One Semester Industrial Training Report

COMPLETED AT

FEDERAL MOGUL GOETZE INDIA LIMITED

Submitted in partial fulfillment of the Requirements for the award of

Degree of Bachelor of Technology

In
Mechanical Engineering

Submitted By
Jashanpreet Singh
University Roll No. 1302560

SUBMITTED TO

DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGG

BABA BANDA SINGH BAHADUR ENGINEERING COLLEGE
FATEHGARH SAHIB
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 CANDIDATE'S DECLARATION
I hereby certify that the project entitled Scrap reduction in Line 2, by Jashanpreet
Singh(1302560) in partial fulfillment of requirement for the award of degree of B.Tech.
(Mechanical Engineering) submitted in Mechanical Engineering Department at Baba Banda Singh
Bahadur Engineering College, Fatehgarh Sahib under Punjab Technical University, Jalandhar is an
authentic record of my own work carried out under the supervision of Er.Charanjeet Singh. The
matter presented in this report has not been submitted by me in any other University / Institute for
the award of B.Tech Degree.

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 ACKNOWLEDGEMENT
I express my sincere gratitude to the Punjab Technical University, Jalandhar for giving me the
opportunity to undergo industrial training and to work on the project during my final year of
B.Tech.
I would like to thank Major General (Dr.) GS Lamba, VSM, Principal, Baba Banda Singh Bahadur
Engineering College, Fatehgarh Sahib for his kind support.
I would like to thank the Dr Lakhvir Singh, HOD, (Mechanical Engineering), Baba Banda Singh
Bahadur Engineering College, Fatehgarh Sahib and faculty members of the department for their
valuable suggestions and healthy criticism during my presentation of the work.
I also owe my sincerest gratitude towards Er. Charanjeet Singh and Dr Doordarshi Singh, Training
Coordinator for their valuable advice and healthy criticism throughout my training which helped
me immensely to complete my work successfully.
I would also like to thank everyone who has knowingly & unknowingly helped me throughout my
project.
Last but not least, a word of thanks for the authors of all those books and papers which I have
consulted during my project work as well as for preparing the report.

Jashanpreet Singh
Uni. Roll
No. 1302560

3
 LIST OF FIGURES
Figur Caption Pag
e No. e
No.
1.5 Products 4
1.5.1 Pistons 4
1.5.2 Rings 5
1.8 Organizational structure 7
2.0 Overview of piston 9
3.0 Process flow 17
3.1 Casting 17
5.1.2 Process flow diagram 24
5.3.1 Monthly scrap percentage of year 2016 26
5.3.2 Pareto Chart for year 2016 27
5.3.5.1 Fish Bone Diagram for Transport 29
5.4 Transportation 31

LIST OF TABLES
Caption Page No.
Plant details 03
List of total number of defects in year 2016 25

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Testing Theories for Transport 28
Solution 30
Scrap Report upto April 30

CONTENTS

Candidate's declaration 2
Acknowledgement 3
List of figures 4
List of tables 5

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1. COMPANY PROFILE 8
1.1 Company Perspectives 9
1.2 Company History 9
1.3 Operations 10
1.4 Manufacturing Plants In India 10
1.5 Product Range 11
1.6 Compnays Policies 12
1.7 Organisational Objectives 13
1.8 Organisation Structure 14
1.9 Introduction To Various Departments 14

2. OVERVIEW OF PISTON 16
2.1 Function Of Pistons 16
2.2 Importance Of Pistons 16
2.3 Piston Type And Its Characteristics 17
2.4 Engineering Requirement Of Piston 18
2.5 Design Considerations For A Piston 18
2.6 Piston Terminology 19
2.7 Various Manufacturing Defects In Pistons 21

3. PROCESS FLOW 24
3.1 Casting 24
3.2 Machining 24
3.3 Surface Treatment 25
3.4 Inspection 25
3.5 Packaging 26

4. PISTON MACHINE SHOP DOMESTIC (PMS D) 27

4.1 Different Type Of Processes 27
4.2 Various Types Of Codes Of Machining Defects 28

5. PROJECT I 30
5.1 Phase I 30
5.2 Phase II 32
5.3 Phase III 33
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 5.4 Result And Discussion 37

6. PROJECT II 39
7. CONCLUSION 43

1. COMPANY PROFILE
Federal-Mogul Corporation is a global supplier of automotive components, systems and modules
serving the world's original equipment manufacturers and the global aftermarket. The
company utilizes its engineering and materials expertise, proprietary technology, manufacturing
skill, distribution flexibility and marketing power to deliver products, brands and services of value
to its customers. Federal-Mogul is focused on global profitable growth to create value for and
bring greater satisfaction to its customers, employees and stake holders. Federal-Mogul World
Headquarters is located at 26555 Northwestern Highway, Southfield, MI 48033, U.S.A. It also
have 111 manufacturing sites worldwide. Federal-Mogul has 45,000 employees in 35 countries.

