INDUSTRY INTERNSHIP REPORT

Submitted in
partial fulfillment of the requirement for the award of a degree of

Bachelor of Engineering
in
Mechanical Engineering
by
Mr. Sahil S. Waghmare

Industry Guide
Mr. Arjun B. Chavan
at
SDTORK CONTROLS PVD. LTD.

Institute Guide
Dr. Ashish Raut
Assistant Professor

Department of Mechanical Engineering

G H Raisoni College of Engineering, Nagpur
(An Autonomous Institute affiliated to Rashtrasant Tukadoji Maharaj Nagpur University, Nagpur)
Accredited by NAAC with an “A+” Grade

May 2023

© G H Raisoni College of Engineering, Nagpur, Year 2023

i
 Declaration

I, hereby declare that the Industry Internship report submitted herein has been
carried out by me in Sdtork Controls Pvt. Ltd. towards partial fulfillment of the
requirement for the award of Degree of Bachelor of Engineering in Mechanical
Engineering. The work is original and has not been submitted earlier as a whole or in part
for the award of any degree/diploma at this or any other Institution / University.

I also hereby assign to G H Raisoni College of Engineering, Nagpur all rights

under copyright that may exist in and to the above work and any revised or expanded
derivative works based on the work as mentioned. Other works copied from references,
manuals, etc. are disclaimed.

Name of student Mobile No Mail ID Signature

(Other than Raisoni.net)
Mr. Sahil S. 9673378863 Sw10102000@gmail.com
Waghmare

Place: Nagpur

Date: 31/05/23

ii
 Certificate
The Industry Internship Report entitled as “Packaging of Actuators and Organizing the
area to store actuators”. was carried out under our supervision in Sdtork Controls Pvt.
Ltd. by Sahil S. Waghmare, for the award of Degree of Bachelor of Engineering in
Mechanical Engineering. The work submitted is comprehensive, complete, and fit for
evaluation.

Mr. Arjun B. Chavan Dr. Ashish Raut

Industry Guide Institute Guide
Management Coordinator Assistant Professor
Sdtork Controls Pvt. Ltd. Department of Mechanical Engineering
GHRCE, Nagpur

Mr. A. D. Pitale Dr.Rupesh S Shelke

III Coordinator, Mechanical Engineering Head
Assistant Professor Department of Mechanical Engineering
Department of Mechanical Engineering GHRCE, Nagpur
GHRCE, Nagpur

Mr. Gurpal Singh Dr. Sachin Untawale

Dean III Cell Director
GHRCE, Nagpur GHRCE, Nagpur

iii
iv
v
vi
 ACKNOWLEDGEMENT

I would like to express my deep appreciation for the invaluable training experience I
gained during my time at "Sdtork Controls Pvt. Ltd." The combination of theoretical
knowledge and practical emphasis provided me with a comprehensive understanding of
industrial management.

I am extremely grateful to Mr. Arjun B. Chavan, the HR manager, for granting me the
opportunity to work in such a prestigious organization. His support and guidance were
instrumental in shaping my professional growth.
I would also like to thank him as the Supervisor, for his invaluable mentorship. His
expert guidance and valuable insights were crucial in enhancing my understanding of the
industry.

I am deeply indebted to Dr. Ashish Raut, Assistant Professor, who served as my college
guide throughout the in-plant training. His unwavering support, guidance, and
encouragement played a pivotal role in my learning journey.

I would like to express my sincere gratitude to our honorable chairman, Shri. Sunil
Raisoni Sir, for incorporating the industry internship into the curriculum. This initiative
not only helped me develop essential skills but also provided valuable insights into the
lives of industry professionals.

Furthermore, I would like to thank Dr. Sachin Untawale, our esteemed director, for his
genuine concern and unwavering support. His efforts in providing us with the necessary
facilities and resources for a successful internship experience were truly commendable.

I am grateful to all the individuals mentioned above for their support, guidance, and
contributions, which have greatly influenced my professional growth and development.

vii
 ABSTRACT

This report provides a comprehensive overview of my internship experience at Sdtork

Controls Pvt. Ltd. Pune, Maharashtra. Throughout my internship, I acquired a wide range
of technical and professional skills applicable to various industrial contexts. I gained
insights into the manufacturing processes of companies and familiarized myself with the
functions of different departments.

Working in a corporate environment not only enhanced my professional growth but also
contributed to my personal development. I received recognition for my contributions
from my supervisor and colleagues in the department. This internship experience has
significantly influenced my career path, as I had the opportunity to observe and
participate in engineering projects and case studies.

Although this report was written within a short timeframe, I have made every effort to
provide meaningful insights into my work at Ashok Leyland Pvt. Ltd. I have also
summarized the industry's overall processes and equipment, along with my learning
experiences as an intern.

Engaging in an industry internship has instilled in me a problem-solving mindset and

research skills. I worked on various case studies related to industry-specific challenges
and collaborated to rectify them, utilizing the knowledge, skills, and equipment available
to us. This internship required me to acquire new skills, and knowledge, and operate
unfamiliar equipment as needed, ultimately providing me with invaluable practical
knowledge that would have been challenging to attain without industry exposure.

