Internship at RNAIPL

56
INDUSTRIAL INTERNSHIP REVIEW (MEE 399) ON AUTOMOBILE MANUFACTURING Internship at Renault Nissan Automotive India Private Limited (RNAIPL) By : MAHENDRA SINGH SISODIA (11BME1051) MARCH 2014

description

Basically it is a point point presentation of the work which I have done / observed during my internship at RNAIPL. When I started making this PPT, I was in great confusion about how a internship PPT looks like. I think it would help many of you. Please let me know if there is any mistake in this PPT , so that I could make a note of it and would not repeat that mistake further. thank you

Transcript of Internship at RNAIPL

Page 1: Internship at RNAIPL

INDUSTRIAL INTERNSHIP REVIEW

(MEE 399)

ON

AUTOMOBILE MANUFACTURING

Internship at Renault Nissan Automotive India Private Limited (RNAIPL)

By : MAHENDRA SINGH SISODIA (11BME1051)

MARCH 2014

Page 2: Internship at RNAIPL

Objectives of internship• To work cooperatively in the company for 28 days

internship as required by the VIT University Chennai Campus.

• To get acquaintance with the functional and operational activities of the company

• To study about how various manufacturing concepts, tools and techniques that we studied are theoretically and practically applied in an industry.

Page 3: Internship at RNAIPL

About Renault-Nissan• The first dedicated Alliance between Nissans and Renaults. Renault–Nissan

Alliance is a strategic Franco-Japanese partnership between automobile manufacturers Renault, based in Paris, France, and Nissan, based in Yokohama, Japan, which together sell more than one in 10 cars worldwide since 1999. It is a modern and highly efficient plant producing top quality cars. But there’s more which also produces zero emission cars. It’s now officially one of India’s safest and most environmentally-friendly factories, too. That’s according to the Confederation of Indian Industry (CII), which has given the plant its top award for excellence in Environmental Health and Safety.

• In February 2008, the Renault-Nissan Alliance signed a MOU with Government of Tamil Nadu to set up a manufacturing plant at Oragadam, near Chennai with a minimum investment of Rs. 4500 Crore over a period of seven years. On March 17, 2010, the Renault-Nissan alliance plant was inaugurated in a record time of 21 months since its groundbreaking ceremony in June 2008. The Plant has an initial capacity of 2, 00,000 units per year and planned to reach 4, 00,000 units per year in full capacity.

Page 4: Internship at RNAIPL

Working Ideology

RNAIPL gives very much importance to the following in production

• Safety • Quality• Cost

Page 5: Internship at RNAIPL

Vehicles Manufactured at RNAIPL

• Renault

• Renault Fluence Renault Koleos • Renault Pulse • Renault Duster Renault Scala

• Nissan• Nissan X-Trail Nissan Teana• Nissan 370Z• Nissan Micra Nissan Sunny

Page 6: Internship at RNAIPL

Renault Duster

Nissan Micra

Nissan Sunny

Page 7: Internship at RNAIPL

MECHANICAL UTILITY SYSTEMS

COMPRESSORSDRYERSHEAT EXCHANGERSPUMPSCOOLING TOWERS

Page 8: Internship at RNAIPL

COMPRESSOR(future)

AIR RECEIVER

AIR RECEIVER

SCREWCOMPRESSOR(7400 Nm3/Hr)

DRYER(9400 Nm3/Hr)

DRYER(9400 Nm3/Hr)

DRYER(9400 Nm3/Hr)

DRYER(7400 Nm3/Hr)

DRYER(7400 Nm3/Hr)

TURBO COMPRESSOR(9400 Nm3/Hr)

TURBO COMPRESSOR(9400 Nm3/Hr)

TURBO COMPRESSOR(9400 Nm3/Hr)

CWR

CWS

COMPRESSED AIR (7 BAR)

CAHM

CALM

COOLING TOWER

CA

CWS

CWR

TO SHOP FLOOR

(6 BAR)