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Worldwide annual sales for year-end 2005 were $6.3 billion. In 2005, OE accounted for 54% of
our annual sales, while aftermarket sales are 46%.
Federal-Mogul design, engineer and manufacture a variety of automotive products for its
aftermarket and OE customers. Its products include, but are not limited to, bearings, pistons, piston
pins, rings and liners, valve seats and guides, dynamic seals, hot and cold static gaskets and seals,
liquid elastomer molded (LEM) seals, systems protection, friction products and aftermarket
products (engine components, gaskets, antifriction bearings and seals, brakes, chassis, wipers, fuel
pumps, ignition and lighting).
Federal-Mogul aftermarket products are sold under a variety of power brands, including, but not
limited to, AE engine products, ANCO wipers, Champion spark plugs and wipers, Fel-Pro
gaskets, Ferodo brake pads, Glyco bearings, Goetze piston rings, Moog chassis products,
National Wheel End Components, Nral pistons, Payen gaskets, Sealed Power engine
products and Wagner lighting and brake products. GOETZE (I) LIMITED, BAHADURGARH
was set up in 1954 with the collaboration of M/S GOETZE WERKE, GERMANY, which started
its production of Piston Rings for automobile industry in 1957. Considering the need of complete
PISTON assembly ESCORTS LIMITED ventured into manufacturing of Pistons. In 1958 with the
collaboration of M/S MAHLE, GERMANY, this delivered the Indian automobile industry its
Piston in 1960. ESCORTS entered in collaboration with M/S SUKO, GERMANY, for Piston Pins
in 1967 and manufacturing started in 1968.To meet the increasing demand of market, in 1977 a
parallel unit for manufacturing Pistons and Pistons Pins was set up in BANGLORE.
Technological leadership matched with innovated thinking has made ESCORTS and GOETZE
products to enjoy a high degree of customer confidence and are the first choices of discerning for
application ranging from BI-WHEELER to BATTLE TANKS. The plant manufacture over 3.4
million & 2.9 million Piston-Pins & Crank Pins annually .Around 50% of its production is being
fitted by original equipment manufacturers of Automobile, Bi-wheelers, Tractors, Stationary
Engines, Generator etc. Among its biggest customers are the MUL for which it manufactures
pistons for Maruti-800, Esteem, Zen etc. Other customers include Peugeot, Escorts Division-
Faridabad, Bajaj, Hindustan Motors, TVS, Rajdoot and many others. The company also directly
supplies its products to all the authorized dealers of the spare part for the above companies
throughout INDIA.
From 1st October, 1996, ESCORTS LIMITED entered into joint venture with M/S MAHLE
GmbH, GERMANY with the formation of new company, ESCORTS MAHLE LIMITED. In 1998,
GOETZE also became the part of FEDERAL MOUGAL, a well known group of U.S.A.
In June 2000, both ESCORTS MAHLE LIMITED and GOETZE have become QS 9000 certified
companies. Wide range of pistons and pins are also exported to U.K., Iran, Bangladesh, Sri-Lanka,
Egypt, Singapore and Malaysia.
In October 2006 name changed Goetze (India) Limited to FEDERAL-MOGUL GOETZE
(INDIA) LIMITED because majority stake holding acquisition by Federal-Mogul Corporation.
Federal-Mogul Goetze (India) Limited is the largest manufacturer of pistons and piston rings in
India Pistons are varying from 30mm to 300mm diameter. The most modern production facilities
at Federal-Mogul Goetze (India) Limited Patiala is certified TS 16949, ISO14001 and OHSAS
18001.

