Jushin Training Synopsis

JPM GROUP

JAY-USHIN LTD

SUMMER TRAINING SYNOPSIS

BY

MAYANK ASHOK BAFNA

MECHANICAL ENGINEERING

SURESH GYAN VIHAR UNIVERSITY

JAIPUR

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A TRAINING SYNOPSIS

INJECTION MOULDING

Submitted in partial fulfillment for the award of the degree of

BACHELOR OF TECHNOLOGY

In

MECHANICAL ENGINEERING

By

MAYANK ASHOK BAFNA

(ME10401206496)

SURESH GYAN VIHAR UNIVERSITY

MECHANICAL DEPARTMENT

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CHAPTER-1

TRAINING SUMMARY

The Training period was from 1st June 2015-30th June 2015.It was held at JPM Group Jay-

Ushin ltd, Gurgaon.I was admitted to manufacturing plant in injection moulding department,

where OEM products were produced first at raw condition.My mentor were Mr. Devesh

Sharma, Senior Supervisor at Jay-Ushin ltd.for first 15 days I observed various products being

manufactured at the plant and the types of materials and machines used for it.Then I was shifted

to Section-2 of Injection Molding department, where vertical Injection moulding Machines were

used. My Training Project was on Injection Moulding, Defects and Use. I was introduced to

various inspection technologies to detect defects in moulding and their prevention. I was also

introduced to the assembly line where Heater panel Assembly and Hazardous Switch assembly

takes place. I was also introduced to various OEM products. There were 92 products to produce

in the plant. There was also a tool room where finishing or maintenance of small moulds were

placed. Each day new Dies were used for various products and were placed by a overhanging

crane using remote control. I also learnt various scales and measures prescribed by automobile

companies for production. During the training span of 30 days I went familiar to all pros and

cons of an OEM Industry and the manufacturing plant where I was placed.

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CHAPTER-2

COMPANY INTRODUCTION

JPM Group is a major entity on the corporate scene having diversified business interests in automotive

electrical and body parts, alternative fuels, energy, sponge iron, etc. The group is growing at a rapid pace

and is an industry leader in most parts manufactured by the group. Quality is the essence, and JPM Group,

have always stressed on the Customer Satisfaction. Consequently in this run for quality, quantity has

always pursued us. Group has ambitious plans to consolidate its position in India and abroad.

Jay-Ushin Ltd. a JPM Group company was incorporated as a Joint Venture company with U-Shin Ltd,

Japan for manufacture of auto electrical, mechanical & electronic components for four wheelers in 1986.

It is a leading OEM manufacturer of automotive assemblies in India. Its products include lock sets,

latches, switches & body parts. The company is a major OE supplier  to almost all makers of four wheeler

as well as two wheelers in India includes Maruti Suzuki Limited, Hyundai Motors India Ltd., General

Motors, Honda Siel, Honda Motor Cycle & Scooters Division, Mahindra & Mahindra and Tata Motors

Ltd..

U-Shin Ltd. engages in the design, development, manufacture, sale, and export of various system devices

and control machines for automotive, industrial machinery, and home security units. It also offers

mechanical, electrical systems, and components for automotive, industrial machinery, and home security

unit. The company operates in three divisions: Automotive Parts, Industrial Equipments, and Home

Security Unit. The Automotive Parts division offers steering lock unit, lock sets, keyless entry, door

latches, heater control panels, door handles, switches, and sensors. The Industrial Equipments division

provides equipments for agricultural/constructive/industrial machines, equipments for telecommunication,

meter gauge for medical use, harness, cable wire, lump, operator's seat, electric fuel pump, electric

measurement, and communication device. The Home Security Unit division offers security system for

home, hotel, and office buildings; touch keys; handle sets; and electronic locks. The company, formerly

known as YUHSHIN SEIKI KOGYO CO., LTD., was founded in 1926 and is headquartered in Tokyo,

Japan.

