COMPANY OVERVIEW / INTRODUCTION :–

In 1986, the Group signed a joint venture with Maruti Suzuki India Ltd for the
manufacturing of sheet metal components and assemblies. The journey began
with a vision to expand the business in the automotive sector by keeping abreast
with market trends and global technology.

JBM Group is primarily a tier- 1 supplier to the automotive OEM industry and
caters services to esteemed clients that include Ashok Leyland, Bajaj Auto Ltd,
Fiat, Ford, General Motors Corporation, Honda, Hero, JCB, Mahindra, Maruti
Suzuki, Renault, Nissan, TATA, Toyota, TVS, Volvo-Eicher, Volkswagen and many
more.

The Group has alliances with more than 20 renowned companies globally and the
associations include Arcelor Mittal, Cornaglia, Dassault Systems, JFE Steel
Corporation and many more. The organization’s structure enables each business
unit to chart its own future and simultaneously leverage synergies across its
competencies.

Over the last 3 decades, JBM Group has created new benchmarks in the
automotive industry, with the manufacturing of Body-in-White, Chassis &
Suspension Systems, Die Casting, Exhaust Systems, Jigs and Fixtures, Skin Panels,
Tool Rooms, Tubes &Tubular Parts, Weld Assemblies and engineering services
among many others.

The Group has a diversified portfolio to serve in the field of automotive,

engineering & design services, renewable energy and education sectors and has
an infrastructure of 35 manufacturing plants, 4 engineering & design centres
across 18 locations globally.

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JAI BHARAT MARUTI PVT. LTD. –

JBM Group collaborated with Maruti Suzuki India Limited as joint venture partner
to set up Jay Bharat Maruti Limited (JBML), the largest joint venture of MSIL for
manufacturing of sheet metal components, welded assemblies at Gurgaon.

LOCATION –

Sector 36, Mohammadpur Jharsa, Near Khandsa Road,

Gurgaon – 122 001

Haryana.

OPERATIONS AND FACILITIES –

1) Press Shop - 20T to 2500T Presses – Mechanically and Hydraulic press.

2) Weld Shop – MIG welding ,Spot Welding and Robotic Projection Welding .

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MAIN PROCESS INVOLVED IN PRODUCT FORMATION-

1) From customer side-

- Quotation of product

- Provide data of product

2) Die department –

- Analyze the data provided from customer

- Conversion of 2-d data into 3-d by designing team

- Die layout and no. of dies required

- Dummy pattern manufacturing

- Casting to form die

- After verifying all the dies, all are assemble together to form main die

- Many trials to be done to check the accuracy of product

- Finally the female die is fixed at lower side of pressing machine and male die
is clamp at upper moving side.

3) Manufacturing department –

- all pressing machines are automatically controlled

- nut, bolt are attached by different welding processes

4) Quality department –

- main work is to ensure that product will be perfectly fit at its desired location

- many checks are performed to make products defect free

Finally the product is delivered to customer.

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PRODUCTION DEPARTMENT -

Main production of parts is carried out by pressing machine. JBM has largest
pressing shop of Asia and have total of 10 different lines of pressing machines.

The plant has total ten lines comprising of different forging machines of different
tones.

Fig. 2

The main reason why JBM is developing very fast is because of innovative
technology they are using in their industries which are totally automatic and are
less dependent on human power. All pressing machines are imported from Japan
companies like KOMATSU, ISGEC etc.

Out of all 10 lines only one line has Hydraulic pressing machine and rest 9 are
mechanically pressing machine. Hydraulic pressing is very slow process and is
used for component which require large bending.

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Hydraulic Presses

Hydraulic presses are a powerful class of machine tools, they derive the energy
they deliver through hydraulic pressure. Fluid pressure, in a particular chamber,
can be increased or decreased by the use of pumps, and valves. Sometimes
devices and systems may be used to increase the capacity of the pumps in more
powerful presses. These presses can operate over a long distance and at a
constant speed. Hydraulic presses are generally slower relative to other press
machine types. This involves longer contact with the work, therefore the cooling
of the work can be an issue when hot forming a part with hydraulic force.
Hydraulic presses are capable of being the most powerful class of presses. Some
may be as large as buildings, and can deliver awesome pressure. The largest
hydraulic presses are capable of applying 75,000 tons of force. The hydraulic press
shown is being used to manufacture a metal forging. Extrusion is also a very
common use for such a press, although extrusion is often performed horizontally.

