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Report by :
Sufian Jawed
Roll no: 115746
Department of Mechanical Engineering
Heritage Institute of Techonology.




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Certification by company
This is to certify that Mr. Sufian Jawed ,Roll no-115746,Department of
Mechanical Engineering ,Heritage Institute of Technology ,has undergone
vocational training under my guidance in Patton International Ltd, production
shop at Garia works for a period of 4 week from 20.06.2014 to 18.06.2014 .





Mr.B.R.Mohanty
Sr. Work Manager
PATTON INTERNATIONAL LIMITED (GARIA WORKS)
572 GARIA MAIN ROAD
KOLKATA - 700084
W. B.
GARIA








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aCKNOWLEDGEMENT :
I would like to thank Patton International Ltd. , for giving me the opportunity to
undergo vocational training at Patton International , Garia works , particularly Mr.
B.R. Mohanty , my training officer and works manager ,who has been my guide
and has helped me with understanding all processes and operations which I
needed to know.
I would like to express my gratitude towards
Mr. R .P. Mondal,
Mr. Sanjib Adak,
Mr. Ayan Banerjee( assistant production manager),
Mr. Bikram Chakraborty,
Mr. Kashinath Samajder,
Mr. Swapan Guha,
Mr. Anupam Kumar,
Mr. S.K.Patra, who had given me the necessary information without which I could
not have completed this report and my training.


Sufian Jawed
Roll no-115746
Dept. of Mechanical Engineering
Heritage Institute of Technology




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TABLE OF CONTENTS :-

Company History
Raw Materials
Production Zone
i. Punching Section
ii. Tapping Section
The Electroplating Department
The CNC Department
Tool Room
Assembly and Packaging
Safety in Manufacturing Industries








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HISTORY OF PATTON INTERNATIONAL LTD.:-
PATTON a Govt. Recognised Export House is an ISO 9001:2008 company and a
premier manufacturer and Star Exporter of Steel Stampings and EMT Fittings of
International quality. It is also a leader in the field of plastic tanks, containers and
PVC pipes, having state-of-the-art manufacturing facilities at various locations in
West Bengal, India. PATTON products have received wide acceptance and acclaim
in the international market. PATTON is a consecutive Winner of Productivity
Awards, FIE Award and recipient of National Awards both from the President and
the Prime Minister of India.
The Patton Promise
PATTON is a Govt. Recognised Export House and a Star Exporter.
PATTON is an ISO 9001:2008 company and a premier manufacturer of Steel
Stampings and EMT Fitting Products as per International quality standards.
A leader in the field of plastic tanks, containers and PVC pipes.
Has 5 sophisticated state of the art multilocational plants in West Bengal,
India spread over 500,000 sq ft equipped with machineries mostly imported
from USA, Germany and Taiwan.
Long and credible history of supplying to major OEMs which itself speaks
of our commitment to Quality and On-Time delivery.
Highest Credit Ranking from our bankers and funding capacity for any
expansion program.
A 100% debt free company.
In house tube mill for captive consumption to reduce raw material
procurement lead time and critical stock out situations.
Extensive In-house product development capacity along with state-of-the-
art plating plant and UL certified mechanical testing laboratory.



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A Customs-Trade Partnership against Terrorism (C-TPAT) compliant
company with close proximity to Kolkata Port and Haldia Port which gives
us better logistic convenience.
Our portfolio of products include sophisticated products like precision
electrical stampings, industrial fasteners, builders hardware, EMT fittings,
pressed steel and plastic water tanks, material handling containers, PUF
insulated boxes, PVC pipes, industrial pallets etc.
Recipient of string of Export Excellence Awards.


Exporting Excellence:-
PATTONs core competence is in its quality which is very well accepted in
International markets.
Products are listed.
Own in-house UL approved lab for mechanical testing.
Quality Control at Raw material procurement, In-process and Packaging
stage ensures defect-free products.
In-house Tool development facility provides for customized products.
Regular Kaizen projects ensure continuous improvement in all factories.
Regular training and small group activities on 5S and 3M practices.
Periodic Internal Audits to ensure continuous improvement.



