Content

List of Figures ………………...……………………………………………………7

List of Table …………………………………………………………………………8

Abstract ……………………………………………………………………………….9

Chapters

1. Introduction ……………………………………………………………………10

2. Product Gallery ……………………………………………………………….14

3. Safety ……………………………………………………………………………...16

4. Department …………………………………………………………………….18

5. Heavy Press Shop …………………………………………………………….21

6. Week Wise Work Sheet ……………………………………………………32

7. Conclusion ………………………………………………………………………34

8. References ………………………………………………………………………35

5|Page
MEPL, Nashik
List Of Figures

i) Mungi Engineers Pvt.Ltd. Nashik…………………………………10

ii) Product Gallery…………………………………………………………..14

iii) Safety kit…………………………………………………………………….16

iv) Assembly Lines …………………………………………………………..18

v) Quality Products …………………………………………………………19

vi) Heavy Press Shop …………………………..……………………………19

vii) Electrical Maintenance Department ……………………………..20

viii) Hydraulic Press Machine ……………………………………………..24

ix) Mechanical Press Machine ………………………….………………..27

x) Raw Material Department...…………………………….…………….29

xi) Production ………………………….……………………………………...30

xii) Working ..…………………………………………………………………….33

6|Page
MEPL, Nashik
List Of Table

i) Week Wise Working Sheet ……………………………………..32

7|Page
MEPL, Nashik
Abstract
Mungi Engineers Pvt. Ltd. Nashik. His manufacture high quality
engineering products, this company is a vendor company to manufacture and
supply sheet metal components to Mahindra and Mahindra (M&M) to preferred
locations as Nashik, Chakan, Haridwar, Zahirabad, etc.

This company is manufacturing different types of sheet metal

components and small or big parts used in vehicles and automobile sector. This
company is providing to 100% accuracy for the customer requirements and
delight them.

We value all our assists & ensure that we used them effectively and
maintain them in immaculate condition. We value human beings working with
us & also associated with us (in all areas) and ensure that all of them are happy
and continuously increase their value.

The plant is probably the largest Cargo manufacturing plant in the

country today where roll formed panels, pressed parts and sub-assemblies are
all under one roof. The plants products 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 in to 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 learning organization.

8|Page
MEPL, Nashik
 Chapter-1

Introduction:

Since our inception in 1984, we have been manufacturing high quality

engineering products for OEM’S from a modest start with 4 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 crores INR). As we march
ahead with time and trust, we look forward to increasing our reach and
conquer bigger markets globally. The company goal is to manufacture world
class quality product at chippiest price with on time delivery. The customers
of company are national as well as international.

Fig.1.1 Mungi Engineers Pvt. Ltd. Nashik

9|Page
MEPL, Nashik
Praful Mungi (C.M.D.)

Leadership team:
Santosh Kulkarni (President)
Kirankumar Aher (Sector Head)
Milind Waghode (Chief Operating Officer)
Prakash Jaisinghani (Head Business Development Strategy)
Vidita Mungi (Director)
Deepak Kukawalkar (GM HR and Group IR Head)
Sandeep Purkar (Chief Financial Officer)

Infrastructure:

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.
The infrastructure of company was well developed. The plants are located at
good places. In future company is set to expand the plants at Pune.

10 | P a g e
MEPL, Nashik
 Certification:

Fig.1.2 Certification
BBB: Rating By ICRA DNB Rating 5A3 VDA 6.3 Qualified

Quality policy:

We at Mungi Engineers Pvt. Ltd. are committed to manufacture and supply sheet
metal components and assemblies by complying with all applicable requirements to
achieve customer satisfactions and strive for customer delight.
We shall achieve this by following quality management system confirming to IATF
16949:2016 with emphasis on continual improvement by doing first time right
through teamwork, training and motivating the employees.

Vision:
To be preferred supplier among domestic and international 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.