Using materials like cardboard and bubble wrap may not be the most sustainable choice
because they are typically single-use items and can contribute to waste generation. By
considering alternative packaging materials, we can aim for a more recycled and eco-
friendly solution. For example, using biodegradable or compostable packaging materials
made from recycled or renewable sources can significantly reduce the environmental
impact of the packaging.

viii
The assembly process for actuators typically involves several workers working together on a
single table. This process can be complex and requires careful handling of the actuators to
ensure proper assembly.

ix
 List of Figures
Fig. No. Name of Figure Page No.
1.1. Sdtork Controls Pvt. Ltd 13
1.2. 1000 Series 15
1.3. 1001-ECO Series 15
1.4. 2000 Series 16
1.5. 3000 Series 16
1.6. 4000 Series 17
1.7. 5000 Series 17
1.8. 6000 Series 17
1.9. 7000 Series 18
1.10. 8000 Series 18
1.11. Drilling Machine 20
1.12. Lathe Machine 21
1.13 Powder Dynamometer 22
1.14. Electric Work Station 23
1.15. Assembly Work Station 24
2.1. SD-3000 Series 27
2.2. SD-3000+BG Series 27
2.3. Packaging of Material open box 32
2.3.1 Packaging with Material 32
2.3.2. Final Packaging 33
3.1 Before Organizing the area to store actuators 42
3.2 After Organizing the area to store actuators 42

x
 List of Symbols

mm Millimeter
Ꝋ Diameter

xi
 Index

Chapter Title Page

No. No.
1 Introduction 13
1.1. About 14
1.1.1. Mission
1.1.2. Quality Works
1.1.3. Professional Team
1.2. Products 15
1.3. Key Customers 19
1.4. Equipment 20
1.5. Work Stations 22
` 2 CASE STUDY 1: Packaging of Actuators 25
2.1. Introduction 26
2.2. Problem Identification 27
2.3. Literature Review 29
2.4. Methodology 29
2.5. Solution 29
2.6. Implementation 30
2.7. Result 31
2.8. Reference 33
3 CASE STUDY 2: Organizing the area to store actuators. 35
3.1. Introduction 36
3.2. Problem Identification 37
3.3. Literature Review 38
3.4. Methodology 38
3.5. Solution 39
3.6. Implementation 40
3.7. Result 43
3.8. References 44

xii
 CHAPTER 1
INTRODUCTION

13
 CHAPTER 1
INTRODUCTION

1. Introduction

Fig. 1.1: Sdtork Controls Pvt. Ltd

Sdtork Controls comprises a dynamic & committed team of young professionals

blended with expertise and experience – Technocrats, Engineers, and managers. Sdtork
Controls introduces the latest technology in valve automation with electrical actuators with
stress on economy, efficiency, and quality. The present trend is ‘speeding’, which means the
replacement of rather sluggish and outdated mechanical devices with faster, and modern
electronic and electrical devices. We are in this business of automation of valves through an
intelligent approach to the same.
We at Sdtork Controls Bangalore since its establishment in 1989 are positioning
ourselves as a 'Specialized Company for Actuators’ used in Process Industries and also
required in all sectors of Industries in the world. Since its foundation by Mr. D. R. Shetty in
1989, Sdtork Controls has developed with his vision who is a technocrat in Actuation
Industry, initially started with smaller automation, and later on turned to be a System
Integrator in the Actuation industry.
We try to maximize customer satisfaction from the standpoint of our customers, by
corresponding to demands from various customers and developing applications. It creates
means of offering a stable product, and flexible service to adapt and exceed our customer's
demands. Sdtork Controls, a people company, we do not just sell products; we sell
14
technology and value addition to the end user. We can also design valves known as 'Custom
Made Valves' to meet customer specific requirements and operation parameters.

1.1. About
Nature of Business: Manufacturing of Actuators.
Industry size: Small-scale industry.
Industry type: Manufacturing.
Annual turnover: 15 Crores.
Number of employees: 50.
Number of plants: one
Products/Service Information: Manufacturing of Actuators.

1.1.1. Mission
 To deliver high-quality products with high-profile features at a reasonable cost.
 The mission is to lead in performance, integrity with a commitment
to safety and quality.
 To achieve excellence through team work and continuous
improvement by innovative means using pillars of total productivity
maintenance (TPM).

1.1.2. Quality Works

We have a quality team who deliver highly accurate products in the market.
Mr. Mathapati – Inward Head
Mr. Bawale – Outward Head

1.1.3. Professional Team

We have a dedicated highly professional experienced team in our organization.

15
The team is as follows:
Mr. D. R. Shetty - Managing Director
Mr. Sunil Kurkute - Director
Mr. Arjun B. Chavan – Management Coordinator

1.2. Products
Several different kinds of Actuators are manufactured here:

1. 1000 Series
STORK Electric Actuator type 1000 Series has been designed for remote control of Ball
valves, Butterfly Valves, Dampers & Other actuating devices, which require up to 90° rotary
actuation & tight closure in end positions.

Fig 1.2: 1000 Series

2. 1001-ECO Series
1001-ECO series has its own characteristics & special design, beautiful appearance, strong
function & operation endurance.
1001-ECO series has a completely, new appraisal from customers with its supper

performance & peerless advantage.

