Bansilal Ramnath Agarwal Charitable Trust’s

Vishwakarma Institute of Technology

(An Autonomous Institute affiliated to Savitribai Phule Pune University)
Bibwewadi, Upper Indira Nagar, Pune-411037

A Semester Internship Project Report

At

“Benteler Automotive India Private Limited”

Submitted by

Tejas Sanjay Dukare (GR. No: - 12120174)

Under the Guidance of

“Prof P.M.Gaigole”

Industrial and Production Engineering Department

Academic year 2022-2023

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 BANSILAL RAMNATH AGARWAL CHARITABLE TRUST’S

VISHWAKARMA INSTITUTE OF TECHNOLOGY

PUNE-411 037
(An Autonomous Institute Affiliated to Savitribai Phule Pune University)

CERTIFICATE

This is to certify that the Project titled “Benteler Automotive India Private Limited”
Has been completed in the academic year 2022 – 2023, by Tejas Sanjay Dukare (GR No:
12120174), in partial fulfilment of B. Tech in Industrial / Production Engineering as
prescribed by Savitribai Phule Pune University.

Prof P.M.Gaigole Ganesh Mane

Institute Guide, IPED Company Mentor
Benteler Automotive India Pvt Lmt

Examiner Prof. Dr. G N Kotwal

Name & Sign Head of Department, IPED

Place: Pune Date:30/11/2023

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 1. Acknowledgement

I am incredibly grateful to my internship supervisor, Ganesh Mane Sir, for their

invaluable guidance and support throughout my internship. From the moment I started, took
the time to get to know me and understand my goals for the internship. They provided me
with clear direction and expectations and were always available to answer my questions and
provide valuable feedback.

Throughout the internship, Ganesh Mane Sir provided me with invaluable

insights and advice that helped me to grow as a professional. Their constructive feedback
helped me to improve my skills and approach to my tasks, and their encouragement kept me
motivated and focused. I am deeply thankful for time and effort, and for their commitment to
my success.

I would also like to express my appreciation to my colleagues and the staff at

Benteler automotive India pvt ltd for their warm welcome and assistance during my
internship. It was a pleasure to work with such a talented and supportive team.

From the moment I arrived, my colleagues were quick to introduce themselves

and make me feel welcome. They were always willing to share their knowledge and expertise
and were patient in answering my questions and helping me to understand the company and
industry.

In addition to my colleagues, the staff at Benteler automotive India pvt ltd were
always helpful and efficient in assisting me with any needs or questions I had. I am grateful
for the opportunity to work with such a dedicated and professional team.

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 2. Abstract

The report covers the following aspects of internship:

 Table of contents.
 Introduction of Benteler Automotive India Private Limited
 Departments of Quality.
 Description of tools and techniques learned.
 Schedule of internship.
 Skills learned.
 My role as an internee.
 Conclusion.

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 Index

Sr. Title Page.

no no
1 Acknowledgement 3

2 Abstract 4

3 Index 5

4 Introduction 6

5 Location 7

6 Plant Training 8

7 Working & Process 9

8 Objectives 14

9 Methodology of the Study 15

10 Data Collection 16

11 Development 17

12 Limitations of the report 19

13 Future Scope 20

14 Result 21

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 15 Conclusion 22

4. Introduction

Benteler Automotive India Private Limited

Benteler Automotive India Private Limited is an unlisted private company incorporated on 17

July 2008. It is classified as a private subsidiary of a foreign company and is in Pune,
Maharashtra.

This company's line of business includes the manufacturing or assembling of

complete passenger automobiles. Products & Services: of Four-Wheeler Spare Parts, Engine,
Automotive Parts. The Benteler Group is organized in two divisions: Benteler Automotive
and Benteler Steel/Tube. The holding company, Benteler International AG, based in
Salzburg, Austria, controls the strategic orientation of the group. In addition to Benteler
International AG, Benteler Business Services, based in Paderborn, Germany, performs
additional holding functions.

