Industrial Case Study Report at:
AGROFAB MACHINERIES PVT. LTD
By-
Roll no. 19 to 28
VI SEM. SEC. A
GUIDE: S. B. SAHARE
DEPARTMENT OF MECHANICAL ENGINEERING
YESHWANTRAO CHAVAN COLLEGE OF ENGINEERING,
WANADONGRI, NAGPUR.
CERTIFICATE
This is to certify that the INDUSTRIAL CASE STUDY at ‘AGROFAB
MACHINERIES PVT. LTD.’ is completed and a satisfactory account of it is given in
this report in academic year 2010-11.
Submitted by:-
ROLL NO. 19 to 27
6th SEM.
SECTION A
Under the guidance of S. B. SAHARE
DR. S. P. UNTAWALE S. B. SAHARE
(HOD, Mech. Dept.) (Lect. In Mech. Dept.)
ACKNOWLEDGEMENT
We take this opportunity to express our deep sense of
gratitude towards our teacher and project guide S. B. SAHARE
for guiding the industrial case study and helping us in our
difficulties.
We also express our sincere thanks to our respected
Head of Department, Dr. S. P. UNTAWALE for providing us
with vital instructions, necessary directives and valuable
advice in various phases of gigantic work.
We are highly obliging to our parents, friends and non-
teaching staff members of the department of their utmost
support and inspiration during the project work.
CONTENTS:
INTRODUCTION
ORGANIZATION STRUCTURE
PROCESSES UNDERTAKEN
PROCESS FLOW CHART
MACHINES USED
INSPECTION
PACKAGING
CASE STUDY:
PROBLEM I & ITS SOLUTION
PROBLEM II & ITS SOLUTION
INTRODUCTION:
AGROFAB MACHINERIES PVT. LTD. is a reputed industry in MIDC area at
Higna Road Nagpur. The main outputs of the industry are machined parts for
tractors of Mahindra & Mahindra tractors located at Nagpur. Over the years
company has successfully provided the required tractor assembly parts to the
company and is continuing their good streak in manufacturing industry. The
company has been able to get accreditation of ISO 9001:2000. The various
products under its manufacturing hood are:
a) C. V. Cylinder Head
b) Differential Gear Housing
c) Distributor Housing
d) Valve Body
The company has very high quality CNC machines from AMS synchronized
with Distributed Control System from FANUC. With this quality of machines
hardly there are any mistakes that could happen during manufacturing. Though
we have tried to take an effort and found out some problems that could be
solved by certain easy measures, thus helping factory to save time and labour.
Let us know more about industry and work carried under it.
ORGANISATION STRUCTURE:
The structure of organization is primarily hierarchical. The organizational
structure of the industry is given as follows:
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PROCESSES UNDERTAKEN:
Inspection of raw material: Here temporary inspection of raw material is
done. Just by finding any visual defects.
Facing: It is operation of moving the cutting tool at right angles to the axis
of rotation of the rotating workpiece.
Spot Facing: It is a machining operation where material is removed from
a surface to make it flat and smooth, usually for a fastener or bearing.
Drilling: It is used to remove material from the inside of a workpiece.
Reaming: It is used to create an accurate sized hole.
Threading: It is the process of creating a screw thread.
OPN 10 RECIEVING AND INSPECTION OF CASTINGS
RECEIVE CASTINGS FROM SOURCE
OPN 20 M/C OPN 30, 35, 110 MCV OPN 35 M/C
RECEIVING AND INSPECTION OF CASTINGS
MACHINES USED:
OPN 65 M/C
OPN 20 M/C OPN 30 M/C STANDBY
PROCESS FLOW CHART:
OPN 96 & OPN 100 M/C MCV 350
OPN 125 M/C OR 1133
NOTE: INSPECTION IS DONE AT ALL STAGES.
OPN 67/50 M/C VMC
OPN 50/67 BLIND BORE OPN 40 VMC
OPN 40 VMC (STAND BY)
OPN 160 PACKAGING AND FORWARDING
OPN 140 DEBURRING TABLE
OPN 150 INSPECTION TABLE TO M&M
Different kinds of machines from conventional drilling to CNC’s both kind
of machines can be found in this plant.
