Jk Report

INDUSTRIAL TRAINING REPORT 2013

AMITY UNIVERSITY RAJASTHAN DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL TRAINING REPORT ON “ rico auto industries pvt Ltd. ” A Summer Training Project Submitted in partial fulfilment for the requirements r equirements of the Summer Internship Programme 2013

Submitted By :

Student’s Name : J.Kartikean Student’s Enroll No : A20422411017 Semester : 5 Institution : AMITY SCHOOL OF ENGINEERING & TECHNOLOGY

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PREFACE

Currently I’m completing a Bachelor’s degree in Mechanical Engineering at Amity University Rajasthan in Rajasthan. Rajasthan. I’m in my 3rd year and therefore I have to conduct a 1 month internship. The reason I choose to do my internship here is because I wanted to benefit from the experience. Industrial Training refers to work experience that is relevant to professional development as an essential component in the development of the practical and professional skill required for an Engineer and an aid to prospective employment. The summer training is an ideal opportunity for the student to have a firsthand experience with the different function of the industry/corporate sector. It is famous saying that “ A Person who has read 1000’s of pages is not worth than the person who has travelled for 100’s of meters of meters ”

Teaching gives the knowledge of theoretical aspects of Engineering but implementation of theory gives practical knowledge of Engineering field. The aim of this training is to introduce the fundamentals and th e basi c prin ciples of va rious o perational fields in real real lif life. e. Prac Practi tica call Knowledge of theory is of greater importance for an Engineering student. This project report is an outline of what I have learnt during my training period at RICO AUTO INDUSTRIES runnin ing g with with PRIVATE LTD, one of the prest igious auto ancillaries s ector compan ies runn vario various us Hi-T Hi-Tech ech mach machine ines. s. I am ve r y th an k fu l t o RICO AUTO INDUSTRIES INDUSTRIES PRIVATE opport rtun unit ity y to work work and and Lear Learn n with with them them.. LTD fo r gi vi ng me s uc h a va lu ab le oppo

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ACKNOWLEDGEMENT

No ta sk is a sing le pe rson ef fo rt. Same is th e ca se with this proj ect. I wo ul d like to extend my sincere thanks to all those people who helped me in accomplishing this project. It has come out to be a sort of great pleasure and experience for me to work in the “QUALITY” Department. I wish to express my indebtedness to those who always helped me i.e. my mentor and senior of my Department my faculties MR. AMIT SHARMA , MR. LAXMAN KUMAR PANDEY & my mentor MR. PRASHANT SINGH during the preparation of the manual script of this text and for inputs given

to me both practically and theoretically to enhance my skills, knowledge and experience throughout my training. This would not have been made successful without their help and precious suggestions. Finally, I also warmly thank to all other senior professionals who encouraged me to an extent, which made the project successful.

Name of Member : J.Kartikean

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TABLE OF CONTENTS Chapter 1 : Introduction …………………………………………………………………….….. v

Chapter 2 : Company Profile & History.....................................................................................vi 2.1 Vision & Goal........ ............................................................................................ vi 2.2 Profile & history ................................................................................................ vi 2.3 Turnover.............................................................................................................. vi 2.4 Current Global Customers.......…………………………………………...…….vii 2.4.1 Two wheel.............................................................................................. vii 2.4.2 Passanger cars.......................................................................................... ix 2.4.3 System suppliers........................................................................................x 2.5 SWOT Analysis Chapter 3 : Manufacturing plant facilities............................................................................... x

Chapter 4 : Work Performed .................................................................................................... xv 5.2 Assembly ........................................................................................................... xv 5.2 Warranty.......................................................................................................... .. xv

Chapter 5 : Reflections ......................................................................................................... xxvii

Chapter 6 : Recommendation and Conclusion……………………………………..……..xxvii 7.1 Internship Experience Summary……………………….…….…………..xxvii 7.2 Recommendations For Company………………………….………………xxix 7.3 R ecommendations For University……………………………...…………xxix 7.4 Internship certificate...................................................................................xxix

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Chapter 1 INTRODUCTION

This industry indirectly has a lot of influence on country’s GDP as a very high proportion of low skilled labour is employed by this Industry. The total turnover of this Industry in FY 11 was $26 billions and export contributed $5 billion to this figure. There are 3 types of markets which the Industry caters to : 1. OE (Original Equipment ) ± Maruti , Honda ,escorts etc 2. Exports 3.After Sales The main advantage to the India Auto Ancillary Industry is the low Employee cost which is to the tune of 10-15 % of total cost whereas in Western countries , the figure revolves around 25-30 % . 

