ACKNOWLEDGEMENT

I would like to thank Ms. Mansi Nitin Chalke Mam from Mungi
Engineers Pvt. Ltd. Nashik for providing training in this internship
opportunity. I have been benefited by his training, valuable suggestions, and
ideas. I would like to express my sincere gratitude to our industry mentor
Mr. Prasad Kulkarni Sir for time-to-time guidance for work related learning
and guidance. I would like to express my sincere gratitude to our industry
guide Mr. Girish Thakare Sir and All supporting shift Engineers Mr. Rohit
Bhoir, Mr. Nilesh Sutar Also, I would like to express my sincere gratitude to
our internship Mentor Mr. Sunil Yeole Sir. and Prof. Dr. Pandit
S. Patil Sir for all the successful planning of this internship and Placement
Opportunity. I am thankful to the Head of Department, Prof. P. L. Sarode Sir,
for providing me an internship opportunity at Mungi Engineers Pvt. Ltd.,
Nashik I am extremely thankful to our Director, Prof. Dr. J. B. Patil Sir for
providing all the required support and guidance.

Vedan Rushikesh Bhave

[PRN:211203001]

Prof.Dr.P.S. Patil Prof. P. L. Sarode Prof. Dr. J. B. Patil

T&P coordinator Head of Department Director

1
 ABSTRACT
Mungi Engineers Pvt Ltd Nashik this company is Vender
Company supply and manufacturing sheet metal compounds
Mahindra and Mahindra Nashik, Chakan etc. This company
manufactures different sheet metal compounds and small and big
parts.

This company provides 100% accuracy for the customer's

requirement and delight them. My organization is an extremely
efficient and quality focused organization. We value all our assets &
ensure that we use them effectively & maintain them in immaculate
condition.

We value human beings collaborating with us & also

associated with us (in all areas) and ensure that all of them are
happy & continuously increase their value. This plant is the largest
cargo manufacturing plant in the country today where roll formed
panels, pressed parts and subassemblies are all under one roof. The
plant's product portfolio consists of floors, front doors, back doors,
fenders, and load body cargo production. The semi-automated
process boosts the production process in the Light and Heavy press
shop.

This is a pressing and assembly unit where we manufacture

door sash, which is the most critical sheet metal part that goes into
assembling a car. It requires top-notch sheet metal roll forming,
stretch bending, welding, and highly skilled metal finishing under
close tolerance.

My organization is a learning organization.

 2

CONTENTS
Abstract

List of Figures

List of Table

Chapter

1. Introduction
2. Product Gallery .
13
3. Safety .16

.
4. Rear Floor Line
18
.
Consumables Material 21

5. Back Door Line . ...

22

6. S201 Line .
...28

Components of Robot . 30

7. Week Wise Work Sheet .

33

8. Conclusion.. . 34

9. References .. .
36
 List of Figures
Fig.1 Company
Fig.1.2 Infrastructure 10

Fig.1.3 Certificate 11

Fig.2 Product Gallery 13

Fig.3 Safety 16

Fig4.1 Rear Floor 18

Fig.4.2 Non- IT Spot Welding Machine gun 19

Fig.4.3 IT Spot Welding Gun 20

Fig.4.4 c02 Machine 20

Fig.5.1 Back Door 22

Fig. 5.2 Poka-yoke Fixture. 23

Fig.5.3 Projection Welding Machine 24

Fig. 5.4 Pedestal Welding Machine 25

Fig. 5.5 Sander Machine 26

Fig. 5.6 Orbital Machine 26

Fig. 5.7 Manual & SPM Clinching Machine 27

Fig. 6.1 Adaptive IT Gun 28

Fig.6.2 Adaptive Robot
...29

Fig.6.1.1 Tucker welding machine .

....31 Fig.6.2.2 Poka-yoke Sensor
33

Fig.6.1.3 Poka-yoke Indictor Panel

. ...33
 List of Table
7.1 Week Wise Work Sheet
33
Chapter-I
Introduction
Since our inception in 1984, we have been manufacturing high
quality engineering products for OEMs. From a modest start with
four presses, 4 men and Rs. 4 lacs as our turnover, today we have
grown many folds to have achieved a turnover of over $200 million
USD (1500 cores INR). As we march ahead with time and trust, we
look forward to increasing our reach and conquering bigger markets
globally.