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CHAPTER-3

ORGANISATION AND EMPLOYEES

MANAGEMENT STRUCTURE

J.P. Minda - Chairman

Ashwani Minda - Managing Director

Anil Minda - Technical Director

Shiv Raj Singh - Director

Ashok Panjwani - Director

Yukichi Harada - Director

Virendra kumar - Director

CHAIRMAN

MANAGINGDIRECTOR

JAY USHIN LTD

JNS INSTRUMENT

S LTDINSTRUMENT

CLUSTERSSPEEDOMET

ERSFUEL UNITS

SPEED SENSORS

JPM TOOLS LTD

TECHNICALDIRECTOR

ANU INDUSTRIES LTD

IGNITION COILS & IGNITION WIRE SETSTARTER, WINKER,A/C FLASHER

WASHER MOTORS & RESERVOIRSRELAY ASSEMBLY, CDI, ACTUATORS

NOISE SUPPRESSOR CAPCENTRE DOOR LOCKING

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EQUITY SHARE

Minda familyU-shinpublic

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CHAPTER-4

PRODUT RANGE

JAY-USHIN PRODUCT RANGE

Lock set Scooter

Activa

Dio

Eterno

Aviator

Pleasure

Lock set Motor cycle

Unicorn

Shine

Stunner

Splendor

Heat

Zeus

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Switches Scooter

Active

Dio

Beat

Lead

Eterno

Aviator

Pleasure

Switches motor cycle

Unicorn

Shine

Stunner

Heat

Zeus

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Lock sets, Switches & Door latch-4 wheelers & 2 wheelers

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Power window switch

Mirror switch

Head lamp leveling switch

A/C Blower switch

Combination switch

HVAC Panel

CHAPTER-5

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CUSTOMERS

TWO WHEELERS CUSTOMER

FOUR WHEELERS CUSTOMER

CHAPTER-6

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ROLE DURING INDUSTRY TRAINING

As an Intern I had two major roles in my industry training:

Trainee- As a trainee I was required to learn and understand all the pros and cons of indutry and

its manufacturing unit.I was admitted to manufacturing department where I learnt about Injection

Moulding Machine. I also learned

To operate moulding machine

To handle human resource at industry and how to manage the labour

I learnt about the Dies used for Moulding

various materials used for Moulding

Precautions to be taken while operating in a industry

How the machine and management works

Total Productive Management

Junior Supervisor- The role is traditionally a difficult one. You must fulfill various

responsibilities to your employees, work group and organization. You also are responsible for

ensuring the work is carried out in such a way that no one's security, safety or health is

jeopardized. We used to help the labor to control the machine and program the machine for

moulding, we were also asked to watch the performance of the machine and determine OEE

(overall effective efficiency).If any maintenance proplem occurred during moulding, we had to

contact the senior supervisor or our mentor

CHAPTER-7

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PRACTICAL TRAINING

My Training was held at manufacturing unit which was a injection moulding department where

OEM Products were maufactured.There were two sections in the plant one was for horizontal

injection moulding and the other was for vertical injection moulding machine.

While the vertical machine was light in weight rating from 100-150 tonnes and were operated to

produce graded plastic product.

Horizontal machine was heavy upto 250 tonnes and were operated for hard plastic

products.Moulding machine were mainly Single Moulding and Multi moulding machine which

were operated manually as well as automatically. During my training period some products

which I inspected and noticed were:

Heater Control Panels: These are control panel base in which the indicator,knobs and Wires are

after assembled.

Indicators: These are produced as four pice per press. These are natural in colour and usually

moulded automatically as defects are negligible according to industrial measures.

Pinions: These are white in colour produced to fit knobs on heater panel.

Some other products were Knobs, Switches, Lock Assembler , Automatic Buzz System etc.

Major Defects that were observed during the production of these products were:

Short shot-Caused due to generation of gas.

Color Streaks- caused due to thermal instability of colouring agent.

Weld Lines- it is a ‘V-shape’ defect formed during incomplete merging of

two separate parts.

Flash- formed due to increase in temperature during moulding.

Stringiness- caused due to improrer surface of mould.

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Sink marks- hollow marks caused at small and delecate moulds

Silver Streaks- caused due to insufficient drying or degradation.

After three time inspection and rejection of defective pieces ,each package of products are

transported to the next line for assembling.

TOTAL PRODUCTIVE MAINTENANCE

TPM descends from Japan and came into existence in the seventies. After Dr W Edward Deming

made an impact in Japan through his teaching of quality, Japanese organization felt a need for

autonomous maintenance and small group activities to support the quality movement. Today

thousands of organizations all over the world are implementing TPM and about 100

organisations are now doing it in India.

