P-3 CELL

INTERNSHIP REPORT
By
Pranavkumar S Dhanedhar

Under the guidance

Of
Ms. Archana Sonawane
(ME Department Head)

DEPARTMENT OF MANUFACTURING
ENGINEERING ENDURANCE TECHNOLOGIES PVT.
LTD. AURANGABAD
2022-23

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CERTIFICATE

MGM’s JAWAHARLAL NEHRU ENGINEERING COLLAGE,

AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

This is to certify that Internship Report submitted by Pranavkumar

Dhanedhar having PRN (1921321612095) is his work during the internship at
Endurance Technologies Pvt. Ltd. and submitted in partial fulfillment of the
requirements for the award of the degree of Bachelor of Technology in
MECHANICAL ENGINEERING of Dr. Babasaheb Ambedkar Technological
University, Loner during the academic year 2022-23.

Netaji Pawar
Mfg. Dept.

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Acknowledgement

I am very thankful to Endurance Technologies Pvt. Ltd. For

giving me the opportunity to undertake my summer training at their
prestigious plant. It was a very good learning experience for me to have
worked at this site. An Internship is a golden opportunity for learning
and self-development. I am indeed a very lucky and honored to get
chance to complete this in Endurance Technologies Pvt. Ltd. where I
have so many wonderful industry managers, staff and guide who led me
through in completion of this internship.
I would like to give my heartfelt thanks to HR manager Mr.
Vishal Dalvi who heartily welcome me for the internship. Mrs.
Archana Sonawane (ME Dept. Head) who guided and encourage me
all through summer training and imported in-depth knowledge of the
program and guided me whenever I needed, also, I would like to thank
Mr. P.S. Maslekar ( Plant Head) and all the department heads of
Endurance for giving their precious time and valuable guidance during
my internship program. I am already thankful to Dr. M S Kadam head
of the department mechanical engineering of MGMs JNEC Aurangabad.
I extend my grateful thanks to Mr. Khedekar and Mr. Sable who took
time to hear, guide and keep me on the correct path. I would like to
thank to our beloved Principal, Dr. H. H. Shinde for his efforts and help
provided to me get such an excellent opportunity. There were so many
who shared valuable information directly or indirectly that helped me in
the successful completion of the activity. The data collected from all the
people from industry have indirectly played a very important role in the
fulfilment of the study.
Thank you.

PRANAVKUMAR DHANEDHAR

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INDEX

Sr.no. Topic Page no

1. About Endurance Technologies 05
2. Introduction of various departments 06
3. Information of Manufacturing Department 07
4. Problem Statement 08
5. Introduction 08
6. Cell Layout 09
7. Operation Sequence and tool specifications 10
8. Dent Damage Study 12
9. Analysis 20

Table Index

SR. No. Topic Page no.

1 Operations Sequence 10

2 Operation wise Tool Specifications 10

3 Dent Mark summary 13-16

4 Burr Locations summary 17-18

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1. About Endurance Technologies

Endurance Technologies Pvt. Ltd. is an Indian multinational company that

specializes in the manufacturing of automobile component system. The company
was founded in 1983 by Anurag Jain and its headquarters is located in Aurangabad,
Maharashtra India. Endurance Technologies has a global presence with 25
manufacturing plants spread across 10 countries. Some of its key products includes
suspension system, braking system in Pune, Maharashtra India by Mr. Anurag Jain.
Today the company has the global foot print, with operations in 9 countries across
3 continents.
Endurance Technologies produces a wide range of components and systems
for the automotive industries, including suspension system, brakes, transmission,
engine components and Aluminium castings. The company’s products are used in
two wheelers, three wheelers passenger cars and commercial vehicles.
Endurance Technologies is known for its focus on innovation and quality.
The company has several research and development centres in India and Europe,
where it develops advance technologies and designs products that meet the highest
standards of performance and safety.
With over 26000 employees and a customer base that includes some of the
world’s leading automakers, Endurance Technologies is one of the most trusted
names of the automotive industry. The company is committed to sustainability and
social responsibility, and it has received several awards and recognition for its
efforts in this areas.

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2. Introduction of Departments

Endurance Technologies casting plant consists of various department.

Detail information of these departments is as given below.