Benteler is the manufacturing company it is making chassis for four-wheeler

cars. Volkswagen, Skoda, Honda and Maruti Suzuki these are the prime business partners of
the company. When metal needs to be formed, joined, cut, milled or punched, advanced types
of robots make products manufactured to the highest quality. Efficiently and consistently.

Benteler Mechanical Engineering develops and manufactures continuous furnaces,

production equipment for chassis components and structural parts as well as equipment for
automated loading and unloading of furnaces and presses. The production of tools for hot
forming rounds off our portfolio.

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 5. Location & Company

 Plot No B14 Midc Chakan Phase Ii Taluka Khed, Chakan, Phase 2, Chakan, Pune -
410501 (Opposite Ge India Gate No 01 And 02 Village Vasuli)

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 6. Plant Training

In plant training is useful to learn the practical knowledge of the different activities going in
the organization. Trainee can learn as well as can apply his knowledge during the trainee
period. Therefore, in plant training is very useful for every trainee.

Scope of the training:

 To enhance the knowledge being an engineer trainee.

 Training in a company like Benteler Automotive India Private Limited gives the idea
of huge. Engineering work in manufacturing industry.
 Training has given us idea of working of different departments like Production,
Quality, QA, Stores, Finance, HR etc.

Objective of training:

 Before to join the actual work, we got 1 week training.

 In the training first they teach us about safety precautions like always wear safety
shoes, gloves, sleeves, glasses and ear plugs.
 And then they are informing us about industries area like walking zone, storage area,
logistics area. Some areas there we didn’t allow to go.
 After that they gives information and start to train us about working process, how to
work happen by the steps.
 Knowledge about robots, CMM machine, tools, switches.
 After that some information about departments which is works together in the field.

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 7. Working and Process
Benteler is the manufacturing company it is making chassis for four-wheeler cars.
Volkswagen, Skoda, Honda and Maruti Suzuki these are the prime business partners of the
company. When metal needs to be formed, joined, cut, milled or punched, advanced types of
robots make products manufactured to the highest quality. Efficiently and consistently.

In the plant I got special training about CMM machine for working on it CMM machine that
rechecking the product and making report on it. CMM machine means coordinate measuring
machine which is measure all the parameters applying on the job or product.

CMM Machine: A coordinate measuring machine (CMM) is a tool that uses discrete points
on an item's surface to detect the geometry of the object. While optical and white light
sensors do exist, mechanical and laser sensors are the most often utilized types of probes in
CMM’s. The probe location may be managed manually by an operator, or it may be managed
by a computer, depending on the equipment. A CMM machine is a device that uses
coordinate technology to measure the dimensions of machine or tool components. You may
be able to measure the target and record the measured data depending on how sophisticated
the CMM machine is. Due to its many benefits, CMM machines are an essential component
of many manufacturing processes. CMM machines have high precision between dimensional
measurements. Measurements can be made with a precision of 1 micron or even less.

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One limitation is the size of the measuring volume, which is the maximum size of the object
that can be measured. This limitation is determined by the size of the CMM and the length of
the measuring arm or probe. Another limitation is the accessibility of the object being
measured.

Product: Benteler is the specialist for the development and manufacturing of chassis
components such as front and rear crossmembers and subframes, twist beam axles and a wide
range of control arms and knuckles.

Many million parts are produced in the plants around the world every
year and delivered in outstanding quality to for customers. Development expertise is often
requested by customers at the pre-development stage. Benteler develop components to best
meet customer requirements, which are then manufactured using innovative materials and
forming and joining technologies.

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This is the twist beam rear axle must provide a combination of driving dynamics and ride
comfort within a predetermined installation space. This makes it one of the more complex
chassis components. We achieve the perfect balance of all required characteristics at the
optimum weight and cost. Quickly and reliably thanks to the use of in-house developed tools,
innovative forming and joining techniques and precisely defined standards. Special solutions
are available for an extended range of applications, for example a higher axle load spread or a
driven rear axle. The twist-beam axle can then also be used as an alternative to a multi-link
axle.

Robot Welding and joining: Robotic welding is a process that helps the industrial sector to
automate its processes, increase accuracy, enhance safety and reduce lead time. The robot
welding process is the most productive when it is implemented for high-volume and
repetitive tasks.

