PRACTICAL TRAINING

REPORT
On
MICRO TURNERS

SUBMITTED TO: - SUBMITTED BY:-

MR.RISHI RAJ DEEPAK

Assit.Prof. (MECHANICAL DEPT.) ROLL NO-ME/905/18D

SEMESTER 8th

VAISH COLLEGE OF
ENGINEERING,ROHTAK
 ACKNOWLEDGEMENT

I sincerely thank to Mr. NARESH DGM; HRD; MICRO TURNERS Ltd. Rohtak, for
designing systematized schedule for my six weeks training in the factory. He regularly
checks discipline and sincerity of students and guide them accordingly. Moreover, I
thank to all the officers and workers in the plants which are very cooperative and
friendly in nature. All the way from engineers to helper of the shops help me in gaining
valuable information about the industry. Mr.Divyansh; Production Department; MICRO
TURNERS Ltd., Rohtak helped me a lot in gathering information and guides me to collect
information precisely and efficiently.
 List Of Figures
Name Of Figure Page No.
Hierarchy Chart 9…

Logos of our clients 10…

Kick Shaft  11…

Sprocket cam chain 11…

Bearing Races 12…

Axles 12…

Cam Brake 13…

Other Precision M/c Components 13…

A.K M/C Shop 16…

CNC M/C Shop 16…

Heat Treatment Section 17…

Mechanical Testing M/C s 30…

CONTENTS
1- Company Profile
2- Product List
3- Policies

3.1-Quality Policy

3.2- Strengths

3.3-Vision

3.4-Quality Assurance

4-Organizational Structure for Company (Hierarchy Chart)

5-Domestic Clients

6-Products List

6.1-Kick Shafts

6.2-Sprocket Cam Chain

6.3-Bearing Races

6.4-Axels

6.5-Cam Brake

6.6-Other Precision Components

7-Manufacturing Facilities

8- Manufacturing Process

8.1-Heat Treatment

8.1.a-About Heat Treatment

8.2-Hardening

8.2.a-Hardening Temperature

8.2.b-Operations Before Hardening

8.3-Quenching

8.4-Tempering

8.4.a-Structural Changes After Tempring

9-Plating

9.1-Cleaning Of Materials
9.2-Electroplating

9.2.a-Material Used

9.2.b-Passivation

10-Quality Control And Inspection

10.1-Objectives Of Inspection

10.2-Types Of Inspection

10.3-Functions Of Inspection

10.4-Inspection Method

10.4.a-Process inspection

10.4.b-Sample inspection

10.4.c-Batch inspection

10.4.d-Final inspection

10.5-Quality Control

10.5.a-Advantages

10.5.b- Responsibilities Of Q.C. Department

11- Laboratory Systems

11.1- Metallurgical Testing

11.2- Corrosion Resistance /Plating Testing

11.3-Laboratory Management Policy

12- Departments

12.1-Packageing Department

12.2- Maintenance Department

12.2.a-Scope

12.2.b-Primary Function

12.2.c- Secondary Function

12.3-R & D Department

12.4- Personal Department

12.4.1- Recruitment
12.4.1.b- General Policy

12.4.1.c- Reservation

12.4.2- Training / Placement

12.4.3- Promotion Guideline

12.4.4- Welfare activities

13-Referrence

14-Conclusion
 Company Profile

The company has successfully implemented ISO/TS16949 Quality System and it was
certified by “DNV” a New Zealand based Company.

The Company was floated under the dynamic leadership of Mr. Anil Sehgal in 1969
manufacturing for automobile and engineering industries.  

Today, we are one of the leading manufacturers of shaft type components to most of
the automobile industries in India. Our manufacturing operations are housed in a
covered area of 40,000 sq. ft.

We are the Leading manufacturer of shifting rods & allied components in India.

> Basic Company Principles

      - Long Term Partnerships
      - Commitment Towards Customers
Policies

Quality Policy
We as a team shall delight the customer by minimizing the variance through total
employee involvement and continuous improvements. The policy aims at following
objectives:
> Improvement in productivity.
> Cost reduction.

Strengths
> Our Biggest Strength is our dedicated man-power.
> Designed S.P.M’s for doing critical operations which are difficult to do in conventional
machining.
> For effective measurement we have designed gauges for every operation even if the
operation is small.

