quality, utmost safety, groundbreaking technology and futuristic

styling. JCBL has to its credit a fine line of Buses, Special Application Vehicles, Election Campaign

Vans, Display Vans, OB Vans, Radar Calibration Vans, Riot Control vehicles, Mobile Homes and

Offices, Life-Saving Ambulances, Cargo Boxes and Power-Packed trailers.

From being incorporated in 1989 as a company that would manufacture high quality Japanese

technology buses and load carriers for Swaraj Mazda, JCBL has today evolved into a highly

successful coach building company.

By diversifying into the manufacturing of several high quality Luxury Coaches, Motor Homes,

Trailers, Special Utility Vehicles and Cargo Boxes, JCBL, has become a name to reckon with in the

automobile industry. So if it’s, trust, reliability and strength built-in a luxurious body that you

are looking for, Just Think, JCBL!

The focus on excellence has driven to set up a state-of-the-art manufacturing plant on the

Chandigarh-Ambala Highway, Spread over a sprawling area of 45,000 sq. meters, the plant has a

manufacturing capacity of 600 mini buses/ambulances, 2400 load carriers, 300 luxury coaches,

1500 mini buses and 5000 cargo boxes per annum.

As a technology led company, each of state-of-the-art manufacturing system is carefully

engineered to ensure optimum and hassle-free performance of the final product.

JCBL, having constant endeavor to produce world class products is backed by state-of-art

infrastructural facilities. The press shop is equipped with a wide range of specially designed

multistage profile rolling machines, a hydraulic press of 500 ton capacity, press brakes, shearing

machines, and power presses of varying capacities and customized press tools for all formed

components.

The body shop, on the other hand, is equipped with Mig, Tig, spot welders, huge welding

fixtures and gauging equipment for all structure assemblies.

Two sophisticated paint lines consisting of 12 tank pre-treatment lines, pressurized and dust-

free paint booths and baking ovens ensure that all the structural components undergo a

superior pre-treatment primer coating and baking process.

Page | 7

While the latest vacuum forming machines and fiberglass components are responsible of the

superbly finished internal furnishings, a well-equipped tool room manufactures new press tools

and undertakes the calibration and repair of tooling to ensure the production of high quality

components.

World class automotive research and development facilities is a key factor that contribute to the

development of highly innovative technical marvels that has helped won trust and applaud of

their discerning customers.

JCBL limited, the largest bus body builder in the country, providing world class mobility solution

in adherence to stringent quality standards like ISO 9001& TS 16949 by TUV. JCBL annually rolls

out 5000 buses/luxury coached and is one of the leading manufacturers of cargo boxes in the

country. The new approach of JCBL is with innovative & advance technology features in

upcoming model “CERITA”. CERITA has revolutionized the integral coach market with launch of

its next generation buses. Partnering with the best King Long (China) for chassis, Cummins for

engines & best aggregate suppliers around the globe. CERTIA offers a wide range of intercity &

intercity & intercity buses with option of low floor & ultra-low floor models with CNG/Diesel

engines. Present capacity is set to cross 200 coaches in a year. JCBL is having three main units

for its production requirement.

PLANT-I

In this plant, the body is installed on the chassis. This is the biggest unit consisting whole

features needed to make a luxury or semi luxury buses. This unit manufactures the different

type of body frame for different transportation vehicle like school buses, luxury & semi luxury

buses, trucks, ambulances etc.

PLANT-II

It is also a biggest unit of JCBL group which includes body formation, installation & testing of

new buses chassis developed here. The project “CERITA” is joint venture with King Long

Company of China also developed here. And other project is- SML, ASHOK LELAND, EICHER,

TATA, and PRIVATE. BUSES & Bus body production. In plant-2.

Page | 8

Milestones of the JCBL/MSL 2014: Delhi Polish & Army Bullet Proof Vehicles Mfg.

2014: J&K Bullet Proof Bus Mfg.

2014: PRTC CNG Bus Mfg.

2014: RSRTC Bus Mfg.

