PAKISTAN MACHINE TOOL FACTORY (PVT) LTD

Internship Report

Submitted to:
MR SHOUKAT ALI DGM(E)

Submitted by:
The students from the Mechanical Engineering Department of

Quaid-e-Awam University of Engineering, Science & Technology

Internship Duration
5th June to 22nd June, 2017

Group Members:
Atif Munir 15ME64 Zeeshan Ahmed 15ME38
Arshad Hussain 15ME04 Aamir 14ME67
Sanaullah Soomro 16ME43 Zeeshan Junejo 14ME15
 Contents

Introduction to PMTF
Design Office
CNC
Forging
Production Control
Production Planning
Light Parts (LP)
Machine Assembly
Heavy Parts (HP)
Store
Special Manufacturing (SM)
Tool Design
Tool Room
Heat Treatment
Die-Casting
Maintenance Department
Introduction to PMTF

Pakistan Machine Tool Factory (Pvt) Ltd. (PMTF) is a precision engineering

goods manufacturing enterprise in Pakistan, established in technical collaboration
with M/s. Oerlikon Buhrle & Co. of Switzerland who are the world's renowned
manufacturers of Machine Tools. The factory came into regular production in
1971.

It is located Off National Highway, about 35 Km from Karachi City near Landhi
Industrial Estate and spread over an area of 226 acres out of which 17 acres are
occupied by works. The factory employs about 1900 engineers, technician,
workers and other service staff. The layout of the factory is according to the best
European standards. This factory is a unit of State Engineering Corporation of
Pakistan and is engaged in the production of Machine Tools, Automotive
Transmissions and Axles Components, Gears for Locomotives, Pressure Die Cast
parts and other products.

PMTF has rich experience in Designing and Manufacturing of precision

engineering goods and its facilities include Designing, Machining, Forging, Heat
Treatment, Assembly, Die Casting etc.

PMTF is certified to ISO 9001.Quality Assurance System and has excellent

Quality Control and Testing facilities to meet the international quality requirement.
Design Office:
PMTF design and drawing their products on the behalf on the standards. In the Design
Office, the records of all the standard tools and components that the factory produces
are available through which they create the designs and drawings.
For the purpose of drawing, drawing sheets and CAD softwares (including AutoCAD,
AutoCAD Mechanical etc.) are available design of products, tools, jigs, fixtures, cutters,
forging & die casting dies, gears, equipments, mechanical devices.
In the drawing, some codes are used such as
C-80 for Assembly Drawing
C-70 for Casting/Forging Drawing
Below C-70 Machine Drawing
H- Drawing code for transmission manufacturing.
L- Drawing code for machine tool.
C- Drawing code for weapons.

CNC:
The CNC machine comprises of the computer in which the program is fed for cutting of
the metal of the job as per the requirements. All the cutting processes that are to be
carried out and all the final dimensions are fed into the computer via the program. The
computer thus knows what exactly is to be done and carries out all the cutting
processes. CNC machine tools capable of performing various machining operations
such as turning, planning, milling, drilling, jig boring, thread grinding, deep hole drilling,
gear hobbing, shaping and shaving, gear grinding, spiral bevel gear cutting, broaching
to the close tolerances specified in the design. During the internship, different types of
CNC machines were seen along Spline Rolling Machine (Cold Rolling).

Following are the CNC machines available at the PMTF.

Names Quantity Status Operation
Galaxy 08 Operation (4 only)
Wega 05 Operation
X2 01 Operation
Mandeli 01 Under Maintenance Turning
Lybnks 02 OK
John Ford 01 OK
VMC 04 OK Milling
Grob 01 OK Rolling
Forging:
Following is the Forging Sequence,
i. Raw Material/ Blank: Plan/ Round bars (low carbon alloy steels) are carried
from outside of diameter 36, 45, 60, 80, 90 (centimeters).
ii. Preheating Process: Burning material in R.H Furnace to make red hot coke, at
1250-1300C.
iii. Upsetting Process: Upsetting is another process for pan cake shape of the
material.
iv. Stamping/ Hammering: Drop gravity hammering is use for hammering purpose.
The Forging shop is equipped with two drop hammers of 3000 kg and 1500 kg
Pneumatic hammers of 600 kg and 300 kg.
v. Trimming Process/ Flesh Trimming or Remove: Removing of the extra
material/ ring takes place as scrap.
vi. Inspection: Visual inspection has been done to check forging defect and if any,
then it is separated.
vii. Normalizing Process: Normalizing is done to refine grain, improve machinability
and ductility, and to decrease hardness.
Required BHN 180-200.
viii. Short Blasting Process: This process is to remove burn stuff.
ix. Sending other dept. for further operations.