1. Human Resources Department: The HR Department is responsible for

managing of the work force of the company. This department handle
recruiting and hiring, employee training and development, compensation and
benefits and employee relations. They also ensure compliance with labour
laws and regulations and maintain employee recorded.
2. Research and Development Department: The R&D department is
responsible for developing new products or services and improving existing
ones. This department usually works with engineers, scientist and other
expert to conduct research and experimentation. They also work with other
departments such as production and marketing to ensure that new product
meet customer needs and are commercially viable.
3. Production department: The production department responsible for the
actual production of goods and services. This departments oversees the
assembly line, machinery and worker, ensuring that everything is running
smoothly and efficiently. There main goal is to maximize the output of
goods and services while minimizing cost and waste. In order to achieve this
goal, they also work closely with other department such as procurement,
supply chain management, and quality control to ensure that all the
necessary resources are available.
4. Quality department: The quality department is responsible for ensuring that
all the goods produced by the company meet the required standards and are
of the high quality. They develop and implement quality control systems,
perform inspections and audits and conduct tests and analysis to identify any
defects or issues with the products.

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3. Manufacturing Department

Manufacturing department in companies are responsible for the production

of goods or products that the company sells. These departments are often the
backbone of a company’s operations and play a critical role in the success of the
company.
The manufacturing department typically contains a range of skilled personnel,
including engineers, technicians, production supervisors and workers. The
department is responsible for various tasks, including:
1. Production planning: the manufacturing department is responsible for
planning the production process including scheduling of resources,
production time and materials. This includes determine the required
production capacity, estimating the raw materials requirements and making
sure that the production process runs smoothly.
2. Production process improvement: The manufacturing department is
responsible for continuously improving the production process by making it
more efficient, reducing cost, and increasing productivity. They analyse the
production data, identify inefficiencies and implement solutions to improve
the process.
3. Maintenance and Repair: The manufacturing department is responsible
ensuring that the machinery and equipment are well maintained, repaired,
and up-to-date. They conduct regular maintenance checks, set up preventive
maintenance programs and keep records of all repairs and maintenance.

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4. Problem Statement
Dent marks are observed on casting of P-3 cell i.e. CT 100 crankcase
casting. The castings are made of aluminium alloy material. Various processes
such as Milling, Drilling & Tapping, Bore finishing are performed on the casting
on CNC Milling machines. During this processes the face resting on the resting pad
is prone to dent marks. These dent marks on crankcase are undesirable as they may
later create a problem of oil leakage or oil starvation. Thus this increases the
rejection of the cell which in turn increases the revenue losses. Along with dent
damage, issue of handling damage also needs to be reduced.

5. Introduction
When machining brass, copper or aluminium alloys, it is noticed that the
part has dents when it was clamped during the CNC milling process. Dent marks
are the small indentions on the machining surface. Dent marks occur due to various
reasons such as high clamping pressure, remains of burr on fixture, ineffective
flushing by coolant, etc. Generally, it is observed that when burr remains on fixture
and new job is clamped on the fixture then due to the clamping force the burr
trapped between resting pad and resting face creates a dent mark on the resting face
of the casting. Dent marks on aluminium alloy die casting are smooth dents on
most of the thick surface of the die casting. This increase the rejection of material.
The root cause being the burr remaining on fixture or on the casting increases the
chances of dent mark. Thus, reducing the amount of burr remaining on fixture or
the casting can significantly reduce the chances of dent mark. This can be achieved
by regularly cleaning the fixture, considering all design attributes of fixture design
and effective flushing of the casting during the machining process which will
ensure that maximum burr is flushed out with the coolant. Fixture design attributes
such resting pads, dowel, supporting blocks design play important role. Hence to
reduce dent mark on casting, a complete root cause analysis is needed to be done.
This project consists of various studies which helped to identify contribution of
various factors in dent damage study.

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6. Machines And Layouts

P-3 cell consists of total 14 Machines which includes 11 VMC, 2 HMC and 1 for
washing. Cell layout is as given below:
P-3 Cell Layout CT 100 CC

VMC=11,
Rough Rough
HMC=2, Full Finish & R-Face
Boring Boring
Washing=1
Total=
14

1m16 2m42s 3m2s

s 35/hr 34/h
63/hr r

M0425 M0487 M0488

← OP40 RH & LH OP20 RH ← OP10 RH

Cell-A
↑ ↙ ←
M4022
M490 M489
OP30 RH & LH ← OP20 LH ← OP10 LH
Makino

3m44 2m19s 2m16

s 35/hr s
←Conveyer belt←

63/hr 34/hr

1m16 2m19s 2m32

s 36/hr s
70/hr 34/hr

M4011 M0434 M4085

← OP40 RH & LH OP20 RH ← OP10 RH

↑ ↙ ←
Cell-B
M4023
M0474 M0486
OP30 RH & LH ← OP20 LH ← OP10 LH
Makino
1m42 2m26s 3m6s
s 36/hr 34/h
70/hr r

