CAREER EPISODE-2

C.E.2.1 INTRODUCTION:
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C.E.2.1.1 DURATION: 10 June 2012 - 15 December 2013.

C.E.2.1.2 LOCATION: Dev Industries, Vijapur ,Mehsana-382870 Gujarat, India.

C.E.2.1.3 COMPANY: Dev Industries

C.E.2.1.4 POSITION: Production Supervisor (Production & Design Department)

C.E.2.2 BACKGROUND:

C.E.2.2.1PROFILE OF THE EMPLOYER: Dev Industries Established in the year 2001, This
company established as a manufacturer of Submersible Pump Parts, then company has started to
provide the satisfactory product to customer. We, Industries has built up a strong reputation in Dev
providing cost-effective and quality reliable casting solutions for our clients from all over the world, so
reorder ratio from same customers are increased. Throughout the history currently casting capacity of
Dev Industries is 150 MT./month. We offered Innovative Sand Casting solutions with shell moulding
technology Complex solutions for integrated components Clear customer orientation Detailed quality
both in the process and in the Products Precision and reliability ancient Parts development Unique
experience of Shell Moulding and know- how Sustainable commitment to the environment and
society Long lasting partnerships with our customer. Today, Dev Industries Is completely focusing on
manufacturing Precision quality of sand casting with Latest Technologies. With the spirit of continual
innovation and unceasing improvement, we are able to provide not only international standard
products, but also customized ones.

C.E.2.2.2 OBJECTIVE:

To plant out the scheduling for performing various operation on "Impeller( i.e For Pump)"
casting job and to complete it within the customer specified time limit.

To inspect the metrological properties of the raw material in Spectra Machine and generate
the report, which clearly show percentage of different metals and its alloy.

To inspect all casting components , and check it for percentage shrinkage allowance and NDT
for find out presence of blow holes and generate the inspection report from with
documentation (Including Q.C Reports).

To maintain Cast quality as per standard and Quality Assurance policy offered by the
Organization.

C.E.2.2.3 ORGANIZATION CHART: The organization chart with respect to this episode is given below:

GENERAL MANAGER (PRODUCTION/QC)

ASSISTANT MANAGER (PRODUCTION)

PRODUCTION ENGINEER (PROD. SUPERVISIOR) MY POSITION

C.E.2.2.4 JOB RESPONSIBILITIES: The responsibilities given for this episode were

To plan the critical activity and schedule them as per the process sequence
required for Impeller (MOC = SS 410) casting , also each process is specified with
perfect time consumption data through which exact delivery date of the product
can be achieved.

To inspect and verify with the Spectra Machine whatever percentage of materials
(metals & its alloys) used in that casting job.

To Assure that the free flowing sand used in the shell mould must be dry and
completely free of clay content as well as having grain size in range 100-150 mesh .

To verify the Heat No. and related TC (Test Certificate) of casting parts and give the
approval for next stage operation in manufacturing process.

To generate all the documents as per the Customer Required Specification for the
casting along with QAP (Quality Assurance Plan) and ISO standard and maintain it
throughout the project as well as send it to the concern department.

To set the operation and final allowance on VMC (Vertical Machining Centre)as per
the functional requirement of die designing.

To prepare material handling sequence chart and arrange the finish goods
accordingly and generate the inventory report at each stage of the production
process for that project.

C.E.2.3 PERSONAL ENGINEERING ACTIVITIES:

C.E.2.3.1 This project was very important for me to learn such metallurgy process involved in casting
and complicated design of riser and gates in mold cavity of Impeller. Also I learn Delcam
software during this project which is very useful to predict the molten metal flow and time
required for solidification process.

C.E.2.3.2 Before starting the metallurgical process for casting component, I planned the schedule of
each stage item-wise to maintain delivery date of the project. Also inspect and generate the
report with the Spectra Machine for raw material used in SS casting process. Raw material
like SS scrape melt in induction furnace and from the Spectra machine report data other
required chemical added for better melting & Casting process.