Vision
> To eliminate human errors in all spheres<

Quality Assurance
We are T.S. 16949 certified by “DNV”.
Organizational Structure for Company (Hierarchy Chart)

BOARD OF
DIRECTORS

CHAIRMAN AND MANAGING

DIRECTOR

QUALITY MANAGEMENT
CORPORATE STRATEGY

QUALITY
MARKETING R&D PLANNING PRODUCTION MANTAINANCE GENERAL
ASSURANCE

CPP
ERL
DE DE
NOA
VE VE LA
TDN PU F
LO SA LO BO PL PL
RUN RC IN HR
P LE P RA AN AN
AC I HA AN D
M S M TO TI T II
LT N SE CE
EN EN RY
I G
T T
O
N
Domestic Clients

UHeavy Commercial Vehicles

Light Commercial Vehicles

Tractors
Cars

U Two Wheelers

Product list
Kick Shaft  and  Kick Shaft  Assembly for
Motorcycles/Scooters : 
We  manufacture   Kick  Shafts  and  Kick Shaft  Assemblies  for  our  valued 
customers like  Bajaj  Auto  Ltd,   HMSI, TVS Motor Company,  Suzuki
Motorcycle & Scooter for  their  various  models.
These  shafts  are  being  manufactured   out  of   raw material  case  carburising 
steel  such  as  SCM415/420  and   Heat  treated   to Customers  specifications.
Sprocket cam chain

Sprocket Cam Chain for Motorcycles & Scooters  out  of   Carbon Steel/  Case 
Carburising steel  duly  induction hardened / case  carburised   for  our  valued 
customers  such as   BAL, TVS MC, SMC, HMSI  for  their  various  models.

Bearing Races

Bearing Races - For Motorcycles, Scooters 

Axles

Front & Rear Wheel  Axles and Shafts Swing Arm for Motorcycles / Scooters We 
manufacture Axles  (Front  and  Rear Wheel) out  of  raw  material  confirming 
to  Boron Steel / Carbon Steel / Alloy  Steel  duly heat  treated  to  8.8 / 9.8 /10.9 
grades  for  our  customers  like  HHML, BAL, TVS Motor Company, HMSI,
Suzuki Motorcycle  for  their  all the  Models  of  Motorcycles /Scooters.

Cam Brake

Brake Cams: Cam  Brake  Front  &  Rear  for    all  the  Models   of  
 Motorcycles  and  Scooters  being  made  by  HHML, HMSI  as  per  their  drg /
specification.

OTHER PRECISION MACHINE COMPONENTS

Manufacturing Facilities
 We have an installed capacity of 14000 MT/ Annum which includes
the state of art machines as given. Our plant machinery is comparable to the best in the
world LPS always upgrades / replaces facilities as required. In line with this, we have
recently installed a 300 MT/ Month capacity Continuous Hardening and Tempering
Furnace imported from Sanyung, Taiwan.

Process Capacity
Cold Forging Diameter 3 mm – 27 mm

(20 M/C) Length 6 mm – 250 mm

Rolling (31 M/C) Circular Type Dia. 6-36 mm

Rotary Type Dia 5-8 mm
Flat Type Dia 3-16 mm
Heat Treatment (18 Shaker Hearth 125 Kg/hr
M/C) Continuous Hardening 500 Kg/hr
Galvanizing 80 Kg/hr.
Pit Type Furnace
Plating (3 M/c) Automatic

Zinc Plating 3.8 MT/Day

Zinc Iron plating 0.6 MT/Day

Manual 0.6 MT/Day

Phosphating (2 M/C) Manual 2.4 MT/Day
Decrotizing Automatic 1.0 MT/Day

Machine  Shop  equipped  with  CNC Machining  Centres make  Mazak, LMW 
with and  without  Bar  Feeder,  Grinding  Shop, Heat Treatment Shop (Through 
Hardening, Gas  Carburising, Induction Hardening, LCN Treatment),  Zinc 
Plating Shop, Standard  Room,  Lab, Tool  Room.

MACHINE SHOP
 Cnc Turning Centers With & Without
 Bar feeders
 Bar feeders Make – Mazak, Nakaura ,tsugami LMW
 SPM

GRINDING SHOP
 Centre less grinders
 Cylindrical Grinders
 Internal Grinders
  Track Grinders Angular Wheel Grinders

COLD FORGING SHOP

 Part formers----National & CEVA make
 Multi station Bolt makers--- National & CEVA make
 Knuckle joint Presses--- AIDA/Cincinatti make
 Hydraulic Presses----
 Long Stroke Headers--- CEVA make

HOT FORGING SHOP

 Induction Heaters
 Resistance heating & Metal gathering machine
 Hydraulic Presses
 Power Presses of National & Ajax make ( 250T ~ 1600T
Cap.)
 Trimming Presses

HEAT TREATMENT SHOP

 Sealed Quench Furnaces—High temp make
 Shaker Hearth Furnaces
 Mesh Belt Furnace line
 Induction Hardening Machines
 LCN treatment Furnace
 Tempering Furnaces
 Gas Carburizing Furnaces

GEAR SECTION
 Gear Hobbing machines—Mitsubishi, Leibher
 Gear Shapers--- Leibher
 Gear Shaving Machines--- Hurth
 Lead & Profile Testers – Osaka, Klingenberg , M&M,MAG
 Gear Roll Testers
A.K MACHINE SHOP A.K AUTOMATICS (MACHINE SHOP)

CNC MACHINE SHOP

 Manufacturing processes

Heat Treatment

Heat treatment is an important operation in the manufacturing process of

machine parts and tools. It may be defined as an operation of heating and cooling of
metals in the solid state to induce certain desired properties into them. Heat treatment
can alter the mechanical properties of steel by changing the size of the grains of which it
is composed, or by changing its microstructure. It is generally employed for the
following purposes.