Fig. 3
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Mechanical Presses
Mechanical presses belong to a class of machine tools that encompass a wide
range of different machine types. Primarily, the mechanical press transforms the
rotational force of a motor into a translational force vector that performs the
pressing action. Therefore, the energy in a mechanical press comes from the
motor. These types of presses are generally faster than hydraulic or screw
presses, (actually the screw press may also be classified as a mechanical press).
Unlike some presses, in a mechanical press, the application of force varies in both
speed and magnitude throughout the distance of the stroke. When performing a
manufacturing operation using a mechanical press, the correct range of the stroke
is essential.

Presses are chosen based on the characteristics of the manufacturing process.

Mechanical press machine tools are commonly used in metal forging
manufacture, and sheet metal working. The desired application of force will
dictate the type of machine required. Extrusion will often necessitate a more
consistent force over a longer distance. However, a mechanical press may often
be a good choice for impact extrusion, since a fast, quickly repeatable application
of force over a limited distance is what is needed for that type of manufacturing
process. The most powerful mechanical presses in modern manufacturing
industry will have a press capacity of about 12,000 tons.

Fig. 4
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BASIC OPERATIONS PERFORMED BY PRESSING MACHINES –

Mainly four types of operations are performed in sequence in 4 different

machines of 1 line. These operations depend on type of die we are using. These
basic operations are –

1)Drawing – in this initial shape formation of part take place.

2)Trimming – this involve cutting of extra part of sample.

3) Piercing – in this holes formation and bending of sample take place.

4) Parting – in this the whole plate is divided into two parts.

Mechanically pressing machine –

Company name – KOMATSU

Have 4 different machines in one line each of capacity 1200 Ton.

Hydraulic pressing machine –

Company name – ISGEC

Have single machine with capacity of 1000 Ton.

Fig. 5

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Types of operation –

1 :- Blanking – sheet metal cutting to separate piece(called a blank) from

surrounding stock.

2 :- Trimming – Cutting processes are those in which a piece of sheet metal is

separated by applying a great enough force to caused the material to fail.

3 :- Piercing –

4 :- Notching – Notching is a shearing process during which a metal scrap piece is

removed from the outside edge of a metal workpiece.

5 :- Flanging – Flanging is a process of bending the edges of sheet metals

6 :- shaving –

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JBM is largest vendor company of different auto companies like MSIL, Eicher,
Ashok Leyland, Bajaj Auto Ltd, Fiat, Ford, General Motors Corporation, Honda,
Hero, JCB, Mahindra etc .

Fig. 6

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10 | P a g e
WELDING –

RESISTANCE SPOT WELDING-

Resistance welding is a welding process which join the metals with the heat
obtained from resistance offered by the work to the flow of electrical current
through the parts being joined.

A pair of copper alloy electrodes conducts electrical current through the two
sheets pressed between the interface. The two sheets offer maximum resistance
to the flow of current, this generates heat, the interface melts and consequently
solidifies under the pressures of the two electrodes, thereby joining the two
sheets at the spot that was under the two electrodes.

Fig. 8

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TYPES OF GUN USED IN SPOT WELDING

X- TYPE GUN

Also known as "scissors" or "pinch".

Fig. 9

C-TYPE GUN

C guns are generally the cheapest and the most commonly used.

Fig. 10

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PROJECTION WELDING

Nut projection welding

Projection Welding Is A Type Of Resistance Welding. High current in less time

is the main feature of this welding.

Fig. 11

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QUALITY DEPARTMENT -

This department has very crucial as well as very important role in company’s
development. A small defect in product can cause big loss economically.

The whole system work as- suppose company get an order of 1 lakh pieces of
patch pieces then the first product from the machine is verified by engineers by
“panel checker” and if it is found accurate then all other product are only visually
checked by workers.

Engineers have all the basic data about product like dimensions, distance
between holes etc , which help them in verifying the product on panel checker.

Fig. 12
If product is not found as per their requirement then it is corrected by hammering
or other methods.

In JBM they follow the following process-

1:- In process quality – Engineers check the first piece by panel checker. Their
main motto is to check –

- Whether the gap between sample and panel checker is continuous or not.

- distance between holes and position of hole.

- any trimming of extra part is required or not.

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2:- FOA(First of approval) – after the first inspection all others product are only
visually checked by workers. They are provided with a type of “defect album” in
which the possible types of defects that can occur are written. Therefore the duty
of worker is to visually check only that area which have the possibility of any type
of defects. Main motto of this is to check any type of crack, flange, dent, wrinkle,
hole shift etc.

Fig. 13
Different types of defects –

1) Crack

2) Flange cut

3) Dent

4) Wrinkle

5) Burr

6) Hole shift

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DIE MAINTAINENCE DEPARTMENT -

A die consist of two parts one is the female part on which steel plate is to placed.
The male part apply force on the sheet metal plate and transfer it in the required
shape.

Fig. 14

The main work under this department is to insure that formation of die is such
that the part form is exact same as the required. Because a very small error can
make very high loss to company.