1.1 Company Perspectives

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Federal-Mogul has over 250 locations, across 6 continents, in 24 countries, with 56,000 employees
worldwide. Headquartered in Southfield, Michigan, Federal-Mogul is a $7 billion automotive parts
manufacturer providing innovative solutions and systems to global customers in the automotive,
light truck, heavy-duty, railroad, farm and industrial markets. A century of people serving
customers through manufacturing mastery has made Federal-Mogul a global leader in the
automotive industry. Recognized by our customers as the supplier of choice for powertrain
systems, sealing systems, and general products of leading edge innovation and technology,
Federal-Mogul is a dynamic, growth-oriented company dedicated to delighting customers.

1.2 Company History

Federal-Mogul Corporation manufactures precision components for cars, trucks, and construction
vehicles, marketing its products to original equipment manufacturers (OEMs) and aftermarket
customers in the United States and around the world under brand names such as "Federal-Mogul,"
"Signal-Stat," and "TRW." It also packages products for third-party private label brands. The
company has about 20 manufacturing facilities in the United States and six other countries.
Federal-Mogul sells its own products to major global automakers, including BMW, General
Motors, and Nissan. It distributes about 150,000 auto parts to nearly 10,000 automotive
aftermarket customers, primarily independent warehouse distributors, but also local parts suppliers
and parts retailers.
The company rose to prominence through a series of expansions and acquisitions, which included
the Bearing Company of America in 1953, the Bower Roller Bearing Company in 1955, and
National Seal in 1956. In the early 1990s, Federal-Mogul sought to offset fluctuating demand in
the OEM market by entering into aftermarket sales.
Goetze (I) Limited, Bahadurgarh was set up in 1954 with the collaboration of M/S Goetze Werke,
Germany, which started its production of piston rings for automobile industry in 1957.
Considering the need of complete piston assembly ESCORTS LTD. ventured into manufacturing
of pistons in 1958 with the collaboration of M/S Mahle GmbH, Germany, which delivered the
Indian automobile industry its piston in 1960.
ESCORTS entered in collaboration with M/S SUKO GmbH, Germany, for piston pins in 1967 and
manufacturing started in 1968.To meet the increasing demand of market, in 1977 a parallel unit to
manufacture pistons & piston pins was set up in Bangalore.
Technological leadership matched with innovated thinking has made Escorts and Goetze products
to enjoy a high degree of customer confidence and are the first choice of discerning customer for
application ranging from bi- wheeler to battle tanks.
From 1st October 1996, ESCORTS LIMITED entered into joint venture with M/S Mahle GmbH,
Germany with the formation of new company, ESCORTS MAHLE LIMITED.
In 1998, Goetze also became the part of federal mougal, a well-known group of U.S.A. In June
2000, both Escorts Mahle Limited and Goetze have become QS 9000 certified companies.

1.3 Operations Done At Federal-Mogul Goetze (I) Ltd

PISTONS Melting, Alloying, Casting Machining, Anodizing, Inspection.
PISTON RINGS Melting , Alloying , Casting , Machining , Chrome Plating, Moly Coating ,
Inspection.
PISTON PINS Machining , Heat Treatment , Inspection.
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1.4 Manufacturing Plants In India
The manufacturing facilities are situated at plants in Patiala, Bangalore, Alwar and Bhiwadi.

Patiala:-The plant at Patiala is engaged in the production of automotive Piston,Piston Rings, and
Pins. The foundry producers cast iron for rings

Bangalore:-This plant is also capable for producing both piston and piston rings. Both the
factories use advanced inspection equipment, quality control technology, mechanical and
machining equipment.

Alwar:-FMGI Ltd. Commissioned its solvent extraction vegetable oil plant in 1993 and began
commercial production in 1994 for processing sunflower, soyabean and mustard seeds.

FMGI Ltd. is planning to exit from this noncore activity i.e. solvent extraction business and is
looking for a suitable buyer. The company is operating its facilities at high level of capacity
utilization as can be evidenced by the below:-

Table 1.4: Plant details

Products Capacity(million) Production Utilization

Piston rings 50.95 39.842314 83%

Pistons 9.14 6.724013 81%
Pins 9.18 7.723972 84%

1.5 Product Range

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 Figure 1.5: Products
Federal Mogul Goetze india Limited manufactures wide range of Piston, Piston rings, Piston Pins.

