SIX WEEKS TRAINING REPORT

AT NEW SWAN AUTOCOMP PVT. LTD. From 11th june To 23rd July.

NAME : ROLL NO. : COLLEGE : BRANCH :

Deepinder Singh 80101115008 GURU NANAK DEV ENGG. CLG. PRODUCTION

CONTENTS
Introduction Statistics Achievements Manufacturing Processes Machinery Used Departments Future Plans Improvements Suggested

Introduction
New Swan Group started manufacturing precision fine blanking parts in its early stage, and later developed metal body part and sub-assemblies manufacturing. This Group provides convenience, comfort and safety to their customers. We certainly accomplish their commitment through ever improvement of production with latest technology.& this therefore puts us in the frontline of quality auto spare part manufacturers in India & global Market. This Group provides latest machinery present in the global world at present.

New Swan Autocomp Private Limited

Location Yr. of Establishment Employees Total Space Production Area Sales (2007-08) QS Standard Power / Self Generation Spare Capacity Product Range
2002

Ludhiana, India (Pb)

Assemblies

260 1,17,000 Sq. Ft. 60,000 Sq. Ft. 5.25 US$ Million TS 16949 : 2002 900 KVA 35% Fine Blanked Components &

Core Competence
Second largest co in India for fine blanking part for automobiles as well other applications. Leading group for catering Stamping, Tubular Parts, Welded ,Coated parts, Cold Forged Parts, Door Latches ,Seat Latches, Hood Hinges, Parking Brake Parts, Gear Shifting Mechanism & Assembly , Seat Recliner to most of Indian Automobile as well global tier 1 cos. 100% tooling support from in-house R&D & advance design tool manufacturing centre for world class manufacturing. Capacity of timely development of products with highest quality & accuracy. Capacity of Stamping, Welding, Assembly ,Heat Treatment & Surface Treatment under one roof. In house facility of Testing Lab, Inspection as well all related endurance test for most of item manufactured. 25 % Export of total group sales.

Mission Statement
MISSION New Swan Group is focusing on providing superior products in automotive market. Our mission is to be locally and globally competitive in quality and value. VALUES Whole standard product to our customers through quality, reliability and technology. PEOPLE We encourage the involvement and reward the contribution of each employee. QUALITY Quality is important in everything we do. Quality is everyone's responsibility, and is achieved through continuous improvement. LOCALIZATION We always look for the local supply of materials in order to reduce disadvantage of import through our own development or the coordination of our reliable suppliers. DESIGN & DEVELOPMENT We design and develop our product to serve the requirement of our customers with the latest technology

Group Companies

New Swan Enterprises , Ludhiana

New Swan Autocomp , Ludhiana

New Swan Components , Gurgaon

New Swan Enterprises II , Ludhiana

Quality

Quality Policy: New Swan is TS 16949:2002 Company. New Swan is committed to continuous improvement in quality of its products and services to exceed the customer expectations.

Achievements

Manufacturing Abilities
FINE BLANKING: The plant is equipped with State of Art Technology of Fine Blanking Presses ranging from 80T to 630T. The following are the ranging : TONNAGE 80T 160T 400T 630T NO 1 No 4 No 1 No 1 No MAKE FEINTOOL FEINTOOL HEINRICH SCHMID FEINTOOL

Fine Blanking Facility

630 ton press ( Fein tool make )

Stamping Facility
Press shop and Production
The Plant is Equippped with latest presses ranging from 20t to 250 t most of them with the automation. Total nearly 250 no. of presses . Presses are maintained in manner for continuous work flow.

Welding Facility
MIG Welding

TIG Welding Going for up gradation of the facilities with Robotic welding

Testing Lab
Computerized UTM SST Chamber Cold Chamber & Hot Chamber Splash Chamber Cupping Test Megna flux Machine (Crack Detection) Endurance Testing Facility

Heat Treatment Lab

SQF Heat Treatment Plant Carburising Carbon Nitriding Hardening Microscope for checking microstructure

Tool Room Facilities

Tool room is equipped with latest machines like : VMC - CNC Wire Cut Machines - EDM - CNC Pipe Bending, CNC Strip Forming & Other Latest equipment related to most modernized tool room ie : Hi-tech Drills, Lathes, Grinders Etc

Surface Treatment Facility

Plating plant : - Tri -Valent plating Bright - Alkaline Bright Yellow Green Golden - Zinc Nickel Plating

Standard Room
Standard room is a place in a company where standard and precious measuring instruments are used for accurate measurements ,for checking dimensions of all components or products very accurately . It has a motto to defect the problem and give actual status. It also requires some environmental conditions : 1. Temperature 22 + 2 degree celcius 2. Humidity 50% + 10% (more than 50% ) 3. Pressure should be positive

Imp. Instruments Used

Digital Vernier Calliper (D.V.C) Digital Micrometer (D.M.M) Digital Height Gauge Linear Height Master (L.H.M) Bevel Protector Profile Projector (lens of 10x and 20x) Slip Gauge Box Torque Wrench Tripod Radius Gauges Roughness Tester

Digital Vernier Calliper

Linear Height Gauge

Digital Micrometer

Linear Height Master

Profile Projector

Roughness Tester

Radius Gauge

Imp. Processes in Std. Room

Caliberation Sample Inspection Layout Inspection S.P.C M.S.A Dock Inspection

Caliberation :
Caliberation is a process of caliberating and keeping a record of any changes to a gauge used for checking the components or products by using its tolerances provided . Any changes to a gauge leads to a reissue of a gauge .

