INPLANT TRANING REPORT

AT

NEEL METAL PRODUCTS LIMITED

REPORT

Manufacturing and Production of fuel tank

SUBMITTED BY

Piyush Patil &

Sumedh Wani
 ACKNOWLEDGEMENT

It is indeed a great pleasure and privilege to present this report on training at NEEL METAL
PRODUCTS JBM GROUP, MAHALUNGE.

I am extremely grateful to my training and placement officer for issuing a Training letter, which
made my training possible at NEEL METAL PRODUCTS JBM GROUP, MAHALUNGE.

First, I thank The HR Head, Miss Harsha Ahire for considering my potential in doing this
summer internship and providing this wonderful opportunity.

I would like to express my gratitude to Mr.___________________ for his invaluable

suggestions, motivation, guidance and support throughout the training. His methodology to start
from simple ant then deepen through made me to bring out this project report without anxiety.

Thanks to all other JBM officials, operators and all other members of JBM, yet uncounted for
their help in completing the project and see the light of success.

I am very thankful to friends, colleagues and all other persons who rendered their assistance
directly or indirectly to complete this project work successfully.

Dated- Oct/Nov 2020 Piyush Patil &

Sumedh Wani
ABOUT COMPANY
JBM Group began its journey of excellence in 1983. The organization commenced operations as a
manufacturer of LPG Cylinders for the Delhi-NCR region of India. Moving strength to strength, assisted
with experience and knowledge, JBM Group entered into the automotive industry in 1985.

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.

Headquartered at Delhi-NCR, JBM Group is a diversified conglomerate with presence in automotive,

engineering & design services, renewable energy and education sectors. The organization’s commitment
towards all stakeholders and community has made it a leading manufacturing and engineering player.

The milestones and achievements of JBM Group gave the energy for diversification and establishment of
multiple business units in order to meet the needs of customers. The organization’s management follow a
unique business model to create empowered companies that enjoy the best of entrepreneurial
independence, assisted with leverage of group-wide synergies.

Overview

JBM Group is a focused, dynamic and progressive organization that provides customers with
value added products, services and innovative solutions. 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 centers
across 18 locations globally.

With turnover of USD 1.2 billion, JBM Group has broadened its horizons by focusing on quality
delivery, solutions approach, product development processes, flexible manufacturing systems
and contract manufacturing.

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, Magnetto (CLN
Group), Ogihara, Sumitomo and many more. The organization’s structure enables each business
unit to chart its own future and simultaneously leverage synergies across its competencies.
 INTRODUCTION TO THE COMPANY

COMPANY PROFILE

Name: JAY BHARAT MARUTI LTD.

Division: NEEL METAL PRODUCTS LIMITED

Head Quarters: DELHI
Established: 1983
Turnover: Rs.4500 Crores(overall)
Employees (No.): AROUND 20000
Vision
“Expanding leadership in our business through people, keeping pace with market trends and
technology.”

Core Values
We believe in ...

Simplicity,by keeping a low profile externally and having clear, open and effective
communication within the organization.

Teamwork, with well-defined responsibilities and accountability.

Relationships of trust amongst people, through well-defined job responsibility and authority.

According top priority to customer focus,through prompt and appropriate response.

Respect and care for all those dedicated to meeting commitments.

TECHNOLOGY
Technology, Innovation and People serve as the 3 key pillars of the JBM foundation. Core to this
philosophy is a constant quest for excellence by enhancing technology, enabling innovation and
empowering people, thereby, creating consistent value for all stakeholders.

JBM Group has always kept a close watch on the dynamic needs of its customers and continues
the journey of efficiency by enhancing the technology at every stage. The organization has
collaborated with best global technology partners; possess state-of-the-art manufacturing
facilities and highly automated processes. These advantages have established new benchmarks
that have aided in providing superior quality and flawless technical perfection to the
organization's deliverables.

