ANITA NANOAMS

AMRITA
VISHWVA VIDYAPEETHAM
UNVERSITY
Established u/s 3of UGC Act 1956

INPLANTTRAINING REPORT

INDOSHELL CASTPRIVATE LIMITED

(A-14,SIDCO Industrial Estate, Kurichi, Coimbatore)

ANUJ JAIN.S
CB.EN.U4MEE16108

DEPARTMENT OF MECHANICAL ENGINEERING

AMRITA VISHWA VIDYAPEETHAM

ETTIMADIA, COIMBATORE-6412

SUBMITTED ON: 15 6] 16

14
 COIMBATORE
MEE16108
UNIVERSITY
AMRITA Sincerely
JAIN.S
ANUJ Hope
perceive
their
Indoshel andManaging May busy
express
to great aThe
continue esteemedMr.
this schedule,T In-plant
also
Ramkumar
who choice
my
opportunity Director use
guided sincere Training
cooperation organisation. this took for
Sir- learning
ACKNOWLEDGEMENT
me fromopportunity timethanks
Mr
that
as
throughout to
withyouin an the Ganesh
hear toand had I
important would I
HR toprofessional all
and undergone
my dept. express to employees
the alsoallow guide
future part
training. and
like my me
development. at
of head me
mycareer to
deepest towhoIndoshell
to0. to the
thank took
of take
correct
all gratitude time Cast
development. Mr. this
the would I
Mahadesh training path. from Pvt.
depts
to Ltd.
their like
1 .at the was
in to
 5 4 3.4 3.3 3.2 3.1 3 2 1 S.no

Conclusion
Bibliography Machining Melting
PackagingandQuality
Control No-mouldVarious
Manufacturing
process
Company
Profile
Acknowledgement Topic

process
CONTENTS
process

carried
and
core out
making

13 12 11 10 9 7 6 3 Pagen0.
 casing. SOME basis
process
PumpRocker Brake
shafts.
5.arm.drum.
4. 3.Cam 2. 1. operation
developedinternational To products
Pvt.Ltd.wheeler
AIron than andmanufacture
producer Indoshell then
Engine and solve diverse
PRODUCTS castings 30 4
variation machining has
problems t5he from that years anengine
cylinder and of Cast
six markets and ISO/TS 200 been
quality
marketing conform of inPrivate
OF reductionsigma well-structured casting cylinder
also facilities activeIndia. one
block.
INDOSHELL solved. 16949:2009 COMPANY
PROFILE
black
problems while in
to high components, With Limited of
to the experience blocks.
various emphasizing (3 the
belt
manufacturing. and in over
CAST: standard, largest was
group low certifiedIndia The
holders. in 55
projects established
a company
pressure in and customers it
scientific Shell is shell
To onthat that company 1 the
are in
achieve efficiency satisfiesstrives dieMoulded USA). largest
has moulding in
identified in the
way castings. by 3
Today shell
manufacturer and
inboth to Germany year
rejection the S.G. outside
on every produce mould precision 1973
company domestic Iron
Indoshell
a
continuous
reduction, step has India and
and foundries
of
casting
ofquality Grey more two since
has the and Cast and
3
 HereAWARDS: customers. Casting
Itis COMPANY
VISION:
7. 6. 5. 4. 3. 2. 1.
2015: 2003: 2001: 1999: 1997: 1996: 1992: are 4. 3. 2. 1. the
some ToProducts,
highest training By
and
By Attaining vision the
Yamaha
Quality Best Best Best
TVS Productivity total our
be outperforming This future...
of
Spectra Foundry
Supplier Performance the
a for ongoing
regard employee is of
Award Award premier Processes Marketachieved
Indoshell
continuous
achievements with
Award Foundry for
Award
from Award
for our
Supplier commitmentleadership by: quality!
and
involvement,competitors Cast
Best givenAward
Honda fromVendor People, growth. Service.
fromAward
and to
for from PSG, to by give
motorcycleHusco the from
milestones Community our to in
Hindustan
Coimbatore exceeding
obtainedContinual the
International Best Customers Quality,
Dr.N. best
Ltd. Castings
Velappan of and through Delivery
Customer quality
Motors the Improvement
Environment. while
Supplier. organisation:
Ltd. education and products
holding expectations
Cost.
of to
4 the and our its
 Lombardini
Daimler
10. Scania 8.
Hytos
9.Hydraulics7.
BorgWarner
ArgoPoclain 4. Eicher 2. company
are: SomeACTIVITIES:
WELFARE
SOCIAL
International
Enfield
Royal
6. 5. Husco Bajaj1. CLIENTS
3.Motors 7.
Arrangement 6. 5. 4. 3. 2. 1.
employees.
Provision Adopting
Supportingeducationfree Periodic
AssistingProviding of
OF the
INDOSHELL
of public temple support medical social
uniforms, people
of
parks welfare and
CAST: loans
soft health
in and
wellness
shoes and need facilities
activities check-up
tree of
etc basic
co-operative
through
plantations. activities
to toand
employees. necessities educational
eye
carried
camps
institutions out
regularly
banks
imparting
to by
5 the the
 Average
dimension(mm)
dimension(mm) Raw Weight
Machined Accuracy CAPACITY
STEPS
clamping. 2. 1.
3. Mould
9.Bolt 8. 7. 6. 5. 4.Production
Sent SprueMould Hot CoreMouldMould IN
production range
OF for to MOULD
area fixing
of OVERALL pouring closing hot hallow dry
castings(kg) covered MANUFACTURING
glue and cleaningPRODUCTION: PROCESS
per and
applying air for
PRODUCTION: (packaged bolt
month(ton) withmould cleaning. using
clamping;
paper.fusing. and air.
in
shots. filter
+/-5+/-0.4
800 dimensional
accuracy
Right 0.0520
to followed
placing.