16
 Fig 1.3: 1001-ECO Series

3. 2000 Series
Stork Electric Actuator type 2000-series is designed for linear, quarter turn & angular
actuation applications for remote control of various types of valves such as Globe, -notch
ball, and Butterfly.
Diaphragm and various types of dampers such as single/multi lover / VIV dampers. Stork's

2000 series is mainly used for control/regulating duty applications.

Fig 1.4: 2000 Series

4. 3000 Series
Stork Electric Actuator type 3000-Series is designed for multitier application for remote
control of various types valves such as Sluice Valve, Gate Valve,
Knife Edge Gate Valve and Sluice Gate.

Fig 1.5: 3000 Series

5. 4000 Series

17
Stork Electric Actuator type 4000-Series is designed for Quarter Turn application for remote
control of various types of valves such as Ball Valve, Butterfly Valve, Plug
Valve and Damper.

Fig 1.6: 4000 Series

6. 5000 Series

Stork Electric Actuator type 5000-Series is designed for Basic Quarter Turn application
which can be converted into Linear one with the help of linkage Application area of 5000-
Series is mainly used to operate Dampers, Flaps, Gates, etc.
.

Fig 1.7: 5000 Series

7. 6000 Series

18
Stork Electric Actuator type 6000-Series is designed for linear application for remote control
of Globe Valve and Dosing Pump.

Fig 1.8: 6000 Series

8. 7000 Series

Stork Electric Cylinder Actuator 7000-Series are stable for the operation of Fan Dampers,
Valves with Rising Stems, Flap Gates, Shutter Valves, Fuel Feed Mechanisms, Blower Pitch
Regulators, Fart Blades, Pitch Adjusters, Fluid Couplings for Speed Control, and many more
similar applications.

Fig 1.9: 7000 Series

9. 8000 Series

19
 Stork Actuator type 8000-Series is designed for multitier applications for remote control of
various types of Knife Edge Gates, Sluice Gates, etc.

Fig 1.10: 8000 Series

1.3. Key Customers

Clients who frequently patronize a particular seller establish patterns that foster consistent
and ongoing business, enabling the seller to create analytical models that enhance production
methods (altering the characteristics or presentation of goods or services) and streamline
supply chains (modifying the distribution or formalizing the transfer of ownership or
entitlement transactions).
Following are the key customers of Sdtork Controls Pvt. Ltd:

 BHEL
 JSW
 ITC Ltd
 Kirloskar
 ACC
 GE
 Aditya Birla
 Cipla

 Johnson

20
1.4. Equipment

1. Drilling Machine
Sdtork Controls relies on a specialized drilling machine to facilitate the manufacturing
process of their high-quality actuators. This versatile machine offers exceptional precision,
accuracy, and high-speed capabilities. With its automated operation, the drilling machine
ensures consistent whole placement and dimension control, enhancing overall productivity in
actuator production.

21
In summary, the drilling machine used at Sdtork Controls is a crucial tool in their actuator
manufacturing process. Its precision, versatility, high-speed capabilities, and automation
features contribute to the production of high-quality actuators with consistently drilled holes.
This allows Sdtork Controls to meet industry demands, maintain its competitive edge, and
deliver reliable performance to its customers.

Fig 1.11: Drilling Machine

2. Lathe Machine
The Manual Lathe Machine at Sdtork Controls is an essential piece of equipment in the
manufacturing of actuators. This versatile machine performs various machining operations

such as turning, facing, boring, threading, and parting. It allows for the creation of precise
and customized actuator components with high accuracy and consistency.

With the lathe machine, Sdtork Controls can produce actuator parts that meet specific design
requirements and customer needs. The machine's capability to turn and shape different
materials into cylindrical shapes, create threaded connections, and cut off work piece
sections to desired lengths enables the production of components crucial for actuator
assemblies. Its precision and versatility ensure that the manufactured parts adhere to exact
22
specifications, tolerances, and surface finishes, resulting in high-quality and functional
actuators. Furthermore, having the lathe machine in-house enhances efficiency and control
over the manufacturing process, potentially reducing lead times and production costs.
Overall, the Manual Lathe Machine plays a pivotal role in the actuator manufacturing
process at Sdtork Controls, enabling them to deliver reliable and customized actuator
solutions.

Fig 1.12: Lathe Machine

3. Powder Dynamometer (Torque Testing Machine)

Sdtork Controls recently acquired the Powder Dynamometer for torque testing of their
actuators. This highly precise equipment offers exceptional accuracy, a wide torque range,
and real-time data monitoring. With its user-friendly interface, it ensures repeatability and
consistent results, guaranteeing the quality of the actuators while streamlining the assembly
line. This investment improves efficiency, minimizes product failures, and enhances
customer satisfaction.

The acquisition of the Powder Dynamometer significantly enhances Sdtork Controls' torque
testing capabilities. This precise instrument enables accurate evaluation of actuator
performance, with real-time data monitoring and a wide torque range. Its user-friendly
interface ensures repeatability, guaranteeing high-quality actuators and streamlined
production. The investment improves efficiency, reduces product failures, and enhances
customer satisfaction by delivering reliable actuators that meet performance standards.

