INTERNSHIP REPORT

Name- Harsh M. Shah

Year & Branch- TYME
Period- from 5.07.22 to 12.08.22
Company name- Kalyani Maxion Wheels
Location- Chakan
 INDEX

Sr.no Topic
1. Acknowledgement
2. Objective
3. Industry introduction
4. Day 1 to Day 39
5. Certificate
6. Conclusion
 ACKNOWLEDGEMENT

Successfully completion of any type of project required help from

number of people. Now, there is a little effort to show my deep
gratitude to the helpful people.

I convey my sincere gratitude to my college mentor Mr. Tushar

Nikumb and my internship supervisor Mr. Sunil Dhakne, supply chain
department head. Without his kind direction and proper guidance my
internship would not have been such a success, in every phase of my
project his supervision and guidance shaped the results to be
successful and perfect.

I would also like to thank my college MIT Polytechnic for giving me

this wonderful opportunity to do my internship at Kalyani Maxion
Wheels. I had a unique experience and a lot of learning which will
help me in my future career.
 OBJECTIVE

1) Real time industry experience which cannot be duplicated in

academic institutes.

2) Make students aware about what kind of skill set is required

in industries.

3) exposure to latest technological developments in mechanical

engineering sector.

4) correlate course knowledge with its industrial applications.

5) familiarise with industrial terminology and working system.

 INDUSTRY INTRODUCTION

KALYANI MAXION WHEELS

-CHAKAN

The former joint venture of Hayes Lemmerz and the Kalyani Group
was founded in 1996 in Pune, India. Today the JV operates under the
name Kalyani Maxion Wheels and has the capacity to produce 1.3
million commercial vehicle steel wheels, serving global OEMs such
as Ashok Leyland, Daimler, TATA Motors, and Volvo.

In 2009, Maxion expanded its operations in Pune and began

production of light vehicle steel wheels. The team is responsible for
manufacturing up to four million wheels per year for global vehicle
manufacturers such as Ford, General Motors, Honda, Hyundai-Kia,
Nissan and VW.

Kalyani Group, established in mid 1960s, is an Indian multi-

national with high technology, engineering & manufacturing
capability across critical sectors such as Engineering Steel,
Automotive, Industrial, Renewable Energy, Urban Infrastructure
and Specialty Chemicals. With end-to-end capability and
manufacturing footprint across India, Germany, Sweden, &
China, the Group has an annual turnover of over 12,000 Crores
and market capitalization of its listed entities approximately
10,000 crores. The group has joint ventures with some of the
world leaders such as Meritor, USA, Carpenter Technology
Corporation, USA, Maxion Wheels, Brazil, FAW Corporation,
China, Alstom, France and David Brown, UK.
Guided by visionary leadership of Mr. B. N. Kalyani, Group
Chairman, with strong emphasis on market leadership through
technology and it's over 10,000 strong engineering global
workforce, the group today is a market leader in all its respective
business segments.

 Largest Forging Company in the world

 No.1 in Engineering Steel in India
 No.1 in Axle Aggregates in India
 No.1 Indian Exporter of Wheels

 
Bharat Forge Limited (BFL), the Pune based Indian multinational
is a technology-driven global leader in metal forming having
trans-continental presence across a dozen manufacturing
locations, serving several sectors including automobile, power,
oil and gas, rail & marine, aerospace, construction & mining, etc.
Part of Kalyani Group - a US $ 2.5 billion conglomerate with
over 10,000 global work force; BFL today has the largest
repository of metallurgical knowledge in the region and offers
full-service supply capability to its geographically dispersed
marquee customers from concept to product design, engineering,
manufacturing, testing and validation.
The world's largest forging company with manufacturing
facilities spread across India, Germany, Sweden and China,
Bharat Forge manufactures a wide range of high performance,
critical & safety components for the automotive & non-
automotive sector. It is the country's largest manufacturer and
exporter of automotive components and leading chassis
component manufacturer in the world. BFL's customer base
includes virtually every global automotive OEM and Tier 1
supplier.
Backed by several decades of experience in metallurgy &
automotive component manufacturing, the company is now
looking beyond automotive and has embarked on an ambitious
and exciting journey to redefine its already existing presence
across several critical business verticals such as energy, oil &
gas, aerospace, rail & marine and other infrastructure related
businesses.
'Expanding into new horizons' will give Bharat Forge a
completely new growth perspective. It will begin the
transformation of the company from an auto component supplier
to an engineering & capital goods company with diverse
complementary businesses in new high growth sectors.
 Quality Assurance
Quality has been the most important driver behind the growth
exhibited and the reputation earned by Kalyani Steels over the last
four decades. It has not only helped us earn approvals from major
OEMs in Automotive and General Engineering segments, but has also
established a status of most preferred supplier.
 