Final
→ Washing → Gauging → Inspection

Fig 1. P-3 Cell Layout

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7. Operation Sequence And Tools

The casting undergoes various processes. These processes are grouped into set of
operations as given below.
Operations for RH Name Operations for LH Name
OP-10 OP-10
Rough Boring Rough Boring
OP-20 OP-20
OP-30 Full finishing OP-30 Full finishing
OP-40 R- Face OP-40 R- Face
Table 1. Operations Sequence
Specification of Tools required for various processes in each operations are as
given below:
OP-10
L.H RH
D11.5 PCD Reamer D20*50FL*100*SHD20 End Mill
PCD Reamer D8*FL35*OAL80 Drill D10.5*11.1
PCD Reamer D14 M12*1.5 Tap
PSSC Drill D5.48*21Sl*105 OAL NTC PCD Reamer D8*FL35*OAL80
HSSE Roll Tap M6*1p 6HSH6 SQ4.9 PCD Reamer D14
OL80
D20*50FL*100*SHD20 End Mill SC Drill D5.48*D55FL*110 OAL
D51.5*15.35L*80 HSSE Roll Tap M6*1P 6H SH6
SQ4.9 OL80
- PSSC Drill D7.35*42FL*80 OAL*
SH8 TC
- HSSE Roll Tap M8*1.25 6H SH8
SQ6.2 OL90
- D51.5*13.8SL*80
Table 2.1. OP-10 Tool Specs.

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OP-20
R.H L.H

PSSC Drill D7.35*43FL*80 OAL*SH8 TC HSS Drill D4*85FL*136 OAL

HSSE Roll Tap M8*1.25 6H SH8 SQ6.2 OL90 SC Drill D5.48*D55FL*110 OAL

D20*50FL*100*SHD20 End Mill D9.4*D20 SF

D8*D13 Hole Mill HSS Roll Tap M10*1.25P 6H SH7 SQ5.5

OL100
SC Drill D5.48/*D55FL*110 OAL HSSE Roll Tap M6*1P 6H SH6 SQ4.9 OL80

HSSE Roll Tap M6*1P 6H SH6 SQ4.9 OL80 -

D12 CHMFR Tool -

Table 2.2. OP-20 Tool Specs.

OP-30 OP-40
D100 Milling Cutter PCD Reamer D36*22SL/D41*110 OAL SHK D20
PSSC Drill D7.35*25SL*D9*40FL*100 D52 P6 Remax Head
NTC
PCD Reamer D10H8 SH10 OAL95 PCD Reamer D8*15 BLA LEN*35FL*80
HSSE Roll Tap M8*1025 6H SH8 SQ6.2 D4 Identification Drill
OL90
SC Drill D5.48*D55FL*110 OAL HSSE PCD Reamer D16H8 * 180 OAL Shank DAH81
Roll Tap M6*1P 6H SH6 SQ4.9 OL80
D12 CHFR Tool PCD Reamer D13*D32*D40
- D52 H7 Remax Head
- PCD Reamer D28 P6* 40FL *OAL100*SH20
- PCD Reamer D8*14/D13*16/D22*OAL
125SHD20
- PCD Reamer D13*D24*D32*D40
- PCD Reamer D108.0H8*5.5SL*150 *96OAL Z4
- Reamer PCD D10 H8 FL15 SH D12-OAL 100
Table 2.3. OP-30 & OP-40 Tool Specs.

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8. Dent Damage Study

To locate position of the dent mark on the job, a coordinate system was
created as shown below. This coordinate system helped to identify the position of
dent.

3
1 2 1 2
4
A 4
A
3

B B

C
C

D D

Fig 2.1. LH P- Face Fig 2.2. RH P- Face

1 2 3
4 1 2 3 4
A
E
B

F
G
C

D H
Fig 2.3. LH Q- Face Fig 2.4. RH Q- Face

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8.1. Operation wise Dent Mark tracking:

