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TO STUDY PROCESS OF PRODUCTION OF TWO PRODUCTS OF

G.S.AUTO INTERNATIONAL PROCESS OF SPRING PIN AND U-BOLT

Submitted to: Submitted by:

Saurabh Bishnoi Jaskaranbir Singh Aujla

13DM082

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LETTER OF TRANMITTAL To

Saurabh Bishnoi

Assistant professor

Birla Insitute of Management Technology ,Greater Noida

Dear Sir,

I am pleased to submit this report as I got as an opportunity in being involved in a short

term project at G.S.AUTO ITERNATIONAL. This report provides on the in depth study of

the processes of two products of the company.

I spent 15 days at the company and studied the process of the two products Spring pin

and U-bolt. The detailed process from procurement of raw material till packaging have

been involved in the processs

I came up with some recommendations which have been included in the report.

Yours sincerely,

Jaskaranbir Singh Aujla

PGDM (operations)

13DM082

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ACKNOWLEDGEMEANT

It is a matter of great pleasure for me to acknowledge my indebtedness to

S. Jasbir Singh Ryait, Chairman , S. Surinder Singh Ryait, Managing Director of M/s. G. S.

Auto International Limited, G.S. Estate, G.T. Road, Ludhiana for their interest in

providing an opportunity to work with the organization.

I would like to thank my professor Mr.Saurabh bishnoi who helped me in carrying out

the project.

I also thank all the workers and foremen for their full co-operation during short term

project for providing valuable inputs and providing me a good feedback.

I am really indebted to the management and the working of the G.S. Auto International

Ltd.

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TABLE OF CONTENTS: Executive Summary 5 Introduction 6 5s-concept 7 Raw material procurement 9 U-Bolt 10 Process flowchart of U-bolt 12 Spring pin 13 Process flowchart of Spring pin 15 Recommendations 16 Appendix 17

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EXECUTIVE SUMMARY G.S. AUTOINTERNATIONAL LTD situated in Ludhiana came into existence in 1938.

This report included the detailed process of producton of two products –Spring pin and

U-bolt. The report gives knowledge of production of these products process starting

from procurement, manufacturing process, use of machines, pacakaging.

The report includes the detailed procedure of production and and recommendations

have been give to improve the process. It includes of improving the utilization capacity

by improving the production control as workers and machines were seen having idle

time and need for improvement of the machines to reduce the ineffective involved in the

process. One recommendation for expanding up of the zinc plating section to reduce the

load on Auto-black section and better functioning.

The recommendations will improve the productivity of the labour and maintenance

Of machine will improve the capacity of plant.

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INTRODUCTION

Industry Profile

Late Baba Gurmukh Singh (1900 - 1979) Founder of G.S.Group The company is a brain-child of S. Gurmukh Singh Ryait with whose efforts the company came into existence in 1938. G.S. Auto International is located inside G.S. Estate along with G.S. Automotives Ltd., G.S. Sales Corporation, Ryait Exports & G.S. Radiators Ltd., spread over an area of 1 million square feet. Products & Infrastructure: The company’s core strength has been diversification which has helped the constant growth. The company is engaged in the manufacture of auto parts which are divided into two categories: 1.Cast Components: To cope with the varying requirements of the customers in the automobile industry; casting unit was set up with complete facilities for die casting, trimming, machining, shot blasting, core making, pattern making, painting & other relevant operations, all under one roof. The unit is now named as G.S. Automotives Ltd. The components have a weight ranging from covering shackles, brackets, clamps for almost all kinds of vehicles. 2.Machined Components: On the strength of its expertise in the development & manufacturing of components the industry has explored new horizons to provide a diverse range of machined components. These include U- bolt, centre bolt, hub bolt, spring pin, king pin, axle stud, shackle bolt & different types of nuts. Customers: The company makes these parts as original equipments as well as for replacement market. The company's customers include:

TATA Motors Maruti Udyog Ltd. Mahindra & Mahindra Hindustan Motors Ltd. Ashoka Leyland Ltd. Delphi Automotive Systems Ltd. Swaraj Mazda Ltd.

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Volvo India Ltd. Eicher Motors Ltd.

The company also has a good reputation in export market exporting to more than 15 countries. Accreditations: The company works on the 5-S concept & is managed by a team of professionals with focus on customer satisfaction, continuous improvement, defect prevention & reducing wastage. This has lead to the conferring of various certifications. These certifications include:

ISQ-9002 certification in 1997 QS-9000 certification in 1999 TS-16949 certification in 2005

The 5-S Concept

The company works on the 5-S concept to conform to standards, reduce wastage, prevent defects & for satisfaction of customers. The concept is explained as follows:

1. Seiri: (sorting): Sort out important & unimportant things &put the unimportant ones away from workplace.

2. Seiton: (Systematic Arrangement): Keep the things on the prescribed place in

continuous & regular pattern.

