INDUSTRIAL VISITS SEMINAR REPORT

1. REPORT ON INDUSTRIAL VISIT TO KERALA AGRO MACHINERY CORPORATION LIMITED.

1.1 INTRODUCTION
Kerala Agro Machinery Corporation Ltd. (KAMCO) was established in the year 1973 as a wholly owned subsidiary of Kerala Agro Industries Corporation Ltd. (KAIC), Trivandrum, for manufacture of agricultural machinery specifically Power Tillers and Diesel Engines. Subsequently KAMCO became a separate Govt. of Kerala undertaking in 1986. Paid up capital is Rs. 161 lakhs and the Present Net Worth of the Company is Rs. 6014.14 lakhs. Total work force at present is 567. Certified for ISO 9001 - 2000 version from September 2002.At present, KAMCO has four units, located at Athani and Kalamassery in Ernakulam District, at Kanjikode in Palakkad District, and at Mala, in Trichur district. With the present work force KAMCO can produce 15000 Power Tillers & 5000 Power Reapers per annum.

1.2 DESCRIPTION
KAMCO's manufacturing facilities include Special Purpose Machines, Specially built General Purpose Machines, and Imported machines. The inspection facilities include modern inspection &testing equipment .KAMCO is equipped with its own Metrology, Calibration & Engine Testing Lab. The following are the main activities of the company: Manufacturing and marketing of Agriculture machines such as Power Tillers, Tractors, Power Reaper, Diesel Engines etc. Power Tiller produced at Athani & Palakkad units. Major components for Power Tiller are manufactured at Athani and all other components bought out from dedicated Venders in India. There are around 250 vendors now. Kalamassery unit produces Engine for Power Tiller Power Reaper produced at Mala

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1.3 PRODUCTS
1.3.1 Diesel Engine Model ER90 KAMCO ER90 Engine is equipped with a radiator and specially designed die cast multi-blade axial fan. The engine can operate continuously for several hours. It can be used as a prime mover either for stationery or for moving application

Specifications
Type : Horizontal Water Cooled, 4 stroke Number of Cylinder : One Bore x Stroke (mm) : 95 x105 Displacement (cc) : 744 Compression Ratio Continuous rated : 20 Maximum output (HP/rpm) : 12/2000 Maximum torque (kg/rpm): 4.5/2000 Cooling System : Pressure Radiator type (0.8kg/cm natural convection) Lubricating Oil : SAE 30 Starting System : By hand cranking assisted by decompression system Cooling Water Capacity(Ltr): 3.8 Fuel Tank Capacity (Ltr) : 12 Crank Case Oil Capacity(Ltr): 3 Overall dimension (mm) : 820 x 512 x 640 Weight : 145 Kg. 1.3.2 Power Tiller IDI KMB200 KAMCO Power Tiller is a versatile machine primarily used for preparation of land for farming operations. With suitably designed accessories the machine can be used for a large number of specific operations like tilling, ploughing, weeding, pumping, leveling, hulling, ridging etc. Dept of Mechanical Engineering, PAACET

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Specifications Model : Engine: ER 90 Tiller KMB 200 Type : Rotary, diesel-powered, water-cooled, with radiator HP : Continuous: 9 Max : 12 RPM : 2000 Fuel consumption : 1.5 litres per hour Fuel tank capacity : 10.70 litres, No.of speeds : Forwards : 6 Reverse : 2 Tilling: 4 Wheel track : Maximum : 930 mm -Minimum : 690 mm Tyre size : 6.00 x 12 Ground clearance : 203 mm Travelling speed : 15 kmph (Max.) Tilling width: 600 mm Tilling depth : 190 mm No. of blades : 20 Tilling capacity : 1 hectare/8hrs. Overall dimensions: 2250 x 820 x 1030 mm Weight: 485 Kg Light Unit: 12 volts, 40 Watts Dept of Mechanical Engineering, PAACET

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1.4 FUNCTIONS OF THE TILLER MANUFACTURING UNIT

1.4.1. Purchase Department Purchase department ensures all raw materials, semi-finished components, fully finished components for production implements and accessories, consumables and subcontracted component are produced from approved vendors. Purchase department accesses vendor capability to affect supplier in accordance with purchase order meeting acceptable quality and deliveries so that they can be listed as approved vendors. The department ensures goods received from order. It also provides feedback to vendors for improving quality of materials. The department should have the responsibility to ensure the vendors performance is recorded, monitored and suitably graded. 1.4.2. Assembly Department The process is to identify the activities to be followed in assembly so that the assembly power reapers meet the specification. The scope of this process covers the assembly of power tillers and reapers with implant and bought out components. Assembly of power tiller is done in separate assembly lines engine lines, transmission line and tiller line. The process plans of assembly are annexed in each of these different lines and several working centres. These work centres are designated as line assemblies and for certain line assemblies there are sub assemblies too. There are three assembly lines, they are Engine line Transmission line Tiller line