1. To improve machinability.
2. To change or refine grain size.
3. To relieve the stresses of the metal induced during cold or hot working.
4. To improve mechanical properties. e.g. tensile strength, hardness, ductility,
shock resistance etc.
5. To improve magnetic and electric properties.
6. To increase resistance to wear, heat and corrosion.
7. To produce a hard surface having ductile interior.

Hardening &
Tempering

Carburizing

Nitriding

Carbonitridin
g

For all Low Carbon ,high carbon steels, tools of heat treatment grade like HDS
,SPK ,High Speed (HSS).

HEAT TREATMENT SECTION

 About heat treatment

It is a process utilized to change certain characteristics of metals and alloys in order to

make them more suitable for a particular kind application Heat Treatment can greatly
influence mechanical properties such as strength, hardness, ductility, toughness, and wear
resitence of the alloys.

Heat Treatment of Carbon Steels and Carbon Alloy Steels:

Heat Treatment  on both type of the steel is done for improving  mechanical properties
such as tensile and yield strength. This is accomplished by altering the molecular
structure of steel in order to produce more durable microstructure. The structure of steel
is composed of two variables:

Grain Structure: The arrangement of atoms in a metal.

Grain Size: The size of the individual crystals of metal. Large grain size is
generally associated with low strength, hardness, and ductility.

During the alloy process elements such as carbon are introduced to the metal. These
added elements interrupt the flow of the individual grains, increasing strength. Thus,
control of the metal crystal structure is a key element in successful heat treating.

A Metal can also exist in various phases: Ferrite, austenite and cementite. To better
understand these phases, look at the Iron-Carbon Phase Diagram. The Y-axis (vertical) is
a measurement of temperature while the X-Axis (Horizontal) is a measurement of the
carbon content of the steel. The far left hand side of the X-axis represents the Ferrite
phase of steel (low carbon content) while the far right hand. Side represents the cementite
phase of steel (high carbon content), which is also known as iron carbide. The curved
horizontal line that occurs just above 1333 ºF represents the austenite phase of steel.

The following phases are involved in the transformation, occurring with iron-carbon
alloys:
 1. L –L represents a liquid solution of carbon in iron.
2. δ-ferrite – δ-ferrite is a solid solution of carbon in iron. Maximum concentration of
carbon in δ-ferrite is 0.09% at 2719 ºF (1493ºC) – temperature of the peritectic
transformation. The crystal structure of δ-ferrite is BCC (cubic body centered).
3. Austenite –Austenite is an interstitial solid solution of carbon in γ-iron. Austenite
has FCC (cubic face centered) crystal structure, permitting high solubility of
carbon – up to 2.06% at 2097 ºF (1147 ºC). Austenite does not exist below 1333 ºF
(733ºC) and maximum carbon concentration at this temperature is 0.83%.
4. α-ferrite – α-ferrite is a solid solution of carbon in α-iron. α-ferrite has BCC crystal
structure and low solubility of carbon – up to 0.25% at 1333 ºF (733ºC). It exists at
room temperature.
5. Cementite – Cementite is an iron carbide, intermetallic compound, having fixed
composition Fe3C. Cementite is a hard and brittle substance, influencing on the
properties of steels and cast irons.

When ferrite (low carbon steel) is at room temperature, it has a body-centered-cubic

structure, which can only absorb a low amount of carbon. Because Ferrite can only
absorb a very low amount of carbon at room temperature, the un-absorbed carbon
separates out of the body-centered-cubic structure to form carbides which join together to
create small packets of an extremely hard crystal structure within the ferrite called
cementic. However, when ferrite is heated to a temperature above the transformation line(
austenite line) the body-centered-cubic structure changes to a face-centered-cubic
structure, thus allowing for absorption of the carbon into the crystal structure.

Once the steel enters the austenitic phase all of the cementite dissolves into austenite. If
the steel is allowed to cool slowly, the carbon will separate out of the ferrite as a cubic-
structure reverts from face-centered back to body-centered. The islands of cementite will
reform within the ferrite, and the steel will have the same properties that it did before it
was heated. However, when the steel is rapidly cooles, or quenched, in a quenching
medium (such as oil, water or cold air) the carbon does not have time to exit the cubic
structure of the ferrite and it becomes trapped within it. This leads to the information of
martensitic; microstructure that produces the most sought after mechanical properties in
steel fasteners.

During quenching, it is impossible to cool the specimen at a uniform rate throughout. The
surface will always cool more rapidly than the interior of the specimen. Therefore, the
austenite will transform over a range of temperatures, yielding a possible variation of
microstructure and properties depending on the position within the material.