HEADER

PRIMARY

PUMPS

COMPRESSED AIR & DRYER FLOW PROCESS CHART

Page 9: Internship at RNAIPL

SUCTION FILTER

AFTERCOOLER

INTERCOOLER

(STAGE - I)LOW

PRESSURE

(STAGE - II)HIGH

PRESSURE

AIR RECEIVER

DRYER

COOLING TOWER

TO PLANT

(2 BAR)

(6.5 - 7 BAR)

(6 BAR)

SCHEMATIC DIAGRAM FOR COMPRESSOR

Page 10: Internship at RNAIPL

PRIMARYPUMPS

PHE

PHE

PHE

PHESEC.PUMP

SEC.PUMP

SEC.PUMP

SEC.PUMP

SEC.PUMP

STAMPING SHOP

BODYSHOP

HEADER

HEADER

CWS

CWR

CWS

CWS

CWS

COOLING TOWER

SCHEMATIC DIAGRAM OF PLATE HEAT EXCHANGER

Page 11: Internship at RNAIPL

SCHEMATIC DIAGRAM OF INDUCED COUNTERFLOW TYPE COOLING TOWER

Page 12: Internship at RNAIPL

WTP (Water Treatment Plant)

• It treats the raw and rain water. Rainwater are collected through surface ponds. • The First main step of WTP is pre-treatment of water before entering RO (Reverse

Osmosis )system.• In WTP Actiflo method is adopted to remove the suspended solids.Actiflo method

is a physico chemical treatment plant. This method has advantage of efficient removal of heavy metal from water.• Then the water is send to Press Sand Filter( PSF) and then to Activated Carbon

Filter (ACF).• Then the water is send to MGF (Multi Grade Filter) , then to anti scalant

dechlorination. The water is then is then send to micron cartride filter (5 micron).• And after first RO, it is feed to the 2nd R0 where every particle are removes and

water for UV filtration is sent in UV Filtration is used to avoid micro organism growth. Its capacity is 10 micro /secs made free from everything and feed to pain shop for painting.

Page 13: Internship at RNAIPL

WWTP (Waste Water Treatment Plant)

• The WWTP gets water from paint shop, water used for hand wash and remaining water from central kitchen is collected at GA &GB tank.

• Then waste water in the tank is uniformly mixed by supplying air. The waste water then moves to the DAF (Dissolved Air flotation) for oil separation. Then lime and alum is added as PH booster.

• Then the polyelectrolyte is added for coagulation. It is kept for 5 hours as the retention time. This water is feed to clarriflocculator (combination of flocculator and the clarifier), this is done to remove heavy metals like zinc, phosphates. Sludge water is moved to the sludge deposit bed where where sludge is removed , then filteration takes place and water is again fed to the collection tank. Then the ferric chloride is added for PH neutralization.

• It is feed to biological tank / aeration tank, here microbial activity takes place. This is done to reduce COD(Chemical Oxygen Demand), BOD (Bio chemical Oxygen demand).COD is reduced to less than 250 and BOD is reduced to less than 20

Page 14: Internship at RNAIPL

• The water is then send to MDR (membrane separation) where suspended particle is removed. To reduce smell we use carbon filter. Then the water is send to MGF (Multi Grade Filter) , then to anti scalant dechlorination. The water is then is then send to micron cartride filter .

• At last water is send to RO plant.The WWTP treated water is used in cooling tower and car washing before painting and for toilet flushes. The sluges are collected to bags and given to govt for disposal.

Clarriflocculator

Page 15: Internship at RNAIPL

BMS (Building Management System)A Building Management System (BMS) is a computer-based control system installed in buildings that controls and monitors the building’s mechanical and electrical equipments. It consists of hardware's and software's.

All the information about utilities (driers, compressors etc.) like operating status, present conditions (pressure, temperature, and flow rate) is transmitted through sensors to BMS. In BMS five displays are using that display the operating status of the all utilities. One main display is used for main control. For safety automatic alarm system is there. If any problem occurs in any utility system then alarm rings and displays show the place where problem occurs.

It also display’s about the problem. It is very fast and time saving system because through these system we can easily know the location of problem, so it’s easy for any specific person to go there and solve the problem so it helps in avoiding the checking of all utilities.