After the production process, the next step is to paint power tiller and its components as per specified process. Pre-treated components and cleaned Power Tiller / Power Reaper engines are applied with one coat of primer and one coat of paint with approved colour is painting booths. Painting process adopted is we-on-wet system and solving enamel is used. Dept of Mechanical Engineering, PAACET

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1.4.3. Quality Assurance Department Quality assurance department at KAMCO ensures: Identification and traceability of all products both bought out and processed inside the plant are established at various stages of process. Identification of in-process materials and raw materials. Quality of bought out components. Quality of assembling process. Control of non-confirming products. For corrective actions, preventive actions, and continued improvement. Criteria for corrective and preventive actions by Quality Assurance Department. Quality of inspection and testing. Quality of maintenance and calibration of measuring instruments. Quality of data analysis

1.4.4. Stores Department The main purpose of the stores department is to spell out in detail how various items are protected and preserved at all stages. The procedure of stores department function is applicable to all areas where materials are handled and stored. The head of the department ensures the compliance to this procedure. Material Receipt: All materials including raw materials, components and production consumables received from different vendors directly through transporters along with dispatch notes are received. Received quality is entered and the item is submitted to quality assurance department for inspection with material tag. Issue of Materials: Raw materials for outside machinery, components and consumables for production, parts for subassembly are issued inconvenient batches against stock issue cum delivery note. Packaging: The finished engines dispatched to customers or dealers are packed in separate wooden box for avoiding damage during transit. The finished Dept of Mechanical Engineering, PAACET

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tillers and reapers including toolkit and manuals are dispatched to various far off destinations with a specially designed mounting frame to keep the tillers vertically down in order to accommodate more number of tillers in a single truck in which case oil and water are drained. Spare parts are packaged in polythene covers and put in wooden box or cardboard box for dispatch. 1.5 ACHIEVEMENTS The Tiller manufacturing facility at Athani, Ernakulum was visited. The objective of study was to familiarize an organizational environment and to get an idea about the functions of different departments. It helped me to given an immense knowledge about the day to day working of the company.

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INDUSTRIAL VISITS SEMINAR REPORT

2.TRAVANCORE TITANIUM PRODUCTS

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2.1.COMPANY DESCRIPTION
Travancore Titanium Products Ltd. was incorporated on 18th of December 1946, to produce pigment grade Titanium dioxide from ilmenite which is abundantly available as placer deposits on beaches near Kollam, 65 Kms north of the capital city, Thiruvananthapuram in the coastal state of Kerala, India. The unit was promoted by the then princely state of Travancore in collaboration with the British Titan Products (BTP) Company Limited, U.K.(now known as Tioxide Group Limited).The administrative control of the company was with a managing agency, Indian Titan Products Company. The Company which started production at a modest rate of 5 tonnes per day, increased its capacity in stages to the present level of 40-45 tonnes per day. Till recently, Travancore Titanium Products Ltd., was the only unit producing Anatase grade Titanium Dioxide pigment, in India.Travancore Titanium Products, became a State Public sector unit in 1960,with the Goverment of Kerala owning 80.94% of the shares. Production of titanium dioxide commenced in the year 1951,and the capacity was raised to 10 tonnes per day in 1960, the year in which the management of the Company was taken over by the Govt. of Kerala. The Company also installed its own sulphuric acid plant to produce acid for captive consumption. In 1963 the capacity of Titanium Dioxide produced was further increased to 18 tonnes per day wuth a commensurate addition to the sulphuric acid production also. Subsequently, a major expansion programme was undertaken and completed in 1973, increasing the realisable capacity to 45 tonnes per day of anatase grade TiO2. To meet the increased requirement of sulphuric acid, a third acid plant of 300 tonnes per day capacity was also put on stream. Subsequently, a modern sulphuric acid plant was commissioned in 1996, which utilizes the tail gas recycling DCDA (Double Catalysis Double Absorption) technology. The alkali scrubbing system incorporated therein helps to keep sulphur dioxide emissions well within permissible limits and helps in maintaining a clean environment. The total man-power employed at present is arround 1300. Dept of Mechanical Engineering, PAACET

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2.2.PROCESS
Ilmenite + Sulphuric Acid-> Titanyl Sulphate -> Hydrated Titanium Dioxide-> Titanium Dioxide

Travancore Titanium Products Limited is currently producing TiO2, antase grade, through the sulphate route. Ilmenite, a mixed oxide of titanium, ferrous iron and ferric iron is the main raw material for the production of titanium dioxide pigment.Ilmenite is reacted with sulfuric acid in reinforced cement concrete tanks called Digesters, lined with lead and acid resistant bricks. Exothermic reaction is initiated by the heat of dilution of the acid with water and a porous cake is formed. The mass in the solid form is dissolved in dilute sulphuric acid to get titanium in solution as titanium oxy sulphate (TiOSO4) along with other metallic ingredients in ilmenite as their sulphate. The liqour is reduced using scrap iron, when the ferric iron gets completly reduced to the ferrous state.