2014: EICHER tender for bus body Mfg.

2013: ASHOK LELAND tender for bus body Mfg.

2011: TATA Approved MSL seats for their Buses, Awarded ARAI approval

2010: Enlistment of MSL as approved vendor to GETS, USA for supply of FRP parts for their

locomotives & Formation of MGL in Joint venture with Happich (Germany) and Ellamp (Italy)

2009: MSL India joint venture’s with Group Happich Ellamp of Italy.

2008: 50% of MSL production sold to customers other than JCBL

2007: Export of Dash pads to USA

2006: Export of Suspension Components and PU Cushions

2005: TS: 16949 Certification, FRP Components to RCF

2004: First Supply to JCBL for Window Frames

2003: ISO: 9001 Certification

2002: MSL Incorporated, First Deluxe Seat Set installed in SML BUS

Page | 9

JCBL Group Manufacturing Activities

Page | 10

Turnover – JCBL Group

Turnover in Cores

JCBL Plant-II

Page | 11

Current Capability

School Buses Luxury Buses Mobile Homes

Bullet Proof Vehicles Refrigerated Vans Skip Loaders

Tip Trailers

Tippers Ambulances

Page | 12

JCBL Network

Page | 13

Building Lasting Relationships — A Snapshot of our Customers

Page | 14

State Transport Undertakings

Page | 15

Bus Building Process

Page | 16

MY TEAM IS IN JCBL DURIND SIX MONTHS INDUSTRIAL TRANNING

IN JCBL

R&D (RESEARCH AND DEVELOPMENT)

&

TEAM PED (PRODUCTION ENGINEERING DEPARTMENT)

R&D PED PRODUCTION

Process Planning

Tool Engineering

Equipments Planning

Work & Time Study (I.E.)

Page | 17

Sections/Shops in the JCBL The main sections/shops in the JCBL are:

1. Component shop

2. Tool room

3. Tube section

4. Press shop

5. Structure shop

6. Body shop

7. Research and Development(R&D)

8. Production Engineering Department(PED)

9. Paint shop

10. Final assembly

11. Pre Dispatch Inspection(PDI)

12. Quality control

13. PPC

14. Purchase Department

15. Information Technology

16. Sales Department

17. Human Resource Department (HR-Department) or Personnel Department

18. Maintenance Department

COMPRISES

� Well-equipped Tool Room

� Press shop consisting of Hydraulics Presses, CNC Plasma Cutting, CNC Tube Bending

� Shot Blasting, Powder Coating machines and Painting Facilities

� PU Machine for soft and rigid PU

� Vacuum Forming and Resin Transfer Molding Machine

� Excellent Testing & Measuring Facilities for seats

� In-house manufacture of all critical components and sub-assemblies

ADVANCED DESIGNING TOOLS

� Established in 1977 as part of JCBL’s backward integration strategy

� Engaged in manufacture of durable coach components that live up to the highest standards

of performance

� Seeks to inspire trust and become the one-stop solution for all the component needs of the

market MSL has evolved into a highly successful company in vehicle components.

Page | 18

Press Shop Press shop contains different machines and like machine presses, nibbling machines etc. where

different types of material are formed in to different sections which are used for making the

structure of the bus.

DIFFERENT TYPES OF MACHINES OF DIFFERENT CAPACITY WHICH ARE USED IN

PRESS SHOP ARE:-

POWER PRESS

Power presses are of following kinds:-

• Mechanical presses

• Hydraulic presses

• Sheering presses

• Break presses

• Bending & punching presses

• NC machines

ROLLING MACHINE

There are two types of rolling machines:-

• Section rolling

• Panel rolling

Rolling

• The process of plastically deforming metal by passing it between the rolls is known as

rolling.

• The work is subjected to high compressive stresses from squeezing action of rolls.

• The frictional force between metal and rolls is responsible for drawing the metal into the

rolls.

RING ROLLS

• Ring rolls are used for tube rolling and ring rolling.

• Ring rolls are made of spheriodized graphite bainitic and parasitic matrix or alloy cast

steel base.