3. Seiso: (Spic & Span): Maintain the cleanliness of the workplace regularly.

4. Seiketsu: (Standardization): Always work on the standard prescribed pattern.

5. Shitsuke: (Self- Discipline): Maintain self discipline.

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G.S. Auto International Ltd. comprises of following plants: Plant- 1 (Machine Shop- 1) It is subdivided in the following sections according to the type of product they manufacture.

(a) Raw material stock (b) Material cold drawing section (c) U-bolt section (d) King pin section (e) Spring pin section (f) Machine nut section (g) Shackle bolt section (h) Grinding section & tool room (i) Zinc plating department (j) Laboratory (k) Induction hardening section (l) Cold forging (m) Maintenance unit

Plant- 2 It consists of the following sections;

(a) Hot forging section (b) Heat treatment section (c) Civil maintenance section (d) Auto-black section

Plant- 3 (Machine Shop- 2) It comprises of following sections:

a) Hub bolt section b) Centre bolt section c) Non- ferrous bush section (casting)

Plant- 4 (G.S. Automotives Ltd.) It consists of following sections:

(a) Foundry shop (b) Fettling shop (c) Machine shop- 3

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RAW MATERIAL PROCUREMENT:

Fig: - Raw Material Yard

Raw Material Supply

As per the quality policy of every industry the raw material for a manufacturing

must be of excellent quality as per the requirement. These materials are passed through

a metallurgy laboratory for inspection and testing as per requirements. Near about the

70% of the total raw material is supplied from Ludhiana steel industries. And the

remaining 30% material is purchased form the out of Punjab. Some of the majors

industries which supply the raw material to G.S. Autos are listed as follow:-

1. Arti Steels, Ludhiana

2. Upper India Steel, Ludhiana

3. Bhushan Steel Limited, Ludhiana

4. Mukand Steels, Bombay

When the raw material is once unloaded in the industry, then the yellow tag is given

to it. Yellow tag is used to show that the material is going under inspection and testing

in the metallurgy laboratory. After the inspection and testing if it is found that material

has a quality and properties as per industrial requirements, then green tag is given to it

and if it fails as per the requirements, then red tag is given to it.

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U-Bolt

The various operations performed in the manufacturing U bolts are given below:-

Facing: The cut round bars are sent to machine shop for facing. Facing is done on both

the sides of the bar by using an SPM lathe machine.

Turning: The rods are then sent for cylindrical turning. The machine is semi-automatic

lathe machine. The work-piece is sent into the machine through a collet which holds it

tightly. Two tools work on the work-piece one after the other. This operation is done on

both the ends of the work-piece.

Threading: The turned rods are sent to the threading machine. The machine is a profile

making machine. The threading is done as a forming operation. The rollers are made of

high carbon steel. The threaded portion is of 76 mm length.

U-bolt bending: The rod with both ends threaded is sent to the induction heating

machine which heats the bar at the centre till red hot. The current that passes through

the rod is 100 ampere. The time for heating is 12 seconds.

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Hardening & Annealing: Then all the pieces are hardened. The pieces are put in the

furnace containing a salt , which helps in heating the pieces to a temperature at 850º-

860º C. Then the pieces are put in quenching oil for hardening. Due to various

operations the material of the work-piece is unevenly stressed. To remove these

stresses & to refine the grain structure the pieces are again heated to a temperature of

400º C

Washing (removal of oil & grease): The next operation is the surface treatment. This

is done in the auto-black section. First of all the U-bolt pieces coming out of machine

shop are checked for any kind of difference in the axis of both the limbs. If so then the

limbs are made co-axial. The work-pieces are then loaded on to a stand. Then these

pieces are dipped in a solution of salt acid & water . This process is called acidification.

There after the pieces are washed with water. Then the activation is done. The U-bolts

are dipped into solution of Actisol (200 ltr.) & water (400 ltr.). This process activates

the auto-black process. This is done at normal temperature.

Auto-black: After activation the pieces are dipped into another tank . All the pieces are

coloured black. The temperature for the process is 30ºC.

Packaging: After the process of auto-black, the product is sent to for packaging where it

is packed according to the requirement of the customer.it is loaded in the trucks and

stored in godown and loaded in trucks for delivery.