11 | P a g e
MEPL, Nashik
 Core values:

Customer Satisfactions & Respectful

RelationshipResponsiveness

Entrepreneurship

Integrity Innovation

12 | P a g e
MEPL, Nashik
 Chapter-2
Product gallery:

Fig.2.1 Back & Front Door Fig.2.2 Mahindra Yuvo Tractor Fig.2.3Bolero (U321/S201)

Fig.2.4Marazzo Seat Frame Fig.2.5 XUV 700 Seat Frame Fig.2.6 Bolero Pickup Cargo

Fig.2.7 Thar Fender Fig.2.7 Bolero Rear/Longer

Floor

13 | P a g e
MEPL, Nashik
 1. Back Door & Front Door: - This is a Mahindra bolero front and back door
assemblies manufacturing and supplied sheet metal bolero back and front door
for the requirement for Mahindra & Mahindra Nashik.
2. Mahindra Yuvo Tractor: - This line manufacture Mahindra Yuvo Tractor Parts
i.e., Bezal, Scuttle, Grill.
3. Bolero U321/S201/W601: - These 3 lines in this company is our projects
name. U321 line is manufacturing Marazzo 36 B/W Parts, S201 line
manufacturing XUV 300 BIW parts, and W601 line manufacturing XUV 700
Seating Mounting parts.
4. Marazzo Seat Frame: - This line manufactures an assemblies of customer
requirement U321 Marazzo Seat Frame.
5. XUV 700 Seat Frame: - This line manufacturing assemblies of the Mahindra
XUV 700 Seat Frame as our daily requirements.
6. Bolero Pickup Cargo: - This line manufacturing a bolero cargo. There are two
types of cargo assemblies this company, short bolero cargo and long bolero
cargo.
7. Bolero Thar Fender: - This line is assemblies for a bolero Thar fender.
8. Bolero Rear/Longer Floor: - This line is manufacturing Mahindra bolero
Rear and Longer floor as our requirements.

14 | P a g e
MEPL, Nashik
 Chapter-3

Safety:

Safety Safety Safety

Helmet Handgloves Shoes

Safety Safety
Goggle Earplug

Fig.3 Safety kit

1. Safety helmet: - Helmet is the most important used in Heavy Press Shop
line because use for the heavy machinery and heavy material pick up for
crane so very used full and protect human head for this helmet.

2. Safety hand gloves: - This is a safety hand gloves used for protecting human
hand for heavy machinery and protect for cutting our hands.

15 | P a g e
MEPL, Nashik
 3. Safety shoes: - This is a safety shoes used in all departments for our leg’s
safety for all the human beings. It is very most important used in Heavy Press
Shop and Manufacturing lines.

4. Safety goggle: - The safety goggle is used in assemblies’ line; it is very most
important used for human eyes protection for spot welding.

5. Safety earplug: - A safety earplug most used in Heavy Press Shop for the
heavy noise and it protect for human ear.

6. Alarms: - The fire alarm and safety alarms are installed to use in emergency
condition to alert the employees.

16 | P a g e
MEPL, Nashik
 Chapter-4

Various departments in our company:

Assembly Department
Quality Department
Heavy Press Shop Department
Electrical Department

Assembly department:

Fig.4 Assembly line

In this department few lines as Cargo line, Back door line, Front
door line (INR/OTR), Dhruv line (Yuvostar & M-Star) and provide
assemblies for Mahindra & Mahindra as our requirements.

17 | P a g e
MEPL, Nashik
 Quality department:

Fig.5 Quality products

In this department to achieve a target manufacture quality product,

part and all over process going on quality policies. This department does not
provide rejected parts to next operation & his allowed only zero-defect
products. The aim of department is to reduce the quality concerns. The
quality engineers and quality inspector are check the parts continuously.

Heavy press shop:

Fig.6 Heavy press shop

18 | P a g e
MEPL, Nashik
 In this shop Press/Stamping to the parts as a capacity of press stamping
100 Ton to 1800 Ton machines. The stamping of sheet metals can be defined
as the process of changing the shape of the sheet metal blank into a useful shape
in the plastic deformation state, using a die and a mechanical press. Press shop
is a main production line in this company. Its manufacture sheet metal
components used in automobile sector.

Electrical department:

Fig.7 Electrical maintenance department

In this department has all the electric maintenance related problem are
solved. This department is very critical and provide to electricity all plant. For
example, transformers, robots, machines, etc.