Cantilever mill roll Tube mill roll Universal roll

Page | 19

Rolling

ROLLING MACHINE

SPECIFICATIONS

Material : CR, HR

Max strip width : 400

Speed : 10 Meters per Minute Max.

Max Length of Section : 4000mm

Max material thickness : 1.2mm to 2mm

Required Electric Supply : 410 Volts, 3 Faze 50 c/s

Page | 20

Other Shops

STRUCTRE SECTION

Structure is main load bearing part of the bus body. Various members being used in structure

are hot rolled formed on 20-stage roll forming machine. The total bus structure is made with

floor, side, roof and rear, which is independently pretreated, primer painted & then backed

before assembly. All structure is done with MIG (Metal Inert Gas) welding and electric arc

welding. But the MIG welding is better weld strength than the arc welding.

MODELS OF SWARAJ MAZDA

� XL,XL wish, XL 50%, XL double door

� 50L, 50L wish, 50L double door

� 50A, 48A, 48D, 26A, 26D, 26D wish

� 26SD, 26SD wish, 40D

Some other models of the buses like Ambulance, sartaj as per order.

STRUCTURE ASSEMBLY

In this stage after completion of different structures these are assembled to form a shell. Cross

bearers are mounted on the assembly fixture. Both right and left hand side structure are fixed

with the cross bearers with the help of MIG welding and electric arc welding. Roof is joined on

the top of the side structure with the help of the welding. After this, the assembly is checked for

the alignment. If the alignment is right then it is ok otherwise it is aligned properly by various

methods. After this the floor is made on the cross bearers by using the gangway z-sections, u-

sections and l-sections. After the completion of the floor driver cabin, front structure, rear

structure is attached with the assembly. After this partition is made between driver cabin and

passenger cabin with the help of tubes and various other sections. In the end whole shell is

painted with the black primer.

SIDE PAENLING & ROOF PANELING

In this stage roof paneling has done with the help of GI sheets which are rolled previously.

These sheets are joined with the MIG welding. On the sides stretch paneling has done with GI

sheets. In the inner sides of the sheets are scratched with the help of abrasive wheel. On this

side sealant is applied which is a kind of adhesive. Then this sheet is clamped on the side

structure. Application of sealant avoids the drumming action. Sides of the sheet are welded with

the help of MIG welding. On the lower side of the structure covered with the dickey lower

panels.

INTERNAL PANELING

In this work station various internal parts are covered with the GI sheets. The doors are

assembled with the main body. These brought from the component shop. All the internal parts

are covered the GI sheets. After the completion of this stage, a outlook of the bus is visible.

Page | 21

Other Shops

CARGO SHOP

“CARGO” stands for the load carrying vehicle or load carriage. In JCBL the load body of the cargo

is manufactured. The body of the cargo vehicle is prepared in different parts that are sides (left

& right), floor, front, and rear door. The different models of the cargo are:-

� DSD(Drop Side Deck)

� FSD(Fixed Side Deck)

� HSD(High Side Deck)

� SHSD(Semi High Side Deck)

� PV(Police Van) cargo

All above cargos are manufactured in different sizes as per requirement (10, 12.25, 14, 17, 21

feet in length).

COMPONENT SHOP

Major component manufactured are-

1. Rear dickey

2. Side emergency door

3. Emergency door

4. Foot step

5. Hat rack

6. Mudguard cover and foot step

7. Passenger door

8. Lower panel

9. D/Door

10. Foot step

11. Rear back

12. P/Door aperture

13. Battery box stand

14. Fire cylinder

15. Diesel tank

16. Lock

Page | 22

Other Shops

PAINT SHOP

In Paint shop, following steps are to be taken for the paint operation.

� Cleaning with thinner.

� Sanding of outer paneling with mammary paper for giving lining & remove dust and to

increase the striking power of primer.

� Air is used to remove dust(by compressed air)

� Thinner is used for cleaning again.

� H-primer is applied.

� Rectification.