Fig.l.l [Company]

7
•Praful Mungi (C.M.D.)

•Leadership Team

1. Santosh Kulkarni (President)

2. Kirankumar Aher (Sector Head)

3. Milind Waghode (Chief Operating officer)

4. Prakash Jaisinghani (Head Business Development Strategy)

5. Vidita Mungi (Director)

6. Deepak kukawalkar (GM HR and Group IR Head)

7. Sandeep Purkar (Chief Financial Officer)

Fig.1.2 [Infrastructure]

E2ES - From design inputs, innovative solutions to flexible

manufacturing 8 plants located in southern and western India.

In-house competency for product & tool design, tool manufacturing

& design validation.

8
Certifications

Fig.1.3 [Certifications]

BBB: Rating By ICRA DNB Rating 5A3 VDA 6.3 Qualified

Quality Policy

We at Mungi group are committed to manufacture and supply sheet

metal, machine & fabricated components to meet "Customer
Satisfaction".

We shall achieve this by following quality management system

confirming to ISO/TS 16949:2002 with emphasis on Improvement in
quality by doing right at the first time through teamwork and training
to employees.

Vision

To be a preferred supplier among domestic and international

9
customers, while adhering to our core values and helping build and
support sustainable communities.

Mission

We supply world-class quality engineering products at a competitive

price, by committing to on time deliveries to domestic and
international customers.

10
'Core Values

Customer Satisfactions & Respectful

Relationships Responsiveness

Innovation

11
 Entrepreneurship Integrity

Chapter-2
Product Gallery
1. Back Door - This is a back door assembly line manufacturing and
supplied sheet metal bolero back door for Mahindra and Mahindra
Nashik.

Fig.2.1 [Back Door]

2. Bolero Cargo- This is a bolero cargo assembly for manufacturing

pick up bolero cargo they are two types of cargo assembly for this
company short bolerocargo and long bolero cargo.

Fig.2.2 [Bolero Cargo]

12
3. Bolero Rear Floor- This is a bolero rear floor assembly. They have
manufacturing two types of floors first center rear floor and second
is longer rear floor assembly.

Fig.2.3 [Bolero Rear Floor]

4. Bolero Thar Fender- This is a bolero fender assembly used for

upper side in wheel.

Fig.2.4 [Bolero TharFender]

5. U321/S201/W601 — This three project line in company U321 this

line manufacturing Marazzo 36 BIW Parts, S201 this line
manufacturing XUV 300 BIW Parts, and W601 this line
manufacturing XUV 700 Seating Mounting Parts.

13
 Fig.2.5 [Bolero U321/S201/W601]

6. Mahindra Yuvo Tractor- This line manufactures tractor parts total

parts manufacturing three parts Bezal, Scuttle, Grill.

Fig.2.6 [MahindraYuvo Tractor]

Chapter-3
Safety
1. Safety Goggle - Goggle is most important for all human being
because theprotect for eyes in welding.

14
 Fig.3.1 Safety Goggle

2. Safety Helmet- Helmet is mostly used for press shop line because
this lineused for the heavy material pick up for crane so very used
full and protect human head for this helmet.

Fig.3.2 safety Helmet

3. Safety Gloves- This is human safety gloves for protect human hand
for using machine time.

Fig.3.3 Safety Gloves

15
4. Safety Ear Plug- This is a human ear protect plug used for press
shopline.

Fig.3.4 safety Ear Plug

5. Safety Shoes- This is a safety shoes used for all department and all
human beingthis is an important for manufacturing line.

Fig.3.5 Safety Shoes

Chapter-4

16
 Rear Floor Assembly

Fig.4.1 [Rear Floor]

This is a rear floor assembly used in bolero car. This line is a small
line here total 7 Non-IT Spot Gun 1 c02 machine is use in last
station. Total three station used in this line.