The project was conducted on mainly Ignition Lock Kit , all of which had Product and Clientele differentiation.



The project also tries to find out the defects and analysis of Ignition Lock Kits in the Company.



One of the analysis of part Indica Lock kit. has been analysed in detail and a Defect Analysis Report has been prepared for It and was concluded.

This project report is an outline of what I have learnt during my training period at RICO AUTO INDUSTRIES PRIVATE LTD, one of the prestigious auto ancillaries sector companies

running with various Hi-Tech machines. I am obliged to receive such a warm welcome and the treatment received during the whole course of my internship. There were many different personalities with different skills, qualificat ion, back gro u n d an d en o rmo us p ot ent i a l ta l ent . I wa s o ff er ed ass is t an c e at ev er y po ss ib le wa y an d gai ned an u nmat che d i ns ight an d ex p eri e n ce. The work culture promotes customer focus, strong work ethics, operational transparency and teamwork. Th e company has well balanced ratio of matured experienced as well as young dynamic workforce. I was assigned in the Quality department which consists of WARRANTY, CUSTOMER END SUPPORT, PDQA- Pre Dispatch Quality Audit. Though all the three departments were deeply understood, but Warranty was the one which gave me a lot of interest and the entire work period was dedicated to it. I learned all the aspects and ethics of warranty and the following report is prepared for my work in this department.

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Chapter 2 COMPANY PROFILE & HISTORY 2.1 Vision & Goal : Visions: To be the preferred supplier to Original Equipment Manufactures across the globe. Goal 1 / 11: “To be a US $ 1 billion Enterprise by 2011”

2.2 Company

Profile and History:

RICO AUTO is a dynamic world class engineering company supplying a broad range of high precision fully machined ferrous and aluminium components and assemblies to automotive OEM’s globally. RICO Group is to be defined as a corporate in commercial, organizational, and technical terms, which is a self contained unit in the System with its own master data and processes.

2.3 THE EARLY YEARS RICO Group was founded in the year 1977 with a ferrous foundry and a machining shop at Ludhiana under the present company name RICO Castings Ltd. In 1984, RICO diversifies into Aluminum high pressure Die Casting by setting up its plant at Dharuhera under the company RICO AUTO INDUSTRIES LTD. In 1992,RICO AUTO started its plant at Dharuhera. By installing Automatic High Pressure Moulding Ferrous Foundry and Machining shop. Subsequently the Aluminum High Pressure Die casting and Machining facility at Gurgaon, Rico soft tech LTD Gurgaon, RICO AUTO INDUSTRIES Inc USA; RICO AUTO INDUSTRIES (UK) LTD, UK were added to its fold in the year 2001, 2001, 2001 & 2004 respectively. RICO Group Companies Account Management, Logistics & Warehousing, Assembly Operations 1. Michigan USA 2. London UK Manufacturing Facilities in India 1. RICO (Dharuhera) – Aluminium Die Casting & Machining 2. RICO (Gurgaon) – Aluminium + Ferrous + Dies & Moulds, R&D, Testing & Validation, CAD CAM CAE 3. Joint Venture – FCC RICO (Manesar) – Clutches 4. Group Company – RCL vi | P a g e


(Ludhiana) – Ferrous Casting & Machining (Low Volume) 5. Group Company – RCL (Manesar) – Aluminum Casting & Machining (Small to Medium Size Parts) 6. Joint Venture – FCC Rico (Chakan Pune) + Planning New Plant RICO (Pune) 7. New Plant RICO (West Bengal) 8. New Plant RICO (Chennai)

2.4TURNOVER RICO Group’s Turnover 10 Times Over Last 10 Years (From 1997 to 2008) Manufacturing & Engineering Capabilities In the Aluminium division, the RICO AUTO INDUSTRIES LTD. has continued to establish its leadership in the high pressure die casting (HPDC). Today it is one of the largest HPDC companies with 76 HPDC machines (from 135 tns to 1800 tns locking force). Its efforts for developing complex and intricate components like high-pressure die cast Cylinder Block, along with its technology provider Teksid Aluminium are on track. During the year 2006-07 it started implementation of low pressure and gravity casting processes and commenced working on Cylinder Heads and Alloy Wheels. In the Ferrous division it has 4 moulding lines. During the year 2006-07 it successfully launched Ferrous Cylinder