1.5.1 Pistons
Federal-Mogul Goetze India has state-of-the-art test bed facilities, design facilities for products
and dies and tooling with CAD/PRO-E.
Products suitable for:
a) 4 stroke engines
b) 2 stroke engines
c) Gasoline engines
Applications:
a) Bi-wheelers
b) Cars
c) SUVs
d) Tractors
e) Light commercial vehicles Figure 1.5.1: Pistons
f) Heavy commercial vehicles
g) Heavy output locomotive diesel engines
h) Stationary engine

1.5.2 Piston Rings

Goetze piston rings of OEMs and Aftermarket in India has state-of-the-art design facilities for
products, tooling with CAD/PRO-E/GLIDE SOFT and test bed facilities.
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Federal-Mogul Goetze India is dedicated to developing new technologies and continuously
improving its products.
Production Capacity: 55 million rings per annum
Product Range: 30mm to 300mm diameter
Goetze manufactures a wide range of piston rings for:
a) Bi-wheelers
b) Tractors
c) Passenger cars & SUVs
d) Commercial vehicles (HCVs, MCVs & LCVs)
e) Locomotive engines
f) Stationary engines
Figure 1.5.2: Rings
1.6 Compnays Policies
Our primary responsibility is to maintain environmental friendliness in pursuance of this effort.
We Commit Ourselves
a.) To strive continually to protect and promote environment.
b.) To provide top priority to conserve valuable resources and to introduce technologies,
process/material that are environmental friendly.
c.) To adhere to the spirit of continual improvement by setting/reviewing objects and
targets periodically.
d.) To prevent pollution, reduce waste and enhance companys image.
e.) To create and imbide awareness towards cost effectiveness and environment friendly,
safety conscious and socially accountable measures.
f.) To comply with all applicable legal and regulation requirements.
g.) Quality Policy
h.) Our primary responsibility is to deliver maximum value to our customers.
i.) To enhance customers satisfaction by meeting their current and future expectation.
j.) To achieve goal of excellence by continual improvement of effectiveness of our product
and process.
k.) To provide environmentally sustainable technologies to meet all statutory and regularity
requirement.
l.) To create an environment to promote involvement, sense of belonging and offer
opportunities for creativity and innovation.

1.7 Organisational Objectives:

These are the following objectives of the company:-

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1.7.1 Primary Objectives
The company has laid down for itself goal of improving the value to the customers through
maintaining the leadership in following categories:-
a.) Market share: to maintain its status as brand leaders in the company for pistons and piston
rings.
b.) Product development: to develop pistons, piston rings and piston pins for all new
applications as identified.
c.) Technology modernization and up gradation of technology to the latest improvements to
meet customer requirements.
d.) Customer satisfaction it shall strive to achieve customer satisfaction rating more than 90%.
e.) Technical requirements: products are manufactured as per specification based on
DIN/JIS.IS.MAHLE NORMS/SUKO NORMS as also against customer specific
requirements.
f.) Quality: To improve quality consistently through quality assurance and process control.
g.) Protection and enhancement of physical resources of society.

1.7.2 Secondary Objectives

a.) To create and distribute a product.
b.) To earn profit.
c.) Protection and security to its workers.
d.) Safety for its workers.
e.) To meet social obligations.
f.) Economy of operations by lowering cost.
g.) Ensure a good quality system.
h.) Training and development of existing workforce.
i.) To satisfy customers.

1.8 Organizational Structure

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 Figure 1.8: Organizational Structure

1.9 Introduction To Various Departments

1.9.1 Security Wing

Security wing keeps the property of the company safe, from thefts and fire. Security wing also
check the entry of the unauthorized persons to avoid any miss-happening in factory premises.

1.9.2 Personnel Department

This department is to maintain personnel files of all workmen up to personnel engineer level, about
their interest in work, behavior and obedience. This department also deals with labour court cases.
The personnel department is divided into following sections:
Time Office
Training and Development
Administrative
1.9.3 Local Purchase Cell
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This department is to purchase item from the local market against purchase requisition to meet day
to day requirement of most urgently needed items of all the departments. In case of any emergency
during machinery breakdown, this department is to act swiftly to minimize breakdown.

1.9.4 Incoming Insepction

Any thing purchased from market or directly received from supplier is subjected to 100%
inspection as per the prescribed norms. Defective material is sent back to supplier.

1.9.5 Material Store

This is the place where all the consumables items purchased or directly supplied by the suppliers
are stored in a systematic way on the racks. All racks are properly categorized. This department
receives purchase requisition from the department and pass on to the purchase cell for action.