23
 Fig 1.13: Powder Dynamometer

1.5. Work Stations

1. Electrical Work Station

The Electrical Work Station at Sdtork Controls is responsible for the assembly and
preparation of circuits, wires, limiting switches, and NO/NC devices, which are essential
components for the company's actuators. Skilled technicians and engineers meticulously
follow wiring diagrams to ensure accurate and efficient production. Equipped with
specialized tools and equipment, the station enables precise electrical work, including wire
cutting, crimping, and soldering. Quality control measures are implemented to maintain high
standards and adherence to safety protocols.

One crucial aspect of the Electrical Work Station is wire harnessing, where technicians
organize and bundle wires using protective sleeves or tapes. This process enhances the
aesthetics and durability of the wiring system, making installation and maintenance easier.
Technicians at the station deeply understand electrical systems and are proficient in
interpreting wiring diagrams. They troubleshoot any issues that arise during the assembly
and conduct thorough quality checks to ensure the final products meet stringent standards.

24
 Fig 1.14: Electric Work Station

In summary, the Electrical Work Station at Sdtork Controls is dedicated to the assembly and
preparation of circuits, wires, limiting switches, and NO/NC devices. Following wiring
diagrams and employing specialized tools, skilled technicians ensure the accurate and
efficient production of these components. Wire harnessing and quality control measures
further contribute to the reliability and longevity of the electrical systems.

2. Assembly Work Station

The Assembly Work Station at Sdtork Controls is where components are assembled to create
sub-assemblies, which are then integrated into the main housing to complete the assembly of
their actuators. Skilled technicians and operators work diligently at this workstation,
following specific assembly instructions and guidelines. They meticulously inspect and
assemble the components, ensuring proper alignment and fit. The sub-assemblies are
constructed using specialized tools, such as gears, springs, sensors, and electrical
connections. Quality control is a priority at the Assembly Work Station, with regular
inspections and tests conducted to maintain high standards and identify any defects. The
technicians prioritize safety and adhere to strict protocols throughout the assembly process.

At Sdtork Controls' Assembly Work Station, skilled technicians and operators play a crucial
role in the production of actuators. They meticulously assemble components to create sub-
25
assemblies, which are then integrated into the main housing. The technicians follow
assembly instructions and guidelines to ensure precise alignment and fit of the components.
Specialized tools are utilized to assist in the assembly process, including gears, springs,
sensors, and electrical connections. The technicians prioritize quality control, conducting
regular inspections and tests to uphold the company's high standards. Safety is also a key
focus at the Assembly Work Station, with technicians adhering to strict protocols and
utilizing personal protective equipment.

The Assembly Work Station at Sdtork Controls is integral to the manufacturing process of
actuators. Skilled technicians and operators meticulously assemble components to create sub-
assemblies, which are then integrated into the main housing. Strict adherence to assembly
instructions and guidelines ensures the precise alignment and fit of each component.
Specialized tools are employed to aid in the assembly process, such as gears, springs,
sensors, and electrical connections. The technicians conduct regular inspections and tests to
maintain quality control, promptly addressing any defects or deviations. Safety protocols are
followed at all times, ensuring the well-being of the technicians and the integrity of the
assembly process.

Fig 1.15: Assembly Work Station

26
 CHAPTER 2
CASE STUDY 1

CHAPTER 2

CASE STUDY 1- Packaging of Actuators.

2.1. Introduction

The current packaging of the actuators is made up of materials such as pieces of cardboard
and bubble wrap. While these materials effectively protect the actuators during

27
transportation, there is a need to explore alternative packaging options that are more
sustainable and environmentally friendly.

Using materials like cardboard and bubble wrap may not be the most sustainable choice
because they are typically single-use items and can contribute to waste generation. By
considering alternative packaging materials, we can aim for a more recycled and eco-friendly
solution. For example, using biodegradable or compostable packaging materials made from
recycled or renewable sources can significantly reduce the environmental impact of the
packaging.

Apart from the sustainability aspect, modifying the packaging can also have benefits in terms
of functionality and presentation. By rethinking the design and packaging structure, it is
possible to create a more user-friendly and aesthetically pleasing packaging for the actuators.
This can enhance the overall customer experience and make the actuators more appealing to
both customers and stakeholders.

Fig 2.1: SD-3000 Series Fig 2.2: SD-3000+BG Series

In addition, a well-designed packaging solution can provide better protection for the
actuators during transportation and storage. By using materials that are more shock-absorbent
or incorporating cushioning features, we can minimize the risk of damage to the actuators,
ensuring that they reach the end users in optimal condition.

28
Overall, the need to alter the packaging of the actuators arises from the desire to improve
sustainability, functionality, presentation, and protection. By exploring alternative materials
and designing a more effective packaging solution, we can meet these goals and create a
positive impact on the environment while enhancing the overall value of the actuators.

2.2. Problem Identification

Actuators are devices used to control and move mechanical systems or components. They
play a crucial role in various industries, including robotics, automotive, aerospace, and
manufacturing. Actuators come in different types and series, such as electric actuators,
hydraulic actuators, pneumatic actuators, and more.

In the given context, it is mentioned that the actuators are currently packaged using fragile
materials like used/raw pieces of cardboard and bubble wrap. This packaging method poses a
risk to the actuators during transportation. Fragile materials may not provide adequate
protection against external shocks, vibrations, or rough handling that can occur during
shipping or handling processes. This increases the likelihood of damage to the actuators,
which can result in financial losses, delays, and compromised performance or functionality.