The continuous commitment towards excellence and consistent efforts to innovate have brought
excellent growth results for the Group. Apart from incorporating sophisticated technology, JBM
Group aims to not only exceed expectations, but to create value through innovation. The long
standing commitment to nurture research and development has brought the organization a long
way since its commencement 3 decades ago.
Environment, Health & Safety

At JBM, sustainability is the way of doing business. The Group aligned its goals
for environment, health and safety, making an impact across its value chain
worldwide. Together with the suppliers, customers and stakeholders, JBM strives
to maintain highest standards to preserve and protect the environment, as well as
enhance the health and safety of the Group’s employees and communities.

DEPARTMENTS IN THE NEEL METAL PRODUCTS JBM, Pune

1) Press shop

2) Paint shop

3) Quality department

4) Engineering department

5) IT department

6) Weld shop

7) Finance department

8) Purchase department

9) Maintenance department
Process flow of Production of fuel tank of 2 Wheeler
1) Storage area:
• The raw material in this process is a low carbon steel sheet.
• The sheet contain 0.003% carbon.
• The thickness of sheet is about 0.7 to 3.2mm.
• There are 3 type of sheets used:
I. GAIF (Galvanizing Annealing Interstitial Free)
II. GA (Galvanizing Annealing)
III. EDD (Extra Deep Draw)

2) Press shop:
a) OP-10 (Strike operation)
• In this operation 3M-machine of 200T KMW mech press is used.
• In this process blanking and drawing operation is carried out.
• The selected sheet is placed on the die and the job is located.
• Operate the push button with two hands and push pressed part to conveyer by new
sheet.
• Specification:
I. Bolster size= 2030*1220 mm
II. Stroke length=400 mm
III. Cushion length=300 mm
IV. Degree of strength=0.06

b) OP-20 (Restrike operation)

• In this operation 3M-machine of 250TKMW mech press is used.
• Both inner and outer are made by similar procedure.
• Take part from conveyer and placed on die.
• Locate the job and operate push button with two hands.
• Check it is dent free or not.
• No rinkles, no scoring marks, no tinning.
• Specification:
I. Bolster size=2030*1220 mm
II. Stroke length=400 mm
III. Cushion length=300 mm
IV. Ram parallelism=0.2-0.3 mm
V. Shut height=800 mm
VI. Degree of strength=0.06
c) OP-30 (Cam Trimming process)
• In this operation 2M-machine of 400TKMW mech press is used.
• Lift the part from conveyer and placed on die and operate push button with two hands.
• Take the scrap and put on scrap conveyer.
• Check outer surface has no burr, no dent, no damage.
• Specification:
I. Bolster size=2030*1220 mm
II. Stroke length=400 mm
III. Cushion length=300 mm
IV. Side adjustment=485 mm
V. Ram parallelism=0.2-0.3 mm

d) OP-40 (Piercing process)

• In this operation 2M-machine of 200TKMW mech press is used.
• Lift the part from conveyer placed on die and operate push button with two hands.
• Check whether cutting and piercing is done properly or not.
• Check no burr, no dent.
• Check profile match to spotting fix.
• Specification:
I. Bolster size=2500*1600 mm
II. Stroke length=450 mm
III. Cushion stroke=800 mm

e) Washing:
• Now both the inner and outer part are cleaned with steam and water.
• It is done so that every inch of fuel tank gets clean.
• The main focus of this process is cleaning the brackets position.

3) Weld Shop:
After the press shop operation and washing process the inner and outer part of tank is passed
to next stage i.e. welding.
a) LH/RH joining with spot welding:
• It is carried out to join the LH/RH part of the tank.
• Machine description=LH-RH joining SPM (Weldcon)
• Consumables required:
I. Knitted hand gloves=50gm
II. Weldcon SPM cap tip
• Power=400W
• RPM=1500RPM

b) Mesh-Seam Welding:
• Mesh seam welding machine used for this process.
• Start the mesh seam from the position as shown.
• Finish the mesh seam welding with 5 to 6 mm over run.
• Consumable:
I. Knitted hand gloves
II. Upper wheel=300*12mm
III. Lower wheel=150*12mm
• Current=61 to 67Amp
• Air pressure=4.5kg/cm2