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locknut nail
c-clamp
Hanger
I BEAM CLAMP

TWO HOLE STRAP
ONE HOLE STRAP




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RAW MATERIALS
The steel authority of India limited (SAIL) is the supplier of raw materials to Patton
international limited,Garia.
The initial raw materials is purchased in the form of the coil of width 1260mm,and
thickness as per demand(range 0.8-12.5mm).such coils of raw materials are
known as mother coil. The large width(i.e 1260mm) of the mother coil is not
suitable from a processing point of view as well as undesirable to meet product
demands.So the width of the mother coil is to be cut down to desired width to
satisfy above requirements. After purchasing from SAIL, the coil is sent to
companies such as Sri Ram enterprises (S.R.E), Sri Ome Enterprise (S.O.E) and
Bharat Steel (B.S) for this purpose. After cutting the coils down to desired size in
the above mentioned companies,finally the raw materials in the form of coils of
desired width and thickness comes to the PATTON manufacturing plant.
The types of raw materials that arrive in the manufacturing plant from SAIL after
cutting down to desired width are basically steel,aluminium and galvanized
iron.The steel comes in two different types
i. COLD ROLLED STEEL (C.R steel)
ii. HOT ROLLED STEEL ( H.R steel)

C.R. STEEL(IS 513 Gr-O):-
The cold rolled steel come as coils, as stated above,whose thickness varies from
1.2mm 2.3 mm.This feature is used for quick visual identification. The
composition of cold rolled steel should be as follows:
Carbon [C] 0.15% max
Manganese [ Mn] 0.6% max
Phosphorus [ P] 0.05% max
Sulphur [S]-0.03% max



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Silicon [Si] 0.03% min
Aluminium [Al] 0.01 % min
The hardness has to be 63 (max) as measured in the B scale of Rockwell hardness
testing machine.
H.R.STEEL ( IS 10748 Gr-2):-
Similarly the hot rolled steel comes as coils with thickness ranging from 2.5mm
12.5mm.As per standards the composition of the H.R coils has to satisfy the
following conditions:
Carbon [C] 0.12% max
Manganese [Mn] 0.6% max
Phosphorus [P] 0.04% max
Sulphur [S] 0.04% max
Silicon [ Si] 0.10% min
The hardness of hot rolled steel coils should be in the range of 63-80 as measured
in the B scale of Rockwell hardness testing machine.
Galvanized IRON :-
The coils which are made of galvanized iron range in thickness from 0.8mm to
1mm.
Galvanized Iron is composition of Iron + Carbon to get steel and then steel is
coated with Zinc. So Iron+Carbon alloy + Zinc) is Galvanized iron.Galvanized iron is
iron which has been coated in a layer of zinc to help the metal resist corrosion.
Steel can also be galvanized. When metal is going to be used in an environment
where corrosion is likely, it is often galvanized so that it will be able to withstand
the conditions. Even with galvanization, however, corrosion will eventually start
to occur, especially if conditions are acidic.
There are two primary techniques which can be used to make galvanized iron.
The most common is hot-dip galvanization, in which the iron is moved through an
extremely hot bath of molten zinc, which may be mixed with small amounts of
lead, depending on the circumstances. When the iron emerges from the bath, the



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zinc will have bonded, creating a layer of zinc on the surface of the iron.
Sometimes, the metal may be passed through a mill to flatten and even out the
coating. Another technique which can be used is electrode position, also knownas
electroplating, although this is rare.

Aluminium:-The raw materials made of aluminium do not come as coils but in
the form of sheets.The sheets come in thicknesses of:
a. 1.6mm ( comes in small quantities)
b. 4.3mm (comes in maximum quantities)
Apart from the above two thicknesses,the sheets also come in thicknesses of
6mm and 10mm.
Raw Material INSPECTION:-
The supervisor of raw materials performs the job of testing the arrived coils to
check whether they comply with standards and the Test Certificate.The Test
Certificate is a data chart,issued by SAIL,containing all the relevant data regarding
hardness,composition etc. of the raw materials.Each type of raw material has its
own test certificate.The supervisor performs the following inspections of the raw
materials (coils and sheets) that have arrived at the plant:
a. Chemical Inspection It is done to check whether the chemical composition
of the raw material coils(H.R and C.R) are within prescribed limits as stated
in the Test Certificate.
b. Thickness The raw material supervisor also measures the thickness of the
coils and the sheets by using micrometer to check whether the dimension is
as required or not.
c. Width The width of the coils is also checked by a vernier caliper in order
to ensure that it is close to ( or equal to) as desired.
d. Surface Roughness- A visual inspection of the raw material surface is made
to check if the surface is too uneven or rough.
e. Hardness The hardness of the raw material is tested in Rockwell hardness
testing machine make sure the hardness is as expected.