It can also be stated as a process in which every single gauge has a particular frequency of time after which the gauge dimensions has to be checked with instruments after particular interval. S.P.C : SPC is a tool, which applies basic statistics to control the process. C.P Process Capability C.P.K Process Capability index C.P >= 1.33 and C.P.K >= 1.67 C.P is always greater than CPK.

M.S.A : Measurement system analysis

R and R R Repeatability (Instruments Variation and within Appraiser ) R Reproducibility (Appraiser Variation and Between Appraiser ) (a) Up to 10% errors Measurement system acceptable.

(b) (10-30)% errors May be acceptable based on importance of acceptance. (c) Over 30% errors Measurement system needs improvement, make every effort to identify the problem and have them removed. BIAS Bias = Observed Avg. Reference Value. ATTRIBUTE STUDY It is only for rec. gauges study (whether its accept the OK pcs. And reject the NG pcs. Or vice versa.) STABILITY STUDY It verifies the Appraiser, Equipments and Environment. LINEARITY STUDY Dock Inspection It verifies the packing standard of the component and pre-dispatch inspection also for the component only.

Types of Gauges used in Caliberation

Receiving Gauges Plug Gauges Snap Gauges Each and every gauge has a upper and lower limit in records which can also be called as its GO and NOGO . For plug gauges its upper limit is NOGO and lower limit is GO whereas it is vice versa for snap gauges.

Each and every gauge has its own speciality and its own purpose :

Plug gauges are the one used for only and only checking holes of different sizes
Receiving gauges are the gauges used mainly for checking its length, breadth and height of a product or component Snap gauges are the one which are used for checking some dimensions for a component . There are also some other types like fixtures which are used for fitting in a machine .

Sample Inspection
Sample inspection is a kind of procedure in which with the help of a drawing we check all the dimensions of a sample or newly designed component with very limited quantity . After checking the sample the report is made named as sample inspection report in which all the dimensions are measured after checking with the instruments also whether the sample is pass or not is mentioned . Some of the mentioned dimensions in this report are c.d , radius , flatness etc.

Layout Inspection
Layout Inspection is the complete measurement of all part dimensions shown on the design record. A layout inspection is required for some customers for all products annually unless another frequency is established in a customer approved control plan. In this inspection all the minor and major readings of the product are checked completely as shown in the drawing of the component issued by the company whose product is to be made.

Other Specialities
Other Facilities Like Expert Design Department Equiped with Workstations and Softwares like Autocad, Solidworks Etc. Various Type of Coating and Surface Treatments, Powder Coating, Cold Forging, are also done in the works

Details of Press Shop

POWER PRESS CAPACITY 250T 150T 100T 75T 50T 30T 20T 10T 5T NOS 1 2 6 4 2 23 1 3 2

HYDRULIC PRESS CAPACITY 80T 160T 400T 630T NOS 1 4 1 1

Detail of hydraulic press Total capacity 80t Max shut ht Min shut ht Max cutting force Total capacity 150t Max shut ht Min shut ht Max cutting force Total capacity 400t Max shut ht Min shut ht Max cutting force Total capacity 630t Max shut ht Min shut ht 400 320 400 360 220t 265 230 100t 215 200 40t

Details of Machine Shop

TYPE Lathe CNC lathe (8 tools) Bench grinder Grinder Edm Wirecut Drill machines Special purpose lathe Broaching Sletion Centre less grinding Special purpose lathe Buffing Boring NOS 6 1 2 6 1 1 20 3 1 1 1 1 1 1

Details of Welding shop

MIG WELDING 18 SETS

PROJECTION WELDING

3 SETS

Raw Materials Used

Carbon Steel -- CRCA, C45,C55, C60, C80, SK5,CS4, Alloy Steel Stainless Steel -- 16MnCr5, SCM 415, SCM 435 -- 304, 409, 304L,439

Special Steel -- 11SMn30

Components or Products
Sheet metal assemblies ,door latches,parking brakes

Fine blanked and other components

Future Plans
To Strengthen the Product line for 4 Wheeler Automobile Segment
To Upgrade the manufacturing Facility with Latest Technologies Setting up new manufacturing plants in various places closer to customers.