After rectification if there is any dent, welding section etc. when these sections are repaired &

then again H-primer & gray primer is applied the section having dents putty is applied for better

surface. Sanding is done by emery paper of 220N (for finishing). After this sealant is applied to

fill the gaps like a rain gutter then banking is done at 140 degree for 30 min then, ‘rectification’

is done.

Paint is done with the help of spray gun. Shell is prepared for final assembly.

Sr No. Operation Process flow chart

1 10 Hang cargo on trolley

2 20 Water removal from joints by air pressure

3 30 Movement to oven

4 40 Baking for drying water

5 50 Movement from baking oven to booth

6 60 Allow to cool upto room temperature

7 70 Spray prepare zimpholite black primer

8 80 Flash off zone (5 to 7 min)

9 90 Spray prepare zimpholite black primer

10 100 Flash off zone (5 to 7 min)

11 110 Movement from paint shop to baking oven

12 120 Primer baking

13 130 Movement from baking oven

14 140 Allow to cool upto room temp.

15 150 Inspection

16 160 Make set model wise

Page | 23

Other Shops

PDI (Pre Dispatch Inspection) SECTION

In this section the section of buses, which are prepared in final assembly are inspected. Firstly to

check the internal leakage of the bus, shower testing is done. In this test bus is placed between

the no. of showers and water supply is on there is one person inside the bus when the water

falls on the windows roofs front & back of the bus then checks the leakage when the water falls

on the bus with the pressure due to which if there in any hole or any gap on the door around

the windows roof then they are repaired.

If there is no leakage then buses dispatched for further inspection one person comes from the

MAZDA7& he checks the bus according to the report which is prepared by JCBL there are certain

parameters like denting, wrinkling, painting, tightening of screws, door, windows locks,

passenger door fitting, seat fitting, inner fitments, under body etc. the person of MAZDA checks

these all the parameters, if the buses OK then bus is dispatched to SWARAJ MAZDA.

TOOL ROOM

Tool room is very important section for the production department. In this section all the dies

are repaired according to the change in the design. New dies are also manufactured in this

department. This operation of manufacturing and repairing is done on the different machines

which are available in the tool room are discussed below:

Machine name No. of machines

Lathe (three jaws) 3

Lathe (four jaws) 2

Planer 1

Milling Machine 3

Shaper 2

Surface Grinder 2

Drilling Machine 2

Page | 24

Other Shops

MAINTENANCE SECTION

Every industry has maintenance section to maintain the machinery because every machine

requires maintenance. A machine runs properly for a long time when it satisfied all the

conditions which it requires maximum output from the machine, but it is possible only when it is

running in proper order and it is also possible when it is checked time to time so it depends on

the maintenance department. To check the machine whether it run in proper order or not it

depends on the maintenance section.

Some time there is breakdown in machine, which may due to mechanical fault or by some other

mean. All these faults are removed by the maintenance department in the industry. In JCBL the

maintenance department has a different type of compressors, which are used to compress the

air, which is further supplied to the different section of the industry. There are different

compressors like:-

� Screw compressors

� Reciprocating compressors

There is also a system called thermopac (a kind of boiler) it is used to heat the water or acids

used in the pretreatment processors.

PRODUCTION ENGINEERING DEPARTMENT (PED)

Production engineering department (PED) in JCBL, the PEDIS also improved & increases in

Productivity & it is design the fixture and it is arranged the manufacturing line and it’s working is

also related upon the Lean Manufacturing Process. PED is increase the production of industry

(JCBL) with the help of our team member. And various working is done by PED is given

bellow:-

Working of PED:-

1.New Release Drawing

2.Add And Delete List

3.Engineering Change Note (ECN)

4.Bill Of Material (BOM)

5.Fixture Design

6.Modification In Bus Designing

7.Productivity Improvement

8.Time Study

9.Productivity increase

10.Plant Layout

11.Man power optimization

12.Process Study

13.Why-Why-Why Analysis

Page | 25

Other Shops

Research and Development (R&D)

R&D department is the main department of JCBL for designing related to bus body

manufacturing. The R&D group is developed the bus manufacturing & Analysis in JCBL and it is

also improved the design of bus body & its Component with the help of team work.

