Report

UNDER THE GUIDANCE-NAME-SC NARULA

SUBMITTED BY:-NAME-DEVILAL SHARMAROLL.NO.- 10/FET/AU(S)/2009

CONTENTS

1) Acknowledgement2) Introduction3) Training detail4) Project detail

ACKNOWLEDGEMENTI take this opportunity to express my profound gratitude to express my profound gratitude & deep regards to my guide Mr.S.C Narula for his exemplary guidance ,monitoring & constant encouragement throughout this training period.The blessing ,help & guidance given by him time to time shall carry me a long way in the journey of life on which I am about to embark.

I also take this opportunity to express a deep sense of gratitude to Mr.N.K saxena (sr.manager production,Fabrication,JBMI) for his cordial support,valuable information & guidance,which helped me in completing this task through various stages.

I am obliged to staff members of JBMI company for the valuable information provided by them in their respective fields.I am greatful for their cooperation during the period of my assignment.

INTRODUCTION

About JBM INDUSTRIES•JBM group has its global presence in automotive,education,engineering services & renewable energy sectors,•Today the company has 33 manufacturing plants,5 engineering & design centres across 19 locations globally.•It has a turnover of USD 1.2 billion.•JBM Group caters to clients in Automobile OEMS like Ashok Leyland,bajaj,Fiat,GM,Hero,Honda,JCB,Mahindra,Maruti suzuki,Renault-Nissan,TATA,Toyota,TVS,VECV,VolksWagon,volvo & many more.•Products-Body Assembly,Body in white,Chasis and suspension system,Die casting,Engineering services,Exhaust systems,Fabrication,LPG &CNG Cylinders,Steel fastener,Skin panels,Steel processing,Tailored Welded Blanks,Tools,Jigs & Fixtures,Tubes & Tubular Manipulations,Welded Assemblies Systems.Wheel assembly.

TRAINING DETAIL

FABRICATION DIVISION

LINE:-1. H/T welding2. D/T welding3. H/T Assembly4. D/T Assembly5. Inner leg6. Outer leg7. S.S Foot 8. Cross box 9. Torsion tube10. Boom11. 2DX line12. Engine mount13. Axle yoke14. Export engine mount.

:- Cylinder formation.:- studied about MIG and TIG welding:- Studied about spm machines.:- Railway doors formation & its Fuel tank formation :- Type of welding done in railway doors.

JCB SECTION

Project NameProject Name:- Reduce In-house

Rework PPM-Outer leg

Outer leg formation

Parts

• U-channel plate• Closing plate• Saddle bracket• Backing plate• Thread bush• Big bush• Reinforcing plate• Small bush• washer

Dimension1) U-channel

Thickness=8mmLength=1233mmBreadth=153mm

2) Closing plateThickness=8mmLength=1233mmBreadth=153mm

3) Thread BushInternal dia=65mm

FLOW CHART

Raw material Raw material

shearingPlasma cutting

Bending Drilling

U-channel plate formed

Chamfering

Both closing plate & u channel plate welded together

Tagging

Welding(line welding on SPM)

2nd layer welding(23*3 Boss,small boss,big

boss,washer welding)

Saddle bracket weldedRNC plate

welded

Final welding

Grinding

Buffing

Punching Dispatch

Part wise contribution in overall PPM

Product Wise Rework PPM (AUG-2013)

Part NameHydraulic

tankOuter leg Diesel tank

Torsion

tubeCross Box S.S foot Inner leg

Total

Produce/R

ework Qty.

Produce

Qty.792 480 784 300 300 1415 1030 5101

Rework

Qty.27 29 21 8 9 7 0 101

PPM 34091 60417 26786 26667 30000 4947 0 19800

Part Name Defects Qty. Contribution in overall PPM

Hydraulic tank 27 5293

Outer leg 29 5685

Diesel tank 21 4117

Torsion tube 8 1568

Cross Box 9 1764

S.S foot 7 1372

Inner leg 0 0

Defects Wise Contribution in Overall PPM P

PM

Defects Name

Defect Qty. PPM

Undercut 12 2352

Overwelding 6 1176

Blow hole 5 980

Welding miss 2 392

Dent 2 392

Uneven welding bead 2 392

2352

1176980

392 392 392

0

500

1000

1500

2000

2500

Undercut Overwelding Blow hole Welding miss Dent Uneven welding bead

Concentration Diagram

Concentration Diagram

Day 1 Day 2

Day 5 Day 6

Day 3

Day 4

Concentration Diagram

Day 7 Day8 Day 9

Day 10

S. No Area

Defects

Welding

undercut

Welding

miss

Bow

holesDent

Over

welding

Uneven

welding

bead

Spatters Total

1 A 2 2

2 B 1 1

3 C 2 2

4 D 4 2 1 7

5 E 12 4 16

6 F

7 G

8 H 2 2

9 I 2 1 3

10 J

11 K

12 L 1 1

Total 16 3 4 2 7 1 1 34

Compilation of Data

Pareto - Zone wise

16

7

32 2 2

1 10 0 0 0

47

68

76

82

88

9497

100 100 100 100 100

0

10

20

30

40

50

60

70

80

90

100

0

5

10

15

20

25

30

E D I A C H B L F G J K

Pareto - Operator wise

98

3

1 1

41

77

9195

100

0

10

20

30

40

50

60

70

80

90

100

0

5

10

15

20

Nirmal Roshan Sunil Rajender Ranjeet

Area Identified On The Basis Of Pareto

Undercut In Area E& D (Thread Boss &Reinforcement plate)

Action Plan For Problem

S. No Cause Activity Responsibility Status

1Welding voltage too high.

Training to be impart to

operator through one

point lesson.

Trainer Completed

S.O.P to be display. Trainer Completed

Improvement To Control Undercut In Thread

Boss.

One point lesson not displayed. Now training given to operator through one point lesson.

Before After

S.O.P not displayed. Now training given to operator through S.O.P.

Before After

Improvement To Control Undercut In Thread

Boss.

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

14.02.13 15.02.13 16.02.13 18.02.13 19.02.13 20.02.13

Result Monitoring

679566 566

340226 226

113

0

500

1000

1500

2000

25002352

1176

980

392 392 392

0

500

1000

1500

2000

2500

Before After

Result