The arc method is one of the most common forms of robotic welding. An electric arc
produces high heat, up to 6,500 degrees Fahrenheit, which melts the metal in this process.

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Molten metal joins parts together, which solidifies into a secure bond after cooling. When a
project necessitates a vast number of precisely linked metals, arc welding is a great option.

Welding robots bring many benefits to the manufacturing process, including precise
results, less wastage, and improved safety. These robots can reach locations that are
inaccessible by human hands and perform complicated tasks much more precisely. Therefore,
the time taken in the manufacturing process is minimised and greater flexibility is achieved.

Quality Department: In most cases, the quality department in an organization plans,

measures, analyses and reports on quality. This is a staff function to support other
departments in the day-to-day improvement of products and services.

Generally, multiple plans, multi-division and multi-national organizations include a

corporate quality group. There are instances in which laboratories report to a divisional
quality manager. In large companies there are often autonomous divisions based on a
particular product line. It is customary for each of these autonomous divisions to have its own
quality department at the corporate staff level.

Quality Processes:

 Quality Planning: - Process of preparing to meet quality goals. It Involves

understanding customer needs and developing product features.

 Quality Control: Process of meeting quality goals during operations. Control

parameters. Measuring the deviation and acting.

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  Quality Improvement: Process for breaking through to unprecedented levels

of performance. Identify areas of improvement and get the right people to

bring about the change.

 Quality assurance: - refers to the planned and systematic activities

implemented in a quality system so that quality requirements for a product or

service will be fulfilled.

Chassis used in these vehicles:

 Volkswagen Virtus, Taigun

 Skoda Slavia, Kushaq

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  Maruti Brezza, Baleno

Honda Amaze

8. Objectives

Now that we all know what is meant by Industrial Training, let’s proceed further and
understand the objectives behind any Industrial Training that is offered by a company.
Industrial Training can be defined as a training program that is provided during the course of
study, with the sole purpose of delivering on-the-field training or practical experience to the
students who are going to become the prospective employees.

This helps in putting their theoretical knowledge into practical

experience. It is provided for a specified tenure and mainly during the course of study.

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Industrial Training also gives an overview of the organization, it’s structure, job
responsibilities to the students.

 To create a learning platform for the students where they can enhance their skills and
prepare themselves for the future.
 To enhance their skills-set in their expertise.
 To convert their theoretical learning into practical experience.
 To make them understand what is expected out of them.
 To equip them with qualities like integrity and leadership.
 To build their self-confidence.

9. Methodology of the study

Methodology refers to the comprehensive actions of research in my internship report. To

achieve the required results to establish the objective, some methods are used. This section
will clarify the methods I used to do this project.

To achieve the required results to establish the objective two basic methods were used:

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Qualitative Analysis:

 Though a smaller number of unstructured interviews were taken, in-depth interview of

some of the employees of Benteler automotive.
 Managers were conducted to get proper insight on the roles of solving the problems.
Asking the questions on any doubt to any employees.
 Analysis the work of employees and their conversation during the work.

Online Searching:

 On any doubt of any subject or confusion happens then I use google and collecting the
information about my doubt.
 I was searching for customer response or feedback about Benteler automotive to
analysis the work of company.
 Reading publications, reports, documents about this company and making the
important points for the study.

10. Data Collection

This report will be based both on Primary and Secondary data

A basic overview of the data collected and used to make this report are described below:

Primary data:

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  Talking with employees and asking questions on any doubt.
 Listening employee's conversation during the work or solving the problem.
 Inspection in different desks.
 Doing actual work in the present of employees.

Secondary data:

 Brochures and instructions guid of machines and products.

 Different journal and publications of Benteler’s automotives.
 Before use any machine or working reading all the guide of that machine provided by
company.
 Watching videos and pictures on internet.
 Reading all the articles and information on Benteler’s web site on google.