The resulting black liquor is clarified, concentrated and boiled by injecting steam to precipitate the titanium content as hydrated titania. The hydrated titania is filterd over drum type rotary vacuum filters. Any ferric iron still present is reduced to ferrous iron by leaching the pulp with dilute sulphuric acid. It is washed free of iron and other impurities and calcined in a rotary kiln is cooled in rotating coolers and deagglomerated in pendulum mills to very fine particles. The fine white powder is packed in 25kg HDPE bags.

2.3.PRODUCTS
2.3.1.RUTILE GRADE TITANIUMDIOXIDE Travancore Titanium Products Limited has recently launched a Rutile Grade Titanium dioxide pigment viz., TTP RD-01. This product wass developed in the year 2002

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indigenously through the Sulphate route pigment. TTP markets this product without surface treatment at very competitive price.

2.3.2.ANATASE (SPECIAL GRADE): This low phosphorous anatase grade is used in the manufacture of special quality welding rods, due to its insulating properties and high melting point. Composition: TiO2 P2O5 S 98 - 98.5% 0.1% (max.) 0.10 (max.)

2.3.3.ANATASE (GP): General purpose pigment is recommended for use in nondecorative paints, cement paints, distempers and rubber products. Composition: TiO2 ------ 97.5% (min.)

2.3.4.ANATASE (GR): This is non-milled granular type of commercial titanium dioxide, having excellent dry mixing and free-flowing properties. For use in vitreous enamel and metallurgical industries. Composition: TiO2 ------ 97.5% (aprox.) 2.3.5.ANATASE (ISI) : This is a pigmentary form of TiO2 having the following desirable properties:- High brightness, tinting strength, good colour, excellent dispersion charectoristics in both aqueous and non-aqueous media. Sutable for use in paints, paper,plastics, linoleum, rubber, leather finishes, soap and cosmetics and other applications. Composition: TiO2 97.5% (min.) Fe. 84 - 140 ppm. Specifications: IS 411:1991 2.3.6.POTASSIUM TITANATE: Potassium titanate possesses low thermal conductivity and high reflectance ranging from ultra-violet to infra-red region. Used in the manufacture of special quality welding rods, due to its high insulating property and high melting point. Composition: TiO2 K2O2 72 - 75% 17 - 20%

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2.3.7.SODIUM TITANATE: Sodium titanate finds use in fluxes for different types of welding electrodes. Composition: TiO2 Na2O 75 - 80% 15 - 18%

2.3.8.ANTASE (RG): Rayon grade anatase pigment with excellent dispersion properties for specific use in Rayons is extremely fine and free from over-size particles. it is used in de-lustring artificial fibre in textile industry. Composition: TiO2 Fe. Residue 97.5% (min.) 100 ppm 0.05 (max.)

2.3.9.TITANIUM DIOXIDE (ANATASE) : Titanium Dioxide is a brilliantly white, non-toxic pigment. The unique properties of Titanium Dioxide which make it supreme among the white pigments are its excellent opacity, extreme whiteness and chemical stability, which lead to considerable economy in usage, when compared to other white pigments. The titanium dioxide of our manufacture is marketed under the trade name of 'ANJATOX' and is available in four grades- ISI, RG, GP and GR.

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3.KERALA MINERALS AND METALS LTD

3.1.INTRODUCTION The history of the beaches of Sankarmangalam and nearby areas is inextricably intertwined with the history of the precious beaches and KMML. Precious, as was discovered in 1909 by the German scientist Dr. Schomberg who found traces of monazite in the sand flakes on the imported coir from Sankaramangalam. The beaches with a wealth of rare earth minerals became the centre of scientific attraction.

