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Acknowledgement

It is always a pleasure to remind the fine people in Engineering program for their sincere guidance we
received to uphold our practical as well as theoretical skills in engineering. It is matter of privilege for us
to present this report of industrial implant training.

Firstly we would like to thank Dr. P. B. Mrunal for meticulously planning academic
curriculum in such a way that students are not only academically sound but also industry ready by
including such industrial training patterns. We would also like to thank Dr.S.B. Chikalthankar for the
positive attitude he showed for our work, always allowing us to question him and giving prompt replies
for our uncertainties in any field. We would also like to acknowledge and our heartfelt gratitude to K. R.
Madavi who continuously supported us in every possible way, from initial advice to encouragement till
this date.

We express our immense pleasure and deep sense of gratitude to Mr. Manoj Kulkarni
for providing us an opportunity to undergo training in Badve engineering pvt. Ltd., Aurangabad. Finally,
we would also like to thank for spending his valuable time and guiding me during the course of training.
I also wish to express my gratitude to the officials and other staff members of Badve Engineering Pvt. Ltd
, who rendered their help during the training program.
Kartik Shashank Chikhalikar T.E. Mechanical

Sr no Name Enrollment number

1 Ayush Dhakate BE16F02F014

2 Abhishek Gedam BE16F02F018

3 Ganesh Meshram BE16F02F025

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CERTIFICATE
Dated: 8 December 2018

This is to certify that the implant work entitled as

“A report on Industrial Training” at BADVE ENGINEERING PRIVATE LIMITED carried

out by following students mentioned below, during 1 st of June 2018 to 21st June
2018, a bona fide work completed under my supervision and guidance in partial
fulfillment for the award of the degree of Bachelor of engineering in the
Mechanical engineering discipline of Government college of engineering,
Aurangabad. During this period, I found him hardworking, sincere and obedient.

The students are

1) Ayush Dhakate Enrollment no. BE16F02F014

2) Abhishek Gedam Enrollment no. BE16F02F018
3) Ganesh Meshram Enrollment no. BE16F02F025
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CONTENT
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INTRODUCTION
Established in 1996, Badve Engineering Private Limited has gained
immense expertise in supplying & trading of Automotive parts, exhaust system, biw & chassis
etc. The supplier company is located in Aurangabad, Maharashtra and is one of the leading
sellers of listed products. Buy Automotive parts, exhaust system, biw & chassis in bulk from us
for the best quality products and service.

1) This training can be carried out in govt. organization or in private sector.

2) Industrial training can also be defined as program which aims to provide
practical training within a specified time frame.

INDUSTRIAL TRAINING OBJECTIVE

 Expose the student to real job.

 Promote team work and good relation among employees.
 Enable student to see the links between theories learnt with practical
work.
 Improve the attitude of honesty and trust worthy, dedicated and
responsible for the task accepted.
 Practice and complay with the safety regulation during the training in
industry.

Outcomes of Training:
1. Awareness about the job functions in the industry

2. Attitudes to adapt to industrial environment

3. Proper practical and relevant knowledge and skills

4. Capabilities to become self-employed

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OBJECTIVE OF INDUSTRIAL REPORT

 Document all task program during training .
 Facilitate the assessment made by report which was prepared by the
student.
 The asset and data is important for student to apply for job interview
later based on excellent report

IMPORTANCE OF INDUSTRIAL TRAINING

 Able to learn and practice the new knowledge acquired in thecourse
of lecture at the college.
 The experienced gain by student can help in improving the knowledge
and self confidence of the students to the working world in the future.
 The students are able to discipline in matters of employment.

OUTCOME
 In plant training provide exposure and experience to students in terms of
technological development, effective communication, team work,
practices, policies, procedures, regulation, professional perspective &
reporting. Industrial training will built momentum & proactive attitude
amongst students & increase the confidence to be a brilliant
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COMPANY PROFILE
o Name of company : Badve Engineering pvt. Ltd.
o Address : Badve engineering limited plot No.- B-16,
MIDC IND. , Waluj, Aurangabad-431136
o Contact : 9881150575
o Website : www.badvergoup.com
o Department : HR, Store, Account, Purchase, TPM, IT,
Development, Finance, Production
o Operation day : Monday to Saturday 7 AM to 9 PM

COMPANY’S AIM
To become zero defect factory i.e. to establish manufacturing process
where quality inbuilt in the manufacturing process itself which lead to
consistent product performance and quality into the hands of customer.