Production Control:
Production control is the process that keeps a watchful eye on the production flow and
size of resources along with the location, of any deviation from the present action and to
arrange for the prompt adjustment so that the production may run according to the
original or revised schedule.
AREAS OF PRODUCTION CONTROL:
Sub-dividing the master schedule into manufacturing and subsidiary orders
Routing

Scheduling

Dispatching

Expediting

Inspection
Routing: Routing is determining the exact path which will be followed in production. It
is the selection of the path from where each unit have to pass before reaching the final
stage. The stages from which goods are to pass are decided in this process.

Scheduling: Scheduling is the determining of time and date when each operation is
to be commenced or completed. The time and date of manufacturing each component
is fixed in such a way that assembling for final product is not delayed in any way.

Dispatching: Dispatching refers to the process of actually ordering the work to be

done. It involves putting the plan into effect by issuing orders. It is concerned with
starting the process and operation on the basis of route sheets and schedule charts.

Expediting: Expediting is that branch of production control procedure which regulates

the progress of materials and part through the production process.

Inspection: Inspection is the process of ensuring whether the products manufactured

are of requisite quality or not. PMTF has material testing lab to inspect the material
supply by the supplier to ensure that the material quality (hardness, tensile strength,
toughness, etc.) is as per requirement. Material testing lab also tests the chemical
composition of material.

Production Planning:
Production Planning may be said to be a technique of forecasting ahead every step in
the long process of production, taking them at right time and in the right degree and
trying to complete operations at the maximum efficiency.
The production planning department of PMTF consist of three section:
Cost estimation
Production pre-planning
Methodology

Cost Estimation: The production planning department estimate the manufacturing

cost of the product which includes material cost, rejection cost, forging cast,
normalizing cost and machine hour rate.
Production pre-planning: Production pre planning section prepare the
manufacturing lay-out which include all the operation required to make the final
product. Also give the operation instruction O.I where necessary. Then make the
material warrant to issue the material.
Methodology: Methodology section does the time and motion study to estimate
the production time. Calculate the standard time and obtain time and difference
between them.

Light Parts (LP):

Light parts section is generally known to make light parts for the PMTF various
operations have been performed with high accuracy by a skilled and great experienced
worker.
Light part section is divided in four sections
Turning
Milling
Drilling
Grinding

In the turning operation, it was observed that the job is in motion and cutter is fixed
whereas the in milling operation, job is fixed and cutting tool is in motion.

The lathe machines available at the shop are as follow.

PRECISION CENTRE LATHE (MODEL C4C, C4D & C4F)

The milling machines available at the shop are as follow.

MILLING MACHINE (MODEL LK6)

VERTICAL MILLING & BORING MACHINE
MILLING MACHINE (MODEL LK4)
ENGRAVING MACHINE (MODEL LP2)
TURRET MILLING MACHINE (MODEL LK5)
The boring machines available at the shop are as follow.

FOUR WAY BORING MACHINE (MODEL LB1)

The drilling machines available at the shop are as follow.

RADIAL DRILLING MACHINE (MODEL LD1)

In turning section, there are various types of turning machines only difference is the size
of chuck in which the job is fixed into the jaws.
There are five types of grinding at the grinding section, mentioned below
i. Cylindrical Grinding
ii. Internal Grinding
iii. Surface Grinding
iv. Spline Grinding
v. Central load Grinding

Machine Assembly:
In the Machine Assembly section, four types of machines are being assembled enlisted
below.
Lathe Machine (C4)
Milling Machine (Light duty and heavy duty; K4 & K6)
Pillar Drill Machine (Portable)
Hacksaw Machine

Heavy Parts (HP):

Heavy parts section deals with the heavy job comparatively than light parts. It was
observed that the different machineries were working on different jobs including lathe
bed (column), tail stock, carriage etc.
Heavy parts section is divided into three sections, which are as follows
Boring
Drilling
Planning

In boring section, vertical boring machine which moves in x and y axis.

In Drilling sections drilling of heavy parts take place.
In surface planning section, Shrill Milling Machines are used to finish surface and
various other machines are used for planning operation.

Store:
There are two divisions for store: Receive and Dispatch.
If any tool or component is required to any department, the MI (Material Indent) is
created. This MI is approved by MD of the PMTF and then Purchase Order is being
made by the approval of DGM and MD. Store Receiving Dept. (SDR) create RR of the
product after the receiving and then inspection is done and send to the concerned
department. The payment is made through the PCM.
There is also a main store, the big store in the factory.

Special Manufacturing (SM):

S.M section, also called SM-300, SM-300 divided in six sub-sections.
SM-302(Turning)
SM-303(Drilling)
SM-304(Milling)
SM-305(Grinding)
SM-306(Gear Cutting)
SM-307(Special Turning)

In this section, it was observed saw about gears cutting from hob and broaching, also
different types of milling machines (square, shrill vertical) are in advanced use. Gear
cutting section has different types of machines gear cutting machines like (spur, spiral
bevel and straight bevel).