Blocks for Maruti Suzuki. It also started supplies of complex turbine center

housing for Honeywell and launched new metallurgies used for higher temperature applications. It has set up casting capacity in advance and is working towards bringing value creating business for the same . PRODUCT RANGE Following are the major components, which are manufactured in RICO AUTO INDUSTRIES LTD.: -

For Motorcycle Parts

For Car Parts bu

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2.5 CURRENT GLOBAL CUSTOMERS

Two Wheelers









Passenger Cars













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



Commercial Vehicles













System Suppliers







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2.6 BUSINESS AND MARKETING STRATEGIES

To receive order from different automobile car/motorcycle companies. No retail / sale marketing by company and spare parts also supply to spare parts division of herohonda and maruti udhog etc.

2.7 GOVERNMENT POLICIES RELATED TO BUSINESS Legal requirement as per law. Registration with all government departments for legal obligations

like- excise, saletax, pollution, labour

department

etc. Benefit

policy

by

the

government like- saletax exemption by the government, tax incentive schmes, excise duty exemption etc.

2.8 TAX ASPECTS In case of manufacturer OEM (original equipment manufacturer) company concession rate of tax charged by the company against tax rebates used by the firms like- C-FORM, D-FORM in haryana.

2.9 SWOT ANALYSIS OF RICO AUTO INDUSTRIES PVT LTD.

STRENGTHS



Innovation



Optimum utilization of scare resources



Adaptability in relation to changing environment



Specialization physical assets by providing training and development program



Future visionary

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Perfection in work through cooperation and coordination within group or department as combined team. x|Page


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Growth and diversification and expansion of units through globalization



Amicable relationship with the shareholder.

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Regular dealing with the customers creates a strong bonding.

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Effective and efficient working of top and middle management through incorporation of SAP Software.

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Certificate honored by Worldwide Organization for, World class quality- ISO TS16949, ISO 14001, Total Productive Maintenance, Six Sigma.



At Rico, its people have always been its most valuable resource. It supports its people with continuous training and education facilities. There are 4129 employees including 1515 contractual employees in the company as on 31st March 2009. RICO’s IT Infrastructure has been keeping pace with the best in the industry. RICO has been successfully running SAP since the last two years.

WEAKNESSES



Computation in currency in relation to other economies of world.



Determining the level of material (minimum and maximum levels). Due to minimum level of material which leads to hurdle in production. On other hand, due to maximum level of material the funds are being blocked.



Same kind of material codes assigned to different material types (ROH and HALB) due to which valuation of material cost is being effect

OPPORTUNITES



The company sees opportunities both in the domestic markets and overseas markets with existing and new customers. To fully explore opportunities with all customers, the company has developed dedicated account teams to focus on each customer. The company has also

Company is implementing a strategic plan to build global scale and capabilities to meet the requirement of its existing as well as its new customers. In the year 2006-07

two Joint

Ventures have been signed, one with continental AG of Germany for Hydraulic Brake xi | P a g e


Systems and other with Jinfei of China for Aluminum Alloy Wheels, which would contribute towards growth & profitability of the company in the coming years. 

On the export front the Company has taken initiatives to develop new export markets for its products and services.

THREATS



The rising rate of interest is a matter of concern as it impacts the automotive demand for vehicles (two wheelers and passenger cars) and also the cost structure of auto component manufacturers.



Availability and cost of power is another area of concern for the industry .The company has been taking steps in this regard to improve both the availability and cost of power.

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Rising input costs and volatility in material is a challenge that impacts margins. The Company is pursuing appropriate indexation mechanisms with its customers, however there is always a lag effect.



The Indian Rupee appreciation vis-à-vis the US $ is an area of concern for exports. This impacts margin for export revenues

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China continues to be a challenge at a global level on account of its prices.

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The Company is exposed to strong competitive pressures both domestic and overseas.