Fig. : A :- Spectra Machine

 Fig. : B :- Report generated by Spectra Machine for molten metal

C.E.2.3.3 After that for mold preparation required raw material like Regin coated sand with binders, I
used Core - Shooter machine to make Core - Mould by sand filling for heating process in the
Core - Shooter machine.

Fig. : C:- Core - Shooter machine

Fig. D : DIE GENERATED SAND CORE Fig. E : S.S SCRAP

C.E.2.3.4 Consequently the Electric furnaces (Tri track) set at temperature 1200 - 1600 to melt the
SS Scrape (S.S. 410),meanwhile the Core - Shooter machine utilized the regin coated sand
and make core -mold. Then the molten metal from the furnace poured in to the core - mold
for casting of SS impeller

Fig. : F:- Tri track melting furnace & pouring process in mold cavity

C.E.2.3.5 After that for better cleaning all the impeller casting going to Shot - Blasting machine, where
steel balls are used for blasting the impeller casting, where steel balls strikes on the casting
body surface with high velocity and removes the unwanted particles.

C.E.2.3.6 Now the surface treated impeller parts having setup stress inside the grain structure, so it
required to remove the stress. I put all the parts inside the heating furnace for annealing
process (Heat Treatment) at temperature 600 for 12 hours of time.
Fig. G: Impeller casting (S.S 104) Fig. H : CNC machine shop

C.E.2.3.7 I calibrated all instruments like fillet gauge , Micrometer, Vernier Caliper, , Height Gauge,
Bevel Protector, Measure tape, etc from calibration approval agency before any fabrication
and prepared calibration plan and calibration calendar which were important documents of
the project as per ISO

Fig.I : Final Inspection &Testing Fig.J : Finish goods (impeller)

C.E.2.3.8 Now for final cut on the impeller accuracy is vital parameter, so as per the drawing required
dimensional parameter achieved on CNC machine. After final machining some parts having
blow holes, pitting effect or wall thickness of impeller vane is not constant in all such cases
the impeller is rejected by the QC department and it again goes to the furnace for further
melting process in furnace.

C.E.2.3.9 I started RCA (Root Cause Analysis) for why the rejected parts having blow holes inside the
casting of impeller body? Through RCA I found that improper solidification time and not
proper mixing of binders with the sand generated the excessive gas during the pouring of
molten metal, it leads to generate blowholes in parent material, I take corrective action
immediately to take care of such issue and pass on the instruction to worker for making
proper mixing of regin coated sand with binders to avoid such kind of problems.
Die making process (VMC-MAZAK) Raw material (SS Scrap)

Core shooting machine

Finished Product

Sand mold Spectra Machine

Testing

Electric furnace

CNC machine shop

casting (SS impeller)

SHELL MOULDING CASTING PROCESS LAYOUT (IMPELLER)

 C.E.2.3.9 After that impeller holds on broaching machine for keyway cutting in oil quenching media,
for further process the it is required to clean the oil film from impeller surface. So oil cleaning
machine is utilized to clean the impeller surfaces.

C.E.2.3.10 After final machining of impeller on CNC machine and broaching machine, all the surfaces
having generated burs, it requires grinding process for edge preparation.

C.E.2.3.11 As per QA policy finished impeller being checked against all the standard parameters and
drawings. Rejected parts diverted to the melting furnace zone and accepted parts now ready
for the packaging. All the finish parts were stored in the storage cum dispatch section.

C.E.2.4 SUMMARY:

C.E.2.4.1 Through this episode, I come to know about metallurgical process, QAP, Process parameter
involved in casting process, different standard followed by the casting process etc.

C.E.2.4.2 From this episode I can learn how to reduce setup stress in the casting component with help
of annealing process. Also understand how to interpret the report generated in Spectra
Machine for molten metal in the electric furnace.

C.E.2.4.3 This episode gave me experience about how to manage the activity on priority base, where
we all worked in co - ordination with internal department to achieve the desired task in
stipulated time period.

C.E.2.4.3 My successful implementation of metallurgical process and in-house development of die in

VMC machine by using Delcam software was appreciated by my head of department.

C.E.2.4.4 Maintaining proper report regarding to all process activity and its importance I learnt from
this episode which would be beneficiary for my future career.