C) Restrike press:
• The hydraulic press of 800T is transfer on the part.
• Specification:
I. Shut height=960mm
II. Bed size=1500*1000mm
III. Stroke=550mm
IV. Press capacity=800KN
V. Working pressure=285kg/cm2

d) Fortation:
• In this process the lock hole created.
• 200T press machine is used for this process.
• Pressure: 200-220bar.
e) Finishing, Rotary & Grinding:
• After fortation the part is transferred for finishing process.
• In this at first stage 120 rotary buffing is done.
• In second stage 180 random buffing is done.
• In final stage rework is done.

f) MIG Brazing:
• In this process weld start positioner is used.
• Locate the clamp outer assembly along with spatter fixture.
• Insert cup assembly along with tool into outer hole.
• Ensure cup resting with help of plates provided on hand tool.
• Move torch on cup brazing area and start cycle.
• Consumable:
I. Contact tip =0.8mm
II. Gas nozzle otg
III. MIG brazing wire=0.5mm
IV. Goggle=Black goggle

g) Process-SPM:
• In the process Inner Outer joining SPM is used.
• In this process the inner and outer part are joined.
• Match inner and outer manually.
• Insert this loose assembly into fixture locate in ‘C’ Bkt reset on nylon pad.
• Join inner and outer with 5 no’s of weld spot.
• Current=8 to14 KA , Air pressure= 4-5kg/cm2
• Consumable :
I. Knitted hand gloves
II. Electrode=SK641184

h) Full Spot:
• In this process spot welding SPM is used.
• Firmly hold inner-outer welded assembly.
• Do the full spot welding.
• Current=6-12KA , Air pressure=4-5kg/cm2
• Consumable:
I. Knitted hand gloves
II. Electrode=SK2420
i) Periseam:
• In this process periferial seam welding machine used.
• Start the periseam from the position as shown.
• Finish the periseam welding with 5 to 6 mm over run as per sample.
• Put job on conveyer.
• Current =9-15KA, Air pressure=3 to 5 bar, Water flow=10LPM.
• Consumable:
I. Knitted hand gloves
II. Dotted rubber hand gloves
III. Periseam upper wheel=300*5mm
IV. Periseam lower wheel=60*12mm

j) Rolling:
• In this process rolling machine is used.
• Firmly hold for rolling of sub assembly.
• Do the rolling and put job on conveyer.
• Air pressure=2to4kg/cm2
• Consumable:
I. Knitted hand gloves
II. Dotted rubber hand gloves

k) CO2 Tack welding:

• The process carried out on CO2 welding machine.
• Locate and clamp rear bkt. –clamp1—clamp2
• Complete rear side weld run, complete side cover tack weld.
• Declamp the job and put tank on convory.
• Current=110-150Amps ,Voltage=18-25V ,Gas flow=15-20 ltr/min
• Consumable:
I. MIG wire=0.6mm
II. Knitted hand gloves ,rubber apron ,goggle
III. Contact tip=0.8mm
l) Drain pipe brazing:
• Lift the torch from stand, brazing wire heat the rod up to 50 mm immediately apply
flux powder on heated rod.
• Heats the brazing area (O.P. and EVAP pipe) of the tank add the filler brazing rod to
seal gap.
• Put the tank on conveyor.
• Acetylene gas=0.5 to 1.5 bar, Oxygen gas=5 to 15 bar.
• Consumable:
I. Brazing flux
II. Brass brazing rod =1.8mm
III. Knitted hand gloves

m) Full welding:
• In this process CO2 welding machine is used.
• Clamp spatter guard on fuel gauge & fuel cock area.
• Complete side cover bkt. Full run and put tank on convory.
• Current=110-150Amps, Voltage=18-25 V ,Gas flow =15-20ltr/min.
• Consumable :
I. Rubber apron ,Goggle , Leg guard
II. MIG wire=0.8 mm
III. Contact tip=0.8 mm

n) Spoiler bkt. Welding:

• Remaining bkt. are joined with the help of welding using copper wire.
• Current=16Amp
• Voltage=2.2vtg.