The successful heat treatment of steels to produce a predominantly martensitic micro

structure throughout the cross section depends mainly on three factors:

1. The composition of the alloy.

2. The type and character of the quenching medium.
3. The size and shape of the specimen.

Hardenability : It is the ability of steel to transform into martensite with a particular

quenching treatment. This is directly affected by the alloy composition of the steel. For
every different steel alloy there is a specific relationship between its mectanical
properties and its cooling rate. It is not “hardness” which is a resistance to indentation;
rather, hardness measurements are utilized to determine the extent of a martensitic
transformation in the interior of the material.
Tempering : It involves heating the steel to a specific temperature below that of ausenite
and allowing it to cool slowly. This cause the crystal structure to relax, thereby increasing
the ductility and decreasing the hardness to specified levels. The specific tempering
temperature will vary based on the desired result for the steel.

The following example will demonstrate the effectiveness of the tempering:

ASTM A193 Grade B7 , SAE J429 Grade and ASTM A574 Socket Head cap Screws are
all made from alloy steels. In fact some alloy steel grades can be used to manufacture any
of the three final products. Such as 4140 and 4142 alloy steel. The final mechanical
properties apper in the table.

Fasteners Produced From AISI 4140& 4142 Steel

Fastener ASTM A193 B7 SAE J429 Gr. 8 ASTM A574 SHCS
Tempering   1150◦F   800◦F   650◦F
Temp.
  Tensile   125,000 PSI min (2   150,000 PSI min 180,000 PSI min
strength 1\2in and under) ( through   ½ in ) 170,000
PSI min
( above   ½ in)
  Yield   105,000 PSI min   130,000 PSI min   153,000 PSI min
Strength (2 1/2in and under)
  Proof     N/A     120,000 PSI 140,000 PSI min
Strength ( through   ½ in ) 135,000
PSI min
( above   ½ in )  
  Hardness   HRC 35 max.   HRC 33-39 HRC 39-45
( through   ½ in ) HRC 37-
45
( above   ½ in )  

The initial heat treating process is relatively the same for the entire three products. The
parts are heat treated until fully austenitized and then are quenched and tempered in the
oil. This tempering temperature dictates the final product. A lower tempering temperature
will produce a harder and higher tensile strength part for these alloys steels. However, the
lower tempering temperatures will also mean lower ductility, impact strength, and
possibly lower fatigue life.
 Hardening

Hardening is a heat-treatment process necessary to impart hardness to any

component. This treatment consists of heating the steel, to a selected hardening
temperature (austenitizing temperature), and holding it at this temperature, followed
by cooling or quenching at a rate fast enough to develop the desired hardness. When
the steel is austenitized, its lattice structure is face-centered cubic. The reason for
heating and holding the steel in the austenite range is to dissolve carbide,cementite
into a matrix; then the steel is quenched. At this stage, the trapped carbon causes a shift
in atoms to form a body centered tetragonal structure. The shift of atoms and trapped
carbon creates a stressed lattice structure. This stressed structure, called martensite is
hard and brittle. It is responsible for the high hardness of the steel. The hardness finally
achieved depends on how much carbon was available and how much of it is dissolved,
the temperature adopted and the rate of cooling. It is subsequently tempered to reduce
the induced quenching stresses caused by the formation of martensite.

Hardening Temperature

The hardening temperature to be employed depends on the

chemical composition, carbon content and section thickness of the steel. The
temperature employed for hypereutectoid steel will be in the range of 20-50 degree
Celsius above Ac3 (upper critical temperature), and for hyper eutectoid steels 30-50
degree Celsius above Ac1 (lower critical temperature). If steel containing, for instance,
0.5% carbon (ferrite and pearlite structure) is heated to a temperature below the lower
critical temperature Ac1, it will not change the original structure of the steel containing
pearlite and ferrite.

SHAKER HEARTH FURNANCE is used for the hardening purpose.

1st Zone temperature - 820-900 degree Celsius.

2nd Zone temperature – 860-900 degree Celsius

Gas generator temperature – 950-1060 degree Celsius

Gas and Air fuel ratio – 1:8- 1:15

Operations Before Hardening

 It is most important that the components to be hardened should
be free from scales, grease, oil etc. In order to achieve the desired hardness, such
components should be cleaned thoroughly. Components having holes, particularly tool
steels, may be packed with clay, asbestos and steel inserts wherever necessary, so that
no hardening can occur in the holes. Special attention may not be required where holds
are relatively large and tools should be quenched in such a manner that the internal
surfaces of the holes harden completely.

DEGREASING TANK is used for this purpose having the concentration of KMnO4 30 40
gm/litre, NaOH 120-140 gm/litre. The temperature in the degreasing tank must not
exceed to 90 degree Celsius and must be above than 40 degree Celsius.

HOLDING TIME IN HARDEING BATH

The time taken to reach hardening temperature depends on several

factors such as the heating equipment and the hardening bath. The rate of heating in
salt bath is considerably faster than that it is possible in a furnace with atmosphere
because heat transfer from a liquid to a solid body occurs at faster rate.