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Process Flowchart:

Raw material procurnt

• Inspection process

•Red for inquality standards , green for quality and yellow for being under inspection process

Manufacturing process

• Facing

•Turning

•Threading

•U-bolt bending

Phosphating

• Zinc plating

•Degreasing

•Hydrogen deembezzlement

•Chromium passivation

Auto black

•Hardening

• Surface treatment

•acidifiaction

Inspection

•Product inspected in Bar drawing shop

Packaging •U-bolt being packaged for the customers

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SPRING PIN

The various operation performed in manufacturing Spring Pin are given as:

Raw grinding: This operation is done in order to remove a very small amount of

material from the work-piece. The machine is a centre-less grinder.

Facing: The cut round bars are sent for facing operation. The machine is an SPM lathe

machine. Both the sides of the round bar are faced with the cutting tool. The work is

held in a collet & tool is advanced to make a cut. The length of the piece is made 139 mm

by the facing operation.

Chamfering: The next operation is chamfering. The chamfer is provided at both the

ends of the work-piece. The machine is hydraulically operated lathe machine.

Stamping: The stamp of the logo G.S. International is marked on one end of the work-

piece. The machine is hydraulic press.

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Drill & tap-hole: The next operation is drilling. The diameter of the drilled hole is 14.50

mm & the length of this hole is 21 mm. the machine is semi- automatic. After the drilling

of hole the tapping operation is performed.

Second & third drilling: Two more holes are made on the same side of work-piece

keeping the same centre line. A hole of 6 mm diameter is made till 35 mm length.

Slot milling: The next operation is slot milling. The operation is done on the milling

machine. Two cutters are there on the machine. One has width 4 mm & the other one is

12 mm wide. Then a grease slot is made at an angle of 90º to the previous two slots.

This slot has a diameter of 34 mm. this is also done on another horizontal milling

machine.

Cross hole: A hole of diameter 5 mm is made in the grease slot. The machine is a

vertical drilling machine. The hole meets the other previously drilled holes at an angle

of 90º.

Induction hardening: To make the pieces suitable for working under high stresses

they are case hardened by induction hardening process. There is an induction-

hardening machine. There is a coil of diameter 3 mm more than the size of the spring

pin diameter. A total of 8 pieces can be put in the holder on the machine, which is of

circular shape. The holder rotates anti-clockwise. The pieces come under the heating

coil one by one & the coil starts moving down. When the coil reaches the bottom of the

piece the heating process starts. The coil then starts moving upwards to the top of the

piece consequently heating the pieces. After heating water falls on the piece

immediately thereby hardening it. The temperature maintained is 950º- 1000º. The

total heating time is 17 seconds. Then to refine the grain structure the pieces are

annealed.

Grinder packing: The pieces are sent to the grinder packing section.

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PROCESS CHART:

Raw material procurement

• Inspection process

•Red for inquality standards , green for quality and yellow for being under inspection process

Manufacturing process

• Facing

• chamfering

• stamping

•drill & tap hole

• slot milling

• cross hole

• inspection

Induction process

• Spring pin processed in induction process for hardnening and strength of the product

Grinding

•7 machines used in grinding process

Phosphating

• Zinc plating

•Degreasing

•Hydrogen deembezzlement

•Chromium passivation

Inspection and Packaging

•Product being inspected and packaged

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RECOMMENDATION:

1. Efficiency in the inspection process can be improved in the spring pin section in bar drawing shop. At this point of time a person uses only one had while inspecting the product as there is only one nozzle in the machine. So two nozzles should be provided so that the worker uses both hands and take exactly half the time.

2 .New space can be created in in zinc plating section, a lot of time is wasted in shifting the product for hydrogen de-embezzlement from zinc plating section to heat treatment section. This can be done by extending this section as nearby space is available for use. 3.There is a need for the improvement in maintenance of machines as on regular basis machines fail to work and product is shifted to other lines which affect the production. 4.The worker head should make sure the person sit idle for early 2 hours in an 8 hour shift including the 1 hour break for having meals. The rest 1 hour, the worker is found stting idle on machine or sometimes the worker leaves the machine and one worker is handling two machines at the same time which affects productivity. It is pretty evident that the company is not utilizing its capacity fully. Many a times workers achieve their shift targets early and then sit idle for the remaining shift. This indicates poor planning of targets and poor control of supervisors on workers. A realistic review of capacity and then setting of new targets will lead to enhanced capacity utilization and that will decrease idle time of workers.

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APPENDIX: Plant layout