To address this issue, it is important to modify the packaging of the actuators. The goal is to
ensure their safe transportation and protection from potential damage. Here are some possible
approaches to improve the packaging:

1. Sturdy Packaging Materials: Replace fragile materials like cardboard and bubble wrap
with more robust packaging materials. This can include using corrugated cardboard boxes,
foam inserts, or custom-designed packaging solutions tailored to the specific dimensions and
requirements of the actuators.

2. Shock Absorption: Incorporate shock-absorbing materials within the packaging to

minimize the impact of external forces. This can involve using foam padding, air cushions,
or other cushioning materials that provide a protective layer around the actuators, reducing
the risk of damage during transportation.

29
3. Secure Fastening: Ensure that the actuators are securely fastened within the packaging to
prevent movement or shifting during transit. This can involve using straps, dividers, or
inserts to hold the actuators in place and minimize the potential for impact or collision.

4. Customized Packaging: Develop custom packaging solutions specifically designed for the
shape, size, and weight of the actuators. Tailoring the packaging to the product can provide a
more secure fit and better protection.

5. Compliance with Transportation Regulations: Consider any specific regulations or

guidelines related to the transportation of actuators. This may involve compliance with
standards for packaging, labeling, handling, or documentation to ensure the safe and legal
transport of the actuators.

By modifying the packaging of the actuators using these approaches, the risk of damage
during transportation can be significantly reduced. This would help to maintain the quality,
performance, and reliability of the actuators, leading to customer satisfaction and avoiding
unnecessary costs associated with repairs or replacements.

2.3. Literature Review

The significance of designing and implementing an effective inspection gauge to decrease

inspection time in industrial manufacturing is the main focus of this literature review. We
investigate relevant research and studies carried out in the area of inspection methodologies,
measurement techniques, and gauge design, specifically concerning Sdtork Controls' Actuator
Series '3000' inspection. By analyzing existing literature, our objective is to discover optimal
methods, creative approaches, and possible resolutions to minimize inspection time without
compromising accuracy and dependability.

2.4. Methodology

To tackle the problem at hand, it is imperative to find sustainable solutions. This requires us
to examine alternative packaging materials that are recyclable and provide efficient
30
 protection for the contents. It is important to explore options made from recycled materials or
those with a lower carbon footprint than conventional packaging materials. By adopting such
alternatives, we can effectively minimize waste. Furthermore, it is crucial to assess the
complete life cycle of these packaging materials, considering their production, usage, and
proper recycling practices. Only by taking this holistic approach can we ensure a truly
sustainable solution to the packaging issue.

2.5. Solution

The recommendation to use thermocol molds as a solution to the issue of fragile packaging
suggests utilizing a more durable and eco-friendlier alternative. Thermocol, also known as
expanded polystyrene foam or EPS, is a recyclable material that can be easily molded into
various shapes, including actuators. By using thermocol molds, the goal is to provide ample
protection for delicate products during transportation.

One significant advantage of using thermocol molds is the enhanced safety they offer to
actuators or any other fragile products. The foam material has excellent shock-absorbing
properties, which helps minimize the risk of damage during transit. This ensures that the
products reach their destination intact and in optimal condition.

In addition to the safety benefits, thermocol molds also contribute to reducing waste
generated by traditional packaging methods, such as cardboard and bubble wrap. Traditional
packaging materials often end up as single-use items that are discarded after use. In contrast,
thermocol molds can be reused multiple times or recycled, making them more
environmentally friendly.

By replacing traditional packaging materials with thermocol molds, companies can adopt a
more sustainable approach. The recyclability of thermocol ensures that it can be diverted
from the waste stream, reducing the environmental impact associated with conventional
packaging methods. This aligns with the growing global focus on reducing waste and
promoting circular economy principles.

31
Moreover, using thermocol molds as a packaging solution can also be cost-effective. While
the initial investment may be required to create the molds, the long-term benefits of
reusability and reduced damage rates can result in cost savings for businesses. By
minimizing the need for costly replacements due to damaged products, companies can
improve their bottom line.

In summary, the recommendation to use thermocol molds as an alternative to fragile

packaging offers a sustainable and cost-effective solution. By leveraging the recyclable and
shock-absorbing properties of thermocol, companies can enhance the safety of delicate
products during transportation while reducing waste generated by traditional packaging
methods. This approach aligns with the growing global emphasis on environmental
sustainability and can be economically beneficial in the long run.

2.6. Implementation

The given statement discusses the cost of an actuator, potential damages during
transportation, and the company's responsibility for ensuring safe delivery. It also suggests
investing in thermocol sheets to protect the product during transportation, with pricing
depending on the quality of material chosen.

An actuator is a device that converts energy into motion, typically used to control or move
mechanical systems. The cost of one actuator is stated to range from 25,000 to 2,00,000
rupees (or 25k to 2 lakh rupees). This implies that the price can vary depending on factors
such as the type, size, functionality, and brand of the actuator.

If the actuator gets damaged during transportation, regardless of the reason for the damage,
the responsibility for bearing the cost lies with the company. This indicates that the company
is accountable for ensuring the safe and undamaged delivery of the product to the customer.