Page 16: Internship at RNAIPL

BMS LPG yard details

Page 17: Internship at RNAIPL

PROCESS TEAM

INPUT

PROJECT ENGINEERING TEAM

VALIDATE & CHECK

DESIGN OF SYSTEMS

VALIDATE & CHECK & PREPARE BOQ

PURCHASE TEAM

TENDER FLOATING TO CONTRACTORS

TECHNICAL ALIGNMENT MEETING

NO YES

YES

YES

NO

TECHNICAL ALIGNMENT MEETING

FINAL BOQ (Technically aligned BOQ)

RNPO

TENDER FLOATING

RESEND QUOTATION

NEGOTIATION BY RNPO

SUPPLIER FINALISATION

PROJECT STRUCTURE AT RNAIPL (PHASE – I)

Page 18: Internship at RNAIPL

KICK OF MEETING

START OF PROJECT

DRAWING APPROVAL DESIGN APPROVAL PROGRESS REVIEW MEET SCHEDULE MONITORING

SCHEDULE MODE OF WORKING WORK METHOD RULES & REGULATIONS

PROJECT COMPLETION

QC &

PREPARING SNAG LIST

SAFETY AUDIT(PRIMARY & SECONDARY)

PREPARE REPORT

CLOSING OF SNAG LIST

HAND OVER TO MAINTANENCE

PROJECT STRUCTURE AT RNAIPL (PHASE – II)

Page 19: Internship at RNAIPL

COIL

STAMPING SHOP

BODY SHOP

TRIM AND CHASIS SHOP

CAR

Manufacturing process of a car goes under these process. This process is also known as

VEHICLE CHAIN

Page 20: Internship at RNAIPL

Stamping Shop

In stamping shop body parts of the car are manufactured using steel sheet alloy. Following sequence is followed in the stamping shop.

1. Blanking2. Pressing and Piercing3. Quality checking

Page 21: Internship at RNAIPL

Layout of blanking line

Page 22: Internship at RNAIPL

Blanking Process

1. Coil-Car: Coils of steel sheet is pick up by crane and transferred to coil-car that transfer the coil to uncoiler.

2. Uncoiler and advance correction machine: It sets the inner diameter of coil to the center of the line by holding device that remove rolling habit of the tip of the coil.

3. Washing: The device that removes the foreign material that has adhered to the coil which is done by oil with the help of roller.

4. Leveler: used for levelling the blank by correcting the shape of the steel sheet and makes it smooth. It works on the principle of less than 1 mm tollerence .

5. Looping: In this process steel plate is stretched into the pit and all the bends are removed.

6. Feeder: Device that adjusts the coil material to press cycle and set the cutting length and sends it to piler.

7. Press: It press the steel sheet and cut the steel into required dimension. Press can be rotated at required angle to cut the steel plate at any angle.

8. Piler: The device that piles the cut material with accuracy. From here cut material are transferred to pressing line. There are Two Piler zone here.

Page 23: Internship at RNAIPL

Pressing and piercing Line

Here are three pressing lines.

Pressing Lines

Line-3 (5400 ton)

L-Line (2400 ton)

XL-Line (5400 ton)

For pressing of larger parts

For pressing of larger parts

For pressing of small parts

Page 24: Internship at RNAIPL

Pressing and piercing Line

Cont.Each line have 4 presses.

PB: By this press,shape is given to steel plate by using specific die according to drawing.

PC: By this press side or extra material is removed. PD: By this press Piercing is done. PE: By this press specific holes is made.

XL LINE AND LINE-3

PB

PC

PD

PE

2400 ton

1000 ton

1000 ton

1000 ton

L-LINE

PB1200 ton

PC400 ton

PD400 ton

PE400 ton

Page 25: Internship at RNAIPL

Layout of stamping line

Page 26: Internship at RNAIPL

BODY SHOP

• Place where the main manufacturing of car body takes place. The car body design manufacturing is done by skilled engineer who have their work divided.

• The parts which have been designed in the stamping shops come here for assembling. engine compartments and mounting points, chassis, hood, front cabin, rare cabin etc are made in the stamping shop while others are supplied by vendors like JBM, Unipress, Technico. Unipress is the major supplier.

• Most of the parts are welded using spot welding while MAG welding is done for filling.