In gear manufacturing, there are following process.

Hobbing process
Shaping process
Gear shaving
Gear grinding

Tool Design:
This department is divided into two main sections.
i. Conventional
ii. CAD
There are four basic sections that are.
i. Tooling System (Brain of the factory)
ii. Die Section
iii. Jigs & Fixtures Section
iv. Equipment Section
Tools are manufactured in accuracy considering micro tolerances.
Jigs and fixture are made in fitting section.
Tool design department, design fixtures, jigs and gauges (Snap Gauges & Plug
Gauges) and broaching.
Tool Room:
The factory has a fully equipped Tool Room facility capable of manufacturing jigs &
fixtures, special tools like drills, gauges, cutters and holding devices, special high
precision machine tools like jig boring, thread grinding, die sinking, relieving lathes,
vertical copying lathes, precision milling machines and special purpose tool grinding of
Swiss and German origin supplements the facility and ensures that all specifications
and tolerances essential for tool room accuracy is met. The Tool Room is linked with
Tool Design Section fully equipped with computer Aided Design facilities and supported
by Metrology section located in same area for precise calibration and control of tool
room products. All recommended international standards are followed for too.

Heat Treatment:
The Heat Treatment shop is the largest and the most well equipped in the country. The
equipment is of French, German and Italian origin. The Facilities has:

For Carburizing and Case Hardening:

Five Sealed Quench Furnaces

Three Gas Fired Pit-type Muffle Furnaces
Two Rotary Hearth Furnaces with Quenching Press
Electrically Heated Tempering Furnace

For Induction Hardening:

Three High Frequency and Medium Frequency Induction

Hardening Machines

For Surface Hardening:

Flame Hardening Machine

For Hardening High Speed Steel:

Salt Bath Furnaces

Hydraulic Presses
Shot Blasting Machines
Sand Blasting Plant
are available for post heat treatment process.
Die-Casting:
Unfortunately this department is no longer in process now a days. But in the past, few
months earlier PMTF die casting department used to manufacture SSGC components
like G4, G1.6.
G4 have two types of component
G4 upper case
G4 bottom case

Other component G1.6, in G1.6 have 4 types of components

GM body
Top cover
Side cover front
Side cover rear

Maintenance Department:
A combination of action carried out to return an item to or restore it to an acceptable
condition. There are six types of Maintenance activities.

Corrective maintenance:
Corrective maintenance is a form of system maintenance which is performed after a
fault to problem emerges in a system, with a goal of restoring operability to the system.
In some cases, it can be impossible to predict or prevent a failure, making corrective
maintenance the only option.
Preventive maintenance:

Preventive maintenance is a schedule of planned maintenance action aimed at the

prevention of breakdowns and failures. The primary goal of preventive maintenance is
to prevent the failure of equipment before it actually occurs.

Reconditioning:

Servicing, readjusting and recalibration equipment or instruments to bring them to near

new or original operational level. Recondition goods are of later model and usually in
better condition than refurbished goods.

Rebuilding:

A process of repairing or replacing worn machine components to restore a machine tool

to its original operating condition and performance level.
Retrofitting:
The changing of the central elements (programmable, controller, computer, numerical
control etc.) of machine or device either in total parts.
i. Fast development and ever changing.

ii. Various types of controls.

iii. Increased operator accessibility and machine capability.

iv. 15% to 20% of rebuild cost.

Refurbishing:

Servicing and renovation of older or damaged equipment to bring it to a workable or

better looking condition, refurbished goods are of older model and usually in worse
condition than reconditioned goods.

Conclusion:
Pakistan Machine Tool Factory is a great factory having vast range of production goods
but its maintenance system is not very efficient due to lack of experienced workers.
Since the company has not hired new engineers since 1998 the company is also facing
lack of engineers. As the maintenance department is a very important department in
any industry the Pakistan Machine Tool Factory is weak in this important part. The lack
of engineers and experienced workers is not only putting bad influence on the
maintenance department but also to the production and other department.
 Report Date: 22nd June, 2017

Preface

This report documents the work done during the summer internship at
PAKISTAN MACHINE TOOL FACTORY (Pvt.) Limited under the guidance
of PMTF staff. The report first shall give an overview of the learning during
the period of internship with technical details.

We have tried our best to keep report simple yet technically correct. We hope
we succeed in our attempt.

Students of QUEST
 Acknowledgments

Simply put, we could not have done this work without the lots of help we
received cheerfully from the whole PMTF. The work culture in PMTF really
motivates. Everybody is such a friendly and cheerful companion here that
works stress is never comes in way.

We would like to special thank Mr. Shoukat Ali (DGM) for providing us a
chance to get this great experience.

Students of QUEST