11. Development

Rear axle chassis: This also called subframe chassis. This chassis is one torsion beam
attached with two side arms on both side of the beam. Chassis are attached to a monocoque
car body. It is often used on the rear end of the car. Most prominent are axle subframes which
are used to attach the wheels and suspension to the vehicle. Subframe chassis are typically
added to a monocoque chassis as a way of isolating the noise and vibration of the powertrain
and suspension components from the rest of the vehicle body monocoque. This type of

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chassis can be stronger and lighter than fully monocoque chassis, however it is not suitable
for larger vehicles due to the cost of monocoque bodies. Subframes can be found in most of
the cars.

Material: The material used for the construction of the chassis is usually carbon steel, but it
is also becoming more commonplace that they are made up of aluminium alloys considering
its light-weight characteristic. Operations such as folding, pressing and rolling are done to
incorporate various chassis members. Press blanking and bending are important stages in the
chassis production and at Pressmark.

Making process: All the parts for making chassis which can import from outside and joining
here. They some steps around there from OP20 to OP60.

1. In the first step OP20 chassis no is printed on torsion beam with the help of printer
machine.
2. Then part goes to OP30/40 here wheel plate attached to side arms on hollow side of
the arms, and then these two side arms attached to both side of the torsion beam with
well balanced.

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3. After that in the OP50/60 process spread shit is attached to the in between sidearms
and torsion beam on both side of the beam, and next circular bushes is attached to side
arms.
4. For next process part is checked on gauge for surface testing of wheel plate, all the
alignment are ok or not with the help of no-go gauge.
5. And the next process is on CMM machine which is rechecking the part on CMM and
making final report on it.

12. Limitations of the Report

 Sometimes the concerned personnel may not provide enough time due to rush office
hours.
 As a matter of fact, six months is too short after that I had tried to give best effort to
my learning purpose.

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 Supervisor give me work on only CMM machine that’s why I didn’t gain so much
knowledge about other sectors of the company.
 During spetial days like visits and all I was not allowed to interact with them.

13. Future Scope

 Benteler optimize electric vehicle manufacturing costs, for example through

functional integration and scalability.

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 Benteler improve the cooling plates integrated in the battery box. This reduces
material usage, weight, complexity and, ultimately, the manufacturing costs of the
entire battery box. In turn, the lower weight increases the range.
 Benteler Electric Drive System, they also enable companies from outside the industry
to enter the field of e-mobility. Cost-effectively, quickly and reliably.
 Benteler are also working on cost-effective solutions in the growth field of e-mobility.
They are urgently needed, because public subsidies are expiring while legal
regulations are changing in such a way that there is no way around there.

14. Result

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 Benteler Automotives great minds and very high quality of work. At the field, they
provide many instruments, and their student will conduct the entire instrument by
their own.
 I got fully knowledge about CMM machine working.
 From this internship I was gain my confidence to interact with different peoples and
discuss on work.
 One special think I get that is there is too much different between theoretical
knowledge and actual work on field.
 It was my first time to do work in company, I was too shy at the starting but slowly I
was confident and now I think I was ready to do work on any field in my future with
different emotions. That was a good change.

15. Conclusion

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It was a great experience to learning and working in this company. They are teaching about
how to be working with robot and handle it or modify it. Checking the parts quality, welding
defects and knowing about car chassis design. Interact with senior officers. Gaining the
technical knowledge. The experience and knowledge during the internship at Graduate
Institute of Regional Innovation Studies, Mie Institute it was great. This organization has a
superb work culture, Benteler Automotives great minds and very high quality of work. At the
field, they provide many instruments, and their student will conduct the entire instrument by
their own. During the internship, I was introduced and learned to handle equipment such as
CMM machine for measure the standard of the parts and making report on it. The knowledge
and skills get from the internship will be used to apply a work and do the final year project.
Working with people from different country was a rare chance and it was another opportunity
to make friends and share ideas. During the internship I saw that Jerman people hardworking
and very helpful. They will help us until the problem is solved. Besides that, when student do
the internship at the abroad, they not only get the knowledge during working, but they also
will learn how to be independent and survive at the foreign country with different culture,
lifestyle and language.

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