• Most of the welding is done manually but welding of few parts are done using Robots.

Page 27: Internship at RNAIPL

• Body shop consist of two main line, six sub lines and 290 sub stations. • The main base of the car is not manufactured or designed , rather the sill plate

is supplied by the supplier in three pieces which are welded to the part they have designed.

• In the first sub line the engine compartment, the front cabin and the rear cabin are assembled using spot welding which is manually done.

• In the second sub line nearby parts of engine, doors, hoods are assembled using welding and nuts.

• In main assembly line side doors, back doors, hood is assembled using automatic nut runner machine. Finally quality checking is done of car body.

• Each car is given with the serial number which corresponds to the paint colour. • The body is sent to the metal line, where the aesthetics, finish doors, any

bumps or the dent or spots are check, If found the body is sent to the sideways where it is sent or tested for the faults. Finally the car from the body shop is sent to paint shop.

Page 28: Internship at RNAIPL
Page 29: Internship at RNAIPL
Page 30: Internship at RNAIPL

Paint shop

• The car body after the body shop is move to this shop for painting. Car body is moved on hanger.

• In paint shop there are two lines i.e. Line: 1 and Line: 2. both lines does the same work.

Page 31: Internship at RNAIPL

Pre treatment line1. Pre-Degreaser-Washing using chemicals and safely removal of oils, greases,

fats and carbon deposited on the car body.

2. Degreaser-2 .- Final washing with chemicals of car’s body.

3. Pre-Raw water Rinse. -Here, car body is washed using raw water of specific ph.

4. Raw water Rinse - Again washed with raw water of specific ph.

5. Conditioner- It is used to make the car body surface rough. Because at rough surfaces coating more adheres.

6. Phosphate treatment zone- car body is coated with phosphate for providing metal cleanliness and corrosion protection to the surface of the car body.

7. Pre-DI (Deionized) water Rinse zone- DI water bath is given to car body. For DI Water rinse Fresh de-ionized water is used that is cleaner than drinking water. If any contamination remains on the surface before the ED coating, it will cause the application issue and raise the potential for product failure.

8. DI water Rinse (D/P). -Final DI water bath is given to car body.

Page 32: Internship at RNAIPL

Electro Deposit Line (ED-Line)

It has 3 stages.

1. ED-Bath-At this stage car body is covered with ED Paint. ED (Electro-deposition) paint (cationic) is used as a primer for car bodies. It imparts rust resistance and chipping resistance to the car body.

2. UF-(Ultra Filtrate)-1-The paint bath can be contaminated with pre-treatment chemicals like e.g. phosphates, chlorides, and chromates. So, a part of ultra-filtrate has to be leaded out to avoid contamination of the paint bath with these chemicals. This process also removes excess paint.

3. Fresh water and Tilting stage-After UF stage car body is washed with fresh water. After washing the car body is tilted to remove all the water and waste paint from the car body. Then car is tilted back to its initial position.

Here ED Line ends.

Cont.

Page 33: Internship at RNAIPL

ED-OVEN

Sealant is applied at every exterior edge of the car. Sealant is used to resist the leakage through the car body. Then car body passes through the Sealer Oven for drying the sealant. Temperature of the varies 150 to 200 degrees.

Sealer-Zone

Then car body passes through the ED Sanding Zone. Here, extra paint is removed to make ED paint layer uniform. This process is completely manual. First workers check the ED paint layer and then remove extra paint using Sanding paper.

ED sanding zone

Car body passes through the ED Oven for drying the ED paint. First, air is heated and passed through oven chamber then car body passes through the chamber. Thus ED paint is dried by hot air. The temperature at the oven varies from 170 C to 200 C. Again after the oven the thickness of the paint is checked manually.

Page 34: Internship at RNAIPL

Body arranging zone

It has 3 lines.

• Side line• Main Line• Repair Line

Page 35: Internship at RNAIPL

Body arranging zone contd.Cont.When car body enters at storage are then barcode of car body is scanned, a paper having code is given at the ED sanding shop , the scanned data is sent to the CCR (central control room) panel.