1. Tacking Station

2. Re-Spotting Station

3. c02 Station

a. Tacking Station- This is the first Station this line there is used in
total 9 compounds and used to the total 4 Non-IT Spot Welding
machine used in heretotal number of spots is 389.

Machine no. WJ-2/1 = 12 Spot

WJ-3/2= 32 spot

WI-2/2= 62 spot

WJ-2/4= 60 spot

17
b. Re Spotting Station- This is a second station and re-spotting
there is total 2 Non-IT Spot Welding machine used in here & total
three compounds used and total 188 spots requirement.

Machine No. SW-121=93

sw-122=95

c. c02 Station- This is the last station for this line and used to the 1
c02 machine forthis line they are 2 tack c02 for wire clip and use
in Non-IT Spot welding machine and total spot is 35 and total 6
compounds are used here.

Machine No. WJ-3/1=35 spots

Also used in pneumatic sender machines for purpose is finishing

and removing tespot burr. Sander wheel diameter is 60*4" & 60*5 "

Also used in Pneumatic orbital machine for purpose is clear

finishing and shining for material. Orbital wheel diameter is 80*5 "

This is all process are following by SOP (Standard Operating

Procedure) & (Control Plane) Bothe are industry document.

They are different- different reports are used in company like a

setup report, first piece's report, carbon test, nugget test etc. Rear
floor is dispatch only Chakan MIDC Pune.

18
 Fig.4.2 [Non- IT spot Welding Machine gun]

This a Non- IT Machine gun because transformer is installed in

upper side and benefits is gun weight is decreasing and work
handle easily and rotated for anyposition.

This a IT spot welding gun this gun transforms is in build for gun
and this gun weightis increasing and required more space for this
gun.

19
 Fig.4.3 [IT spot Welding Gun]

This is a c02 machine used for c02 gas and uses c02 wire. The wire
diameter is 0.8mm in manual machine and c02 robot wire required
is diameter is 1 mm. c02 cylinder is 30kg are this line.

The rear floor line daily production plane is 80 floors in 8hrs duty
and 12hrs duty production is 120 floor means hourly production is
10 floors.

Fig.4.4 [c02 Machine]

20
4.1 Consumable Materials

1. Gun Tip

2. c02 Wire

3. c02 Gas

4. White goggle

5. Gloves

6. Cotton Tap

7. Welding White glass

8. Welding Black glass

9. Carbon Paper

10. Sander Wheel

11. Orbital Wheel

Chapter-5

21
 Back Door Assembly

Fig.5.1 [Back Door]

This is a back door line, and this line is a big line. This door is used
in bolero vehicle forall modules. Back door is total stage is four.

1. Stage-

1. Projection Welding.

2. Pedestal Welding.

3. c02 Welding.

2. Stage-

1. Reinforcement Assembly.

2. Inner to reinforcement assembly.

3. Stage-

22
 1. Inner Assembly Respoting.

2. Inner to Outer Assembly.

4. Stage

1. Clinching

2. Finishing

They are total 4 stage and total 9 substage this line. They are total 6
non-its gun used here, one projection welding, and one pedestal
welding machine used, 2 c02 machine used here.

Back door is passing through total 9 fixture. They are total four
fixture is used poke-yokeSensor are used.

Fig. 5.2 [Poka-yoke Fixture]

Poke- yoke is one of the Japanese word this sensor is avoid the
human error of working time. They are providing one indicator box
for mention the fig. this box indicates the sensor is working or not.

Total no. of fixture is 9 for this line.

23
1. SPF- BIO [Back door hole pressing] this is a poke-yoke fixture.

2. SPF- B9 [Inner nut plate spot].

3. SPF- B2 [Inner to reinf-assembly] this is a poke-yoke fixture.

4. SPF- Bll [Inner & reainf respoting].

5. SPF- B3 [Inner & reainf respoting].

6. SPF- B4 [Inner outer assembly].

7. SPF- B5 [Back door clinching].

8. SPF- B12 [Back door clinching SPM machine] this is a poke-yoke

fixture.

9. SPF- Bl [Reinforming assembly] this is a poke-yoke fixture.

This line total 6 non- it spots gun used here and total spot is
219here.

