JOSTS ENGINEERING CO.

LTD
SUMMER INTERNSHIP REPORT
(10/6/2013 - 15/7/2013)

Submitted by:
Kavyesh M Nair
Second year B.E. student
Saraswati College of Engineering, Kharghar
7/16/2013





2


INDEX



Sr. No. CONTENTS PAGE NO.
1. Acknowledgement 3
2. Introduction 4
3. Production Department 5
4. Daily Internship Report 6
5. Process Chart 11
6. Quality Assurance and 12
Quality Control
7. Product Description 15
8. Conclusion 16

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ACKNOWLDGEMENT
I am very thankful to JOSTS ENGINEERING COMPANY LIMITED for giving me an opportunity
to undertake my summer training at their prestigious MATERIAL HANDLING EQUIPMENTS
MANUFACTURING PLANT. It was a very good learning experience for me to have worked at this
plant. I would like to convey my heartiest thanks to Mr. Chitale, Senior Factory Manager, who heartily
welcomed me for the internship. I would also like to give my heart-felt thanks to Mr. Production
Manager, Mr. who guided and encouraged me all through the summer training and imparted in-depth
knowledge about various manufacturing processes. Also I would like to thank Mr. who assisted and
guided me whenever I needed help. I would like to thank all the department heads for giving their
precious time and valuable guidance during my internship programme.
Last, but not the least, I would like to thank all the staff at JOSTS Engineering Company Limited, for
being so helpful during this summer training.






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INTRODUCTION
ABOUT THE ORGANIZATION
Established in 1907 as a fan supply and engineering company limited, Carl Jost started this esteemed
company with the manufacture and supply of kerosene operated fans. The companys name was later
changed to JOSTS Engineering Company Limited in 1930 owing to its multifaceted production line. By
1950, JOSTS emerged as important manufacturer and supplier of material handling equipments and
technology based engineering solutions. JOSTS paint application products and systems along with
Combustion systems were integrated into a separate division, by 2005. By 2007 JOSTS organized into
three core business areas viz.

Material Handling Department
Industrial Finishing Division
Engineered Products Division


Material Handling Department
JOSTS Material Handling Division is committed to provide innovative material handing solutions
for internal material handling needs of its customers to improve the efficiency of their processes.
Saving labor, time, space and material is the result of effective material handling. JOSTS pioneered
the concept of internal material handling among industries in India. The popular JUMBO, PYGMY
& JOTRUK brands produced by JOSTS are synonymous with internal material handling equipment.
JOSTS has been serving various segments of industry with excellent sales and service support and
delivering value by the virtue of its experience in the field.
JOSTS offers customized "all-round solutions" for stacking, transporting, warehousing. A
comprehensive range of material handling products and consulting covers the entire field of intra-
logistics. This includes planning and implementation of complete logistic systems. And all this
comes with a broad spectrum of services which offer an economical solution for every kind of need.



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PRODUCTION DEPARTMENT
ORAGANIZATIONAL CHART


DEPARTMENT PROFILE
The main functions of the department are
1. To carry out the production as per the Production and Dispatch plan
2. To carry out the production processes such as Sub Assembly, Final Assembly, Electrical
Assembly, Fabrication and Painting based on the inputs given by PPC.
3. Stage inspection of components and assemblies.
4. Controlling of non confirming components
5. Ensuring the safety and good housekeeping practice during the production processes.
6. Maintaining the drawings, layout diagrams, relevant records related to production.
7. Reviewing the effectiveness of corrective action taken.


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DAILY REPORT


WEEK 1

DAY 1 Over view of various products and services provided
DAY 2
Study of Sub- Assembly:
JoTruk
1.Main Chassis
2.Front Axle
DAY 3
Study of Sub- Assembly:
JoTruk
1.Rear Axle
2.Steering Mechanism
DAY 4
Study of Sub- Assembly:
JoTruk
1.Traction Motor
2.GearBox with Propeller shaft
DAY 5
Study of Sub- Assembly:
Jotruk
1. Brake System
2. Platform
DAY 6
Study of Sub- Assembly:
JoTruk
1.Electric Controller
2. Battery

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WEEK 2

DAY 1
Study Of Final Assembly:
Jotruk
DAY 2
Study of various Fabrication Processes:
1.Cutting
2.Shearing
3.Drilling
4.Nibbling
5. Gauging
6.Embossing/Levering
7.Welding
MIG welding
Co
2
welding
CNC Machining
DAY 3
DAY 4
Study of Sub Assembly:
JumboElectric
1.Transmission Unit
2.Break Mechanism
DAY 5
Study of Sub Assembly:
JumboElectric
1.TopShaft
2.BottomShaft
3.FrontCover
DAY 6
Study of Sub Assembly:
JumboElectric
1.GearBox
2.Pinion and Sprocket
3.Chain Adjusting Sprocket



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WEEK 3

DAY 1
Study of Sub Assembly:
JumboElectric
1.Rear Axle and Wheel
2. Hydraulic Ram
DAY 2
Study of Sub Assembly:
JumboElectric
1.Control Panel
2.Reverse-Forward Switch ,Accelerator
3.Chassis Accessories
DAY 3
Study of Final Assembly:
JumboElectric
DAY 4
Study of Sub Assembly:
Forklift(Battery)
1.Transmission Drive
2.Drive Axle
DAY 5
DAY 6
Study of Sub Assembly:
Forklift(Battery)
1.Rear Wheel