Apart from numerous recognitions from our customers, Kalyani
Steels is certified as per quality management systems of International
Standards. We have 100% in-house testing facilities, state-of-the-art
equipment and a dedicated & experienced QA team to rely upon.
 
We are capable of producing Ultra-clean steel with very low levels of
Oxygen and non-metallic inclusions. We have benchmarked our
products with that of international steel mills for Rotary Bending
fatigue.
 
We can manufacture steel for high temperature creep-resistant
applications for Super-critical and Semi-critical boilers.

STAR PRODUCTS

Clads Vehicle Wheels

VersaStyle Vehicle Wheels

 Vehicle Wheels

All about my Internship

 - WEEK 1 -

Day 1

My very first internship, it was my first day and I was very excited for
it. when we reached at Kalyani Maxion Wheels, it was just
astonishing. we entered the industry and saw a huge manufacturing
plant right in front of us, with utmost curiosity we searched for our
industry mentor and on meeting Mr. Sunil Dhakne he introduced us to
the industry norms and all his colleagues, we were delighted then he
also introduced us to the HR and got us registered as interns in the
industry system. we also got are ID cards which would help us to
enter the company on daily basis.

Day 2

Today, with our industry mentor we visited the first manufacturing

plant, for that we were asked to wear safety shoes, ear plugs,
eyeglasses, and hand gloves for safety purposes. Kalyani is world’s
leading wheel manufacturing industry and the largest forging industry
in the world. The first plant that we visited was the truck wheel plant,
r mentor helped us understand the whole manufacturing process and
how all the machines worked, and he even cleared all are doubts
regarding the truck wheel manufacturing process.
After going through the manufacturing process of the truck wheels we
also visited earth storage facility where they stored all the raw
materials required for its manufacturing, the manufacturing unit and
the storage space both were humongous in size, and it took us almost
2 hrs to complete our tour.

Day 3
Firstly, we thought that on Thursday’s manufacturing industries
usually have holidays, but this industry was different they had a fully
functional day on Thursdays as well. we visited the second
manufacturing unit that was the car wheel manufacturing plant which
was just a little ahead of truck wheel manufacturing plant.

This plant was also very huge and had a staff capacity of about 300
people, hey here we were accompanied by
Mr. Parchure and he showed us around the whole plant and explained
us the whole manufacturing process step by step he also elaborated on
how each and every machine worked and what their purpose was.
After explaining everything he also cleared all are doubts regarding
the process and introduce us to the department heads in the car wheel
plant.

Day 4
After clearly understanding where everything was in the industry and
how it worked, we were finally assigned with our first project supply
chain department, in this project are head was
Mr. Ravindra Pujari. In this project we were basically supposed to
redesign the whole truck wheel plant storage space as it was last
redesigned in 2012 and recently due to corona virus outbreak
everything was very chaotic in the storage space and also certain
section of the storage space had been preoccupied by waste machines
so everything needed to be organised efficiently again. we were also
required to save as much space as possible while efficiently
redesigning it, on receiving this project we were very excited and
enthusiastic about it as it was our first project, and we were ready to
show our skills and potential to all our colleagues and gain a certain
position in the industry apart from just rookie interns. This was also a
great opportunity for us to learn a lot of things like time management
coordination skills, communication skills and it would also teach us
punctuality and importance of things.
 Day 5
- Saturday –

(On weekends the company is usually closed for everyone

unless there is some matter requiring urgent attention)

Day 6
- Sunday -
 Day 7

Our second week of internship starts, and we have recently received

our first project in the industry that is to redesign the storage space.
with all our energy and concentration, we finally start working on our
first project, after coordinating with r project head, we geared up by
Wearing our helmets, ear protectors, eyeglasses,
safety shoes and our safety shoes. We Were given a 5-metre
measuring tape in order to record all the dimensions of the storage
facility in the truck wheel plant.