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I. B scale is used to measure the hardness of raw materials.
II. C scale is used to measure the hardness of the die and punch of the
punching machine.
Finally, after inspection is made,the supervisor puts tags on the coils,which have
successfully passed the inspection process, indicating their characteristics ( such
as thickness etc.).
After this entire procedure is completed,the coils are sent to the production zone.

H.R COILS






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PRODUCTION ZONE:-
The products which are manufactured in the production zone are classified into
two categories :-
a. LOCKNUT
b. Other products i. Hanger
ii. One hole strap
iii. Two hole strap
iv. Nail
v. Beam clamp
vi. Compression connector
vii. Compression coupling
The production manager controls all the operations in the production zone. After
receiving the raw materials from the store, he makes calculations as to how long
will be required to manufacture the desired quantity of products.Subsequently,
he divides the production into different machines and employs labourers to finish
the job in desired time.
The machines used for production in this plant are as follows:-
a. Punching Press
b. Tapping machine ( Special purpose)
c. CNC lathe
PUNCHING PRESS :-
One of the most important machines in this plant is the PUNCHING PRESS
machine. It plays a vital role in the production of locknuts as well as in the
production of other products like hanger ,straps and nails.The punching machines
present in this factory are of two types:-



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i. Pneumatic Punching press
ii. Manual Punching press
The punching presses come in capacities of 63tons, 100 tons, 250 tons and 350
tons (maximum).The press of 63 ton capacity is used when the raw material
thickness is 1.2mm-1.8mm.The presses of 100 ton capacity are used for
production when the raw material thickness is 2mm.The pressesof the highest
capacity ( 350 ton) are used when the raw material thickness range from 10mm
12.5mm.
PNEUMATIC PUNCHING PRESS:-These machines are a category of
automatic machines which require very little or no human intervention during
production.The word pneumatic is used to specify these machines as the
feeding operation of raw material into the machine is done pneumatically.
Different Mechanisms in the Punching press:-
i. Decoiler:-The initial raw material, which is in the form of a coil is
placed in the decoiler.the basic purpose of the decoiler is to unroll and
straighten the coiled raw material and supply it to the feeder.The
working principle of the decoiler is as follows : as the feeder pulls the
coil it passes through the decoiler and the portion of the coil already
between the feeder and the decoiler straightens and tends to lift up.A
lever is placed over this portion.As it tends to lift up the lever also moves
up.The other end of the lever contacts a limit switch in the process.As
soon as the limit switch is contacted by the lever ,the circuit supplying
current to a motor is closed.Hence the motor starts and through a
mechanism of bevel gears.chain drives.V-belt drives the rotation is
transferred to the coil-straightening rollers which pull the raw material
through it and supplies it to the feeder.When the feeder doesnot pull
the coil the portion of straightened raw material between the decoiler
and feeder falls to the ground(no tendency to lift up);consequently the
lever moves down and contact with the limit switch is broken and
thereby the circuit is made open.Hence the motor stops.



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ii. Feeder:-The feeder is a device which is present in the pneumatic
punching presses and not in the manual presses. It basic purpose is to
supply or feed the raw material between the punch - die. It functions
through the co-ordinated action of a cam-shaft, a pneumatic circuit
consisting of single acting cylinders ( actuator) and solenoid operated
Direction Control valves. The cam controls the timing when the feeder
will feed the coil so that feeding and punching does not occur together.
iii. Slider-crank mechanism:-
The initial power is derived from a motor of capacity about 7.5 kw. The
rotation from the motor-shaft pulley is transferred to another pulley
through a V-belt.This large pulley is placed on a shaft on which another
small gear is mounted.This smaller gear in turn is connected to a large
gear which functions as a flywheel and drives the crank.The rotation of
the crank is converted to a linear reciprocrating motion of the
piston(ram) at the front of which the punch is attached.

In manual presses there is another mechanism by which the flywheel keeps on
rotating but the crank rotates only when the operator desires; otherwise
remains stationary.This is achieved by means of a pedal-key mechanism.There
is a foot pedal near the operators foot by pressing which,through a lever
mechanism,he can operate a spring loaded key which is used to establish
connection between flywheel and crank when rotation is desired.When the
operator leaves the pedal the connection between crank and flywheel is
broken and the crank stops rotating.But the flywheel continues to rotate.