To identify the amount of dents contributed by each operation we conducted
a operation wise study. In this 50 jobs each for all operations were observed and
location of dent marks was traced for both LH and RH. During this process it was
observed that OP-20 and OP-40 were the major contributor and generally dents
occurred on P-face. Table shows dent marks contributed by each operations.
Date: Part: Crankcase RH
Quantity.: 50 jobs each Model: CT100 ( A-CELL)
OP-10 OP-20 OP-30 OP-40 WASH.T FINAL INSP. TOTAL
A1 - - - - - - -
A2 - - - - - 2 2
A3 - - - - - - -
A4 - 1 - 1 - 1 3
B1 - - 1 - - - 1
B2 - - - - - - -
B3 - - - - - - -
B4 - - - - - - -
C1 - - - 1 - - 1
C2 - - - - - - -
C3 - - - - - - -
C4 - 1 1 2 - 2 6
D1 - - - - 1 1
D2 - - - - - 2 2
D3 - - - - - - -
D4 - - - - - - -
E1 - 1 - - - - 1
E2 - 1 - - - - 1
E3 - - - - - -
E4 - - - - -
F1 - - - - - - -
F2 - - - - - - -
F3 - - - - - - -
F4 - - - - - - -
G1 - - - - - 1 1
G2 - - - - - - -
G3 - - - - - - -
G4 - - - - - - -
H1 2 - - - - - 2
H2 - - - - - - -
H3 - - - - - - -
H4 1 - - - - - 1
TOTAL 3 4 2 4 - 9 -
Table 3.1. Operation wise Dent Mark A-Cell (RH)

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Date: Part: CT100 Crankcase RH

Quantity.: 50 jobs each Model: CT100 ( B-CELL)
CT100 Crankcase DDS RH Summary (B-Cell)
OP-10 OP-20 OP-30 OP-40 WASH.T TOTAL
A1 - - - - - -
A2 - - - - - -
A3 - - - - - -
A4 - - - - - -
B1 - - - - - -
B2 - - - - - -
B3 - - - - - -
B4 - - - - - -
C1 - - 1 - - 1
C2 - - - - - -
C3 - - - - - -
C4 - - - - - -
D1 - - - - -
D2 - 1 - 1 - 2
D3 - - - - - -
D4 - - - - - -

E1 - - - - - -
E2 - - - - - -
E3 - - - - - -
E4 - - - -
F1 - - - - - -
F2 - - - - - -
F3 - - - - - -
F4 - - - - - -
G1 1 - - - - 1
G2 - - - - - -
G3 - - - - - -
G4 - - - - - -
H1 - - - - - -
H2 - - - - - -
H3 - - - - - -
H4 - - - - - -
TOTAL 1 1 1 1 -
Table 3.2. Operation wise Dent Mark B-Cell (RH)

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Date: Part: CT100 Crankcase LH

Qut.: 50 jobs each Model: CT100 ( A-CELL)
CT100 Crankcase DDS LH Summary
OP-10 OP-20 OP-30 OP-40 WASHING FINAL INSP. TOTAL
A1 - - - - - - -
A2 - - - - - - -
A3 - 1 - - - - 1
A4 - - - - - - -
B1 - - - - - - -
B2 - - - - - - -
B3 - - - - - - -
B4 - - 1 - - - 1
C1 - 1 1 - - - 2
C2 - - - - - - -
C3 - - - - - - -
C4 - - 2 - - 2
D1 - - - - - -
D2 - - - - - - -
D3 - - - - - - -
D4 - - - 2 - - 2

E1 - - - - - - -
E2 - - - - - - -
E3 - - - - - - -
E4 1 - - - - 1
F1 - - - - - 1 1
F2 - - - - - - -
F3 - - - - - - -
F4 - - - - - 1 1
G1 - - - - - - -
G2 - - - - - - -
G3 - - - - - - -
G4 - - - - - - -
H1 - - - - - - -
H2 - - - - - - -
H3 - - - - - - -
H4 - - - - - - -
TOTAL 1 2 2 4 - 2 11
Table 3.3. Operation wise Dent Mark A-Cell (LH)

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Date: Part: CT100 Crankcase LH

Qut.: 50 jobs each Model: CT100 ( B-CELL)
CT100 Crankcase DDS LH Summary
OP-10 OP-20 OP-30 OP-40 WASHING TOTAL
A1 - - - - - -
A2 - - - - - -
A3 - - - 1 - 1
A4 - - - - - -
B1 - - - - - -
B2 - - - - - -
B3 - - - - - -
B4 - - 1 - - 1
C1 - 1 - - - 1
C2 - - - - - -
C3 - - - - - -
C4 - - - - - -
D1 - - - - - -
D2 - - - - - -
D3 - - - 1 - 1
D4 - - - - - -