We Started recording all the dimensions after coordinating with the

raw material storage space manager and noted them down in a
systematic manner, side by side we also created a rough layout which
would give us a clear idea an understanding of how everything was
placed in the available space and this would also help us in
improvising on the final layout ahead.
 Day 8

After having r breakfast at the industry, we continued working on r

project, once we had taken all the dimensions and created a rough
layout of how everything was placed in the storage space, we started
segregating everything efficiently and placed them according to are
understanding and company requirements. all this was done roughly
on a sheet of paper but was done using all the recorded dimensions.
All the raw material was segregated on the basis of their size,
quantity, daily requirements and time period on which they are
received monthly and yearly. Doing this took us almost the whole day
as they were approximately 120 different types of raw materials that
were being stored in that facility on a daily basis.

Day 9

Now that we had segregated everything with utmost efficiency and

companies’ recruitments, we started preparing a fair layout using
AutoCAD software which was taught to us during our 4th semester of
college. it was very helpful in this situation have known AutoCAD
beforehand, we created the fare layout keeping all the dimensions in
mind and although requirements of the industry. Creating this fare
layout took us almost 2 days, as it required a lot more details than
which we had assumed beforehand, and it also needed to be changed
twice due to new requirements that were being put before us at any
given point of time.
 Day 10
Finally, after rigorous hard work, multiple changes and concentration,
we finally completed the layout of the raw material storage space for
the truck wheel plant with satisfaction and all the requirements placed
in front of us. The storage space layout was even approved by the
plant head, and it also got implemented in the plant. We Completed
our task by arranging and reorganising everything with maximum
efficiency and also saved at least 17% space. This Is how we
completed our first project in the industry.

We also got the appreciation from multiple department heads for our
precise work.
Final layout
 Day 11

We had finally completed our first project successfully. Today our

industry mentor showed us the inventory of truck wheel plant, this
inventory had more than 6000 items stored in it. Here we met the
inventory head Mr. Ganpat Langote, we helped him in his work there
and also put informative tags on multiple items stored there who's
locations had been recently updated.
Later that day we also helped other department heads in their work
like filling up sheets and replying to mails or drafting informative
messages. We were also asked by Mr. Langote to create an excel
sheet for recording annual your attendance of 20 employees working
in the inventory.
 Day 12
- Saturday –

Day 13

- Sunday –
 Day 14

Submitted the new excel sheet to the elementary coordinator

regarding the annual attendance of 20 employees working in the
inventory. Today a new supervisor was assigned to us
Mr. Santosh Wagh, he gave us our second project regarding the
annual physical inventory. We for asked to create an informative PPT
which would help in better understanding of the physical inventory
process it would help us as well as the board of directors to
understand how the physical inventory process is carried out annually.
It took us the whole day to clearly understand the annual physical
inventory and to create the informative PPT.
 Day 15

After the completion of this PPT we explained the whole process once
to our supervisor and after learning that we know everything correctly
he asked us to understand the company policy once and also to update
the PPT and include the company policy as well for further clarity.

We were invited to the inventory meeting which was conducted

further that day in this meeting all the people who would be involved
in the physical annual inventory count were present and we were
introduced to all of them as well as to the whole board of directors of
the industry, we explain the whole process to these people.
 Day 16

Major part of our second project started today, now that we had
clearly understood how physical inventory was carried out we were
actually asked to carry one out.
PNT- Stores Inventory        
Tag No. :- 1     Date:-  
Sr No. Part No. Description Location Unit
BALL SCREW WITH
DOUBLE NUT,SIZE-
1 PUN0108070380 160 X 2 SR8/1 NOS
BACK GAUGE GUIDE
(MTD-16558) FOR
2 PUN0602291291 1000MM SR8/1A NOS
SHAFT FOR LIFTER
3 PUN3333031280 PLATE 211/133/128 SR8/1A NOS
WORM SHAFT
(CODE: MTC-4811)
4 PUN0602290050 SPARE FOR G SR8/1B NOS
GUIDE BAR FOR 1ST
SHRINKING
5 PUN3333032040 211/133/204 SR8/1B NOS
6        
7        
8        
Counted by:-  Harsh Shah      
 Hars
Entered by:- h
Checked by:-  Harsh Shah     Shah
The company was going to hire 5 to 6 employees for carrying out this
annual inventory and we were supposed to manage everything, for
this inventory to be carried out we had to make detailed tags for each
and every item our product that was present in the inventory, there
were approximately 6000 items that were placed in this inventory.
Hence, we started creating the detailed tanks which would involve
each items location description quantity in the inventory ,
immediately.
On this day we made approximately 1500 tags.