Then the end of ED sanding involves 3 lines. In First and second line the body are arranged according to FIFO(First In First Out) technique, in which the car body of same color are arranged first for time management. If any car body of different color comes in that line then it will be shifted to side line till it groups with another bodies of same color. It is fully automated process according to the color car bodies are arranged automatically in their respective line.

If after the ED Sanding stage body paint is not uniform or if some other faults are found in ED paint then car body is transferred to repair line. From here body is sent to repair zone for repairing.

Page 36: Internship at RNAIPL

Dust Off zoneDust from the body is removed before painting. So that dust doesn’t contaminate the paint. Feathers of Emu bird are used for dust removal. The reason behind using EMU bird feathers is that the feathers has long life.

• ACC (Anti corrosion Coating) (only for foreign country vehicle)• Primer coat (Sprayed by robots) (35 micron thickness)• Primer Paint (Manually for more accuracy)• Primer flash off zone (Drying of primer paint)• Base Zone (For main paint, first sprayed by robots ,then

manually) (70 micron thickness)• Base flash off zone (Drying of base paint)• Clear Zone (For clearing car surface for shining, First by

robots then manually for more shining purpose.)

TOPCOAT ZoneIn this zone car is painted through following zone.

Car body is transferred to Trim & Chassis shop

Page 37: Internship at RNAIPL

The main purpose of this shop is to mold the parts. The parts include the bumper, mirror cover and finisher. The waste plastic material is again used in order to avoid wastage. The waste material which is used for the first time is called virgin material and the waste material which is used for more than one time is called reused material.

The process starts from the plastic i.e. polypropene (PPE) which is supplied by the supplier is stored. The pure polypropene and the grinded body part that has produced by grinding the defected parts is sent to the drying chamber where the moisture is removed.

The PPE are then passed to the blending machine which uses vaccum to transfer the PPE. The two purpose of blending machine are that it act as a carrier between the dryer and extrusion machine just like an intermediate and it also mixes the pure and impure

The PPE are then moved to the intrusion machine. There are three intrusion machine in the plastic shop two are mechanically operated while one is electrically operated. In the extrusion machine the necessary operation take place like plasticizing the PPE and mold into the shape take place. The temperature for plasticizing is 200 C.

Plastic shop

Page 38: Internship at RNAIPL

The heating takes time till the temperature reaches the melting point of PPE ,thus it will be time consuming hence production will be effected. So the heating is done before the die is loaded to the extrusion chamber. Cooling is done using water as coolant. The coolant control system is placed near the extrusion machine for quick accesses.

• Electrical molding machine is preferable because it requires less maintenance and works with good accuracy. In both types of machines hydraulic forces are applied.

• The time for extruding the one part is 28 seconds approximately. The time require for changing the mold is 8 minute 20 seconds approximately which is a programmed technique for changing the die. . For changing the mold for different units QMC (Quick Mold Change) System is used. It is completely automated and controlled by PLC.

The parts has been produced are collected by the robot which places them on to the conveyor. At the end of manually the defects are checked and then the parts are then send to the plastic paint shop.

Page 39: Internship at RNAIPL

Bumper Paint Shop

In this mainly the plastic body like bumper, finisher and mirror cover are painted as well as finishing ,mostly in the same way as main body. Here, punching and drilling operation are done for generating holes in bumpers

In this zone bumper is painted through following zone.

• Heating Zone (Low speed conveyor) (bumper is heated. For heating fire is applied by the two robots. Fire flame length is 250 mm)

• Dust off zone (air is applied to bumper surface for clean the dust.)• Primer coat (Sprayed by robots)• Primer Paint (Manually for more accuracy)• Primer flash off zone (Drying of primer paint)• Base Zone (For main paint, first sprayed by robots ,then manually)• Base flash off zone (Drying of base paint)• Clear Zone (For clearing car surface for shining, First by robots then

manually for more shining purpose.)• Backing Zone 1 & 2- (High Speed Conveyor) Both backing zones are

maintained at 120 degree Celsius temperature. By passing hot air in banking chamber paint is dried. Then bumper is shifted from high speed conveyor to low speed conveyor

Page 40: Internship at RNAIPL

Bumper Paint Shop

Cont.• Quality checking-Here, quality inspection is done. If any fault found in bumper then it is sent for repair. If no fault is found then bumper is unloaded from low speed conveyor and sent to vehicle chain.