Soaking time of 3 sec. is given for piece having 1 mm dia. And soaking period of 50
sec. is given for a bolt having length of 3.5" and dia ¾".

Quenching
After the component is held at the hardening temperature
for a desired length of time, it is taken out for cooling, or quenching, in order to obtain a
hard martensite structure. The rate of cooling must be controlled, so that the formation
of soft pearlite or bainite is prevented.

The medium seed for quenching depends upon the chemical composition of the
steel, the hardness required, permissible degree of distortion, and the complexity of the
component. Water, oil, brine, molten salt and polymer are quenched by the quenching
methods which are:

1. Direct quenching
2. Martempring
3. Austempring
4. Delay quenching
5. Time quenching
6. Die quenching
7.
 Tempring

When steel is hardened it acquires the structure of tetragonal martensite and a

certain amount of retained austenite. Steel in this condition is hard, brittle, highly
stressed and liable to develop quench cracks, particularly in tool steels. Thus steel in the
"as-hardened' condition are of limited usefulness. To overcome this, the hardened steel
should have a potential tendency to pass into a stable condition. But this equilibrium or
stable state cannot be achieved at room temperature because of low mobility of atoms.
As the temperature rises, the mobility of atoms increases which accelerates diffusion
rate, and this result in a structural change of hardened steel to give rise to a stable state.
This, in effect, is the process of tempering. By tempering, ductility can be increased, and
hardness and strength decreased. In the majority of structural steels, the purpose is to
obtain a combination of high strength, ductility and toughness. Thus, the tempering
process, after hardening, makes the steel more useful by providing a stable structure.

Structural Change After Tempring

Tempering consists of heating the steel to some temperature below the critical range
(Ac1), and holding it for the desired length of time and subsequently cooling it in air.
Investigations by various physical methods have established that as the temperature is
increased, the hardened carbon steel passes through four stages:

1. At a temperature between 80 and 200 degree Celsius, a carbon rich transition

product known as carbide is precipitated from the tetragonal martensite
reducing the lattice to cubic ferrite. This reaction is called the first stage of
tempering. During this period, due to the release of carbon, the martensite
lattice volume contracts. The carbide that forms in martensite during the first
stage of tempering is designated as Epsilon carbide.
2. At a temperature between 200 and 300 degree Celsius, the retained austenite
is decomposed into a bainite-like product, a state of aggregation similar to
tempered martensite; and this transformation is called second stage of
tempering. At this stage, there is an increase in volume of steel.
3. At a temperature between 300 and 400 degree Celsius, there is the formation
and growth of cementite from the carbide precipitation during the first stage
and second stage of tempering. It is marked by a considerable decrease in
volume and overlaps the austenite decomposition reaction of the second
stage.
4. At a temperature between 400 and 700 degree Celsius the growth continues
and spheriodization of cementite takes place.
5. At still higher temperatures, the formation of more complex carbides takes
place in steel in which strong carbide forming elements are present. This
process is designed as the fourth stage.
Plating

Plating consists of both the cleaning and plating of the product

manufactured by the company after performing Forging, rolling, turning , threading,
heat treatment etc.

Cleaning Of Materials

Cleaning operations are performed both preparatory to finishing operations and

after finishing operations. They are primarily used to remove dirt, oil, oxides, scale, and
other harmful ingredients that ultimately affect the life of the product. The unwanted
surface contaminants that generally exist may broadly be classified into six groups:

1. Pigmented drawing compounds.

2. Unpigmented oil and grease.
3. Chips and cutting fluid.
4. Rust and scale.
5. Polishing and buffing compounds.
6. Miscellaneous surface contaminants.

Electroplating

Electroplating may be described as a process of covering a surface or object

usually metallic with a thin adherent coating of the same or other metal by electrolysis.
The form and details of the original parts are retained.

Essential elements of plating process are cathode, anode, electrolyte and direct
current at low voltage. The articles are connected to cathode bar, and on the anode bars
are suspended plates of metal being deposited.

In LPS large rotating drums having holes containing nuts/bolts are connected to
cathode usually 10-15 volts.

The technique of electroplating is basically the same for a metals, although there
are certain variation in some of the details. Since electrodeposited metal will adhere
firmly only to clean surface, the need for thorough cleaning of the parts to be plated is
of fundamental importance. The cleaning or polishing operation may, therefore, require
any one of the following steps :
 1. Removal of all oil, grease or organic material by immersing the parts in hot
alkaline solution, and lastly by rinsing in clean water; and
2. Removal of surface irregularities, scale, and oxide by picking or by use of a file,
abrasive wheel, or wire brush. The work place must then be polished and
buffed to ensure adhesion or to obtain the desired appearance.
3. This is basically the clearing and activation of the products so as to get an
adherent deposit (i.e. Oil removal etc.) on the products.

Material Used
The product are mainly zinc plated, depending upon the requirement of the customer.
This is done to improve the corrosive resistance of the material. Electrolyte used during
plating is solution is combination of (Zinc metal +Zinc Chloride +Boric Acid).