Day 17

Having a target of completing over 6000 tags as soon as possible,

toady we completed tags for approximately 2000 items in the
inventory and also stated their location unit and description in each
tag.
doing these 2000 items took almost 7 hours of consistency and focus
doctor. On completing these tags in order to take a small break we
decided to help the HR ma’am Mrs. Poonam Bhat in segregating
performance sheets of some employees.
 Day 18

After completing around 3500 tags delivery at many to do show be

continued making the tags for the leftover items today and
successfully completed over 2000 tags today and sue to the excessive
urgency of receiving the tags, we did the rest at home and completed
making all the tags. Later that day we also went through the whole
inventory process step-by-step as it was required by us to conduct the
annual physical inventory in the truck wheel plant on Monday, 25th of
July.
Right after our lunch at the industry, for a small break we helped the
HR once again.

PNT- Stores Inventory        

Tag No. :- 1421 1468   Date:-  

Sr No. Part No. Description Location Unit

PUN311201006 EJECTOR GUIDE ROD OD 60
1 0 X 1935 MM WITH SR8/3 NOS
PUN311201076 ADAPTOR OD255X535MM
2 0 FOR WF 730322306 SR8/3 NOS

3        

4        

5        

6        

7        

8        

Counted by:-        
Entered by:-
Checked by:-        
 Day 19
- Saturday –

Day 20
- Sunday –

Day 21

After all the tags we made working day and night it was finally
time to the annual physical inventory process in the truck wheel
plant and under the supervision of Mr. Santosh Wagh we would
be carrying out the physical inventory and guide the hired men
throughout the process. During this process our main
responsibility was to issue tags according to the requirements
raised by any of the employees. Due to some mis-understanding
that took place in the inventory, locations of more than 1000
items had been updated without notifying us so because of this
mistake we had to redo all the 6000 tags all over again. In this
case we decided to start with those tags whose requirements
were being raised by the employees, so on Monday the first day
of inventory we ended up making 1700 item tags based on the
raised requirements. To do this, it was a great task as everything
was a rush and had a certain goal and time limit.
 Day 22

Due to the excessive urgency, we completed all the remaining 3300

item tags at home working throughout the day, we handed these tags
over to the assigned location executives one-by-one. Due to shortage
ion manpower, we also joined the employees and started counting
items in their locations, doing this took almost all of my day and as
soon as on location was done, we used to hand over the list to the
hired typist who would later update the location and quantity of all the
items in the industries database. We counted items in 6 locations this
day and also helped the typist in updating the database.
 Day 23

Continued helping and supporting the hired members in physically

counting the items in inventory on particular locations and also filled
the forms the duck quantities that we came across during our physical
count. Completed approximately it new locations And filled 13 new
sheets, by updating the locations that we came across. later we handed
these sheets over to the typist and help him update the new locations
in the industry database.

Day 24

Physically counted items on another 6 locations and fill another 11

sheets, also updated their locations in the industrial database along
with the typist hired by the company. to take a break we again helped
the HR in segregating the list of employees who had interviewed for
jobs in the industry. later we also helped our industrial mentor Mr.
Sunil Dhakne with his mails by drafting some important messages
that were to be sent.
 Day 25

The inventory process needed to be ended today but due to lack of

manpower it was not possible but still we counted items on the
remaining locations and also stayed over time I think apologise for
that show dad maximum work could be completed today. we also
help the typist search in updating the locations in the industrial
database after during the last hour.
 Day 26
- Saturday-
Even though it was a Saturday as completing the inventory was
a matter that required immediate attention, we had to com to the
industry to complete the inventory process successfully.
Today we completed filling up all the informative sheets and
also updated locations and quality of all the items existing in the
inventory in the database of the industry and concluded are
physical annual inventory count.