To protect the actuator during transportation, the suggestion is made to invest in thermocol
sheets. Thermocol, also known as expanded polystyrene (EPS), is a lightweight and
insulating material commonly used for packaging. The statement mentions that the pricing
for the thermocol sheets will vary based on the chosen level of quality. The better the quality

32
 of the material selected, the higher the price. However, regardless of the quality chosen, it
assures the customers of obtaining good value for their money.

In summary, the statement emphasizes the cost range of actuators, the company's
responsibility for damaged products during transportation, and the option to invest in
thermocol sheets as a protective measure. It highlights the variability in pricing based on the
quality of the thermocol sheets, while assuring customers of receiving satisfactory value for
their investment.

2.7. Result

The implementation of the specialized inspection gauge for the output flange of Sdtork
Controls Actuator Series '3000' yielded significant improvements:
i. Time Reduction: Main parameter measurement time was reduced by 77.78% (from 45
seconds to 10 seconds). Total inspection time was reduced to 2 minutes and 10 seconds, a
21.21% reduction.

ii. Improved Accuracy: The inspection gauge enhanced accuracy and ensured compliance
with specifications.

iii. Enhanced Efficiency: Increased throughput, enabling handling of higher volumes without
compromising quality.

iv. Operator Satisfaction: Ergonomic design improved operator satisfaction and reduced
fatigue.

v. Process Optimization: Standardized measurements and minimized variations, optimizing

the inspection process.

The implementation demonstrated the effectiveness of the inspection gauge in reducing time,
improving accuracy, enhancing efficiency, and optimizing the inspection process. It
successfully addressed challenges, improving productivity and meeting quality standards.

33
 fig 2.3 packaging of material open box

fig 2.3.1 Packaging with Material

fig
fig. 2.3.2 Final Packaging of Material

34
 2.8. Reference

i. "Optimizing Inspection Processes in Manufacturing: A Review of Techniques and Case

Studies" (Sharma et al., 2019)

ii. "Statistical Analysis Techniques for Quality Control in Inspection: An Overview" (Wu et
al., 2018)

iii. Kajdas, C. Major pathways for used oil disposal and recycling, Part 1.
Tribotest J. 2000, 7, 61–74. [Google Scholar] [CrossRef]
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management methods. Environ. Sci. Technol. 2004, 38, 353–358. [Google
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v. IARC (International Agency for Research on Cancer). Polynuclear Aromatic
Hydrocarbons, Part 2, Carbon Blacks, Mineral Oils (Lubricant Base Oils and
Derived Products) and Some Nitroarenes. In IARC Monographs on the
Evaluation of Carcinogenic Risks to Humans; IARC: Lyon, France, 1984.
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vi. Francois, A. Waste Engine Oils Refining and Energy Recovery, 1st ed.;
Elsevier Science and Technology Books: Amsterdam, The Netherlands, 2006;
pp. 15–31. [Google Scholar]
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D.W. Re-refining makes quality oils. Hydrocarb. Process. 1978, 57, 141–145.

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flocculation. Ind. Eng. Chem. Res. 1988, 27, 1222– 1228. [Google Scholar]
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Handbook of Lubrication and Tribology; George, E.D., Totten, E., Eds.;
Taylor and Francis: New York, NY, USA, 2007. [Google Scholar]
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Manufacturing Technology 66 (2013).
xi. L.R.K. Gillespie, Deburring technology for improved manufacturing, Society
of Manufacturing Engineers (SME), Dearborn, MI, USA, 1981.
xii. K. Przyklenk, Advances in Non-traditional Machining, ASME, PED 22
(1986) 101-110.
xiii. H. Beier, R. Nothnagel, Development of a high-speed-deburring tool,
University of California, Berkley, 2004.

CHAPTER 3
CASE STUDY 2

36
 CHAPTER 3

CASE STUDY 2 - Organizing the area to store actuators.

2.9. Introduction

The assembly process for actuators typically involves several workers working together on a
single table. This process can be complex and requires careful handling of the actuators to
ensure proper assembly.

37
Actuators come in different series, each with its own specific components. Some common
components found in actuators include a worm wheel, a worm shaft, and a spring cover.
These components play important roles in the functionality and movement of the actuators.

The assembly of the main housing is a crucial step in the process. It usually requires the
collaboration of 4 to 5 workers, who work together to assemble the various parts of the
housing. This can involve fitting the worm wheel onto the worm shaft, attaching the spring
cover, and ensuring that all the components are securely connected.

Once the spare parts for the actuators have been properly assembled, the wiring process takes
place. Wiring involves connecting the necessary electrical components within the actuator,
such as sensors and motors, to enable its functionality. This step is important for ensuring
that the actuators can be controlled and operated effectively.

Overall, the assembly of actuators is a meticulous process that requires attention to detail and
careful coordination among the workers involved. Proper handling of the actuators and
accurate assembly of their components are essential to ensure their optimal performance and
functionality.

2.10. Problem Identification

1. Lack of organized storage: The poor management of space within the company has
resulted in a lack of organized storage for actuators. Without designated storage areas or
systems, it becomes challenging to keep track of the actuators and locate them quickly when
needed. This leads to wasted time and delays in the assembly process.