1.9.6 Finance Department

This department is to maintain all types of account books concerning with finance and to disburse
salary to the workmen, junior staff and to release payments to the outside parties. There is another
cell with in this department, which works out the costing data of the product that o he piston pins,
rings and informs the marketing department for the finalization of the products price with the
customers.

1.9.7 Time Office

The employees and manager including the supervisors are well at Federal-Mogul Goetze (India)
Limited. The employees are given an employees identification no (EIC) on the basis of which they
are issued identity cards. This follows the cards punching system for timing and attendance
recording. All employees right from the workers to the chief general manager have to get their
cards punched in on arrival & out on departure. Time office maintains all attendance records with
the help of electronic data processing unit. Time office also maintains their leave records

1.9.8 Piston Machine Shop

PMS Domestic: In Piston Machine Shop we are manufacturing pistons for Diesel and petrol
engines. Production is 5.5 lakhs piston per month. In this department there are 14 production lines,
they are manufacturing the piston not for OEM, but for aftermarket also. Latest CNC machines and
tooling are using to make piston. The manpower strength of the domestic piston plant is 500 in
numbers. Major customers are bajaj, Hero Honda, Maruti etc. I got the an opportunity to work in
PMS domestic (most advanced piston manufacturing machine shop)

1.9.9 Pms Exports (Malden Shop)

Malden shop is 100% Exports unit and was transferred from Malden America to Patiala in the
year 2006. The Main motive to transfer the plant from America to India to have benefit of low
manufacturing cost (easy availability of raw material and low man power cost). The manufacturing
capacity Malden shop is about 2 Lakh pistons per month.

2. OVERVIEW OF PISTON
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Piston is a disk or cylindrical part tightly fitting and moving within a cylinder, either to compress
or move a fluid collected in the cylinder, as air or water, or to transform energy imparted by a fluid
entering or expanding inside the cylinder, as compressed air, explosive gases, or steam, into a
rectilinear motion usually transformed into rotary motion by means of a connecting rod .

Figure 2: Overview of Piston

2.1 Function Of Pistons
To convert chemical energy of fuel into mechanical energy. It develops power, which is converted
from reciprocating motion to rotary motion. It acts as a carrier of piston rings i.e. it acts as movable
light plug which in turn required to seal the gases escaping from the piston crown down to the
crankcase. It transmits the force of explosion to connecting rod It forms a guide and bearing to the
small end of connecting rod and takes the side thrust due of rod.

2.2 Importance Of Pistons

The heart of any internal combustion engine is the piston assembly, which channels the explosive
force of fuel and converts it into the driving force of the engine. Piston is a major and important
part of I.C. engine It is the part of the reciprocating mechanism. The piston experiences the
reciprocating motion in the cylinder of the engine .The reciprocating motion of the piston is
converted to the rotary motion through connecting rod and the crankshaft. On the one side of the
piston, after ignition stroke, the pressure is developed which pushes the piston to other side,
through the crank and connecting rod the motion changes to rotary motion. The pistons are
generally made of aluminum alloys.
The main reasons for using aluminum alloys are described below:
Light in weight that improves engine efficiency.
Corrosion resistance.
Mechanical properties such as strength, hardness can be altered by alloying and heat
treatment.

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 Ease of machining.
Low melting point that is 660C as compared to cast iron 1440C therefore problem of
melting and pouring are greatly simplified.
The coefficient of thermal conductivity of aluminum is about three times that of cast iron.
As regards strength and wearing quality aluminum is better.

2.3 Piston Type And Its Characteristics

These are the following types of pistons and their characteristics:-

2.3.1 Solid Skirt Piston (Cast and Forged):

With cast and forged solid skirt pistons, the crown, ring belt and skirt form a rigid and solid body.
Solid skirt pistons are used in engines of all kind ranging from moped and motorcycles to large
sized engines. Extremely light weight designs are used in passenger car engines. Special
machining profiles on the skirt ensure small fitting clearances and hence smooth running.

2.3.2 Expansion Controlled Pistons:

Auto thermic and Auto thematic pistons are characterized by exceptionally smooth running and
long life. The steel struts cast between the skirt and the pin together with the surrounding light
alloy, form controlling elements which reduce the thermal expansion of the skirt in the thrust axis
direction where the piston is closely guided in the cylinder bore. Autothermic pistons are chiefly
preferred in petrol engine for passenger cars and Autothermatic pistons are used in Diesel engines
when smooth operations over long periods are the objectives.