PUNCHING PRESS MACHINE :-
Mechanism of delivering power to the ram, two types of punching machine
give below in figure:-



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16





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LOCK NUT:-
A locknut, also known as a lock nut, locking nut, prevailing torque nut,stiff nut or
elastic stop nut, is a nut that resists loosening under vibrations and torque. Elastic
stop nuts and prevailing torque nuts are of the particular type where some
portion of the nut deforms elastically to provide a locking action. The first type
used fiber instead of nylon and was invented in 1931.Locknuts , jam nuts, lock
washers, and thread-locking fluid are ways to prevent vibration from loosening a
bolted joint.
The major product manufactured in PATTON International Ltd.,Garia, is the
Locknut.Having more than 75% of market share in the stamped locknut market,
PATTON is already catering to most locknut requirements in all varieties. For the
past 25 years we have been continuously serving the electrical trade needs,
gearing up to any quantity requirements asked for.
PATTON has a well equipped, modern press shop with Press machines upto 800
tons capacity. These Presses are run with multi cavity Progressive toolings and
high speed pneumatic feeders for continuous operation. An In-house tool room
enables sufficient tooling to ensure continuous round the clock production and to
meet customer specified requirements. Over 50 numbers of bent-axis tapping
machines are specially designed to handle large volume locknut tapping
requirements.
We manufacture all sizes of Locknuts from stamped steel and are the pioneers in
manufacturing 5 and 6 locknuts.
PATTON is proud to be the One-Stop Shop for full range of locknuts:-
Steel Regular (Non UL)
Steel UL (Heavy and Light)
Steel Sealing (UL)
Steel Extruded
Steel Grounding (Regular and UL)
Aluminium Locknut (Regular and UL).



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There are two types of locknut
which are produced in the plant. One type is the Non-UL locknut while the other
type is known as the UL locknut.The difference between these two types is that in
the former , the thickness of zinc coating after electroplating is only about 4
m;while that of the latter is about 13m.That is why the Non-UL product is less
expensive compared to UL product . In UL locknuts, the letters UL are printed
on the outer surface of the locknut while there is no such provision in case of
Non-UL locknuts.
The locknut is manufactured through the following process in a press machine :
Firstly after the feeder feeds the raw material to the die,the first set of punches
embosses on the raw material against the prints made on the die to create the
different markings on the locknut surface (size in inches, UL, company name,
Patton etc). Then the second set of punches accomplish the piercing operations
whereby holes are made in the incoming raw material.Finally, the last set of
punches make the blanking operation.These punches are provided with a small
projection upfront which is known as the pilot.The function of this pilot is to hold
the pierced holes centrally to avoid eccentric punching during blanking. So after
these pilots hold the pierced holes the blanking punch strikes the raw material
against the die ( where holes of desired shapes are made) and the blanked out
portion (the Locknut)passes through the tapered hole in the die and collects at
the bottom in a container.The tapered hole is provided in the die for easy removal
of the blanked out portion ( locknut) so that this exit passage is not jammed.



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UL LOCKNUT
LOCKNUT WITH PVC SEAL




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The production supervisor performs the job of inspection during the ongoing
locknut manufacturing process.Inspection is of two types-First off inspection and
Sampling inspection.First off inspection is conducted by the supervisor a little
after the production starts where the supervisor picks up a few manufactured
locknuts and checks whether they are as per drawing meeting customer
requirements.If not he immediately reports to the production manager, who
stops the production process or else production is continued.Sampling inspection
is the process by which the supervisor performs the inspection process after every
3-4hrs by picking up a few samples of manufactured locknut to check the
dimensions,presence of burrs etc.
The Locknuts thus manufactured in the production zone are now brought into
another zone known as the Tapping Zone.