2. Difficulty in inventory management: Without proper storage, inventory management

becomes a cumbersome task. It becomes difficult to maintain an accurate count of available
actuators and track their movement within the facility. This can result in overstocking or

38
understocking, leading to inefficient production planning and potential lost sales
opportunities.

3. Increased risk of damage: Actuators are delicate and sensitive components that require
proper care and protection. Inadequate storage can increase the risk of damage to the
actuators, leading to product defects and customer dissatisfaction. Without a designated
space to store the actuators safely, they may be exposed to environmental hazards, such as
dust, moisture, or temperature fluctuations.

4. Inefficient assembly process: The poor management of space affects the assembly process,
as finding and retrieving the required actuators becomes time-consuming. This can slow
down the production line and impact the overall productivity of the company. Additionally,
the lack of space may limit the number of actuators that can be stored, requiring frequent
reordering and causing further delays in fulfilling customer orders.

5. Increased costs: Inefficient storage practices can result in increased costs for the company.
The risk of damage to actuators means potential losses due to scrapped or rejected products.
Moreover, the time wasted in searching for actuators and the delays in fulfilling customer
orders can result in missed business opportunities and potential revenue loss.

6. Negative impact on customer satisfaction: Delays in fulfilling customer orders and

potential product defects due to poor storage management can significantly impact customer
satisfaction. Customers expect timely delivery of their orders and high-quality products.
Failure to meet these expectations can lead to customer complaints, negative reviews, and
loss of future business.

To address these issues, the company should invest in optimizing their storage space by
implementing proper shelving systems, organizing inventory with labeling and tracking
systems, and ensuring a clean and controlled environment to protect the actuators. This will
improve efficiency, reduce costs, and enhance customer satisfaction by enabling the
company to meet the demand for actuators promptly and deliver high-quality products.

2.11. Literature Review

39
The significance of designing and implementing an effective inspection gauge to decrease
inspection time in industrial manufacturing is the main focus of this literature review. We
investigate relevant research and studies carried out in the area of inspection methodologies,
measurement techniques, and gauge design, specifically concerning Sdtork Controls' Actuator
Series '3000' and its output flange inspection. By analyzing existing literature, our objective is
to discover optimal methods, creative approaches, and possible resolutions to minimize
inspection time without compromising accuracy and dependability.

2.12. Methodology

To address the issue at hand, we need to focus on sustainable solutions. Here is a breakdown
of the key points:

1. Sustainable solutions: The first step is to prioritize sustainability. This means exploring
options that are made from recycled materials or using low-cost fiber tables with an iron
structure. By opting for recycled materials, we can reduce waste and minimize the
environmental impact of our operations.

2. Increased space: Utilizing fiber tables with iron structures allows us to optimize space.
These tables are sturdy and can support heavy loads, providing us with additional storage
capacity. By maximizing the available space, we can efficiently organize and store inventory,
equipment, and materials, leading to improved productivity.

3. Enhanced storage capacity: Increasing and managing the storage capacity of the company
is crucial. With more space, we can store a larger number of actuators, which are essential for
our operations. This enables us to meet customer demands and fulfill orders promptly,
leading to customer satisfaction and repeat business.

4. Productivity boost: A well-organized and optimized storage system leads to increased

productivity. With easy access to materials and efficient inventory management, employees
can find what they need quickly, reducing downtime and improving workflow. This
enhanced productivity can positively impact overall company performance and profitability.

40
 5. Fulfillment of customer orders: By addressing the storage issue and increasing capacity,
we can fulfill customer orders for a larger number of actuators. This not only ensures
customer satisfaction but also opens up opportunities for growth and expansion. Satisfied
customers are more likely to recommend our products and services, attracting new clients
and boosting sales.

In summary, seeking sustainable solutions through the use of recycled materials or low-cost
fiber tables with iron structures can help increase space and manage storage capacity. This, in
turn, leads to improved productivity and successful fulfillment of customer orders,
contributing to the overall success of the company.

2.13. Solution

Using affordable and long-lasting tables is a potential solution to address the storage problem
faced by a company. Here is a description of this solution, organized in point form:

1. Storage Capacity: Affordable and long-lasting tables offer an effective way to increase the
storage capacity of a company. By utilizing tables as storage surfaces, more space can be
made available to store various items, including actuators.

2. Dual-Use: These tables can serve a dual purpose by accommodating different tasks
simultaneously. The top surface of the table can be utilized by the assembly team, providing
a dedicated space for them to work on assembling the actuators. At the same time, the wiring
team can utilize the bottom surface of the table to carry out their wiring tasks. This
arrangement optimizes the use of space and enhances productivity by allowing multiple tasks
to be performed concurrently.

3. Organization: By assigning specific areas of the table for assembly and wiring, the work
process becomes more organized and streamlined. The separation of tasks ensures that each
team has a designated space to focus on their specific responsibilities, minimizing the
chances of confusion or overlap.

4. Post-Assembly Storage: Once the actuators are fully assembled, the tables can be
repurposed for storage purposes. The sturdy and durable nature of these tables ensures that
41
 they can safely accommodate the assembled actuators without the risk of damage or
deterioration. This enables efficient storage of the completed products, preventing clutter and
enhancing accessibility when retrieving them for further processing or distribution.