The software is used for designing in R&D (JCBL):-

1.AUTO-CAD

2.CATIA

3.HYPERWORKS

4.NX

5.MAYA

AUTO-CAD: -

AUTO CAD used in JCBL for 2D & 3D designing of bus structure, bus body parts, and its

component etc.

HYPERWORKS: -

HYPERWORKS used in JCBL for finite element analysis of Linear and non Linear.

CATIA: -

CATIA used in JCBL for 3D form designing of bus and its parts.

NX: -

NX used in JCBL for designing of bus body in to 3D form.

MAYA: -

MAYA used in JCBL for Animation of bus and bus body and other things.

Page | 26

Project:-

Final project report during 6th month’s industrial training in JCBL.

My Project in JCBL during 6th

month’s Industrial Training:-

1.TIME STUDY

2.MACHINE STUDY

3.PROCESS STUDY

4.WHY-WHY-WHY ANALYSIS

5.BUS BODY MANUFACTURING STUDY OF JCBL

6.BILL OF MATERIAL

Page | 27

Project- 1

Name of the project:-

Product development and Time study of the ‘roll forming’ of the various components and its

production.

Time study

Time study is defined as a work measurement technique for recording the times and rates of

the working for the elements of a specified job carried out under specified conditions and for

analyzing the data so as to obtain the time necessary for carrying out the job at a defined level

of the performance.

The instruments required for the time study are

� Stop watch

� Time study forms

The basic steps in the time study are

1. Obtaining & recording all the information about the job, operator and the surrounding

conditions.

2. Record the description of the method and break operations into elements.

3. Examining the breakdown to ensure the most effective method is used.

4. Note down the time consumed in each step with the help of stop-watch.

5. At the same time, assess the effective speed of working operator corresponding to the

steady rating.

6. Find the basic time from the observed time.

7. Give the required allowances.

Roll forming

Roll forming is the process used to change the shape of coiled stock into desired contours

without altering the cross section area. The process utilizes a series of rollers to gradually

change the shape of the material as i.e. passes through them.

Now on rolling machine, the various components having different cross sections

are produced which are listed below

Regular Hat Top Brim Special Sill Cross

U-section LC-Hat Regular Sill Cross

Bottom Angle Special Hat Side Channel

Floor Sheet Side Sheet Floor Channel

Rain Gutter Member Outer Member Inner

Page | 28

Project- 1

Time study

Following are the steps which are used to produce roll forming component

1. Set/Arrange the various rollers on the rolling machine to get the desired shape and

section.

2. Fix the die of proper section on the press to cut the metal piece of any length as per

required.

Above steps are to be taken when the new (changed) section is to be produced.

1. Hold the coil of metal sheet on coil drum and clamped it.

2. Allow the metal of coil starts flowing through the guide rollers and starts the rolling

machine.

3. As the metal passes through the various sets of rollers, it gets the desired shape and

sectioning.

4. After getting the desired shape, the metal is cut by an attachment of press to get

required length.

5. At last, the prepared metal piece is lifted and is kept into the rack manually.

(1) ROLLING MACHINE-1

Machine No : JCPM-12

Operator Name : Sukhwinder/Kamal

Component to be manufactured : Member Outer

18

4

44

18 18

32

Dimension of Coil used : 123*2

123 mm- Width

2 mm- Thickness

Material : HR (Hot Rolled)

Cutting Die used : CPT 005A

Page | 29

Project- 1

Observations

No. of workers required 2

Length of piece which is to be cut 2025 mm and 2225 mm

Machine cleaning 00:15:00

Roller setting time (A) 00:30:00

Coil loading time (B) 00:20:00

Die and punch setting (C) 00:10:00

First piece setting (D) 00:25:00

First piece observation (x) 00:00:24

Second piece observation (y) 00:00:25

Third piece observation (z) 00:00:23

Setup Time = (A+B+C+D)