After final painting process piercing robot is used to generate holes in bumper

Robots generate small holes in bumper by drilling operation. Holes are used for placing small sensors in bumper. Rare punching machine: It is used to generate big holes in bumper. These holes are used for placing little big sensors, lights and other components.Front punching machine: It is used for generate big holes in rare bumper and Front punching machine is used for generate big holes in front bumper

Page 41: Internship at RNAIPL

Trim and Chassis shop

• Here all the components of car are assembled. In this department the body from the paint shop is brought into the trim and chassis department.

• Initially the body is under the PBS( paint body storage). The body from the paint body is stored. The body is brought under the conveyor which is under the CCR (central control room).

• SCM (Supply chain Management) area contains all the parts which are supplied by CCR (Central Control Room).

• The green signals are passed whether the parts are been supplied for the body are for Micra, Duster or any other and thus help is avoiding mishandling.

Page 42: Internship at RNAIPL

There are two main lines Line-1 and Line-2. Both lines are same.

• At each line total 31 stations are there. • At each station 3-4 parts are assembled in car body.• There are six sub lines in each main line:

Primary line Trim Line Chassis Trim line Engine assembly Pre final Tester Line

Cont.

Page 43: Internship at RNAIPL

Cont. Primary line- Car body comes from paint shop. Doors are separated. Trim Line- Interior components are assembled manually. Ex. Seat

belt, floor cover ,Front and rear glass ,CMM (Speedometer, Tachometer etc.). CCR controls the assembly.

Chassis and Engine Assembly line – Exterior parts are assembled. Ex. engine, suspension system, exhaust system, fuel tank, exhaust heat observer, brake system Chassis and Trim line- All assembled components are checked. front and rear wheels.

Pre-final line- pre final line brake oil, fuel and coolant are filled using combo filling machine. (The brake oil depend on the countries climatic conditions and thus chosen accordingly.)

Final Line- Doors are assembled. Tester Line- wheel alignment, Speed, braking system, Leakage are

tested.

Test Drive and Sale

Page 44: Internship at RNAIPL

Internal component assembly

Page 45: Internship at RNAIPL

Engine fitting in car at Trim and Chassis shop

Page 46: Internship at RNAIPL

Tester Line

Page 47: Internship at RNAIPL

Power Train Line

Three Lines are here

• JXX gear box assembly line• Engine Line:1• Engine Line:2

Page 48: Internship at RNAIPL

Cont.

Gear box assembly Line Process

1. Gear box Scanning2. Assembly of gears.3. Gear shifter (for 1st and 2nd gear) attached to

secondary shaft4. Primary shaft, secondary shaft with gear shifter

and differential are assembled in clutch housing5. Gear shifters for 3rd, 4th and reverse gear are

assembled with both shafts. 6. Differential housing is assembled with clutch

housing 7. By using mechanical housing tire side of the gear

box is closed8. In gear box a magnet is placed

Page 49: Internship at RNAIPL

Cont.

Gear box assembly Line Process

9. Primary shaft thickness measurement10. Sealant Deposition11. Then mechanical and clutch gear boxes are fixed and closed

using nut12. Gear Box leakage testing by pressurized air.13. Final Testing of gear box by assemble it with engine.14. First gear box is scanned.15. All tests are control by a PC. 16. maximum speed at different gears, Noise level (Manually)

Speed at different torques, power required at different slops at different speed are tested. It is a one time process.

17. unloaded at gearbox area.18. Testing of machine by blue and red gear box.19. All blocks for gear box are imported from Renault France

Page 50: Internship at RNAIPL

Cont.Engine Shop Line

• At line-1 K9K (Diesel) engine is manufactured.

• At line-2 XH (petrol) engine is manufactured Gear Box leakage testing by pressurized air.

Page 51: Internship at RNAIPL

Cont.