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The Company is also exposed to financial risk from changes in interest rates, foreign exchange rates, and commodity price

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Chapter 3 MANUFACTURING PLANT FACILITIES RICO has a strong integrated production system with wide range of rugged, high speed automatic machines to achieve high level of accuracy of clutch parts. It’s facilities also include machines ranging from simple general purpose machines to specialized cnc machines,which are fine tuned to

meet

diverse

requirement

of

it’s

customers

All it’s equipments ensure a high level of consistency in operations, thereby giving them the much-needed

extra

edge

over

their

competitors.

The in-house manufacturing facilities, which are presently at. RICO are as follows:

3.1 PAPER BASE FACILITY – The paper base clutch friction Disc is made of heat – resistant cellulose, cotton fibers and copper wires moulded together. Cellulose is used to prolong life of the clutch and provide more torsional strength. Paper CFD has more life than cork base friction material as it possess :-



More heat resistant property.

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Low wear and tear characteristics.

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High endurance



Low warranties

To support the manufacturing of Paper Base Clutch Friction Disc they have brought a high tech customised machine that have been imported from Japan. In addition, other dedicated SPM small SPM machine are available to perform & support the different other operations of aforesaid machine.

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3.2 CORK BASE FACILITY – The cork base clutch friction Disc is made of heat – resistant, non-asbestos cork, cotton fibers and copper wires moulded together. Grooves are cut into the friction material to aid cooling and release of the clutch Disc. In some cases, rivets are used to bond the friction material to both sides of the metal body of the Disc.

To support manufacturing of cork material & Clutch Friction Disc we have lined up a set of SPM's to perform individual special processes. Some of the SPM include Kneeder, Roller, Presses, Moulding Machine & Deflashers.

3.3 CNC TURNING AND DRILLING – In order to maintain & sustain the accuracy of clutch parts, imported CNC machines are available to perform operations with highest degree of accuracy. There are SPM's available to perform repeated operations with same degree of accuracy.

3.4 PRESS SHOP e have established an inhouse pressing facility area where the critical parts of clutches like clutch plate & core plate are produced. These parts are subjected to severe quality tests & inspection so that there are no chances of any commulative error on clutch due to these parts. Some of the press facility includes :

Press -160 Ton



Grinder



Leveller



Sand Blast Machine



Washing Machine

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3.5 SHRINK FITTING – In four Wheeler clutch Assembly there is critical operation of assembly of flywheel and Ring Gear. The assembly is done on principle of heat contraction and expansion. This shrink fit SPM has been equipped with all the mechanism to perform this critical operation with same accuracy.

3.6 AssemblyRICO has modern Assembly lines. The emphasis is on Poka-Yoke implementation for defect prevention, lean manufacturing to ensure JIT, cycle time to match customer tact time. We are planning for effective automation and man in motion concept in Assembly lines.

3.7 Paint Shop Facilities : 

Illumination of 200 lux for better visual control



Temperature controlled environment



On line inspection facility

3.8 Design and Development : 

Fully integrated Design Cell.



FEA & Simulation support from dedicated suppliers & VECI.

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Rapid Prototyping Capability thru’ dedicated suppliers.

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Concept Design Capability (Black Box Design).

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Designing Software : 

PRO-E wild fire – 2



Catia V – 5 Workstation



Uni Graphics

3.9 Tool Manufacturing Facilities:

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Advanced in-house tool making capability.

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Di-edifice software for die casting tools.

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“Maho Deckel” CNC Milling Machine.

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“Charmills 290P” Wire Cutting Machine.

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“AGIE” Wire Cutting Machine.

3.10 QUALITY : Quality assuring activities start from supplier's quality system development to receipt of final products by the customers. To ensure these, the company has created a dedicated suppliers improvement cell, sample inspection cell and Incoming inspection facilities. Calibration activities, in process inspection and pre-dispatch quality audit are supported by Quality Planning Activities. An international level laboratory is installed to validate new products,undertake life testing of products and periodic endurance testing to maintain consistent product quality. Here environment and field simulated testing is also carried out.

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Chapter 4 WORK PERFORMED ASSEMBLY: 



Visiting the Assembly line. Identify the components of Assembly line .

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To study and understand functioning of automobiles.

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To identify each child part used in the assembly & its functioning.

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To understand the basic mechanism of Gears and clutch.