Depend on the type of process ,selection of the die is to made like for cutting we
have different type and like piercing we have different . For single product we
have to do pressing, cutting, piercing, final shaping therefore approximate 8 dies
are required.

For every single order from parent company, new die needs to be made and after
completion of that order that dies have no use and are sold in scrap.

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Basically a die consist of two pairs one is called female part which is the lower
part and the other one is called male part which is the upper one.

Fig. 15
Female part of a die is fixed and male part move up and down. Some important
component involved are:-

1) Cushion pin or pressure pin :- A pin used in conjunction with an air cushion
that transfers pressure from the air cushion to the bottom of the die.

2) Air Cushion :-An air-actuated press accessory that is placed below or inside die
block, which is used to increase pressure on the die using pressure pins. The air
cushion can also be used to lift the part out of the die.

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 PROJECT TITLE

TO INCREASE THE PRODUCTION OF PRESS SHOP

WITH THE HELP OF GANGING OF DIES.

ABSTRACT

Now a days we see industry works on 6 factors. These factors are very
much responsible for the growth of a industry. These are
1) Safety
2) Productivity
3) Quality
4) Cost
5) Delivery
6) Moral

But here in this project we are concentrating on only on factor i.e. increase
in productivity. Here we are using a method of ganging of dies in which
two similar dies are mounted on a press machine. This help us reduction
of productivity time. Which will enhance the productivity. So this method is
very much effective in increase the productivity of the material. This is cost
and time saving method which will help in the betterment of the industry.
PART NO.-DZ161013

PART NAME : GUSSET HEAD

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THEORY:-
Here the work is done on 250T press machine. In the production of gusset
head there are mainly 4 steps are involved. These processes are also
shown in table according to there steps. Suitable dies are used with
respect to the process followed. Gusset head is generally a BAJAJ part
which are used in platina bikes. These parts gives the support to the
engine.

The pictorial view of gusset head is shown in the figure which is given below.

Fig. 16
METHODOLOGY:-
1. First step all the sheets of metal is procured from the vendor.
2. The grade of the material is checked by the inspection
department. In inspection these three things are checked.
Wrong size of the metal sheet, grade of the metal sheet
and the visual defects of the metal sheet.
3. Now the first operation is to be performed i.e. Blanking. It is
done to extract the profile sheet from the metal sheets. In
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 this the operation the profile sheet should be according to
our need . it should be dent, scratch and burr free.
4. Second operation which to be performed is Forming. In this
draw is done on the blanked profile sheet. In this operation
complete bend should be done, scratch should be taken
care of through oiling, crack/ thinning should be regularly
checked.
5. After this Piercing is to be performed. It a type of operation
which is totally opposite of blanking. In this pierced profile
sheet is avoided rest is considered. Dimension of us/os has
to be maintained,& location of hole should not be
displaced.
6. Last step is Bending and Trimming. In this side part of
gusset is bend and extra part of the sheet is trimmed.

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TABLE:-

Process Incoming Product Expected/actu

Descriptio source of charactersti al strokes (per
n variation cs hour)
Receiving Wrong size 1.5+/-0.1
Inspection
Wrong grade 260*1250 +/-2mm

Visual defects

Blanking Improper profile Free from

Dent/scratch Burr

Dent 250/150

Crack

Forming Incomplete bend Free from

Scratch Burr

Crack Crack 250/160

Dislocation Scratches

Piercing Dim us/os Free from

Hole/slot size Burr 250/170

Location Crack

Visual defects

Bending-trimming No thinning Free from

Incomplete profile Burr

Scratch Crack 250/180

burr Thinning

Visual defects

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Blanking-

Fig. 17

FORMING

Fig. 18

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Piercing

Fig. 19

Bending-

Fig. 20

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NOW IF APPLY 2 DIES IN SAME PRESS THEN THE OPERATION CAN
BE PERFORMED AT FASTER RATE

TO USE GANGING OF DIES THE FOLLOWING THINGS SHOULD BE TAKEN INTO

CONSENDERATION
1. Power of the press.
2. Size of the bluster bed.
3. Size of the dies.
4. Shut height of the die.
5. Shut height of the press.
6. Tonnage required for the die.

Now let’s assume that the die is having the same shut height and is
between in given range of shut height of the press.

Condition for dies

are :- Length –

910mm

Shut height -

650mm Width –

500mm

Now consider we are having a press which is having the bluster bed
which can accommodate approximately 2 dies. We are having such
presses in our industry.