COMPANY OBJECTIVE
 To eliminate the customer complaint due to child part missing
phenomenon.
 To improve customer satisfaction.
 Resolve problems as fast as possible.
 Follow through commitments.
 Be flexible in solving problem.
 Pro actively keep customer inform.
 Get closer to the customer.
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DEPARTMENTS AND THEIR FUNCTIONS

 HR DEPARTMENT

SPECIFIC ROLE AND RESPONSIBILITIES:-

 Providing resources (manpower)
 Facility of bus
 Focus on working environment
 To give hospitality to workers
 To provide salary time to time
 To take review of job satisfaction of the employees
 Monitoring the performance of the workers and employees
 By performance review gave timely based increment (promotion)

 TPM
A] KOBETSU KAIZEN:-
1)Following 5 ‘S’

1S :- Seiri = sort out ( take out unnecessary items )

2S :- Seiton = Organize ( place for everything and everything in its place )

3S :- Seiso = Shine ( clean up your workplace )

4S :- Seiketsu = Standardization (evolve standards and implement throughout the

Organization. )

5S :- Shitsuke = Self discipline (bring about self discipline among the employees.)
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2) Overall equipment efficiency

P: productivity, Q:Quality, C:Cost, D: Delivery, S: Safety, M: Moral

Monitoring the manufacturing chassis timely on productivity.

To maintain overall condition . To maintain the data collection , training, defining
sell leader, under cabin by making various zone to achieve target as well as
provide facility

3) KK losses
o Breakdown loss
o Startup loss
o Setup loss
o Speed loss
o Motion loss
o Minor stoppage loss
o Tool change loss
o Management loss
o No electricity
o Defect loss
o Shutdown loss
o Logistic loss
o Major adjustment loss
o Yield loss
o Energy loss
o Die/jig/tool loss
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B] JH ( Autonomous Maintenance ) :-
It is based on I operate and I maintain parameter to worker. In
this, ownership of each machine/robo is given to specific person and he/she has
to take care of the machine in all aspects. He should follow CLIRT ( C-clean, L-
lubricate, I-inspect, RT-retightening ).

For ex.- If nut is loosened, breakdown may occur and

unnecessary problems may be created. So to reduce such problems operator
must visit everyday to check the machine.

C] PM ( PERSPECTIVE MAINTAINANCE) :-
Taking preventive measures of machine and production:-

1) CBM ( Conditional based maintenance):-

For example, In a RO based plant, maintenance is required
whenever the filtering is expired. So filter expiration is condition for
maintenance.

2) TBM (Time based maintenance) :-

Replacing and checking are required at specific interval of

time to maintain it.

D) QM (QUALITY MAINTAINANCE):-
Focuses on quality of machine and its part ( zero customer
complaints.
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E) SHE (Safety, Health, Environment):-

1) Safety:-

If there is to occur any major or minor accident, it creates unsafe

conditions. Main work of SHE is to identify the problem and solve it proactively. :-

2)health:-

By taking previsions to reduce health problems.

3)Environment:-

Reducing outer water drainage, reducing production noises

which are hazardous to environment, by following norms of the government.

F) DM (Development management):-
Maintenance prevention resources.

G) E&T (Education & training):-

It gives training to working peoples to improve their skills and
knowledge from level 1 (L1) to level 4 (L4).

L1:- Cannot perform the work

L2:- Can perform work but requires supervisor

L3:- Can perform but cannot teach to others

L4:- Can perform and teach to others too

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This bring effectiveness and it helps in monitoring in assembly line.

Organization also train and educate them to perform on various machines & do
various tasks.

H) OTPM (Office TPM):-

Take look on customer satisfaction.