Total productive maintenance (TPM) is a proven strategy for medium to large industries to get

superior business results and develop people skills to take on future business Challenges. Unlike

ISO certification process, in TPM, focus is on maintaining the equipment and process in perfect

condition- to get best quality products and involve all employees in Collectively carrying out loss

elimination, using analytical problem solving tools. The fundamental belief is that if the

equipment is maintained well and setting is done by a conscious, skilled operator, once can get

the best quality product. The whole concept of TPM is built around this belief and hence the

name total productive maintenance. However, this concept can be applied to places other than

plant and equipment and instead we could name Total productive Management rather than just

maintenance

Some of the Priciples applied in the Industry were:

1. KAIZEN RULE-A Japanese term used in the business sense and applied to the workplace,

kaizen refers to activities that continually improve all functions and involve all employees from

the CEO to the assembly line workers. It also applies to processes, such as purchasing

and logistics, which cross organizational boundaries into supply chain

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By improving standardized activities and processes, kaizen aims to eliminate waste Kaizen was

first implemented in several Japanese businesses after the Second World War, influenced in part

by American business and quality management teachers who visited the country. It has since

spread throughout the world and is now being implemented in environments outside of business

and productivity.

2. 5 S Rule

There are five 5S phases: They can be translated from the Japanese as "sort", "straighten",

"shine", "standardize", and "sustain". Other translations are possible.

Seiton Systematic Arrangement)

Can also be translated as "set in order", "straighten" or "streamline"

Arrange all necessary items so they can be easily selected for use

Seiri (Sort)

Remove unnecessary items and dispose them properly

Make work easier by eliminating obstacles

Seisou (Shine)

Can also be translated as "sweep", "sanitize", "shine", or "scrub"

Clean your workplace completely

Seiketsu (Standardize)

Standardize the best practices in the work area.

Maintain high standards of housekeeping and workplace organization at all times.

Shitsuke (Sustain)

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To keep in working order

Also translates as "do without being told" (though this doesn't begin with S).

The above were the major information I came to learn during my training, while I also witnessed

the whole inspection process, setup and installation of Rotating Injection Moulding

Machine.Some minor rules like 3 M Rule (Muda, Muri,Mura) and 3 G Rule (Genchi,Genbutsu,Genjitsu) were also observed.

Wage System:

One of the most important part I came through was the wages incentive system.

The Company’s wages system was based on hour basis i.e the labour force was provided incentive on the basis of production time.These also helped in maintaining the production of the company and helped to avoid any contradiction regarding wages. And if overtiming was done then extra incentive were paid.

Each Machine had two engaged workers , one for moulding other for inspection. After inspection the lot was inspected by a supervisor.

Summarising the Industrial Training experience , it helped me a lot to learn new and basic concepts in manufacturing.

CHAPTER-8

IMPACT OF ENGINEERING ON MANUFACTURING PROCESS

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The impact of engineering is also believed to have important implications for the level of

’optimal’ scales. Contrary to the previous ’mass production’ technological paradigm where

increasing scales were crucial to cost reductions, engineering is said to provide "opportunities to

switch production between products and so reverse the tendency towards greater scale". A

similar view is put forward by Acsetal (1990), who argue that flexible production means that the

"optimal size of plant and firm declines and entry occurs by small-scale-flexible producers".

This ’de-scaling’ view is shared by a large proportion of the economics, management and

engineering literature that focuses on the impact of recent technical change on scale in

manufacturing production.

The main argument will be that, although engineering may have a significant scale reduction

effect at product level, it is not clear they would have a similar impact at plant level.

Furthermore, the impact at firm level may be ’scaling-up’ rather than ’de-scaling’. Although the

overall impact of engineering on scale is very difficult to gauge at this stage, as some of the

newest technologies have not completely ’diffused’ and little research has been done on the

topic, it seems that the trend, if any, will be towards larger firms and organizations rather than

smaller ones. This statement, however, does not mean that smaller firms are doomed nor that

opportunities are totally closed for them. Small firms will continue to emerge, as they have

always done, catering for specialized markets or by selling service linked products. NT will offer

small firms the possibility to improve quality standards and to coordinate and share fixed costs.

Major Impact:

1. Helps to reduce cost of production

2. Increase in Production margin

3. New Technology helps to solve industrial challenges

4. It helps in management and to systemize the firm.

CHAPTER-9

CONCLUSION

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“I hear and I forget. I see and I remember. I do and I understand.” – Confucius

Training develops students’ professional and practical skills, encouraging them to apply skills

and knowledge acquired through study in a real-life environment. Students are placed with an

employer to work on a research project or undertake work experience under the guidance of

industry and academic supervision.

Training is a key factor in enhancing the efficiency and expertise of the workforce. The Students

Work Experience program prepares students for labor markets. It has become an innovative

phenomenon in human resources development and training in India. Increased specialization of

skills means that the term “profession” is now used for certain occupations which enjoy prestige

and which give esoteric service. Such professions include architects, surveyors, doctors,

librarians and information scientists, and engineers, among others.

It helped to understand various norms of industries. Provided an intellectual increase regarding

manufacturing and production.

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