Beruflich Dokumente
Kultur Dokumente
(JUNE-JULY 2016)
ON
SUBMITTED BY:
ACKNOWLEDGEMENT
It is always a pleasure to remind the fine people in the Engineering Workshops for their
Sincere guidance I received to uphold my practical as well as theoretical skills in engineering.
It is indeed a great pleasure for me present this Summer Training Report on RICO AUTO
INDUSTRIES as a part of the curriculum of B.Tech. Course MAE (Mechanical and
Automation Engineering).
D.G.M- HR Mr. PRATAP SINGH of the Industrial Training Unit of the Faculty are very
much thanked for allowing me to have my training in Engineering Workshops
First and foremost I would like to extend my sincere thanks to my Guide,
Mr. Rajeev Yadav Dept. of HPDC - Prod. DIE CASTING
Mr. Amrish Bhardwaj Dept. of HPDC - Prod. MACHINE SHOP
Mr. RB Yadav Dept. of HPDC Maintenance
Mr. Pawan Andhana of HPDC Quality
I was privileged to experience a sustained enthusiastic and involved interest from their side.
This fuelled my enthusiasm even further and encouraged me to boldly step into what was
totally dark and unexplored expanse before me.
Finally I apologize all other unnamed who helped me in various ways to have a good
training.
DEEPAK KUMAR
2nd Year Student
DTC, Greater Noida.
PREFACE
Training is important phase of student life. During this the student gets the knowledge of both
theoretical of the subject. Training also impresses students overall approach to life and
enhances his/her confidence to undertake takes which have been done or guided.
My training was at RICO AUTO INDUSTRIES LTD, GURGAON. My training was from
13 June 2016 to 30 July 2016.
RICO is an establishment which supplies components and sub-system assemblies to OEMs.
The following report discusses all the activities, problems and solutions undertaken to
provide high quality casting production at the cheapest rates.
The report rotates about a general process followed to manufacture a component.
TABLE OF CONTENTS
1. Company Profile
1.1
1.2
1.3
1.4
1.5
1.6
Storage
Inspection of Aluminum Alloy
Melting of the Aluminum Alloy
Casting Process
Inspection of Casting
Fettling
Machining and Assembly
Packaging and Labelling
Faculty Name
Rank
Assistant Professor
Signature
Assistant Professor
Assistant Professor
Assistant Professor
Dr. Dwesh
Assistant Professor
Assistant Professor
Assistant Professor
Assistant Professor
1. COMPANY PROFILE
1984-86
First Aluminum High Pressure Die Casting Plant set up in Dharuhera (50 Kms from
IGI Airport
Delhi)
Preferred relationship with Hero Moto Corp and Maruti Suzuki
1990-92
Ferrous Casting & Machining Plant set up in Gurgaon (20 Kms from Delhi, India)
Entered International Market as OEM Supplier to MEC Japan.
1994-96
FCC RICO (50:50) JV formed
Started supplying globally to USA & UK (Eaton, Cummins, GM etc.)
1998-00
Second Aluminum HPDC & Machining Plant set up in Gurgaon
2000-02
Set up full service Engineering, Design & Development function.