Zinc Metal = (25 gms to 35 gms)/lts.

Zinc Chloride = (100 gms to 120 gms)/lts.

Boric Acid = 30 gms to 35 gms)/lts.

During plating Zn plate is positive charge and material to be plated is negatively charged.
Plating tank is combination of two electrodes one of which is consumable i.e. Anode and
electrolyte.

Passivation
This is done to increase the corrosive resistance of the steel. The process is called
passivation. According to the requirement, Zn plated or phosphated (black finishing)
products are dipped into the respective passivation solution. The product is kept for 1
miniute in the solution and dried afterwards.

Different colours imparted during Passivation are:-

Colours Solution

Yellow Nitric Acid + Sulphuric acid + Sodium Dicromate

(8ml to 10 ml)/lts. (55ml to 60 ml)/lts. (330 gms)/lts

White Nitric Acid + Ginthon Oil 550

(4 gms to 6 gms)/lts (8 ml to 10 ml)/lts.

Green Olive 862

(120 ml to 140 ml)/lts

Black Kempass 66A + Kempass 66 B

(90 ml)/lts. (90 ml)/lts.

Quality Control And Inspection
Inspection means comparing materials, products as performance with standards.
Whenever products are manufactured, some will be the outside the limits of allowances
provided. All the required specifications are stored-out, and rests are sent for remark as
scrapped. It stops the wrong production and thus time and money wastage due to
rejection can be effectively controlled. To maintain the desired accuracy and quickens
special devices are used.

Objectives Of Inspection

a. To detect error in the manufacturing system and to prevent the production

defection items.

b. To save the manufactured products and defect rejected products thus

maintaining the quality of the product.

c. To take information of these methods, responsible for faulty production.

Types Of Inspection

1. Inspection of raw material

2. Inspection during manufacturing.

3. Metallurgical and metallographic inspection.

4. Purchase part inspection

5. Finish good inspection

6. Tool inspection

Function Of Inspection
  Dimensional inspection
 Testing of mechanical properties
 Surface finish inspection
 Performance testing

The inspection is done commonly at two places, stage inspection and final
inspection, but sometime patrol inspection is also done to check the effectiveness
and efficiency of the machines. Thus patrol type of inspection is done to
manufacturing of components.

Inspection Method
In a repetitive type of manufacturing inspection should be done at several places.

 Process inspection
 Sampling inspection
 Batch sampling inspection
 Final inspection

Process inspection

Process inspections the inspection of the component during the manufacturing. It is also
referred as inspection to prevent scrap, rework, reduce operation levels and detect
hidden defects and to attain a higher quality of finished products.

Sampling inspection

In sampling inspection, sample is taken and analyzed for machined and totaling faults.
Stage inspector performs this type of inspection. This inspection helps in detecting only
fault that may be present in machine's tooling. This report also benefits the operator by
letting him know his quality of work.

Batch sampling inspection

This type of sampling is generally concerned to the parts which have been removed
from the shoo door and sampled accordingly to statistical methods based on past
experience.
Final inspection

Final inspection is done at the end of all the operations being performed. All the
parameters are checked again. This inspection is very critical and all the parts are
screened and combed to any faults which might have crept in during manufacturing.

QUALITY CONTROL
Quality control means degree of perfection achieved. It is not absolute but it can be
judged and realized by comparing with some standards.

Advantages

Quality of the product is improved and thus more consumers are attracted with the
effect quality control, scrap, rejection and re-working are minimized and thus avoiding
wastage, which reduces the cost of production.

Responsibilities Of Q.C. Department

1. To allow sale of products of uniform and required specification.

2. To reject the defective goods and shield the consumer from defective
items.
3. To correct the rejected goods if possible.

Standard Room

In standard room calibration of instrument is done periodically

Calibartion

The process in which we compare the performance of testing and measuring

instruments of unverified accuracy to the testing and measuring instruments of verified
accuracy or higher accuracy to detect any deviation.

Instrument color coding system is utilized for the calibration of instrument for every
month. The instruments in which tip is coated with the month's color code than this will
indicate that the instrument is calibrated in that month. If any instrument is coated with
red color, it means the instrument is 'out or order' or ‘rejected’.

Colour Month
 WHITE JAN / JULY

GREEN FEB / AUG

BLUE MAR / SEP

YELLOW APR / OCT

BROWN MAY / NOV

PINK JUNE / DEC

RED SCRAP

(A.V – AVERAGE VALUE, T.V – TRUE VALUE)Various standard instruments

used for calibration in the standard room of L.P.S. industry are as follows :

1. Slip Gauge Box ('0' Grade)

2. Slip Gauge Box ('1' Grade)
3. 3. Floating carriage dia. Measuring machine.
4. Dial calibration
5. Torque wrench tester.
6. Electronic comparator (E.C.)
7. Surface roughness tester
8. Profile projector
9. Roundness tester
10. Contractor

Laboratory Systems
 In, A.K.Automatics Ltd., Fastener manufacturer process under goes various testing
process to ensure the quality assurance as well as standards. Plant has a good set of Lab
equipment for carrying out Dimensional Inspection, Mechanical Testing, Metallurgical
Testing, Corrosion/Plating Testing etc.