4) Leak test:
• To check whether any leakages are present in fuel tank this process is carried out.
• Tank capacity=200ltr, Air pressure=0.3 to 0.5kg/cm2.
• pH value of water is 9 to 12.
• The leak testing rubber for gauge and cock are used.
• The chemical named BONDERITE-S is added in water.
5) Paint shop /Powder coating:
• In paint shop there are different chemicals used in various tank.
Pre-treatment:
• There are 11 pre-treatment tank which contain different chemicals are as follows:
I. Hot water
II. Chemical=Redolight 13-52, for 1 pt it uses 5kg.
III. Hot water + Redolight 13-52
IV. Water rinse
V. Water rinse
VI. Accuration-AC 50 +565 redolight
VII. Phosphate -952 + M+R+565+tonner 130, for 1 pt M=9ltr, R=9ltr, 565 =0.1 to
reduce 1ltr.
VIII. Water rinse-2 =1200ltr
IX. Water rinse-2=1200ltr
X. Passivation 54 MC to reduce pH-1/2 ltr=4.5pH
XI. Crystium water
• After pre-treatment process it is passed through heating-WD oven then booth-powder
coating and then finally through PC oven.
• After that final inspection is done to check whether the coating is proper and where it
is not good a worker rectifies the mistake and solve it.
6) Finished product / Dispatch:
• In this process firstly nut and marking check is done.
• Then the painted screws are taken out and instead of it new screws are put in along
with ‘O’ ring.
• Then two different types of pipes are installed which are drain pipe and fuel pipe.
• A new tank cap is also installed.
• Dry Leak Test:
I. The fuel tank is kept on the DLT machine.
II. Air with atm. Pressure is allowed to fill the tank.
III. If the tank has any leakages the air does not get filled.
IV. If the tank has no leakages the tank get fill with air to a specific atm. Pressure.
V. OK (Range:147 to 159)
VI. Not OK (Zero)
• Various attachments like damper JL173110, JL171030 & JL171029 are also installed.
• Then the fuel tank is sealed and special barcode is generated.
• Resistant testing:
i. It is done on RT machine.
ii. OK (range 104-105 )
iii. Min. (range 7-13 )
iv. Max. (range 97-103)
v. If the fuel tank is not OK then a siren start playing.
• After this the final check on the product is carried out and the fuel tank is ready to
dispatch.
• About 1200 to 1300 K4 tank are dispatched per day
• 400 to 500 K3 tank dispatch.
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 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.
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.
 SHEET METAL WORKING
1. Introduction

Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms
used in metalworking , and can be cut and bent into a variety of different shapes. Countless
everyday objects are constructed of the material. Thicknesses can vary significantly, although
extremely thin thicknesses are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are
considered plate.

2. Sheet metal processing

The raw material for sheet metal manufacturing processes is the output of the rolling process.
Typically, sheets of metal are sold as flat, rectangular sheets of standard size. If the sheets are thin and
very long, they may be in the form of rolls. Therefore the first step in any sheet metal process is to cut
the correct shape and sized ‘blank’ from larger sheet.

3. Sheet metal forming processes

Sheet metal processes can be broken down into two major classifications and one minor classification

• Shearing processes -- processes which apply shearing forces to cut, fracture, or separate
the material.
• Forming processes -- processes which cause the metal to undergo desired shape changes
without failure, excessive thinning, or cracking. This includes bending and stretching.
• Finishing processes -- processes which are used to improve the final surface
characteristics.
3.1 Shearing Process

1. Punching: shearing process using a die and punch where the interior portion of the sheared
sheet is to be discarded.
2. Blanking: shearing process using a die and punch where the exterior portion of the shearing
operation is to be discarded.
3. Perforating: punching a number of holes in a sheet
4. Parting: shearing the sheet into two or more pieces
5. Notching: removing pieces from the edges
 6. Lancing: leaving a tab without removing any material