by
air
cleaning.

6
 Advantages Features:
industry.
involve;
prepared PLC development moulding
in0.30 which Indoshell to
Cast VARIOUS The materials
good supplier materials
and jigs, The PURCHASE
2. 1. Inbuilt1. the lack
curing controlled mm "Supplier
quality purchase
fixtures
High Good range of
intricate in infor PROCESSES not stock and
rough line OF
surface ensures of its 50 of in
proof)
shellpoka-yoke(fool plants bulk Quality services department
services and RAW
machine gwith Pvt . materials the th e
casting to
quality
moulding proper shaped production. list;
company spare MATERIALS:
withinternational 20 accountsfor Ltd. CARRIED Manual" ONE are are
imensional kg. has supplied.
500 is apprisedprocured parts is
control castings used. For equipped
process tons The OUT:
TIME has responsible
shell is
standards. used
PURCHASE to required
of of On dimensional superior
processits
accuracy temperature.
are: system used metal moulding purchase the infrom
to
an
itself for
guide a
inaverage, 1 for the
reliable
for used The with decision week
hydraulic a
accuracy
materials/services
the production purchase
castings4 advanced
pre-heating semi-automatic instation supplier of
a supplier.
month.12000 is every
and produced casting of for taken of
castings
technological in month. process. The raw
Applications
and automobile moulds maintaining by
materials,
MD/VP. from required
mould weigh is If
are +/ and any due The
7
 products.
system 14
MAKING:
CORE e rollover
Advantages: process,thmould isbegins
binder
preparation
the withmoulding No
PROCESS:
NO-BAKE
MOULD Challenges
faced
are:
semi-automatics 2 1 5. 4. 3.
Provides the Bake Faster Less Thin
better 4. 3. 2. 1. High High
to Requires It It process
readied
then
creates is for chemical sand. is production
pattern manpowerwalled
produce adaptable moulded
sand for a production
casting
low high is filling The and
he
used tbinder costs.
complex PLC skill sand costs and
complex
strength to hardening of rate
controlled dimensional
control to and the process
and any taken
handling the is moulding
away isremove and
quality the
mould. then
shell labour
moulds that casting castings
process.
catalyst.
transported
vertical
cores the skills
requirements. A uses
prices. can
frommolten
the mould After mixer required
for core When chemical be
hydraulic from the is to made
shooters the then the
casting.metal.
compactionthe sand mould binders
used
and with After
pattern
abox.
The
exits to
fil to
automobile
poka-yoke blend
shakeout process, the station bond
mixer,
sand the
a in
 RH curing time (sec) 120+/- 10
RH shooting pressure(kg/cm^2) 4
RH temperature (C) 240
LH temperature(C) 230
Line pressure(kg/cm^2) 6

Investment time(sec) 102

Features:
Control process parameters such as sand shooting pressure, sand
investment time and sand curing temperature.