Mean Time = (x+y+z)/3

By calculations, we get

Avg. production per hour : 120 pieces

Production time observed : 25 seconds

Normal time = observed time x observed rating

Standard time = normal time + allowances

Let observed rating is = 95% = 0.95

Let allowances (relaxation, contingency) = 8%

Page | 30

Project- 1


Machine No : JCPM-27

Operator Name : Sajay/ Kumar Pal

Component to be manufactured : Floor channel

37 37

75

Dimension of Coil used : 137*2.80

137 mm- Width

2.80 mm- Thickness

Material : HR (Hot Rolled)

Cutting Die used : BPT 106

Observations


Length of piece which is to be cut 5900mm


Roller setting time (A) 00:35:00

Coil loading time (B) 00:08:00

Die and punch setting (C) 00:10:00

First piece setting (D) 00:30:00




Setup Time = (A+B+C)






Standard time = normal time + allowances



Page | 31

Project- 1


Machine No : JCPM-11A

Operator Name : Seo Ram

Component to be manufactured : Floor sheets

Dimension of Coil used : 720*1.55

720 mm- Width

1.55 mm- Thickness

Material : CR (Cold Rolled)

Observations


Length of piece which is to be cut 5162mm


Coil loading time (A) 00:20:00

First piece setting (B) 00:07:00




Setup Time = (A+B)






Standard time =normal time + allowances



Page | 32

Suggestions on the basis of the Time Study

• Steel yard should be near to the rolling area to get the material as soon as possible, which

would save the time.

• Use of conveyor system to lift and transportation of the rolled material to the racks would

greatly reduce in time.

• ‘Oil pickling’ process should be used for the material to release the stresses; to increase

the flexibility of the material so that the speed of rolling increases and hence, it may save

the time.

• Automation of the machine can save the time.

• Parting die to be implemented instead of punching dies in power press attached to the

rolling machine to reduce scrap.

• Redesigning of proper space between rolling and feeder to avoid waviness in items

produced.

• There are lots of problems of vibrations in press machine during cutting of product formed

due to which calibration get disturbed and accuracy of cutting is reduced. Thus machines

should be made free from vibration by properly bolting the foundation and base of the

machine and by placing some proper type of isolator.

• The left out coil should be measured before passing it through the rollers, so that it can be

used at some other place.

If we concentrated on these points, then we can save the time and our average production will

rises.

Page | 33

Preventive Maintenance check list for Rolling Machine

1. Check the intake current of motor and check the function of limit switch (W).

2. Check the lubricating system of machine and the power press (W).

3. Check the panel of the machine. Tighten all the loose connection; repair and replace all

the spare kits of starter motor (M).

4. Check the terminal of motor. Tight them and grease the bearing of the motor (M).

5. Check the status of the coupling (M).

6. Check the gear box and grease the gears (M).

7. Check the drum gear (M).

8. Check the loading mechanism of the machine (M).

9. Check the coil winding drum (M).

10. Check the foundation of the machine and tighten the bolts (M).

11. Check the power press of the machine (M).

12. Check the guide rings of the pillar. Tight all the bolts (M).

13. Check all the bushes and lubricate them (Q).

14. Check the working of lib oil pump, clean the pump. Overhauling of the pump (HY).

15. Check the condition of the gears of the machine, if found torn out replace them (Y).

16. Check the bearing of the gear shaft and gears, also check the speed changing and

reduction gear boxes, and overhaul them(Y).

17. Check the bushes and moving mechanism of power press, replace the bushes if required

(Y).

18. Check any leakage in the main tank, remove if present. Replace the main oil filter if

required otherwise dehydrate it (Y).