Dimensional Inspection: Various parameters are taken into the accounts for the
dimension parameter which includes Length, Thread, Internal Diameter, Outer Diameter,
Angle, Radius, Major Diameter, Pitch Circle Diameter Chamfer, Recess, Depth etc. The
latest equipments for the purpose are available in the lab to check it

.
Mechanical Testing: It measure the various process of fastener such as :

 Hardness- HRA, HRB, HRC, Vickers & Micro

 Tensile – 2 Tons, 60 Tons & 100 Tons
 Torque – upto 3000Nm
 Impact – Low Temp as well as Room Temp
 Twist – On Spring Washers
 Proof Load – of Nuts & Bolts
 Double shear Strength

Metallurgical Testing:

In A.k, for the testing purpose metallurgical test is also done to check Chemical
composition, De carburization, Microstructure, Grain Size, and Inclusion rating by the
various equipments such as Microscope, Spectrometer, etc.

Corrosion Resistance /Plating Testing:

Corrosion Testing is done to test the influence of corrosion on fasteners. LPS Limited
has the capabilities to many other corrosion, thickness, adhesion, torque-tension and
related test. These include SST, Coating Thickness, and Hydrogen Embrittlement.
Different equipments used for corrosion testing which includes Fixture for HE Test,
Coating Thickness Tester, SST chamber, etc.
Optical Emission Spectroscope: For ascertaining chemical composition of Raw Material.
Metallographic examination involves Microstructure, Inclusion rating.

Image Analyzer: Grain size, Decarb, Microstructure, Inclusion, Thread life etc along with
statistical analysis. Decarburization, Gram size, Thread laps etc. along with statistical
analysis.
Fisher scope (X-ray analysis) : For ascertaining coating thickness by x-ray method and
material analysis by spectrum needless to mention the other equipment, we have i.e.
Metallurgical Microscope, Magna Hardness Tester, Major flux testing, Universal Tensile
Testing M/c, Hydrogen De-embrittlement Testing, Torque testing etc. Eddy current
testing, Rockwell cum superficial hardness Tester, Stereo Microscope & salt spray
testing.

Mahr's Perthometre Concept: For measurement of any type of contour (Including

threads and surface toughness).

Laboratory Management Policy

The laboratory at M/s A.K.Automatics Ltd., is committed to produce Quality

Reports/Certificates. The most important criterion of quality is the satisfaction of
customer both National and International.

This shall be achieved by:-

1) - Following a well defined management system in line with ISO/IEC 17025-2005

requirements and proper training has been given for successful implementation of
the system.

2) - Optimum utilization of resources.

3) - Imbibing a culture of continuous Quality improvement of motivating and planned

training of all employees, and

4) - Continuously upgrading its testing capabilities by adopting latest technologies and

specifications.

Departments
Packageing
In the modern world most of the goods are available in the packages. The packaging
protects and preserves the goods and offer convenience in transport, handling and sales
also. The goods in packaging should retain their original form, shape and properties, the
packages should be convenient and attractive.

A primary package is the one, which come in contact with the product. Therefore, the
selection of the material plays a vital role and it should be compatible with the product
to be packed. The main function of a transport package is to give the required
protection to the packaged commodity against incidental hazards during transportation
handling and storage. The fundamental factors affecting the design of a package are :

a. Product characteristic
b. Modes of distribution
c. Marketing distribution
The technical considerations that influence the package design are hazards during
transportation, such as shocks and vibrations, transmitted to the product during
transportation by rail, road, sea and air.

Hazard during handling such as impact due to drop, compression and puncture.

Hazard during storage (for e.g. the greater the tacking height in a warehouse, more the
need for strong and rigid package to withstand compression) and Hazard due to climate
change.

The packaging should be of best quality and be produced at competitive costs. Various
materials used for packaging are plastics, metals, glass, wood and paper (including
corrugated packaging).

Now mechanical packaging times are employed and fully automated high-speed
production systems are being introduced. Traditional packaging materials like tin and
glass are being forced to give way to plastics and paper the whole concept is to give the
consumer the most economical packaging material.

Maintenance Department

Basically, the reason for operating a maintenance-engineering group is to

attended the day to day problems of keeping the physical plant machinery, buildings,
services in good operating conditions.

Scope

Although in practice the scope of the activities of maintenance engineering department

is different in each plant or in institution and is enhanced by plant size and type,
company policy and industry wide and sectional precedent, its possible to group these
activities into the two general classification-primary function, secondary function that
are assigned to the department for the reason of expediency know how as precedent .

Primary Function

1. Maintenance of existing plant equipment.

2. Maintenance of existing plant building and groups.
3. Equipment inspection and lubrication
4. Utilization generation and distribution.
5. Alternation to existing equipment and building.
6. New installation of equipment and the building.