19 | P a g e
MEPL, Nashik
 Chapter-5

Heavy press shop:

I am working in Heavy Press Shop as an Apprenticeship Trainee (Production

Engineer)

20 | P a g e
MEPL, Nashik
 Information about heavy press shop:

All the production process is going on Quality System Process (QSP),

Standard Operating Procedure (SOP) & Control Plan (CP) with safety.

There are three press production lines in company:

Line_1 contains 6 machines L1P1 to L1P6
Line_2 contains 7 machines L2P1 to L2P7
Line_3 contains 9 machines L3P1 to L3P9

Our projects are:

S201 (XUV 3OO)
S201 (XUV 4OO-EV)
U321 (Marazzo)
SC-DC (Scorpio)
W601 (XUV 7OO)
DHRUV (Yuvostar & M-Star)
Thar (M&M)

Documentations used in heavy press shop: -

Operator Meeting Sheet
Daily Safety Check Sheet
Daily Start-up Check Sheet
Daily Stroke Monitoring Sheet
Setup Approval Report
Hourly Production Report
Safety Deviation Report
Rejection Tally Report
Shift Wise Losses Report
First Hour Report
Shift Communication Logbook
Why-Why Analysis Report
Line Throw-Back Report
Android tab entries like Memo, Indent
21 | P a g e
MEPL, Nashik
 Press shop planning & production flow chart:

Press Shop

Capacity Planning Safety i.e., man/machine/tool

No. Of Machines M/C operating knowledge
Specification Of Machines Die Setting Process, SMED
No. Of Project & their Parts Setup Approval Report
Monthly Schedule & Per Control Plan, PFC
day requirement Types of Defects & Its Causes
Press loading plan Manpower Handling
Shop floor scheduling Standard Operating Processor
System vs actual strokes Android Entries
Raw material requirement Daily Work Management Line
Documents & Check Sheet
Rejection Rework
Production Documents

Departments in heavy press shop-

Production Department
Quality Department
Machine Maintenance Department
Tool Maintenance Department

22 | P a g e
MEPL, Nashik
 Chapter-6

Types of machines used:

i) Hydraulic Press Machine

ii) Mechanical Press Machine

Hydraulic press machine:

A hydraulic press is a machine press using a hydraulic cylinder to
generate a compressive force. It uses the hydraulic equivalent of a mechanical
lever, and was also known as a Bramah press after the inventor, Joseph Bramah,
of England. He invented and was issued a patent on this press in 1795. As
Bramah (who is also known for his development of the flush toilet) installed
toilets, he studied the existing literature on the motion of fluids and put this
knowledge into the development of the press.

T
Fig.8 Hydraulic Press Machine

23 | P a g e
MEPL, Nashik
 Working principle: -

The hydraulic press depends on Pascal's principle-the pressure

throughout a closed system is constant. One part of the system is a piston
acting as a pump, with a modest mechanical force acting on a small cross-
sectional area; the other part is a piston with a larger area which generate
a correspondingly large mechanical force. Only small diameter tubing (which
more easily resists pressure) is needed if the pump is separated from the
press cylinder.
A hydraulic press consists of two different cylinders of two different
diameters. One cylinder is of smaller diameter that contains a plunger, and
another cylinder is of larger diameter that contains Ram. These two cylinders
are connected through a pipe/hose which contains hydraulic fluid through
which pressure is transmitted.
When a smaller force F is applied on the plunger, pressure is produced
in the liquid. As per Pascal’s law, this pressure is transmitted equally in all
directions and act on the Ram. Thus, the Ram is pushed forward, and heavier
objects can be easily lifted.

Components of hydraulic press machine:

1. Pipe/Hose 9. Safety Sensors

2. Hydraulic Motor 10. Hand desk
3. Reservoir Tank 11. RAM
4. Direction Control Valve 12. Cushion
5. Pressure relief valve 13. Base/Bed
6. Pressure gauge
7. Limit switch
8. Hydraulic cylinder

24 | P a g e
MEPL, Nashik
 Application:

Hydraulic presses are widely used for automotive folding and forming
applications. Brake pads, sealing components, insert molding, truck bed liners,
electrical connectors and insulators, fuel delivery parts, etc. are the vehicle
parts manufactured using hydraulic presses.