2.3.3 Piston for 2 Stroke Engine:

In 2stroke engines the thermal loading is exceptionally high due to more frequent impact of
combustion heat during every down stroke. In addition, 2stroke piston must control the scavenging
process by opening and closing the intake, exhaust and scavenging ports placing additional thermal
and mechanical loading on the piston. Their external shape may vary from designs with open
windows to execution with solid skirts.

2.3.4 Piston with ring Groove Insert:

On pistons with Ring groove inserts, the top ring groove is cut into a ferrous ring groove insert,
which is cast in the piston base material by metallurgical bonding. It is particularly resistant to
wear due to friction pounding. The top groove and the top ring, the most endangered areas, are thus
protected very efficiently. This is a great advantage at high operating temperatures and pressures,
as they occur specially in Diesel engines.

2.3.5 Oil Cooled Pistons:

Various types of oil cooled pistons with cooling coil or gallery are used to ensure intensive crown
cooling and to counteract the elevated temperatures at the ring belt resulting from high specific
engine power. The cooling oil is supplied through nozzle at the connecting rod, or nozzle vertically
arranged at the crankcase or it is force fed through channels in the connecting rod and the piston
pin.
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2.4 Engineering Requirement Of Piston:
The material being used for making pistons operating at high speed should meet with following
conditions :-

2.4.1 High heat conductivity

A piston head is always exposed to high temperature, so the heat of the piston should be
transmitted to cylinder walls. The piston, as a heat passage, is requires high heat conductivity.

2.4.2 Low specific Gravity

Low specific gravity is required for reducing the inertial force, which produces vibrations, due to
high revolution. A piston should be as low as possible under specific conditions.

2.4.3 High temperature strength and fatigue strength

A piston head is sometimes exposed to the temperature as high as approx. 2500C, which may turn
the piston material brittle and result in blowby due to high pressure. It is also required to be
resistant to fatigue breakage due to continuous revolution.

2.4.4 Low thermal Expansion

It is preferable to use piston material of as low thermal expansion coefficient as possible, because
great change of piston size due to temperature change makes it extremely difficult to obtain stable
performance.

2.5 Design Considerations For A Piston

2.5.1 Design: The architecture of a piston must have a design with least weight, less friction, less
noise, vibration and harshness, less skirt collapse

2.5.2 Material: The aluminum alloys is used as material because it provides a high performance at
low cost.

2.5.3 Process: A finished cast crown is used and skirt thickness is considered to have optimized
weight.

2.5.4 Surface: The coating should be such that it should provide less wear, less friction, less NVH
and least scuffing.

2.6 Piston Terminology

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2.6.1 Land
That part of the piston above the top ring or between ring grooves. The lands confine and support
the piston rings in their grooves.

2.6.2 Heat Dam

A narrow groove cut in the top of some pistons to reduce heat flow to the top ring groove. This
groove fills with carbon during engine operation and reduces heat flow to the top ring.

2.6.3 Compression Distance

The distance from the center of the pin hole to the top of the piston where groves are machined.

2.6.4 Ring Belt

That area between the top of the piston and the pin hole for the installation of piston rings.

2.6.5 Piston Head

The top piston surface against which the combustion gases exert pressure. The piston head may be
flat, concave, convex or of irregular shape.

2.6.6 Piston Pins (Wrist pins or gudgeon pins)

Connections between the upper end of the connecting rod and the piston. Pins may be held in one
of three ways:
a.) Anchored in the piston with the bushing in the upper end of the connecting rod oscillating
on the pin.
b.) Clamped in the rod with the pin oscillating in the piston.
c.) Full floating in both connecting rod and piston with lock rings or other devices preventing
the pin from contacting the cylinder wall.
2.6.7 Skirt
That part of the piston located between the first ring groove above the pin hole, and the bottom
(open end) of the piston. The skirt forms a bearing area in contact with the cylinder wall.

2.6.8 Pin Hole

An opening through the piston skirt to carry the piston pin.

2.6.9 Major Thrust Face

That portion of the piston skirt which carries the greatest thrust load. This is on the right side when
viewing the engine from the flywheel end with the crankshaft rotating counterclockwise.

2.6.10 Minor Thrust Face

That portion of the piston skirt which is opposite the major thrust face.