NOTE:- ALL THE PILLERS GIVEN ABOVE ARE RELATED TO EACAH OTHER.

 FINANCE DEPARTMENT

 Managing company’s expenses like machinery parts, petrol cost, travel

expenses in case of company’s work falls under finance department.
 Department pays money from company’s account.

 PURCHASE DEPARTMENT:-
There are two types of purchases:-

1) Direct purchase:- a)Parts requirement on assembly line.

b)Related to press fabrication and welding technology.

2) Indirect purchase:-a)Parts related to machine maintenance.

b)Spare parts, wire housing.

In three wheeler chassis total 154 parts are required for 1 chassis.
We cannot manufacture all the parts in the plant so some parts are need to be
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transported from outside. Ex:- Suppose we require 1000 parts to complete the
production target per day then we order parts from venders with extra 10%
allowance in case of failure.

o DIVISION OF PURCHASE DEPARTMENT :-

1) Supply chain

2) Vendor development

3) Material planning

4) Material procurrment

o WORK OF PURCHASE DEPARTMENT:-

1) Provide information about material and its grade

2) Finalize the rate of component by taking care of company’s profit ( rate finalize
on the basis of press tonnage, press part, stock rate, die size, CGST, SGST)

3) It also collects data through SAP system

 IT DEPARTMENT
1)USER SUPPORT:- Solving day to day problems, hardware, providing networking
services.

2) PROCCUREMENT:- To fulfill users requirements, MIS report, asset requirement,

management system works.
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DATA CENTER

CORPORATE IT

Software, licence update, services, agreement, approval,

Assets:- approval of rate, rate varifocation,comparison, cost approve.

In IT department there are two types of work:-

1)TECHNICAL:-

 Plant works
 Daily routine
 Networking
 Hard work
 Software trouble shouting
 Application support
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2)FUNCTIONAL:-

 MIS
 Corporate IT
 Master department ( master role vendor port create)
 Item code
 Management report
 Provide back office work

DEVELOPMENT DEPARTMENT :-
(NPD) NEW PRODUCT DEVELOPMENT :-

Customer gives design of the part as per their

requirement . The work of development is to observe and study the design
parameters . They make sample inspection report and sends to customer . If
customer conforms about the product , then documentation process is carried out
in which they make IPO (Input , Process , Output ) sheet amd gives it to the
production department and if part is not according to the customer requirement
tthen it is reanalyzed and modified according to requirement , this process
reapeted till customer is satisfied . Each modification is given number as MOD
1,MOD 2 , etc. When design is provided by customer first time , its MOD is 0 .
Required operations are decided by development department which includes
cutting , forming , piercing operation ,etc. The press part operations are blanding ,
forming , piercing , check quantity by guage ,reaming , shaving , extrude quantity ,
etc.

PRODUCTION DEPARTMENT :-
The main work of production department of our company is to produce chassis .In
this company , there are mainly two types of chassis are manufactured .
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1) 2 Wheeler Chassis = 135cc Pulsar , 150cc Pulsar

2) 3 Wheeler chassis = bajaj auto

Chassis is basically the main base of vehicle on which whole body of vehicle is
mounted .In this company there are two separate departments of production line
as 2 wheeler and 3 wheeler chassis . Each department is given with daily target
about 1000-1200 chassis/day ( 3 wheeler ).

In 3 wheeler department there are separate chambers for making the assembly
and manufacturing the full frame ,upper frsme , lower frame , half frame .

Different types of robot arms are used for the assembly of chassis .In this
department mainly 2 robots are used they are ,

1) Mig Welding Robot

2) Spot Welding Robot ( Panasonic , ABB mig welding robot , fanuc robot ,etc.