Metal forming operations:

1. Deep drawing operations
2. Punching operations
3. Blanking operations
4. Molding operations
5. Clinching operations
6. Forging operations

Advantages:
1. Accuracy is very good.
2. Heavy weight controlling capability through a small component.
3. Hydraulic motor and pump can be installed under water.
4. Fast forward and reverse capability.
5. Single pump can control multiple actuators and hydraulic motors.
6. Hydraulic system has No short circuit possibility.
7. Less system failure.
8. Easy to find out malfunctions.
9. Compact size of hydraulic system.
10. Easy Installation.
11. Easy to maintenance.
12. Less maintenance cost

25 | P a g e
MEPL, Nashik
 Disadvantages:
1. Oil leakages is the main disadvantages of hydraulic system.
2. Contamination is the causes of hydraulic system failure and damages.
3. Hydraulic oil losses viscosity for excessive overheat of the system.
4. Components speed can be varied for the selection of hydraulic oil grade.
5. The operation speed is slow.
6. They consume high energy.

Mechanical press machine:

A mechanical press is a machine that is used for forming manufacturing
sheet metal and metal extrusion. Press machines are the perfect and normal
machine tool that can be separated into a hydraulic press and mechanical press.
A mechanical power press shears, punches, forms, or assembles metal or other
materials by means of tools or dies attached to slides or rams.

Fig.9 Mechanical Press Machine

26 | P a g e
MEPL, Nashik
 Working principle:

The design principle of the mechanical power press is to convert the

circular motion into a linear motion, and the main motor outputs the force to
drive the flywheel. The clutch drives the gear, the crankshaft (or the eccentric
gear), the connecting rod, etc. to achieve the linear motion of the slider. The
motion of the motor to the connecting rod is a circular motion. There is a need
for a circular motion and a linear motion transfer point between the connecting
rod and the slider. The design has roughly two mechanisms, one is a spherical
type, and the other is a pin type (cylindrical type), and the circular motion is
performed via this mechanism to a linear motion of the slider. The presses
release the force on the material to plastically deform it to obtain the required
shape and precision. Therefore, it is necessary to match a set of molds (dividing
the upper mold and the lower mold), placing the material between them, and
applying pressure by the machine to make it deformed, the reaction force caused
by the force applied to the material during processing is absorbed by the
mechanical body of the press.

Components of mechanical press machine:

1. Motor 10. Safety Sensor

2. Bolster 11. Pitama
3. Flywheel 12. Hand Desk
4. Air tank 13. Ram/Slide
5. Crankshaft
6. Base/Bed
7. Clutch
8. Cushion
9. Brakes

27 | P a g e
MEPL, Nashik
 Application:
They can quickly perform functions such as bending, deep stretching,
crimping, and perforating. A mechanical press machine exerts pressure to
change the shape or size of the material. They are named after punches, which
are pressurize components attached to a reciprocating pressure head.

Advantages:

1. Fast running speed

2. High working efficiency
3. Low cost
4. Easy to maintain
5. Relatively simple control part

Disadvantages:

1. Limited capacity
2. High maintenance cost
3. Lower accuracy
4. More system failure

28 | P a g e
MEPL, Nashik
 Process of production:
All the production process is going on Control Plan (CP), Standard
Operating Processor (SOP), Quality System Process (QSP) & all production
related documents with safety. After the process is systematically arranged &
cleanliness. Shift engineer issues SOP, control plan, and then give awareness to
machine operator and operator carry out production activity according to SOP.
In the production process all the engineers/supervisors issue the control plan
and SOP after then give awareness to machine operator. After then this process
is going on the planning of manufacturing parts and setup to the machine.
After that, this process complete to start the machine and first five-piece
check to the quality inspector after then start to production of the parts.
Complete of all production process to supply the material to the customer as
dedicated pallets and trolleys.

Shearing department:

Fig.10 Raw Material shearing department

Raw material shearing department is store all type of material unloading,

and before the unloading material checking by engineer his chemical and
mechanical properties to the Test Certificate.
29 | P a g e
MEPL, Nashik
 Raw material supplier:
TATA Steel
Mahindra Steel Service Ltd.
Mahindra Accelo Ltd.
Posco, etc.