E1 - - - - - -
E2 - - - - - -
E3 - - - - - -
E4 - - - - - -
F1 - - - - - -
F2 - - - - - -
F3 - - - - - -
F4 - - - - - -
G1 - - - - - -
G2 - - - - - -
G3 - - - - - -
G4 - - - - - -
H1 - - - - - -
H2 1 - - - - 1
H3 - - - - - -
H4 - - - - - -
TOTAL 1 1 1 2 - 5
Table 3.4. Operation wise Dent Mark B-Cell (LH)

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8.2. Burr Trapping Location study:

The main reason for dent marks was the presence of burr on fixture. To
eliminate this burr it was important to ensure that no burr remains in the pockets,
drill holes, dowels, etc. which in turn remained on fixture resting pads. A study
was conducted to identify burr trapping locations of all operations for both LH and
RH. 50 jobs of each machine were observed. This helped to identify the highlight
locations in which burr was trapping. The highlight locations of each operations
are given in table.
Date: Part: CT100 Crankcase LH
Qut.: 50 jobs each Model: CT100 ( A&B-CELL)
OP-10 OP-20 OP-30 OP-40 WASHING FINAL INSP.
A1 - - - - - -
A2 - - - - - -
A3 - - - - - -
A4 - - - - - -
B1 - - - - - -
B2 30 - - - - -
B3 - - - - - -
B4 37 - - - - -
C1 45 - - - - -
C2 - - - - - -
C3 - - - - - -
C4 40 - - - - -
D1 - - - - -
D2 43 - - - - -
D3 22 - - - - -
D4 20 - - - - -
E1 - - - - - -
E2 - - - - - -
E3 - 32 - - - -
E4 - - - - -
F1 - - - - - -
F2 - - - - - -
F3 - - - - - -
F4 - - - - - -
G1 - - - - - -
G2 - - - - - -
G3 - - - - - -
G4 - - - - - -
H1 - - - - - -
H2 - - - - - -
H3 - - - - - -
H4 - - - - - -
TOTAL 237 32 0 0 0 0

Table 4.1. Burr Trapping Study (LH)

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Date: Part: CT100 Crankcase RH

Qut.: 50 jobs each Model: CT100 ( A&B-CELL)
OP-10 OP-20 OP-30 OP-40 WASH.T FINAL INSP.
A1 - - - - - -
A3 - - - - - -
A4 - - - - - -
B1 25 - - - - -
B2 - - - - - -
B3 - - - - - -
B4 - - - - - -
C1 - - - - - -
C2 - - - - - -
C3 - - - - - -
C4 18 - - - - -
D1 - - - - - -
D2 - - - - - -
D3 - - - - - -
D4 - - - - - -

E1 - 15 - - - -
E2 - 22 - - - -
E3 - - - - - -
E4 - - - - - -
F1 - - - - - -
F2 - - - - - -
F3 - - - - - -
F4 - - - - - -
G1 - - - - - -
G2 - - - - - -
G3 - - - - - -
G4 - - - - - -
H1 - - - - - -
H2 - - - - - -
H3 - 25 - - - -
H4 - - - - - -
TOTAL 43 62 0 0 0 0

Table 4.2. Burr Trapping Study (RH)

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8.3. Clamps and Resting Pad Location:

Fig 3.1. L.H. Resting Pads location summary

Fig 3.2. R.H. Resting Pads location summary

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9. ANALYSIS

A set of processes were followed in order to complete the Dent Mark Study.
This included dent mark position identifying, which helped to find the major
contributing operation. Then burr trapping study was conducted to identify
the locations at which burr/chips were remaining after each operation.
Followed by this clamping and resting locations were traced. It was found
that the location’s at which burr was trapping, dent marks generally occurred
at the same milling face locations. This included various drill holes and
dowel holes near the clamping and resting pad locations.
Based on daily inspection data, the dent damage daily trend was
observed. This included data from 17th March to 30th April. The results
came out are summarized below.

P-3 Cell Dent Mark Summary

12.00
11.08

10.00 9.58
8.76
8.418.42
8.02
8.00 7.67
7.10
6.656.68
6.06
6.00 5.51
5.21 4.94
4.69 4.42 4.25
4.734.78 4.56
4.14
3.77 3.81
4.00 3.56 3.53
3.07 3.23
3.00
2.71
2.83 2.74
2.20 2.33
1.91
2.00
1.10

0.000.00 0.00 0.000.0 0.00 0.000.00 0.00 0.000.00

0.00 0

Percentage

Fig 4. DDS Summary

20