VENDORS :-
1) Sri Lakshmi Industries

2) Shree Industries

3) Shreenath Enginnering

4) Badve engineering Ltd II

5) Dham Fasteners

6) Electromech

7) Sai Pushpa industries

8) Pawan Enterprises
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DEFECT PHENOMENON :-
1) Part Missing
2) Welding Spatter
3) BKT Position not OK
4) Welding Shift
5) Dent
6) Welding Missing

PULSAR 150 and PULSAR 135 DEFECTS :-

1) Welding shabby
2) Welding burnt / blow hole
3) Welding incomplete
4) Welding missing
5) Welding lumps
6) Welding shift
7) Child part missing/ broken
8) Boring absent/ out
9) Spatter inside /threading

10)Head pipe dent / damage /spatter

11) Spatter on frame

12) BKT bond / Damage

13) Pipe damage

14) Other defect

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WELDING PROCESS :-

1. Gas Shielded Arc Welding Processes

The application of bare wire welding with gas shielding was developed in the
1960s, and was quickly adopted for the welding of lighter steel structures in
shipyards, as well as for welding aluminum alloys. Gas shielded processes are
principally of an automatic or semiautomatic nature.

a. Tungsten Inert Gas (TIG) Welding

In the TIG welding process the arc is drawn between a water-cooled non-
consumable tungsten electrode and the plate. An inert gas shield is provided to
protect the weld metal from the atmosphere, and filler metal may be added to
the weld pool as required.

Ignition of the arc is obtained by means of a high frequency discharge across the
gap since it is not advisable to strike an arc on the plate with the tungsten
electrode.

Only plate thicknesses of less than 6mm would normally be welded by this
process, and in particular aluminum sheet, a skilled operator being required for
manual work. This may also be referred to as TAGS welding, i.e. tungsten arc gas-
shielded welding.

b. Metal Inert Gas (MIG) Welding

This is in effect an extension of TIG welding, the electrode in this process

becoming a consumable metal wire. A wire feed motor supplying wire via guide
rollers through a contact tube in the torch to the arc. An inert gas is supplied to
the torch to shield the arc, and electrical connections are made to the contact
tube and workpiece. A filler wire is coated with copper metal to increase the
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electric conductivity. Welding is almost always done with a DC source and

electrode positive for regular metal transfer, and when welding aluminum to
remove the oxide film by the action of the arc cathode. Generally larger wire
sizes and heavier currents have been employed in this work, metal transfer in the
arc being by means of a spray transfer that is metal droplets being projected at
high speed across the arc. Early work on the welding of mild steel with the metal
inert gas process made use of argon as a shielding gas; but as this gas is rather
expensive, and satisfactory welding could only be accomplished in the down hand
position, an alternative shielding gas was sought. Research in this direction was
concentrated on the use of CO2 as the shielding gas, and the MIG/CO2 process is
now widely used for welding mild steel.

In MDL more economic mixture CO2 + Argon: Cargon is used. Using higher
current values with thicker steel plate a fine spray transfer of the metal from the
electrode across the arc is achieved, with a deep penetration. Wire diameters in
excess of 1.6mm are used, and currents above about 350 amps are required to
obtain this form of transfer.

3 Weld Inspection:

Welding is an essential manufacturing process performed in almost every major

industry. Therefore, weld quality and integrity are critical to safety in an extremely
wide range of products and structures.

Inspecting welds can also reduce costs by detecting discontinuities in the early
stages of manufacturing, reducing the cost of rework and extending the life of
components by detecting and correcting flaws. NDT (non-destructive test)
methods can identify cracking, porosity, incomplete penetration, misalignment,
inclusions, lack of fusion and similar conditions, which can compromise weld
strength
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Conclusion :-

This industrial training of a month made us acquainted with lots of

practical things. It made us aware of the various challenges of an industry and
how to deal with them. We learnt about various machineries and their functioning
and also about their maintenance. We visited various sections in which the parts
of the chassis are manufactured and also visited the slipways on which these are
assembled to form the chassis.

We learnt about various problems faced by workers and also by the

engineers. It was really a great experience.

The scheduling and routing methods in machine shop were studied.

Various types of tools used in machine shop for various processes were observed
with details of inserts used for the operation. Also, complete care of safety and
hygiene of workers is also focused equally.
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It was learned that, quality at the right cost is the key to successful
manufacturing. Again thanks to college and also to the industry who helped all
through our training.
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