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WEEK 4

DAY 1
Study of Sub Assembly:
Forklift(Battery)
1.Mast
2.Load Chain
3.Chain Roller Bracket
DAY 2
Study of Sub Assembly:
Forklift(Battery)
1.Fork
DAY 3
Study of Sub Assembly:
Forklift(Battery)
1.Tilt Cylinder
2.Middle Cylinder
DAY 4
Study of Sub Assembly:
Forklift(Battery)
1.Master Cylinder
DAY 5
Study of Sub Assembly:
Forklift(Battery)
1.Chassis Accessories
2.Electrical System
DAY 6
Study of Final Assembly:
Forklift(Battery)

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WEEK 5

DAY 1
Study of Sub Assembly:
EJE
1.Chassis
2. Transmission
DAY 2
Study of Sub Assembly:
EJE
1.Steering/Control Handle
DAY 3
Study of Sub Assembly:
EJE
1.Hoist Frame Lifting Device
2.Hydraulic System
3.Electric System
DAY 4
Study of Final Assembly:
EJE
DAY 5
Study of Various Quality Control Measures
DAY 6

11

PROCESS CHART


12

QUALITY ASSURANCE
AND
QUALITY CONTROL

At JOSTS Engineering, Quality Standards have been internalized and documented in Quality Assurance
manuals. JOSTS Engineering recognizes the crucial significance of human element in ensuring quality.
Well designed training programmes ensure that every employee is conscious of his/her role and
responsibility. JOSTS Engineering has a well established and documented Quality Management System
and is taking appropriate steps to improve its effectiveness in accordance with the requirements of ISO
9001:2008. Relevant procedures established clearly specify the criteria and methods for effective
operation, control and necessary resources and information to support the operation and monitoring of
these processes.

QUALITY IMPLEMENTATION AT SHOP FLOOR
JOSTS Engineering has established procedures for monitoring measuring and analyzing of the various
processes and to take necessary actions to achieve planned results and continual improvement of these
processes. It has also maintained relevant procedures to identify and exercise required control over
outsourced processes, if any. Systems and procedure have been established for implementing the
requisites at all stages of production.

LIST OF QUALITY CONTROL RECORDS
1. Check sheets: Assembly
2. Check sheets: Fabrication and Painting
3. Check sheet: Electrical
4. Resource and Productivity Calculations
5. Drawing and Wiring Layouts
6. Records of Measurements and Monitoring of processes
7. Records of Measurement of Performance
8. Corrective and Precaution Action records

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PRODUCT DESCRIPTION
JOTRUK

These platform trucks come with extremely high degree of maneuverability and are indispensable for the
economical transport of goods inside workshops as well as for outside applications like inter plant
transportations. These trucks have enormous tractive force which can be driven continuously for about
30 minutes

Jotruk consists of following Sub Assemblies:
A. Main Chassis
B. Front Axle
C. Steering Mechanism
D. Rear Axle
E. Gearbox with Propeller shaft
F. Traction Motor
G. Brake Systems
H. Drive controller
I. Platform
J. Battery









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A. Main Chassis
The main chassis is fabricated from M.M channels and angles. The front frame is enclosed with sheet
metal cover to support control panel and head lights are mounted on it

B. Front Axle
Main central axle, two stub axles, axle pins, brake units wheel hub with taper roller bearing and seals
together constitute the front axle
Front axle is mounted to main Chassis with leaf springs and shock absorber
Two solid non skid rubber bonded tyres are mounted on wheel hub

C. Steering Mechanism
The steering mechanism consists of common automotive type worm gear, steering gear box, round
steering hand wheel, drop arm, steering linkages and ball joints through connecting rod to stub axle link
and tie rod

D. Rear Axle
Consists of steel axle tube, differential casing, housing bevel crown wheel, pinion, cross shaft and
planetary gear set, special steel axles, wheel hubs with taper roller bearing, oil seals and break units

E. Gear Box with Propeller Shaft
A fully enclosed oil bathed gear box mounted directly on motor consist of helical gears of special steels
The P.T.O shaft of gear box is connected to rear axle differential input shaft with universal couplings
through spline type sleep action propeller shaft

F. Traction Motor
The D.C. series wound F class insulated totally enclosed motor of igh torque capacity rated to 3.5 HP-
1700 rpm and 36 volts
It is rated for one hour continuous traction duty

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G, Brake Systems
The Break system consists of internally expanding double shoe type hydraulic brake units and special
cast brake drums on rear wheels operated by a foot pedal through Master cylinder. Hand brake is also
provided for parking purpose.

H. Drive Controller
Microprocessor based MOFSET controller for smooth and step less control of speed and acceleration.
The controller circuit has high life cycle contactors. Alternatively four step resistance control is installed

I .Platform
The platform is from M.S. plate. A M.S chequered plate cut into two halves is fitted onto each other and
fixed on main chassis which is well supported by means of angles and channel with nut bolt and rested
on rubber shock absorbing pads

J .Battery
The vehicle is fitted with lead acid traction battery 36V/299Amps.















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CONCLUSION

On the whole it was a great learning experience. The company has a great vision and work culture.
The employees were very friendly and eagerly shared their knowledge and experiences with me. I
learned a lot about various aspects of production system and cutting edge manufacturing
technologies used at the plant. I am sure that this experience will greatly help me in shaping my
future career.