Some of those machine are stated and their purpose is explained below:
CNC LATHE:
The machine is controlled electronically via a computer menu style
interface; the program may be modified and displayed at the machine, along
with a simulated view of the process. The setter/operator needs a high level of
skill to perform the process, however the knowledge base is broader compared
to the older production machines where intimate knowledge of each machine
was considered essential. These machines are often set and operated by the
same person, where the operator will supervise a small number of machines.
CNC MILLING:
Most CNC milling machines are computer controlled vertical mills with the
ability to move the spindle vertically along the Z-axis.CNC machines can exist in
virtually any of the forms of manual machinery, like horizontal mills. The most
advanced CNC milling-machines, the multiaxis machine, add two more axes in
addition to the three normal axes (XYZ). Horizontal milling machines also have a
C or Q axis, allowing the horizontally mounted workpiece to be rotated,
essentially allowing asymmetric and eccentric turning. The fifth axis (B axis)
controls the tilt of the tool itself. When all of these axes are used in conjunction
with each other, extremely complicated geometries, even organic geometries
such as a human head can be made with relative ease with these machines. But
the skill to program such geometries is beyond that of most operators.
Therefore, 5-axis milling machines are practically always programmed with CAM.
Milling Machine:
A milling machine is a machine tool used to machine solid materials. Milling
machines are often classed in two basic forms, horizontal and vertical, which
refer to the orientation of the main spindle. Both types range in size from small,
bench-mounted devices to room-sized machines. Unlike a drill press, which holds
the workpiece stationary as the drill moves axially to penetrate the material,
milling machines also move the workpiece radially against the rotating milling
cutter, which cuts on its sides as well as its tip.Workpiece and cutter movement
are precisely controlled to less than 0.001 in (0.025 mm), usually by means of
precision ground slides and leadscrews or analogous technology.
INSPECTION & SAMPLING:
An inspection is, most generally, an organized examination or formal
evaluation exercise. It involves the measurements, tests, and gauges applied to
certain characteristics in regard to an object or activity. The results are usually
compared to specified requirements and standards for determining whether the
item or activity is in line with these targets. Inspections are usually non-
destructive.
In this industry various types of gauges to maintain accuracy and precision
at various stages of machining are performed. Each stage involves checking of
dimensional accuracy. The commonly used gauges at plant are:
a) Go-Nogo gauge
b) Calipers ( inside caliper, vernier caliper )
c) Micrometer screw gauge
d) Pneumatic gauge
i) INSPECTION USING PNEUMATIC GAUGE ii) GO-NOGO GAUGES
PACKAGING & TRANSPORTATION:
The final product after going through inspection & sampling is oiled for
protection against corrosion. And then product is finally packed inside a plastic
bag. Thus the final product is ready to be transported to other industry.
CASE STUDY:
The case study was carried out at AGROFAB MACHINERIES PVT. LTD.,
MIDC, Hingna Road, Nagpur.
The raw material was provided by Mahindra & Mahindra procured from
casting unit at Chennai.
Various machining processes were carried out to make castings fit to use.
The plant runs 24 hours a day. The production work is carried out in 4
shifts and each shift consists of 6 hours.
The production rate of the industry is 800 parts per day.
PROBLEMS:
PROBLEM 1: Blind boring
A through bore was sunk across the thickness of the part.
SOLUTION:
The bore was required only upto a certain depth.That process was unnecessary
and was consuming more time, power and labour.
This could be overcome by just attaching a stopper with drill bit at the optimum
required length. This will reduce time, save labour & avoid unnecessary wearing
of tool.
PROBLEM 2: Chip disposal
SOLUTION:
Centralized chip disposal system can be suggested over this problem. We suggest
that the disposal of chips can be carried out by using a conveyor disposal system.
This system will run periodically to carry chips to disposal area.