THE TAPPING SECTION:-
The word tapping usually means cutting of threads.Threads are cut on the inner
surface of the locknuts in the tapping section.To serve this purpose specially
designed machines have been brought into the plant. These machines are called
Special Purpose Tapping Machines.
The tapping supervisor makes calculations as to how many tapping machines
should run simultaneously to produce the required quantity of threaded locknuts
within desired time.The locknuts of large thickness are commonly called Heavy
gauge locknuts.Similarly those of smaller thickness are called Light gauge
locknuts.
The mechanism of tapping is described as follows: There is a motor from which
power is supplied to a pump and through a system of bevel gears to the chuck
holding the cutting tool.The pump performs the function of pumping the lubricant
from a tank located below the machine to the metal cutting zone where thread
cutting occurs.The tap or the cutting tool is held in a device called the mandle
which in turn is fitted in the chuck.There is also a fixture or another chuck for



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holding the job.Here the job consists of a number of locknuts.The number is large
if locknut thickness is small and vice versa.The operator of the machine puts in a
number of locknuts in the job holding fixture and manually by turning a lever and
in turn a pinion over a rack brings the job holding fixture towards the tap.The tap
is made of HSS and is selected based on the thread pitch that is to be formed on
the locknut inner surface.After thread formation of the locknut, the operator
removes the chips accumulated in the metal cutting zone and then manually
removes the thus manufactured threaded locknuts by turning the lever and
pinion over the rack an bringing the job holding device along with the threaded
locknuts away from the tap.Sometimes if the locknut thickness is small enough
then the threaded locknuts,after manufacturing are pushed through by the
operator to pass them through a channel after which they are collected in a
container.
INSPECTION in the Tapping zone:-
The tapping supervisor also performs the job of First-off inspection and Sampling
inspection. Here the process of inspection involves the usage of two gauges
i. GO-gauge and NO GO-gauge
ii. PLUG gauge
The GO and NO GO gauges are collectively sometimes known as thread plug
gauges. Different GO and NO GO gauges are available depending on locknut size.
A threaded locknut if pass through the GO and gets jammed in the NO-GO easily
then that locknut is as per specifications and is accepted.If any of the above
conditions is not satisfied then that locknut is rejected.However locknuts of
higher thickness ( 6mm, 10mm ) are threaded during tapping in such a way that
even the NO-GO remains free along with the GO- gauge.The reason behind this is
that thicker and heavier locknuts are employed in heavy works;as such they
require greater zinc thickness during electroplating to avoid corrosion rusting
etc.So after electroplating to a greater zinc thickness it will not pass through the
NO-GO gauge thereby meeting product requirements.
The plug gauge is a stepped gauge of varying diametres as per specifications.It is
used to check whether the inner (hole) diameter of the locknut is within limit.If



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the locknut of a certain size plugs(jams) against the corresponding size(which
gives the maximum limit of locknut hole diameter) in the plug gauge then the
product is satisfactory and is accepted. The tap ( cutting tool) pitch is sometimes
checked by a device called Floating Carriage Micrometer.
After a lot production is completed,the inspection is carried out by the QUALITY
DEPARTMENT whereby they check burrs, surface roughness, dimension, gauge
passing, ear lift dimension, tab length etc to stamp the product as acceptable or
not.If accepted,then the threaded locknut goes to the ELECTROPLATING SECTION
from the TAPPING SECTION.





THE PLATING SECTION:
WHAT IS ELECTROPLATING?
Electroplating is a process that uses electrical current to reduce dissolved
metal cations so that they form a coherent metal coating on an electrode. The



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term is also used for electrical oxidation of anions onto a solid substrate, as in the
formation silver chloride on silver wire to make silver/silver-chloride electrodes.
Electroplating is primarily used to change the surface properties of an object
(e.g. abrasion and wear resistance, corrosion protection, lubricity, aesthetic
qualities, etc.), but may also be used to build up thickness on undersized parts or
to form objects by electroforming.
The process used in electroplating is called electrodeposition. It is analogous to
a galvanic cell acting in reverse. The part to be plated is the cathode of the circuit.
In one technique, the anode is made of the metal to be plated on the part. Both
components are immersed in a solution called an electrolyte containing one or
more dissolved metal salts as well as other ions that permit the flow of electricity.
A power supply supplies a direct current to the anode, oxidizing the metal atoms
that comprise it and allowing them to dissolve in the solution. At the cathode, the
dissolved metal ions in the electrolyte solution are reduced at the interface
between the solution and the cathode, such that they "plate out" onto the
cathode. The rate at which the anode is dissolved is equal to the rate at which the
cathode is plated, vis-a-vis the current flowing through the circuit. In this manner,
the ions in the electrolyte bath are continuously replenished by the anode.
Other electroplating processes may use a non-consumable anode such as lead or
carbon. In these techniques, ions of the metal to be plated must be periodically
replenished in the bath as they are drawn out of the solution. The most common
form of electroplating is used for creating coins such as pennies, which are
small zinc plates covered in a layer of copper.