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To learn & identify the defects and able to rectify it.

Following components observed: 

Parts of gear.



Parts of clutch.



Parts of engine



Various die casting processes (HPDC & LPDC)

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Chapter 5 REFLECTIONS

REFLECTION ON PERSONAL DEVELOPMENT DURING INTERSHIP:

I set up goals halfway during my internship, to develop and improve areas that I find needed to be improved. The working areas I develop and improved in during my internship are the following:

Work effectively I want to learn how to work effectively. I have achieved this halfway my internship

by working and using a to-do list. This to-do-list that my seniors were assigning throughout the day. The to-do-list existed of work that needed to be done first and had more priority than other daily tasks.

Work precisely I want to work more precisely. At the beginning of my internship, I noticed that there

are lots of mistakes found in my work. Mistakes in calculating and analysing but also in delivering work that is not finished. Halfway my internship, I have improved in this area by reading, listening and focusing better on my work.

Improve my communication I want to improve my communication skills. At the beginning of my internship, I

realized that I didn’t communicate often. This is because I was at the time unsecure about my Inferiority. Halfway my internship I have improved this by communicating more with the interns that I have worked with and talking to them about all kind different subjects.

More initiative I want to show more initiative during internships. At the beginning I had trouble

getting involved in the assembly line process. This is because I wasn’t aware of how the process was conducted and I didn’t have all the background information of it. Halfway my internship I have

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improved in this area by getting more involved and becoming more aware on how the production line is conducted.

Chapter 6 RECOMMENDATION AND CONCLUSION INTERNSHIP EXPERIENCE SUMMARY The past months of my internship have been very instructive for me. RICO has offered me opportunities to learn and develop myself in many areas. I gained a lot of experience, especially in the Die casting field. A lot of the tasks and activities that I have worked on during my internship are familiar with what I’m studying at the moment. I worked in many areas where I did different work. This gave me the chance to find out which areas I want work in after my education. The area that I found most interesting is Quality control. By developing a warrant analysis sheet, I had to do lots of research where I had to find the best way of finding the defect. I learned many things about Quality control by using and learning about QC tools.

Before my internship started my ideas did not match the experiences that i have gained during my internship. There is a big difference in the college projects and the tasks and activities during the actual work. In college we learn how to describe the work in projects, where in work you learn how to implement them in reality. This internship was definitely an introduction to the actual work field for me. I have learned to work in a business organisation and apply my knowledge into practice. I learned a lot from the different interns that I have been working with during my internship. Each intern had a different educational background and that made it interesting for me. By working with them I got to learn from them and become aware educational background. My mentor during my internship was Mr.Prashant Singh who I have also learned a lot from during my internship. He has also lots of knowledge in the working area that I have described such as Quality control, Customer End approach. He was very helpful and always willing to give me advice and feedback which I appreciate. I have tried to learn as much as possible from him and the interns during my internship. The conversation through group discussions with him and other members of operation department is also an important learning moment for me during my internship. He had always time to answer all my questions concerning my internship.

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I had fun following my internship at RICO . I learned a lot about the areas Warranty, PDQA, Customer end support. Interning at RICO was definitely a learning experience. The most interesting event that I have attended during my internship a live project by attending the customer end and then analysing the problem and rectifying the problem along with my mentor by the various process solving steps I have learned.

I really enjoyed attending this event and was definitely experience to remember. This internship was definitely beneficial for me and I’m grateful and thankful that I got to experience and learn many things.

RECOMMENDATIONS FOR THE INTERNSHIP COMPANY RICO is a great learning company for interns. RICO is a MidCap company and helps interns improve and develops their skills. I would recommend RICO to keep hiring interns with different educational background, to help build and improve the company with the knowledge they gained from their studies.

RECOMMENDATIONS FOR THE UNIVERSITY Now after following an internship where analysing through the Quality control tools is important. I realize the how important is this for any business organization to maintain their quality of products. Luckily, I have followed internship where I learned the basic knowledge of Quality department through quality control tools. Unfortunately the education system does not encourage such deep study of this subject to the students with practical knowledge. I am suggesting introducing of the Industrial friendly management education. With technology of today and development of new technology managerial study

is the future in

engineering department. That is why the Advanced Managerial education has to be implemented, teaching the students more about actual industrial experiences.

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