Secondary Function

1. Store Keeping
2. Plant Protection
3. Waste disposal
4. Salvage
5. Other services just like property accounting pollution and notice control.

The maintenance engineering department seems to be cure for many other add
activities that no other single department can handle. Although its human increases the
scope of one's department, care must be taken not to dilute the primary responsibilities
of the maintenance area to handle their secondary services.

Research And Developement

 The company's R & D efforts continue to be dictated by the need for market
orientation.

In the face of stiff competition in order to maintain the profit margin, the focus is
on developing products of increased value addition. Accordingly manufacture of seems,
track bolts, automotive and fastener components like steering knuckles, gudgeon pin,
starter motor, pinions are being planned. The fully computerized five-station part
former and bolt washer assembly machine presently under installation and
commissioning/ ordered would facilities this. Stainless steel fasteners and fasteners
which are percolated with micro capsulated anaerobic thread cocking adhesive are
being considered as value added products.

Special products machines and CNC turning centers are being added to the
manufacturing facilities to increase productivity and consistency in quality of special
fasteners, especially for the automotive applications.

Since the tool from the considerable part of the manufacturing cost, in house
heat-treatment of the tools has already started. Plans are being drawn up to introduce
vacuum hardening, organic treatments and other tribological coating coating to improve
the tool life.

In order to cut down development cycle time for special fasteners in the
automotive industry which is the largest consumer's for company's products technical
collaboration is being entered into with a leading manufacturer of automotive fasteners
in the world, the company's efforts on the whole should meet the today's customer's
requirements, namely, zero defects, low cost, just in time delivery and short
development cycle times.

Personal Department
The activities of personnel department are :
 1. Recruitment
2. Training / Placement
3. Welfare activities

Recruitment
It is based upon the workload for a predetermined target and is done with the
consent of the managing director. The qualification standard for each post is laid down
as approved by the M.D.

General Policy

According to the company all the promotions vacancies are fulfilled, through
internal recruitment. Usually recruitment from outside is for the workmen grade
category administration department and trainees in the technical department.

Reservation

For the persons of project area and the state in which the project is situated are
given some preferences for recruitment for the posts of lower grade. All the unskilled
workers can be recruited from the project area and first preference is given to the
persons displaced from the project are a provided they satisfy all other conditions.

In the case of skilled workers, clerks and other staff member whose scale of pay
are comparatively low and whose basic qualification and experience and equal,
preference can be given on the priority as mentioned above. The vacancies are also
notified to the local employment exchange and they sponsor candidates belonging to
the state.In the case of medium level technical and non-technical and non-technical
posts having high salaries, recruitment is done in all Indian Bases.

Training / Placement

The company has different types of training programs. Trainees are trained to
improve the basic skill and work knowledge on the basic machine. After completion of
the two years training, the specialists trainees, Engineer trainees. Technician trainees
and Trade Trainees are posted as Foreman and two increments.

Promotion Guideline

In almost all cases the vacant posts are fulfilled from the concerned section /
department. The promotion guidance lay down a method of determining the eligible
employee who is considered for placement to higher post by promotion principle. The
promotion shall only be to the next higher post in the wage section. Promotion shall be
considered only if there is vacancy in next higher post. For engineers, the vacancy will be
fulfilled based upon test interviews. Promotion of the employees will be considered only
when they have secured a minimum period of eligibility in the lower post. Change of
trade on promotion will be permitted in exceptional cases on the basis tests and
interviews. Promotion of employee should be considered one month after the date of
increment in the lower scale. Promotion will make on the merit and seniority basis.

Welfare activities

As per factory act following are the welfare activities for worker activities for worker and
staff :

a. STATUTORY ACTIVITIES

1. Provision of toilets
2. Provision of drinking water.
3. Separate washing facilities.
4. Sitting facilities inside the factory
5. First-aid and medical facilities.
6. Subsidized canteen facilities
7. Rest room and lunch room
For every 2000 employees there will be one welfare officer. For every additional
500 employees. one additional officer is posted.

b. NON-STATUTORY ACTIVITIES

1. Transportation facilities
2. Quarters / Housing
3. House building allowance scheme
4. Uniforms
5. Recreation activities
6. Death relief
Reference

Reference For This Report Are:

1- H.R.M (Mr. Daljeet Malik) of A.K. Automatics

2- http://seminarprojects.com/s/a-k-automatics-training-report
 Conclusion

The training session at A.K. AUTOMATIC Ltd, ROHTAK was the most enjoyable
session for me. I Joined plant on 25 March 2021 under the guidance of Mr.
Divyanshu(Product dept.) Training session ended on 15 July 2021 and this
report includes the summary of the training.

I learned the manufacturing procedure for production of automobile parts.

It was nice experience for me since I could realize the

importance of production.

At last, I am thankful to Mr. Divyanshu and all the staff of Factory for
providing me an opportunity to enjoy the thrill of production and providing
all the necessary documents and related procedure.