W- Weekly M- Monthly Q- Quarterly

HY- Half Yearly Y- Yearly

DAILY MAINTENCE AND OPERATION CHECK LIST

SR NO. CHECK POINT ACCEPTANCE CRITERIA

1 Cleaning of machine Should clean before start &

after production

2 Check the lubrication oil level in FRL Upto level

3 Check the hydraulic oil level if any Upto level

4 Drain moisture from filter Avoid storage

5 Check the air/hydraulic pressure if any Set in range

6 Check the chemical/lub/oil/water/comp. air leakage if

any No leakage

7 Set machine parameters for safe working at the

machine Avoid accidents

8 Focus on cleaning, lub, inspection & tightening of

machine tools parts if any Check before start

9 Lubricating all moving parts/slides if any Smooth moves

10 Observe any abnormal sound, forced detonation if

any No abnormal

Page | 34

Project- 2

Name of the project:-

Machine Study:- Used of the ‘Machine’ in JCBL for Production.

PRESS: - The press is a sheet metal forming machine tools designed to shape or cut the metal by applying

mechanical force or pressure.

DETAILS OR CONSTRUCTION OF PRESS:-

It is a hand operated press. It has a fly wheel, with operating handle. The screw of the press

operates in a nut, fixed in the vertical columns of press body. A ram is attached to the lower of

the screw. When the screw is operated by the handle; the ram moves in a vertical direction in the

slides on the press column face. A punch is fixed in the ram. A die is fixed on a bolster plate

which is mounted on the table.

SHEARING:-

Shearing is a sheet metal operation without formation of chips or the use of burning or melting.

BENDING:-

Bending is defined as the plastic deformation about a linear axis little or no change in the surface

area.

LATHE MACHINE:-

The lathe machine is one of the earliest machine tool and one of the most versatile and widely

used as machine tool for performing the machining operation.

MILLING MACHINE:-

Milling is a process of metal removal/cutting by means of a multi-teeth(point) rotating tool called

milling cutter. The form of each tooth of cutter is same as that of the single point cutting tool,

used in the lathe machine.

DRILLING MACHINE:-

Drilling machine is a machine tool designed for drilling round holes in metallic and nonmetallic

materials. The cutting tool is a multi-point cutting, known as drill or drill bit.

Page | 35

Project- 2

SHAPER MACHINE:-

The shaper also called shaping machine, is a reciprocating type of machine tool in which the ram

moves the cutting tool backward and forward in a straight line to generate the flat surface. The

flat surface may be horizontal, inclined or vertical.

PLANER:-

The planer (also called planning machine) is used to produce plan and flat surfaces by a single

point cutting tool when the work piece is very large in size. It is similar to shape but its size is

very large so used for producing flat surfaces on much large work then a shaper. The major

difference between shaper and planer is that in a planer. The tool remains stationary and the work

reciprocates whereas in the shaper, the work remains stationary and the reciprocates.

SURFACE GRINDER :-

It is a method of grinding horizontal flat surface. The wheel spindle can be horizontal or

vertical. Grinding is a process of removing material by the abrasive action of a revolving wheel

(called as grinding wheel) form the surface of a work piece, in order to bring it to the required

shape and size. It consists of sharp crystal, called Abrasives, and held together by a binding

material or bond. The wheel may be a single piece or solid type or may be composed of several

segments of abrasive blocks joined together. In most cases, it is a Finishing operation and a very

small amount of material is removed from the surface during the operation.

Page | 36

Project- 3

Name of the project: -

Process Study: - Product development and Process study of the ‘Final Assembly’ of the

various components.

Process Study-1

Page | 37

Project- 3

Process Study-2

Page | 38

Project- 3

Process Study-3

Page | 39

Project- 3

Process Study-4

Page | 40

Project- 4

Name of the project: -

Why-Why (5) Analysis: - Product development and Why-Why Analysis of the wrong Process. And with the help of Why-

Why Analysis we improve the Production.

5-Why- Analysis-1

Page | 41

Project- 4

5-Why- Analysis-2

Page | 42

Project- 4

5-Why- Analysis-3

Page | 43

Project- 4

5-Why- Analysis-4

Page | 44

Bibliography

� www.jcbl.com

� www.google.com

� Daily Diary

JCBL FINAL PROJECT REPORT

Documents