Submitted by

Hansraj
Roll no. 14007170054
Mechanical engineering
Govt. polytechnic manesar,
Gurgaon
Acknowledgement
I Express My Deep Sense Of Gratitude To Caparo Maruti
Ltd. For Providing Me An Opportunity To Have My Summer Training
In Their Company In Weld & Press Department. I Am Highly
Thankful To Mr. Chander Singh Who Was Kind Enough To
Familiarize Me To The Plant Operation.
And I Am Also Very Much
Thankful From Bottom Of My Heart To My Parents. Without Their
Kindness It Could Have Never Ever Be Possible.
PRODUCTION DEPARTMENT
In production department metal sheets are given desired shape through stamping
process. Stamping press is use to produce stamping operation.
What is stamping press?
A stamping press is a machine that houses the stamping tools and carries them
around according to the kinematics indicated by the users.
The knowledge of the press used for a stamping operation provides us with useful
clues regarding:-
 Values and distribution of restraining forces.
 Tools deformation caused by stamping process.
 Contact and gap between tools and blank
However, we should recall that at, the moment when the die design is carried out,
the press is usually not yet known so that its characteristics are rather a factor
of noise than a useful information. Therefore it will be important to have a
design that is robust with respect to press type.
What is stamping tool? What is process design?
GLOSSARY:

Design surface part at designed to fit in the car

Blank holder surfaces that hold the blank

before the forming operation,
including the restraining

Production junction between the two

former surfaces.

Surfaces/run-offs protecting the design surface

and controlling material flow

Die face run- offs + blank holder

Welding department
Resistance welding is a welding process, in which work pieces are welded
due to a combination of a pressure applied to them and a localized heat
generated by high electric current flowing through the contact area of
the weld.
a) Spot welding (RSW)
 Spot welding is a resistance welding process in which two or more
overlapped metal sheets are joined by spot welds.
the method uses pointed copper electrodes providing passage of
electric current the electrodes also transmit pressure required for
formation of strong weld.
diameter of weld spot is in the range 1/8” – ½” (3-12mm).
spot welding is widely used in automotive industry for joining vehicle
body parts.
b) Resistance butt welding
Resistance butt welding is a resistance welding(RW) process, in which ends of wires or rods are
held under a pressure and heated by an electric current passing through the contact area and
producing a weld.
Quality control section
As the name suggests this section houses all sorts of tools and measuring instruments like vernier
calipers, vernier height gauge, slip gauges, surface plates, radius gauges, inside/outside micrometers,
depth gauges and hardness testing machines etc. For checking the components purchased from the
vendors from outside the firm before being stored into the store lying adjacent to this section.
The section monitors whether the components supplied by the allied vendor party covers the quality
specifications of the company or not and according takes corrective action as and when required. It
also keeps a track record of stock of components inside the store.
The quality policy of company can be quoted as :
 Producing world class tractors in quality and reliability.
 Total customer satisfaction through services.
 Creating a culture among all employed toward total quality concepts.
 Constant up gradation of technology and human excellence.
Quality improved steps followed by caparo:-
 5S
 Kaizen
 3R
 3M
 1 .5S
5s is the name of a workplace organization methodology that uses a list of five Japanese words which are
seiri,seiton,seiso,seiketsu and shitsuke.
English meaning of 5S
a) Sorting( seiri):
Eliminate all unnecessary tools, parts, and instructions. Go through the all tools
materials, and so forth in the plant and work area keep only essential items and eliminate what is not required,
prioritizing things per requirements and keeping them in easily- accessible places. Everything else is stored or
discarded.
b) Stabilize (seiton):-
There should be a place for everything and everything should be in its place. The place
for each items should be clearly labeled. Item should be arranged in a manner that promotes efficient work
flow, with equipment used most often being the most easily accessible. Worker should not have to bend
repetitively to access material.
c) Sweeping(seiso):
Clean the work space and all equipment, and keep it clean, tidy and organized at the
end of each shift, clean the work area and being sure everything is restored to its place. This makes it easy to
know what goes where and ensure that everything is where it belongs.
d) Standardizing(seiketsu)
Work Practices Should Consistent And Standardized. All Work Stations For A Particular Job Should Be
Identical. All Employees Doing The Same Job Should Be Able To Work In Any Station With The Same Tools
That Are In Same Location In Every Station.
E) Self-discipline(shitsuke)
Maintain And Review Standard. Once The Previous 4s’s Have Been Established They Become The New Way
To Operate. Maintain Focus On This New Way And Do Not Allow A Gradual Decline Back To The Old Ways.
While Thinking About The New Way, Also Be Thinking About Yet Better Ways.
2. Kaizen
Masaaki Imai Defined Kaizen As “A Mean Of Continuing Improvement In Personal Life ,Home Life, Social
Life And Working Life. At The Work Place, Kaizen Means Continuing Improvement Involved Everyone
Managers And Workers Alike. The Kaizen Business Strategy Involves Everyone In An Organization Working
Together To Make Improvement Without Large Capital Investment.
The Five Main Elements Of Kaizen:-
 Team Work
 Personal Discipline
 Improved Morale
 Quality Circles
 Suggestions For Improvement
3.3R:-
 Reduce, reuse, recycle, a hierarchy of waste management strategies
to minimize waste.
4. 3M:-
i. Muda
ii. Mura
iii. Muri
“Muda” meaning activity that is wasteful and doesn’t add value.
“Mura”, meaning “unevenness”
“Muri” meaning “overburdening”.
 Manufacturing of parts
For the manufacturing of the parts first of all the overview of the plant is given.
Different operations are performed during the manufacturing of the different
parts.The operations performed during the manufacturing of different parts. The
following processes are involved:-
(1) Press shop
(2) Welding shop
(3) Quality section
1. Press shop
During the press shop firstly the sheet of aluminums passes through
the different presses and perform different operation on it. The different
presses and different operations which are performed on sheet are:
the different kind of presses used in press shop is:
Type of press No. of.
800 tones 1
400 tones 2
The various operations are performed on the sheet during the press shop are

1. drawing
2. Trimming
3. Restrike
4. Punching
During the drawing the sheet can be passed through the press of 800 tones and the specific
shape of given part provided to the sheet and during trimming the extra part of the sheet which is not
in work can be trim by the press and the extra part can be thrown in the scrap. During the process of
restriking the die can be strike on the part again so that it can acquire the exact shape of the part and
the during the process of punching the different holes can be drawn according to the shape. Press
contains different parts such as:
1 cushion bed
2. Lower die
3. Upper die
The inner parts of a press which helps to support the die are:
i. Damping unit
ii. Air cylinder
iii. Lubrication system
Different parts of press:
1. Cushion bed
2. Lower die:

3. Upper die:
The different internal parts of press are:
a) Damping unit
b)Air cylinder:
c)Lubrication system:

Loader & unloader

Transfer Belt