THE PROCESS OF ELECTROPLATING LOCKNUTS AND THE
OTHER PRODUCTS:
The plating process to which the locknuts and all the other products are subjected
to is basically the same. The entire plating procedure is divided into two sets of
processes:



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a. The first set of processes are collectively called the CLEANING PROCEDURE.
b. The second set of processes are collectively called the PLATING
PROCEDURE.
THE CLEANING PROCESS :The locknuts ,produced after punching and
tapping , and the other products ( hangers, straps etc) , produced after punching
process ( as they do not require threading ) are sent directly to the plating
section. These products first go through the cleaning procedure.
Firstly, products of similar kind are grouped together and are placed in a barrel
(whose surface is porous).Then through a overhead lifting crane the barrel is lifted
up and placed in the first chamber of the cleaning zone where there is dilute
solution comprising caustic soda and water .The purpose of this chamber is to dry
the oil present on the surface of the products. Then the barrel is again lifted up by
the overhead crane and placed in the second chamber. Here there is a
concentrated solution of caustic soda and water. Here electric current is passed
through the solution by creating a polarity and thus a magnetic field is created.
The positive terminal of the supply is connected to the barrel while the negative
terminal of the supply is connected to the surrounding plates which are kept
dipped in the solution .Thus due to this positive-negative polarity electric current
and hence a magnetic field is created which pulls magnetic particles, like iron,
from the product surface(iron is present due to rusting of product surface) and
deposits them on the surrounding plates. After removal of these magnetic
particles, again the barrel is brought in a third chamber where there is simple
water for further washing of the products within the barrel. Finally the barrel is
brought in a fourth chamber where there is a dilute acid solution ( HCl + water).
HCl and water react to produce hydrogen which is passed through exit pipes
provided so that it does not accumulate within the plant and cause harm. The Cl
-
ion which is present in the solution reacts with metallic positive ions present on
the product surface thus dissolving metal from the product surface so that the
plating is better. The surface is also smoothened. However this also reduces the
product thickness; so the barrel is not kept in this chamber for more than 10mins.
Hereafter, the barrel is again placed in a fresh water chamber for final washing.
Finally the barrel is lifted by the overhead crane and brought to the plating
chambers.



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THE PLATING PROCESS :
Here, there are a number of chambers,containing zinc solution, side by side. The
barrel is place in any one of these chambers. These chambers contain zinc plates
dipped into solution which serves as the anode. These plates are connected to the
positive terminal of the power supply and serve as the anode. Apart from this,
these chambers also contain potassium chloride , boric acid etc. Specific voltage,
pH and temperature has to be maintained in these chambers for proper plating .
The Cl

ions present in solution react with zinc plate to form ZnCl2 where from
Zn
+2
ions come in solution and are attracted towards the negative cathode which
is actually the barrel, connected to the negative terminal of the power supply.
Thus on migrating towards cathode the zinc ion accepts electrons and get
deposited on the surface of the products. Thus zinc plating is accomplished. This
process is continued until plating of desire thickness is achieved.
Thereafter, the barrel is again placed in a water chamber to clean out the
impurities which may be present on the surface after plating. Then the barrel is
taken out of the water chamber by lifting and hereafter by opening the barrel the
plated products are collected. Then the products are washed in nitric acid solution
for further cleaning of impurities present after Zn-plating.Then again the products
are washed in fresh water solution.Subsequently they are placed in another
chamber for chromating( colouring). This chamber contains Dichrome and HNO3
solution which helps in forming a light bluish tinge on product surface.This gives
the product better appearance as well as helps to avoid rust formation. After a
final water-wash, the products are placed in a Centrifugal drier, provided with a
heater, for drying of the electroplated products.

PURPOSE OF ELCTROPLATING ON METAL PRODUCT:-
Any metal can be plated through the zinc electroplating process, but the most
common are steel and iron, on which the process offers sacrificial protection.
Zinc is a bluish-white deposit, which serves as a decorative and inexpensive
protective metal with the following advantages: Acts as a coating against
atmospheric corrosion of iron and steel parts Zinc coatings prevent oxidation by



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forming a barrier and acting as a sacrificial anode when the barrier is damaged
Zinc oxide is a fine white dust that prevents the breakdown of the substrate's
surface integrity as it forms.