Process

1. Cylinder block scanning.2. Oil jet is fixed in cylinder by Oil jet press (2 Hydraulic and 4

Pneumatic)3. Marking of engine code on cylinder block.4. Oil level indicator assembly.5. metal pieces are assembled in cylinder block support the crank

shaft. These metal pieces work as a bearing.6. Then D dimension machine measure the height between bottom

dead center and top dead center for selecting the proper piston.7. then crankshaft, piston, connecting rod are assembled in

cylinder block8. oil filter, oil pump and oil pan is fixed 9. In H dimension machine piston is inspected that the piston is

perfect or not for the corresponding bore.

Page 52: Internship at RNAIPL

Cont.

Process

10. cylinder head is fixed on the cylinder block using nut bolt.11. Then Cam shaft is fixed. Then fuel injector and high pressure fuel pump is

fixed.12. Timing Pulley and Timing belt is fixed.13. Timing belt and gear transfer the power or motion from crank shaft to other

engine accessories like cam shaft, high pressure fuel pump. Fuel pump, cam shaft and other accessories are synchronized with crank shaft.

14. Flywheel, vacuum pump ,Fuel pipe line, EGI harness cable, Intake manifold, exhaust manifold , Then EGR (exhaust gas recycle) unit stabilizer, exhaust air intake ,exhaust air filter, Clutch kit (clutch plate and disk), friction plate are assembled.

15. Engine Testing16. Then quality of engine is checked and visual inspection of engine is done. If

any fault is found then engine is sent for repair. Then finally engine is sent to the SCM (supply chain management).

Page 53: Internship at RNAIPL

Casting Shop

In casting shop cylinder head and cylinder blocks are manufactured by casting process.In this shop two casting machines are here.

1 HPDC (High Pressure Die casting): Cylinder blocks are manufactured by High Pressure Die Casting because they are heavy in weight.2 LPDC (Low Pressure Die Casting): Cylinder heads are manufactured by Low Pressure Die Casting Process.

HDPC process is same as LDPC. Only difference is that pressure and die moving velocity is higher in HDPC i.e. 60-70 Mpa and 308 m/s.

Page 54: Internship at RNAIPL

• The furnace capacity was 1.5 ton means 1.5 tones is melted per hour. The material of ingot which is fed is (ACD 12 Al alloy Rectangular rods).

• The ingot is melted in moving furnace which is LPG operated (1 bar) then it is moved to holding furnace (maintains temp 70 C) while air is fed using blower.

• Then the molten metal is moved to degassing unit where poisonous gases are removed by forcing nitrogen through carbide rod. Then the molten metal is moved to LPDC machine which moves it to electric heaters for re melting and while LPG heaters maintains temperature.

• Then the core will be placed in the die and the molten metal will be poured into the die. Near each die casting machine there is shell core machine which prepare the sand core thus eliminating the need of die to be destroyed if the new model comes.

• The castings are then air cooled at temperature 100 to 150 degree Celsius. The other coolant like water is not used because others will drastically reduce the temperature which will be harmful for the castings while air reduces the temperature gradually.

• Then the casting goes to the knockout machines where 90 – 95% of the sand will be removed which removed and by vibration. After that it goes for finishing operation where runner and riser are removed.

• Then it goes for heat treatment process at 495 C which also helps in removing remaining sand. Then it is quenched using water at 60 C. After that it again goes for hardening process at 200 C and after that it is air cooled. After that Quality checking for cracks, Visual inspection ,Air leakage checking

LPDC (Low Pressure Die Casting)

Page 55: Internship at RNAIPL

Overall this internship was very useful in providing enormous experience about how a engineering is applied in industries. I have gained new knowledge, skills and met many new people. I got insight into professional practice. I learned the different facets of working. I have experienced how every second is important for a manufacturing company and they work in minimizing it. I have learnt that work management, is an important factor for the progress of projects. Regarding the engineering related subject I have learnt about the stamping shop, body shop , casting shop and welding. This company gives very much importance to safety of workers and quality of product. Every worker in the company was aware of what their life means.

Energy conservation is very important aspect of this company. From energy audit to waste water treatment plant , it shows the importance of reducing the consumption of it. At last this internship has given me new insights and motivation to pursue a career in automotive field.

Conclusion

Page 56: Internship at RNAIPL