In summary, utilizing affordable and long-lasting tables as a storage solution offers several
advantages for companies. These tables not only increase storage capacity but also provide
dual-use functionality, allowing different teams to work simultaneously. By designating
specific areas for assembly and wiring tasks, organization and efficiency are improved.
Moreover, these tables can be repurposed for storage once the assembly process is
completed, further optimizing space utilization.

2.14. Implementation

1. Actuator production has experienced a substantial increase, leading to several benefits for
businesses. This surge in production has resulted in higher profits for companies operating in
industries that rely on actuators, such as manufacturing, robotics, and automation.

2. Actuators play a critical role in various applications, including controlling and manipulating
mechanical systems. They are responsible for converting energy into physical movement,
allowing machines to perform specific tasks or functions. As the demand for automated
systems and machinery continues to grow, the need for actuators has increased significantly.

3. The cost of producing a single actuator can range between 25,000 to 2 lakh rupees,
depending on factors such as size, complexity, and functionality. Although this cost may seem
high at first glance, it is relatively small compared to the potential income generated by the
businesses utilizing these actuators.

4. One of the key reasons why the increase in actuator production has been beneficial to
businesses is the higher profit margins they can achieve. The income generated from using
actuators in various applications far exceeds the relatively low cost of producing the actuators
themselves.

5. For example, if a business produces and sells tables, the cost of one table may be around
1000 rupees. However, if the same business incorporates actuators into their tables, the added
42
functionality and automation can significantly increase the selling price. This price difference
allows businesses to generate higher profits and improve their overall financial performance.

6. Actuators enable businesses to create products with enhanced features and capabilities,
making them more desirable to customers. The ability to automate certain processes or provide
convenient adjustments enhances the value proposition of these products, further justifying the
higher selling price and contributing to increased profitability.

7. Moreover, the rise in actuator production also promotes technological advancements and
innovation. With more actuators available in the market, businesses have greater flexibility
and options for incorporating automation into their products and processes, leading to
improved efficiency, productivity, and customer satisfaction.

8. Overall, the significant increase in actuator production has been a boon for businesses. It
has allowed them to tap into new markets, create higher-value products, and ultimately
increase their profitability. By embracing automation and leveraging the capabilities of
actuators, companies can stay competitive in today's fast-paced and technologically advanced
business landscape.

43
Fig 3.1: Before Organizing the area to store actuators

Fig 3.2: After Organizing the area to store actuators

44
 2.15. Result

The implementation of the specialized inspection gauge for the output flange of Sdtork
Controls Actuator Series '3000' yielded significant improvements:
I. Time Reduction: Main parameter measurement time was reduced by 77.78% (from 45
seconds to 10 seconds). Total inspection time was reduced to 2 minutes and 10 seconds, a
21.21% reduction.

II. Storage Capacity: Affordable and long-lasting tables offer an effective way to increase the
storage capacity of a company.

III. Enhanced Efficiency: Increased throughput, enabling handling of higher volumes without
compromising quality.

IV. Organization: By assigning specific areas of the table for assembly and wiring, the work
process becomes more organized and streamlined.

V. Process Optimization: Standardized measurements and minimized variations, optimizing

the inspection process.

The implementation demonstrated the effectiveness of the inspection gauge in reducing time,
improving accuracy, enhancing efficiency, and optimizing the inspection process. It
successfully addressed challenges, improving productivity and meeting quality standards.

45
 References

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2000, 7, 61–74. [Google Scholar] [CrossRef]
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Hydrocarbons, Part 2, Carbon Blacks, Mineral Oils (Lubricant Base Oils and Derived

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Risks to Humans; IARC: Lyon, France, 1984. [Google Scholar]
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refining makes quality oils. Hydrocarb. Process. 1978, 57, 141–145. [Google Scholar]

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47
 5. MY EXPERIENCE AND CONTRIBUTION

1.1) EXPERIENCE -
I worked in the company for a span of six month and during my
stay I gained a lot of practical knowledge which can never be acquired
through any other means. My contribution to the industry might be small
however I still made some important decision through data collected
through case studies. I came in touch with all the major department eof
the industry and worked with quality, production, sale and design team,
learning a systematic approach any problem. All the major learning from
UG about quality control, manufacturing process and supply chain
management came in hand while working in this challenging
environment. Major portions from the material engineering were useful to
know exactly why the following type of material is used and its
significance in the product.
The design department is one of the important aspects of this
industry and this is where I learned about new software used to fill pre
dispatch inspection, this internship has helped me to get a different
perspective towards opportunities in the field. This internship has helped
meto deal with difficult condition of the company. The experience and
the knowledge from the industry will definitely shape my career in a
better way.

1.2) CONTRIBUTION -
I got an opportunity to work in the quality department of the
industry and this is where I got the opportunity to work as a quality
inspector under the guidance of quality head. I was assigned to make in-
line inspection. The job was to check all the part on the shop floor
according to their standard parameter and design table and check for their
length, thickness and height. In this inspection if a product did on fit the
parameter, then it would be discarded. In this way I worked as a quality
engineer at Palkar Industries.
48
49
From Left to Right: Sahil Waghmare (Me), D. Deshmukh (Supervisor), A. B.
Chavan (Management Coordinator cum HR), Atharva Yenurkar

1
fig. Industry Internship Feedback form

2
Fig . Diary Front & Last page