INSPECTION of PLATED products: The supervisor of the electroplating
department collects a few samples of plated products and observes the following
:
Whether zinc is loosely adhered to product surface and if it is coming out or
not
Whether black voltage spots are present on the surface of the products or
not.
If the desired thickness of zinc has been plated on the product surface or
not. This is done by measuring plating thickness by an instrument called
Mikrotester.



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Whether rusting of the nut, bolts, electrodes and electrical connections
within the plating and cleaning chambers have occurred or not.
If the first three of the four conditions mentioned above are satisfied for the few
testing samples, then the lot of plated products is accepted and is sent to the
packaging section from the plating section.
ELECTROPLATED PRODUCT






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Electroplating chambers






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The CNC Department:-
Computer numerical controlled ( CNC) lathes are rapidly replacing the older
production lathes (multispindle, etc.) due to their ease of setting, operation,
repeatability and accuracy. They are designed to use modern carbide tooling and
fully use modern processes. The part may be designed and the tool paths
programmed by the CAD/CAM process or manually by the programmer , and the
resulting file uploaded to the machine, and once set and trialled the machine will
continue to turn out parts under the occasional supervision of an operator.
The machine is controlled electronically via a computer menu style interface , the
program may be modified and displayed at the machine, along with a simulated
view of the process. The setter/operator needs a high level of skill to perform the
process, however the knowledge base is broader compared to the older
production machines where intimate knowledge of each machine was considered
essential. These machines are often set and operated by the same person, where
the operator will supervise a small number of machines (cell).
The design of a CNC lathe varies with different manufacturers, but they all have
some common elements. The turret holds the tool holders and indexes them as
needed, the spindle holds the workpiece and there are slides that let the turret
move in multiple axis simultaneously. The machines are often totally enclosed,
due in large part to occupational health and safety (OH&S) issues.
With rapid growth in this industry, different CNC lathe manufacturers use
different user interfaces which sometimes makes it difficult for operators as they
have to be acquainted with them. With the advent of cheap computers, free
operating systems such as Linux, and open source CNC software, the entry price
of CNC machines has plummeted

The CNC ( computer numerical control) machines available in this plant are all
CNC Lathe machines.



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CNC LATHES:

These machines basically consist of a turret holding the cutting tools or the tool
inserts, and a spindle where the job is held. The job is a long cylindrical bar which
can be fed into the chuck either manually or through a bar feeding mechanism. In
this plant each CNC lathe has 3 motors one for rotating the chuck holding the
job, the second one for driving the pump supplying the lubricant from a tank to
the metal cutting zone and the third one for driving the conveyor belt. The G-
Code and the M-Code are programmed into the machine. The machine performs
its different functions like turret indexing, bar feeding, turning , threading ,
chamfering , parting etc on a proper sequence as designated by the installed G-
Code and M-Code . A conveyor is also provided near the machine base which



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performs the job of carrying out the chips from within the machine to a drum
placed outside so that the chips do not accumulate within the machine and
hamper the proper functioning sequence of the machine.
The G-Code basically specifies the direction of X-axis and Z-axis and also tells the
machine at what angle and upto which coordinate the cutting tool has to move to
get the desired contour on job surface. Apart from this the G-Code also instructs
various other things to the machine.
The M-Code, programmed into the machine , decides when the coolant supply
will be made on or off, when the conveyor belt motion will be switched on or off
when the chuck will be clamped ( after bar feeding) and declamped ( before bar
feeding) etc.
In this plant, the X-axis is taken along the diameter of the job and the facing
operation is done along this X-axis. The Z-axis is taken along the length and
various forms of turning operations are carried out along this direction.

THE PRODUCTS MANUFACTURED IN THE CNC LATHES :
Compression Connector : This externally threaded mechanical
component is used for joining of two pipes . The diameters on opposite
sides of the connector are different. This junction is further sealed and
tightened by means of a locknut. The process sequence carried out in CNC
lathes in order to manufacture these connectors from long cylindrical mild
steel bars are :
i. Facing
ii. Turning (external chamfering also occur during turning)
iii. Boring (internal chamfering also occur duringboring )
iv .External Threading
v. Parting (whereby the products are sheared of from the parent job)



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On one side of the connector straight turning is carried out while on the opposite
side a slight taper turning is carried out with a taper of about 1.47 degree.
Compression Connector
Compression Coupling : This is also an externally threaded
mechanical component for joining of two pipes. However the basic
difference between connector and coupling is that in a connector the
diameter of the holes on two opposite sides are different whereas in a
coupling they are almost the same. The process sequence for
manufacturing compression couplings from the cylindrical MS bar are :
I. Facing
II. Turning
III. Boring
IV. External Threading
V. Parting
Compression coupling



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After these products are manufactured in these CNC lathe machines, they are
sent to the plating department for electroplating.