Once we completed this up to the mark, we were appreciated by

all the heads and employees that we worked with for our time
management skills, prioritizing skills, speed and efficiency of
work and output. Here our second project ended with success.

Day 27
- Sunday –
 Day 28

Now that our Inventory project had ended, we were back under
our industrial mentor Mr. Sunil Dhakne.
He gave us a list of items that required attention and needed to
be segregated on the basis of their quantity, price and sizes,
there were many items so it took us the whole day to complete
this task, this task would help us in better understanding of how
things are segregated in an industry.

Total

80000000
70000000
60000000 Total
50000000
40000000
30000000
20000000
10000000
0
A B C

Day 29
(Took a leave due to excessive stomach-ache and illness)
 Day 30

Got assigned with a minor project that was to physically count

all the marking punches start the truck wheel plant used on a
daily basis and make a list of all these punches according to the
sequence kept in the rack like 1-rb ,2- mx ,3- aa. Also, we were
required to create a list of quantities of each marking punch that
was available in the industry. for completing this task, it took us
over 2 days as there were around 800 to 1000 marking punches
that needed to be counted.
Today we counted around 400 marking punches and made 3
lists according to requirements raised.
 Day 31

Continued counting the marking punches and updated their quantise,

sequence, and update the punches that were mot stated in the system.
Today we completed physical counting of all the marking punces,
also we updated the newly made list in the industries database. Doing
this took 5 hours as there were a lot of marking punches that needed
to be counted.
 Day 32

As internship was coming to an end, we decided to change our

department and then after posting this request we got assigned under
the maintenance department, here Mr. Rajesh Nikam was going to
supervise us. On our first day in Maintenance department, we were
asked to research about TPM and Kaizen, so that we were understand
what all is necessary for neat, clean, and organized space in the
industry.

We were also asked to monitor and understand what all is being done
in the maintenance store and how all the machines were being used
and how they worked. He asked us to note down every specification
about each machine-like tools used, dimensions, power, volts, process
of use, etc.
 Day 33
- Saturday -

Day 34
- Sunday -

Day 35

Observed everyone in the maintenance department, noted down what

all was going on, which all machine parts needed maintenance.
Communicated with the employees and understood how maintenance
was being done. They also showed us how all the tools that were
being used worked, also asked to research about industry 4.0 and
understand the concept thoroughly. It was out task to list down was in
which the industry could contribute to this 4th industrial revolution.
 Day 36

Today we got our final project, to work on a laser cut nesting proposal
for the industry. laser cutting was used in auto cut blanks of sheet
metal which would later be used to cut rims for wheels. Our work in
this project was to create a design which would efficiently fit
maximum number of rims and word save a lot of raw material that
was being wasted, this would also help in major cost cutting of the
industry. We were going to put all our energy in this project as it was
our last one, with our supervisor’s guidance we started our research
and tried multiple ways to fit maximum blanks in the sheet sizes
provided to us. After trying for an hour, we finally came up with the
most efficient design that would help the industry in saving a lot of
money and will also reduce the raw material consumption and reduce
environmental damage. Completing the first sheet after figuring out
the perfect layout took us quite some time.
 Day 37

Completed all the other sheets for the laser cut nesting proposal, there
were 6 different sizes of sheets that we worked on in order to create
most efficient patterns that would help in reducing material wastage.
Doing so we saved almost 22% more raw material than what was
being wasted earlier.
Later we spent more time in the tool room understanding all the rest
and got to know more about CMM as well.
After completing our 3rd and final project successfully we decided to
finish our internship logbook and get it signed by the heads who
supervised us throughout.
 Day 38

( Raksha bandhan Holiday)

Day 39

Today was the last day of our internship, we visited both the
manufacturing plants once again and went through the whole process,
we also met all our supervisors who had helped us throughout the
internship. And had taught us many new things, they wish us luck for
our future careers. later we also received are internship completion
certificates and for are hard work and support to the industry we also
received a token of appreciation which was given to us by the plant
manager. We had a pleasant and memorable day.
Certificate
 Conclusion

This internship went well and taught us many things that we would
not have got to learn in our college. The internship was very
important for us as it helped us more about our future careers and
streams that we were going to choose, we also got to implement are
learning in real life and realised how much more we need to learn and
skills we need to develop to be a part of this huge manufacturing
sector. over oil the internship helped us a lot and will be a memorable
time.