Added Customers: Ford, Jaguar, Land Rover
Certified TS 16949, ISO 140001, OHSAS 18001
2002-04
Enhanced Ferrous & Aluminum Capacity
Added Customers: Caterpillar, Honeywell, Detroit Diesel, Volvo
2004-06
R&D Center started
Added Customers: Nissan, Tata, Perkins
2007-09
JV (50:50) with CONTINENTAL GERMANY (Hydraulic Brakes)
JV (50:50) with MAGNA INTERNATIONAL (Oil and water pump)
JV (92.5:7.5) with JINFEI CHINA (Aluminum Alloy Wheels - 2 Wheelers)
Added Customers : Renault, BMW, JATCO, Magna
2010-14
Gurgaon
Bhiwadi
Haridawar
Chennai
Sanand
Manesar
Dharuhera
Bawal
PLANT LAYOUT
BASIC LAYOUT:
RAW MATERIAL
MATERIAL STORAGE
STORAGE
RAW
FURNACE
(MELTING)
FURNACE
(MELTING)
FOUNDARY SHOP
PAINT SHOP
MACHING ROWS
(TURNING, BROACHING8
FACING, DRILLING Etc)
ASSEMBLY ROWS
1. WHEEL HUB ASSEMBLY
2. BRAKE PANEL ASSEMBLY
3. CLUTCH ASSEMBLY
QUALITY UNIT
FINAL PRODUCT
ADMINISTRATION
BLOCK
STORAGE
PRODUCT RANGE
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STRATEGIES
World Class Quality
ISO TS 16949, ISO 14001, OHSAS 18001
Total Productive Maintenance (TPM) & 6 Sigma
Integrated Services
Design, Development & Engineering Services
R&D, Testing & Validation
Tooling & Prototyping
Casting (Aluminum & Ferrous)
Machining & Assembly
Packaging & Logistics
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Preferred Supplier
Customer Focused Enterprise
Efficient Account, Program & Launch Management
People
Regular Training & Skill Building
Empowerment & Leadership
Globalization
Global Presence & Scale
Global Teams
Shareholder Value
Focus on Return on Capital Employed
RECEIPT THE
ALUIMIUM ALLOY
INPECTION OF THE
ALUMINIUM ALLOY
STORAGE OF ALUMINIUM
ALLOY
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MELTING OF ALUMINIUM
ALLOY
INSPECTION OF THE
MOLTEN METAL
STORAGE OF THE
MOLTEN METAL
CASTING PROCESS
INSPECTION OF CASTING
FETTLING OF CASTING
MACHINING
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FINAL INSPECTION OF
CASTING
PAINT SHOP
ASSEMBLY
PACKAGING AND
LABELLING
DESPATCH
2.1 STORAGE
Storage Facility
The raw material is categorized and stored as depicted above depending on their
grade.
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Ni : 0.5% max
Ph : 0.1% max
Mg : 0.3% max
Sn : 0.05% max
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Maximum Capacity: 1800 Tonne These machines are mainly procured from the following
manufacturers: Toshiba
INSPECTION:
1. INCOMING INSPECTION :
Dimensional inspection
Surface inspection
Material inspection
2.
IN PROCESS INSPECTION :
RPM of the machine
Tool change frequency
Finished good inspection
Process flow diagram of product
3. FINAL INSPECTION :
The number of pieces of the products are checked on CMM (Coordinate Measuring
Machine) and then filled in the pre delivered inspection report.
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19
There are 15 CNC machines in the machine shop. These machines are used to perform
different machining operations.
The CNC works a/c to the program written by the operator. CNC have two or more
programmable directions of motion called axis. An axis can be linear or rotary.
Common linear axis names are X, Y and Z.
Common rotary axis are A, B & C.
The axis of any CNC machine is required for the purpose of causing the motion needed for
the manufacturing process.
LATHE MACHINE :
There are five lathe machines in the tool room shop.
These all have self-centered chucks.
GRINDING MACHINE :
Cylindrical grinding machines are used for surface finishing.
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required dimensional accuracy and finish placed this machining operation in a prominent position.
From that reason, electric discharge machining has found broad applications in industry. The
absorbing interest for electric discharge machines has resulted great improvements in EDM
technology. Nowadays, sophisticated electric discharge machines are available for most of
machine shop applications
Basically Electric Discharge Machining (EDM) is a process for eroding and removing material by
transient action of electric sparks on electrically conductive materials. This process is achieved by
applying consecutive spark discharges between charged workpiece and electrode immersed in a
dielectric liquid and separated by a small gap. Usually, localized breakdown of the dielectric
liquid occurs where the local electrical field is highest. Each spark melts and even evaporates a
small amount of material from both electrode and workpiece. Part of this material is removed by
the dielectric fluid and the remaining part resolidifies rapidly on the surfaces of the electrodes.
The net result is that each discharge leaves a small crater on both workpiece and electrode.
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Application of consecutive pulses with high frequencies together with the forward movement of
the tool electrode towards the workpiece, results with a form of a complementary shape of the
electrode on the work piece.
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