By 1932, a visionary private entrepreneur established the F. X. Perira and Sons (Travancore) Pvt. Ltd, the forerunner to KMML. During the course of time, KMML changed hands three times over. In 1956 it was taken over by the state government and was placed under the control of the industries department. The unit was subsequently converted as a limited company in 1972 by the name of The Kerala Minerals and Metals Ltd. with the following broad objectives. 1. Optimum utilization of mineral wealth found along the sea coast of Kollam Alappuzha Districts. 2. Large scale generation of employment in the state in general. 3. Overall growth and development of the local area in particular and the state in general. The construction of Titanium Dioxide Pigment using chloride technology started in 1979. The same was commissioned in 1984 as the first and only integrated Titanium Dioxide Plant in the world. Today, with over 2000 employees and a range of products, KMML has become part and parcel of local and international life.

3.2.KMML PRODUCTS KMML always maintains high standards of perfection, achieving technical excellence in every phase of production. Catering to strict guidelines, KMML offers a wide range of products for quality conscious customers. Their products go into the manufacture of a variety of products used in everyday life. Dress materials, facial creams, tablets,

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newsprints, wood paints, emulsions, enamels, plastics, tooth paste, rubber products, cosmetics, and printing ink All contain titanium dioxide.

3.3.THE PROCESS The Kerala Minerals and Metals Ltd (KMML) is the worlds first fully integrated Titanium Dioxide Plant. KMML is also Indias first and only manufacturer of Rutile Grade Titanium dioxide by chloride process.

Titanium dioxide (TiO2), also referred to as Titania, is a substance as old as the earth itself.

Titanium dioxide is readily mined in its purest form from beach sand. The beaches of Sankarmangalam and nearby areas in Kollam are inextricably intertwined with the history of this substance and KMML.

Dr. Schomberg, a German Scientist, discovered in 1909 traces of monazite in the sand flakes on the imported coir from Sankaramangalam. The beaches with a wealth of rare earth minerals became the centre of scientific attraction.

KMML is the worlds first fully integrated Titanium dioxide plant. Established in 1932 as F. X. Perira and Sons (Travancore) Pvt. Ltd., by a visionary private entrepreneur, it was taken over by the State Government in 1956, and became a public limited company in 1972 in the name The Kerala Minerals and Metals Ltd. (KMML).

Titanium Dioxide is essentially harvested from sea. The Mineral Separation Unit (MS Unit) of KMML is engaged in the separation of Ilmenite, Rutile, Leucoxone, Monazite, Silliminite etc from the beach sand. The MS Unit employs Gravitational, Magnetic & High Tension Electrostatic Techniques for separation of minerals from the sand.

Raw Ilmenite is chemically processed to remove impurities such as iron, leaving the pure, white pigment available for use.

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KMML is Indias first and only manufacturer of Rutile Grade Titanium dioxide by chloride process.

The chloride process produces TiO2 products by reacting titanium ores with chlorine gas.

The chlorides of impurity metals are removed from Titanium Tetra Chloride (TiCl4) through various processes to complete the recovery of TiCl4. It is further purified by distillation to obtain pure Titanium Tetra Chloride in the liquid form which is stored in storage vessels. Titanium Tetra Chloride is vaporized, pre heated and oxidized with oxygen in the Oxidation Plant to produce raw Titanium Dioxide at a high temperature.

Beneficiated Ilmenite (BI) is the raw material for the Pigment Production Plant. BI from Ilmenite Beneficiation Plant is chlorinated in the Chlorination Plant to produce Titanium Tetra Chloride (Tickle). Chlorine reacts with Titanium Dioxide and other metallic oxide impurities in BI in the presence of petroleum coke at a temperature of 9000C in a fluidised bed chlorinator to produce chlorides of Titanium and other impurity metals.

The raw Titanium Dioxide is then classified and surface treated with various chemicals, filtered and washed to remove the salts, sent to the dryer and then to the microniser, in the Pigment Surface Treatment & Finishing Plant. The Titanium Dioxide pigment (in powder form) is subsequently packed.

The plant uses recycling and regeneration methods at various levels of processing, including acid regeneration, which ensures negligent pollution. Responsible harvesting from the seas reaffirms our commitment to the environment.

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3.4.PROCESS CHART The Manufacturing Plant at KMML comprises the Mineral Separation (MS) Unit and the Titanium dioxide Pigment (TP) Unit. The MS Unit is where the separation of Ilmenite, Rutile, Leucoxone, Monazite, Silliminite etc from the beach sand takes place, through the various stages in the Wet Concentration Plant, Dryer Plant, Dry Mill, Rutile & Zircon Recovery Plants. The MS Unit employs Gravitational, Magnetic, High tension electrostatic techniques for separation of minerals from the sand. The TP Unit is where the raw Ilmenite obtained from the MS Unit is taken for further processing, through the various stages in the Ilmenite Beneficiation Plant, Acid Regeneration Plant, Pigment Production Plant, Oxygen Plant & Utility

Section. Titanium Dioxide is manufactured here using the chloride route.