TOOL ROOM:-
A toolroom is a room where tools are stored .In a factory it includes a space
where tools are made and repaired for use throughout the rest of a factory. In
engineering and manufacturing, a tool room is everything related to tool-and-die
facilities in contrast to production line activity.
Originally a toolroom was literally in one room, but like emergency room, the
term has been figuratively extended in both substantive and adjectival senses to
all such places and the methods used there, regardless of the physical space.

PURPOSE OF TOOL ROOM IN PRODUCTION PLANT :-
A broader use of the term includes a space where tools are made, repaired,
inventoried (kept track of), and distributed for use throughout the rest of a
factory. This extension of sense reflects the development of greater systemization
in manufacturing. The basic purpose of tool room making, reparing, and storing
the tool.Machine use in tool room are :-
Grinding machine
Universal Lathe machine
Milling machine
Drilling machine






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SURFACE GRINDING:-

UNIVERSAL LATHE MACHINE:-





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ASSEMBLING AND PACKING:-
After the inspection is done in the electroplating zone the plated product is sent
to the assembling and packing zone where the products are assembled and
packed according to the desired requirement of the customer. After packing the
final inspection process takes place which involve the inspection of the packed
product ,which includes checking whether the number of pieces per box is as
desired, the name of the proper company is printed or not, if there is any thread
damage or box damage etc.
In this section a number of packets are grouped together to form a pallet over
which a plastic wrapping is done with the help of a special machine called the
Stretching-Wrapping machine.
A number of such pallets are boarded on trucks and sent to the desired
destination.






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SAFETY IN MANUFACTURING INDUSTRIES :
A wide range of mechanical equipment is used in the manufacturing industry such
as guillotines, wood working machines, bench saws, band saws, planers, routers
and sanders. Mechanical equipment can be hazardous. The most common injuries
are to hands and fingers, which may be cut, sprained, dislocated, broken, crushed
or severed by machinery or tools. These injuries can cause lengthy periods of time
off work and sometimes they result in permanent disability.
Eye injuries caused by mechanical equipment accidents include being hit by an
object (e.g. small particles such as metal shavings as well large objects or pieces of
equipment), heat, radiation, hitting an object and falls, trips and slips.
The most serious injuries are from kickback (e.g. angle grinders) where the disc is
thrust violently away from the object it is grinding, and back towards the
operator. Kickback can result in severe cuts to hands, arms, head, torso and legs.
When mechanical equipment hazards cannot be eliminated or sufficiently
reduced by engineering controls or safe working procedures alone, the worker
may need to wear personal protective equipment (PPE) to improve protection.
PPE may include safety glasses or goggles, earplugs or earmuffs, protective gloves,
overalls or other close fitting clothing and safety shoes or boots with steel toe-
caps to protect your feet if any items are dropped.
The employer must
have a maintenance program to make sure all equipment and machines are in
safe working order and that where necessary, guards are fitted
have a system in place for locking out and isolating machinery during
maintenance, cleaning and repairs
train the workers to operate any item of mechanical equipment before they use
it, and make sure they are supervised when they use it. If they are in doubt about
using any mechanical equipment, they must ask their supervisor for instruction.



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The supervisor should provide any personal protective equipment (PPE) needed
and tell the machine-operator how to wear and use it correctly.

The operator of the machine should remember the following:
When they are operating any mechanical equipment, they must follow safe work
procedures as instructed by their employer or supervisor. These may include:
wearing clothing that will not catch in moving parts
wearing any personal protective equipment provided by their employer
operating the machinery and equipment correctly and safely according to their
training
keeping all guards in place
making sure any guards removed during maintenance, repair or cleaning are
replaced by an authorised person before they use the machine again
switching off machinery and equipment when it is not in use
locking out and isolating machinery before any repair, adjustment, cleaning or
maintenance is done
concentrating on the job, as distractions can contribute to injuries, and
keeping the area around the equipment or machinery clean.