WJ 31/1 this gun used in fixture B 1, and total spot is 40WJ 32/1
this gun used in fixture B2, and total spot is twenty-four.

WJ 32/2 & 32/3 this both guns used in fixture B3/B11 total spot is
62 WJ 33/1 this gun used in fixture B4 total spot is fifty-seven.

SW 123 this gun used n fixture B9 total spot 14SD09 total spot is
twentytwo.

24
 Fig.5.3 [Projection Welding Machine]

Projection welding machine used in welding for stud and nut.

25
 Fig. 5.4 [Pedestal Welding Machine]

This a pedestal welding this machine used in small parts welding for
using this machine.

This line also used in sander machine for finishing purpose and
using the orbital machine for the shining purpose.
REDMI NOTE R
Ml DUAL CAMERA

26
 Fig. 5.5 [Sander Machine]

This is a Pneumatic sander machine using the air pressure. Sander

machine purposeis finishing the product and part.

Wheel Dimension- 60*4" or 60*5" Sander machine RPM is

between 8000 to 11000 (rpm is dependent on pressure range.)

Fig. 5.6 [Orbital Machine]

This a Pneumatic orbital machine using the air pressure. Orbital

machine purpose inshining the product or part.

Wheel Dimension - 60*5"

Orbital machine rpm is 8000 to 10000 (rpm depend on
pressure range.)

27
 Fig. 5.7 [Manual Clinching]

This is a manual clinching machine this machine is for bending

the door sheet.

Fig. 5.8 [SPM Clinching]

This is a clinching machine but operate is SPM and bending the

door sheet.

Chapter-6

S201 [Xuv 300 & xuv 400 -Ev]

S201 is a company project, and all parts are manufacturing
Mahindra XUV 300 and EV XUV 400. They are total XUV 300 part is
31 one part is press part and other 30 partis assembly parts.

XUV 400 total part is 12 parts are manufacturing. All parts are
assembled by robotsand manual. There are total robots is in this
line 10 robots and total non-it gun is 8 They are 7 gun is adaptive
gun and one gun is non adaptive gun.

The total robots are 12.

28
Robots No. Ro-3, Ro-4, Ro-5, Ro-6, Ro-7, Ro-8, Ro-9, Ro-10, Ro-11, Ro-
12, Ro-13, Ro-14.

Robot No is Ro-3, Ro-4, Ro-5 they are total robot is non- adaptive
robot and other robot is adaptive.

Adaptive adaptive robot is the change the current automatic as per

sheet metal thickness.

Non- Adaptive non- adaptive robots are the do not set current is
automatic.

Fig. 6.1 [Adaptive IT Gun]

29
 Fig. 6.2 [Adaptive Robot]

This robot is the 6-axis robot.

1. S- axis [Rotation]
2. L-axis [lower arm]
3. U-axis [Upper arm]
4. R- axis [Wrist rotation]
5. B- axis [Wrist swing]

30
 6. T- axis [Wrist rotation]
6.1 Components of Robot
1. Manipulator
2. End effector.
3. Actuators
4. Sensors
5. Controller
6. Processor
7. Software

1. Manipulator

The manipulator is the main body of the robot which consists of the
links, the joints, and other structural elements of the robot.

Simply a manipulator is a structure where all other important

parts are fixed. Withoutany other elements manipulator alone is
not considered as a robot.

2. End effector.

This part is connected to the last joint (Hand) of a manipulator that

generally handles objects, lift parts, makes connections to other
machines, or performs the required tasks.

3. Actuators

Actuators are known as the muscles of the manipulators. Robot

joints and links are moved by the actuators only through the signals
received from the controllers.

Servomotors, Stepper motors, Pneumatic actuators, and Hydraulic

actuators are some common types of actuators used in robots.

31
4. Sensors

Sensors are used to collect information about the internal state of

the robot or to communicate with the outside environment.

The robot controller needs to know the location of joints or needs to

move the actuators depends on the input signal, mainly the input
signals were given by the sensors.