CALCULATION :- (Cost Estimation)

Procurement for the metal sheet- 45 rupees

per kg Dimensions of sheet -1230x260mm

Weight of on sheet-

1.020 kg Thickness of
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the sheets- 1.5mm

Scraps cost -25 rupees

per kg

Generally cost is estimated with the help of 5 M. These are

1. Man
2. Machine
3. Material
4. Management
5. Method

but as per general idea we are calculating as cost 2 rupees per strokes
ignoring all the all other hidden cost.

Now according to table

Cost estimated for blanking-

2x150=Rs300 Cost estimated for

forming- 2x160=Rs320 Cost

estimated for percing-

2x170=Rs340

Cost estimated for bending-trimming-

2x180=Rs360 Total cost-Rs1320

This is a rough calculated cost in this hidden cost are not involved like
maintainace, worker availability etc. are not included.

Now if re plan our process and mount 2 dies in

one press For example

Blanking and forming at a time in a single press having different dies. This
will save time as well as machine cost.

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And similarly at the same time piercing and bending trimming

operation can be done. Now the calculation of cost

Cost for blanking and forming-

2x150=Rs300 Cost for piercing and

bending-2x170=Rs340 Total

cost=Rs640

This is a rough calculated cost in this hidden cost are not involved like
maintainace, worker availability etc. are not included.

Advantages of ganging of dies

1. Cost saving
2. Time saving
3. Man power saving
4. Less press machine required
5. Utility of press machine increases
6. Pace of work is fast
7. Production is high

Disadvantages of ganging of dies

1. Require bigger bluster bed
2. May require a dummy cushion when one die require cushion and other’s
didn’t so dummy cushion is given to the second die in order to balance it.
3. Tonnage of press should be greater or equal to the die required.
4. Shut height of both the dies should be same and should be in press shut height range.

Conclusion of Project
This method is very much effective in increasing the production rate. This
works quite efficiently. By using this method we can cover some parameter
which is very much important for every industry.

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Dies and its Types:

Die:
The die may be defined as the female part of a complete tool for producing
work in a press. It is also referred to a complete tool consists of a pair of
mating members for producing work in a press.

Types of dies:
The dies may be classified according to the type of press operation and
according to the method of operation.

(A): According to type of press operation:

According to this criterion , the dies may be classified as cutting dies and forming
dies.

1: Cutting Dies:
These dies are used to cut the metal. They utilize the cutting or shearing
action. The common cutting dies are : blanking dies , perforating dies ,
notching dies , trimming , shaving and nibbling dies.

2: Forming Dies:
These dies change the appearance of the blank without removing any
stock. Theses dies include bending, drawing and squeezing dies etc.

(B) According to the method of operation:

According to this criterion, the dies may be classified as : single
operation or simple dies , compound dies , combination dies ,
progressive dies , transfer dies and multiple dies.

1: Simple Dies:
Simple dies or single action dies perform single operation for each stroke
of the press slide. The operation may be one of the operation listed under
cutting or forming dies.

2: Compound Dies:
In these dies, two or more operations may be performed at one station. Such
dies are considered as cutting tools since, only cutting operations are carried
out. Figure shows a simple compound die in which a washer is made by one

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stroke of the press. The washer is produced by simulation blanking and
piercing operations. Compound dies are more accurate and economical in
production as compared to single operation dies.

3: Combination Dies:
In this die also , more than one operation may be performed at one station.
It is difficult from compound die in that in this die, a cutting operation is
combined with a bending or drawing operation, due to that it is called
combination die.

4: Progressive Dies:
A progressive or follow on die has a series of operations. At each station , an
operation is performed on a work piece during a stroke of the press. Between
stroke the piece in the metal strip is transferred to the next station. A finished
work piece is made at each stroke of the press. While the piercing punch cuts
a hole in the stroke , the blanking punch blanks out a portion of the metal in
which a hole had been pierced at a previous station. Thus after the first stroke
, when only a hole will be punched , each stroke of the press produces a
finished washer.

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6: Transfer Dies:
Unlike the progressive dies where the stroke is fed progressively from one
station to another. In transfer dies the already cut blanks are fed
mechanically from one station to other station.

7: Multiple Dies:
Multiple or gang dies produce two or more work piece at each stroke of the
press. A gang or number of simple dies and punches are ganged together to
produced two or more parts at each stoke of the press.

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 CONCLUSION

It’s always a great opportunity to experience the valuable exposure of an

industry. There is lot of difference between the Theories and Practices. This
Training enables me to understand the aspects of professional life. I like the
working environment followed at JAI BHARAT MARUTI PVT. LTD. and come to
know how to deal with our colleagues. The company’s members are well cultured
& well mannered.
An effective process is followed at JBM but it would become more valuable and
impressive by implementing certain efficient measures. The company is
constantly focusing on providing better services, quality and reliability to
customers, and running successfully in this era of competition.

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