MELTING:

Indoshell Cast Pvt.Ltd. uses 4 medium frequency; 1-toncapacity Induction

furnaces. 2 are used for shell moulding purpose and 2 for No-bake
moulding process. On an average 800 tons of metal is melted every
month. The composition of raw materials added varies form different iron
types; but mainly consists of:

1. Pig Iron
2. S.G. Iron Borings
3. Mild steel scrap
4. Carburizer (shellcoke or anthracite coal)
5. Foundry returns
6. Mg treated wire
*Not all materials are added for every type of
lron.
Features:
The melting department is equipped with
spectrometer for the
analysis of composition of various elements. For S.G. Iron the percentage
% drop in
Mg is analysed in the first and last pouring of particular melt.

9
 1. Standards and Spherodisation is carried out by PLC controlled
magnesium wire treatment process.

QUALITY CONTROL:

Quality inspection is an important part of manufacturing process. Quality

controlstarts right from selection of resources. The process followed is:
1. After the rough casting is made, the castings are cleaned by
shots in a rotating table in the fettling dept.
2. Then the castings are grinded, deburring done and heat number
punched on it.
3. Then it goes through 3 stages of visual inspection and gauge
measurement.
4. It is sent for dimensional inspection, endoscopic inspection and
magnetic particle testing
5. Internal defects are found with ultrasonic waves and sent for
radiographic testing; for confirmation.
Features:
1. Hardness testing done with advanced techniques like Brinell
hardness test and Rockwelltest.
2. UTM used to find the compressive strength of core and
moulding sand.
3. Other tests carried out are moisture test, stick point test, tensile
strength of sand and peel back test.

IndoshellCast is familiar with and implementation of:

1. APQP- Advanced Product Quality Planning
2. FMEA- Failure Mode Effect and Analysis
3. MSA- Measurement System Analysis
4. Parato analysis for defect analysis

10
 MACHINING:
The machine shop at Indoshell Cast not only focusses on value addition to
the product but also on maintaining very low rejection PPM at the
customer end. The products that are machined have less than 100 PPM
rejection from customer end.
The machine shop is equipped with latest CNC turning centres,
vertical and horizontal milling centres (with 4" axis machining facilities)
and conventional milling centre. The machines imported from Japan are
from Makino company that give very high dimensional accuracy. The
primary focus is machining of complicated hydraulic castings. This requires
vey lowcontamination levels in work area. An ultrasonic cleaning machine
is installed that gives cleanliness levels of less than 10 mg.
State of the art measuring devices like CMM and height master.
Mitutoya CMM with advanced software facility and metrology lab is there
too. To measure complicated angles and curves profile projectoris used.
Devices to measure surface finish and flatness is used.

PACKAGING:

At Indoshell Cast superior products with sound quality control process

matches with excellentdelivery system. Packaging is custom designed to
suit the specific requirements of domestic and international supplies.
Many crucial factors are taken care of like seaworthiness, shelf-life, rust
prevention, pest and termite control and handling system at the customer
end are considered with due attention.

11
 CONCLUSION

objective of this report is a description of the practical

The primary
of training I closely
knowledge attained during this visit. In this period
Indoshell Cast; right from
studied the detailed process followed by
machining and
purchasing, designing, production, quality testing,
know the aspects of
to
packaging of a customer's product. I also came
methodologies and learnt the art of
practical applications of various
The following points would
solving various problems faced inthe foundry.
conclude by report:
commence any task. Practical
1. Theoretical knowledge is insufficient to
ideas are also very important.
man power, climatiC
2. Various factors like resource availability,
completion of
conditions and health of workers play a vital role of
any task in time.
ensure safety of its
3. The company has taken various steps to
employees.
needed for successful
4. Co-operation and team work among workers is
working of any company.

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 BIBLIOGRAPHY

1. www.indoshellcast.com
2. www.indoshellfoundry.com
3. www.iron-foundry.com

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