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3.5.APPLICATIONS

KEMOX RC 822 from KMML is a multiple application pigment, which is in great demand in the world market. We also produce other grades of Titanium Dioxide pigments like RC 800 PG, RC 800, RC 802, RC 813, RC 822 and RC 808. Minerals like Zircon and Monazite are used in the development of Nuclear Technology. We manufacture Iron oxide bricks from the waste Iron Oxide, which is used for building purpose. The KMML Titanium pigments are reputed for their high degree of gloss, tint retention capacities and ease of dispersion.

Following are some of the major / common applications of the products that KMML manufactures:

TITANIUM DIOXIDE PIGMENT (RUTILE) Paints Printing Inks Plastic Paper Rubber Textiles Ceramics TITANIUM TETRA CHLORIDE Titanium Dioxide Pigment Titanium Dioxide Pigment Titanium salts Butyl Titanate Titanium Oxychlorides

LEUCOXENE Welding electrodes Titanium Dioxide pigment Titanium Tetra Chloride Titanium Compounds MONAZITE Rare earth industry Nuclear technology RUTILE Welding electrodes Titanium compounds Titanium Dioxide Pigment Titanium metal/sponge Titanium Tetra Chloride

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ILMENAITE Synthetic Rutile Titanium Tetra Chloride Ferro Titanium alloys Welding electronics Titanium Dioxide pigment Titanium salts SILLIMANITE High temperature refractory Ceramic industry

ZIRCON Ceramics Foundries Refractories Zirconium Chemicals Zirconium metals Nuclear technology IRON OXIDE BRICKS As building Material

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4.KERALA AUTOMOBILES
4.1. INTRODUCTION KAL incorporated in 1978 as a Government of Kerala undertaking, is set up 16 km south of TVM in Aralammoodu, in Neyyatinkara Ttaluk. It is a public sector automobile manufacturing company in Kerala, India. The company manufactures three wheels suitable for passengers and goods traffic. The prudent product range comprises of auto rickshaw, pickup, delivery van, local carriers etc. KAL is also manufacturing sophisticated components to be used in space programs of VSSC/ISRO. Since commencement in 1984, the company has manufactured and marketed more than 85,000 there wheelers. The company is ISO 9001:2000 certified.

4.2. PLANT LAYOUT

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The plant consists of an assembly unit, a fabrication unit, and workshop. The store room is placed near to Inspection and testing unit. The layout resembles to a process layout, but it also had the features of a line layout. But the machine in the plant placed according to the convenience of the workers.

4.3. PLANT DETAILS 4.3.1. MACHINE SHOP

The machine shop contains many machines for performing various operations. They include semi automatic and fully automatic machines. Some of the machines include: CNC Lathe

CNC Lathes CNC Milling Machines Drilling Machines Conventional Lathes Turret Lathe Capstan Lathe Grinding Machine Angular grinding Machine Power Hacksaw etc.

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4.3.2. OPERATION

These machines where used to perform a verity of operations. Some of them include:

Cutting Facing Drilling Turing Grinding Threading etc.

4.3.3. FABRICATION Fabrication when used as an industrial term, applies to the building of machines, structures and other equipment, by cutting, shaping and assembling components made from raw materials. The plant also contains a fabrication department. All the fabrication works were performed here. Some of the machines used for fabrication works include, Hydraulic Press Power Hacksaw Arc welding machine X-ray welding machine Sport welding machine Sheet forming machine. Etc.

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4.3.4. ASSEMBLY SECTION

The Kerala Automobile has got separate assembly unit, where the assembly operations are performed. This section mainly deals with the assembly of gearbox and gearbox-engine. The engine is fitted to the chassis and them to the drive mechanism. After this the body is assembled to the chassis. The electrification stage succeeds the above operations. The assembly operations were aided by following machines, Hoists, universal Toll kits, fixtures, painting booths.

4.3.5. QUALITY CONTROL

KAL uses computerized design system and testing equipment to ensure the international standards. Quality assurance achieved through satisfied quality control methods has helped KAL to achieved ISO 9001:2000 Certification. Verification inspection are done on each step of manufacturing and assembled to provide the required specification and stranded. This has been made possible using equipments such as Universal testing Machines, Dynamometers, Exhaust Analyzer, Digital Height Master, Eddy Current Tester etc. The QC system is designed to provide routine and consists checked to ensure data integrity, correctness and completeness. Qc activities includes general such as accuracy checks on data acquisition and calculation and the use of approved standardized procedure for emission activates include a planned system of review procedures conducted by personal not directly involved in the inventory development process.

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