5. Controller

This controller gets the necessary inputs from all sensory items do
the motions of the coordination, actuator or joints links. Without
controller, we cannot do the exact robot operations.

6. Processor

The processor is considered as the brain of robots. It calculates all

the motion, it calculates how much speed was needed for moving to
the destination point, checks the coordination points for the
function.

7. Software

Robotic software is used to calculate the necessary motion of each

joint based on thekinematic, inverse kinematic equations of the
robot. This information is sent to the controller.
REbM1 9 000
Ml DU

32
 TE 6 PRO
CAMERA

Fig.6.1.1 [Tucker welding machine]

This is a Tucker welding machine used purpose for install the

threating nut in parts. They are working on pneumatic air pressure.

They are all assembly passing through the sensor. Using for high
quality sensor are using the S201 line.

Fig.6.1.2 [Poka-yoke Sensor]

This a poka-yoke sensor. This sensor detects the nut, threating

bold, and other smallpart detect this sensor and the any one part
are absent clamp are not operating.

33
 Fig.6.1.3 [Poka-yoke Indictor Panel]

This a sensor indicator panels this indictor panel used for all
fixtures and robots.

Chapter-7
Week Wise Work Sheet
Weak Work Time

Weak 1 Collect the information of Company history, 8:30 to

vision, Mission. 5:00

Weak 2 Collect the information of Assembly Line. 8:30 to

5:00

Weak 3 Collect the information of Robotic Line. 8:30 to

5:00

34
Weak 4 Collect the information of product with their 8:30 to
subParts. 5:00

Weak 5 Collect the information of no of spots 8:30 to

required and thickness of parts. 5:00

Weak 6 Collect the information of flow chart and cycle 8:30 to

time. 5:00
Weak 7 Collect the information of Press Shop and 8:30 to
their Machines. 5:00

Weak 8 Collect the information of Tool Maintenance, 8:30 to

Raw Material and Quality Department. 5:00

Weak 9 Collect the information of First Piece Report, 8:30 to

DWM, All Machines Working. 5:00

Weak 10 Why-why analysis and their use. 8:30 to

5:00

Weak 11 Production planning and hourly report. 8:30 to

5:00

Weak 12 Daily Setup, Poka-Yoke, batch entry and All 8:30 to

Tests. 5:00

35
 Conclusion
•All assembly lines understand and how to manufacture S201 BIW
parts.

•How to handle the line and how to face situations for critical line
manpower handling. Then achieve target for daily production.

'Understand for all important document and how to fill the all-important
document.

•Which types of raw material used for the manufacturing company and
which company provide the raw material.

•Then which types of machines are used by the manufacturing

company, and which position they are very important.

•Then understand the SOP and control Plain both are very important
document.

36
References
Il Puschner, P., Kölzer, G. , Geisler, F. Neuartige Schweißsystem für eine
flexible Fertigung. Tagungsband 21. DVS-Sondertagung
"Widerstandsschweißen 2010". 2010 May 05-06

21 Mikno et al. describe a new control system and the results of its operation,
particularly visible in projection welding. Mikno et al. present a new control
system used during the welding of sheets with an embossed projection.

31 The time of welding could be extended, which significantly affected the

generation of welding power in the most important areas, i.e. in the projection
material and in the contact area between materials being welded. Despite the
lower value of welding current, the extension of projection height reduction
time led to the generation of higher welding power in the projection material.

41 Deen, M.J., & Basu, P.K. (2012). Silicon Photonics: Fundamentals and
Devices.

51 Moses, M., Yamaguchi, H. , & Chirikjian, G.S. (2009). Towards cyclic

fabrication systems for modular robotics and rapid manufacturing. Robotics:
Science and Systems.

6] Aguilar, J. , Zhang, T. , Qian, F. , Kingsbury, M. , Mclnroe, B. , Mazouchova, N.

,
Li, C., Maladen, R.D., Gong, C., Travers, M.J., Hatton, R.L., Choset, H.,
Umbanhowar, P., & Goldman, D.I. (2016). A review on locomotion
robophysics: the study of movement at the intersection of robotics, soft
matter and dynamical systems. Reports on progress in physics. Physical
Society,
41