Fig.1Shearing Operations: Punching, Blanking and Perforating

3.2 Forming Processes

• Bending: forming process causes the sheet metal to undergo the desired shape change by
bending without failure. Ref fig.2 & 2a
• Stretching: forming process causes the sheet metal to undergo the desired shape change
by stretching without failure. Ref fig.3
• Drawing: forming process causes the sheet metal to undergo the desired shape change by
drawing without failure. Ref fig.4
• Roll forming: Roll forming is a process by which a metal strip is progressively bent as it
passes through a series of forming rolls. Ref fig.5
 Fig.2 Common Die-Bending Operations

Fig.2a Various Bending Operations

Fig.3 Schematic illustration of a stretch-forming process.

 Fig.4 Schematic of the Drawing process.

Fig.5 Eight-roll sequence for the roll forming of a box channel

3.3 Finishing processes

Material properties, geometry of the starting material, and the geometry of the desired final
product play important roles in determining the best process
4. Equipment

Basic sheet forming operations involve a press, punch, or ram and a set of dies.

5.1 Marking and measuring tools

• Steel Rule - It is used to set out dimensions.
• Try Square - Try square is used for making and testing angles of 90degree
• Scriber – It used to scribe or mark lines on metal work pieces.
• Divider - This is used for marking circles, arcs, laying out perpendicular lines, bisecting lines, etc.

Cutting Tools
• Straight snip - They have straight jaws and used for straight line cutting.
• Curved snip - They have curved blades for making circular cuts.

Striking Tools
• Mallet - It is wooden-headed hammer of round or rectangular cross section. The
striking face is made flat to the work. A mallet is used to give light blows to the
sheet metal in bending and finishing.
Strong Points of Neel Auto Pune

• Very good infrastructure

• Good resource like machineries and technologies
• Dedicated team
• Skilled work force
• Multi-client base
• System Oriented Organization
• Strong HR practices
• Management very much care and focused about safety

OFI at Neel Auto Pune

• Very poor 5S,Need to improve lot in the 5s

• No standardized work flow /Single piece flow at some areas.
• Resource are under utilized
• Lot of NG inventory in the shop floor
• Tooling and machine maintenance is need to improve lot and all temporarily
managed
• Loss monitoring in place ,but no actions taken place for root cause
• Unwanted WIP lying on the shop floor and surroundings
• Every process is reworked once or twice
• Engineering is set the process in temporarily way
• Coordination between the people missing
• Cleanness of washrooms need to improve

If Maintain the resources properly then we can definitely increase its life
 • COSUMABLES LIST
Item/Material Life(Jobs/day) Specifications (mm)

1)Weldcon Cap Tip 750 15*8

2)Copper electrode 12000 300*12
wheel(upper)
3) Copper electrode 4000 150*12
wheel(lower)
4)MIG brazing wire 1300 0.5
5)Contact tip 240 0.8
6)Electrode 12648 SK2420
7)Electrode 11200 SK641184
8)Periseam upper 6200 300*50
wheel
9) Periseam lower 620 60*12
wheel
10)Tack welding 1000 0.8
(MIG wire )
11) Tack welding 240 0.8
(Contact tip )
12)Brass brazing rod 10 Job/1 rod 1.8
13)Brazing flux 1200 1 kg
14)Full welding 735 0.8
(MIG wire)
15)Full welding 240 0.8
(Contact tip)
16)Bonderite-S 1800 30 ltr
17)Acetylene gas 500 0.5 to 1.5 bar
18)Oxygen gas 500 5 to 15 bar

• How to sustain in this situation

Tools and techniques for cost reduction

1. Value Analysis.
2. Just in Time approach.
3. Standard costing.
4. Total Quality Control.
5. Cost saving projects.
6. Benchmarking
7. Inventory Management and Control.
 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 NEEL METAL PRODUCTS
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 NEEL METAL PRODUCTS LTD. 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 .

Thank You