First, the planning of production as a customer requirement and check

the material of shearing department. And after this process to as a required
parameter material provide to shop floor by shearing department. All the
material is identified by the parts production is our Grades.

Production department-

Fig.11 Production

30 | P a g e
MEPL, Nashik
 The production department is achieving a daily schedule target as a customer
requirement and complete this. A Production engineer is responsible for feeding
raw materials into machinery, assembling goods on production lines, and monitoring
the process. In addition, they carry out basic quality checks such as testing of
product or packaging before shipping by adequately storing all necessary supplies.
A production department is a group of functions within a business that is responsible
for the manufacture of goods. Production management is organizing and controlling
the production of goods or services. It includes the planning, coordinating, and
managing of all resources and activities necessary to produce a given product or
service. The three main function of production Planning, Control, and co-ordination.

31 | P a g e
MEPL, Nashik
 Chapter-7

Week wise work sheet:

Weak Work Time

First day all students visit the company and
Week 1 observation for all departments and work. Next 8:30 to 5:00
day clear the all is documents formality to HR
department. They introduction for safety and
introduce all company related information.
Then start induction training for company related
and all department and shear the all-department
Week 2 work and what total department in company 8:30 to 5:00
how to work for all department. Then shear the
one-by-one line information how many types of
machines used. Then after induction training
completed to allow the line of Heavy Press Shop.
I am only observation this line, how to work and
Week 3 what is the process of working in this line, which 8:30 to 5:00
types of machines used in this shop, and I am
understood the process of this shop in one week.
Week 4 Learning to shift handover, Daily work 8:30 to 5:00
management, how to be going on production
process.
Week 5 To monitor daily production plan as per with 8:30 to 5:00
respect to customer requirement.

Week 6 I am learning to proper and clear communication 8:30 to 5:00

within departments.
To attend daily morning meeting and learn to
Week 7 initiate action with proper cause analysis. To take 8:30 to 5:00
lessons from daily rework/rejections/and its
analysis through quality tools.

Week 8 To monitor and maintain safety-PPE zero 8:30 to 5:00

accident on the shop floor.

32 | P a g e
MEPL, Nashik
 Week 9 To have knowledge about all the production
process, documentation filling, Android entries. 8:30 to 5:00
Week 10 To learn preventive maintenance of machines
and understanding cycle time of operation 8:30 to 5:00
running.
Week 11 Learn to maintain system and process 8:30 to 5:00
requirement through control plan, contingency
plan, process validation
Week 12 To ensure knowledge of SOP and control Plan 8.30 to 5.30

Table.1 Week wise work sheet

33 | P a g e
MEPL, Nashik
 Conclusion:

All production lines understand and how to be manufacturing rear floor,

back door, all customer requirement parts. I am also observed and tried. How
to handle the line and how to face situations for critical line manpower handling.
Then achieve a target for daily production. Understand for all line important
documents and hoe to fill the all documents after the shift over. Which types of
raw material used for manufacturing in the company and which company provide
raw material. Then which types of machines used for the manufacturing in the
company, and which position they are most important for parts manufacture.
Then understand the system of processor (SOP) and control plan (CP), These 2
documents are most important for this company. The company is well developed
and good for training to new apprentice. The facilities of company are good.

The company is well known for his low-cost products with good quality.
In future company has planned to start more plants. The motive of company is
to build the good society.

34 | P a g e
MEPL, Nashik
 References:

1. Bhandari, V.B. (2009), “Design of Machine element”, Tata McGraw-Hill

Education.

2. Khurmi, R.S. and Gupta, J.K. (2005), “A Textbook of Machine

Design”,Eurasia Publication House (P.V.T.) Ltd. 14th Edition.

3. A.Cowley and S. Hinduja, “The finite element method for machine tool

structural analysis.” Ann. CIRP 9, (1971), pp. 171

4. Under the guidance of mentor of Head Assist. Press Shop

Mr. Yogesh Gangurde and his Team of MEPL, Nashik

5. https//: mungigroup.com

35 | P a g e
MEPL, Nashik