2.6.11 Piston Pin Bushing

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A bushing fitted between piston pin and piston pinhole to obtain a better bearing material. Used
particularly with iron pistons.

2.6.12 Oil Ring Groove

A groove cut into the piston around its circumference, at the bottom of the ring belt or at the lower
end of piston skirt. Oil ring grooves are usually wider than compression ring grooves and generally
have holes or slots through the bottom of the groove for oil drainage to the interior of the piston.

2.6.13 Compression Ring Groove

A groove cut into the piston around its circumference, in the upper part of the ring belt. The depth
of groove varies depending on piston size and types of rings used.

2.6.14 Scuff Band

A narrow raised band or bands machined on the top land of some pistons to reduce the possibility
of scuffing.

2.6.15 Groove Depth

The distance from the cylinder wall to the bottom of the ring groove with the piston centered in the
cylinder.

2.6.16 Groove Root Diameter

Diameter of the piston measured at the bottom of the groove. The root diameter of each groove on
any given piston may differ, depending on the type of ring to be installed.

2.6.17 Land Diameter

Diameter of the land being measured. In some piston designs all lands are equal diameter. In others
they increase from top to bottom.

2.6.18 Land Clearance

The difference between the diameter of the land and cylinder diameter. (R shows 1/2 of total
clearance)

2.6.19 Skirt Clearance

The difference between piston skirt diameters measured in a plane perpendicular to the piston pin
and cylinder diameter. (S shows 1/2 of total clearance)

2.6.20 Skirt Groove

A groove cut into the piston around its circumference below the pin hole to carry an oil ring.

2.6.21 Offset Pin Hole

On some pistons the pin hole is offset to one side of the piston centerline.

2.6.22 Top Groove Spacer

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Badly worn top grooves must be re-machined before installation of new rings. A steel spacer is
installed above the ring in a reconditioned groove to reduce the side clearance to the recommended
dimension.

2.7 Various Manufacturing Defects In Pistons

In the manufacture of pistons there are various problems that are being faced by the firms. Some of
these are:-

2.7.1 Step On Groove Ground

With the step on groove ground, the ring does not fit properly and the piston assembly could not be
installed.

2.7.2 Groove Width

Groove Width is one of the very important parameters of a piston because if the width of the
groove is more than the ring then the ring will be loose in the assembly and the gases may escape
from the ring surface to the bottom of the piston.
Whereas, if the groove width is less than the ring will not fit and the assembly could not be
installed.

2.7.3 Groove Diameter

If the groove diameter is less than the ring will start fluttering and the gases may escape from the
piston top to the bottom of the cylinder.Where as, if the diameter is more, than the ring will not fit
and problem will be faced during the assembly installation.

2.7.4 Weight
In case of multi-cylinder engines the pistons are assembled according to weight as it has a lot of
impact inside a running engine.
The weight of the pistons are kept in the range of 2 grams because if there is too much variation
in the weights of the pistons inside a running engine than the pistons may exert an unbalancing
force on the crankshaft which may bend the crankshaft.

2.7.5 Skirt Size

Skirt size is also one of the main parameters of the pistons.
If the skirt size is more than the given tolerance than it will seize the engine and if it is less than the
lubricating oil will start leaking and the lubrication will not be done properly.

2.7.6 Step On Skirt

A step on the skirt will increase the diameter of the skirt more than the tolerance which may either
damage the cylinder lining or seize the engine or both.

2.7.7 Pin Hole Diameter

The PH. Diameter is also an important parameter which is being checked.

21
If the diameter of the pin hole is more than the pin will be loose, which will allow fluttering of the
pin causing damage to the boss.
Whereas, if the pin hole is tight than the pin will not pass through the hole.

2.7.8 Pin Hole Squareness

The pin hole squareness means that whether the crown is perpendicular to the axis of the pin or
not.
If the squareness is not ok than the piston will move in a tilted state and will damage the cylinder
lining.

2.7.9 Pin Hole Offset(acc. to drawing)

In pin hole offset the pin is tilted horizontally. Offset is decided according to the design of the
connecting rod. If the offset is more than the required value, the connecting rod may touch the skirt
of the piston and damage it.

2.7.10 Unclear Pin Hole

If the pin hole is unclear than it will not result in smooth functioning of the pin, as the pin will not
rotate smoothly .

2.7.11 Damage In Pin Hole

Due to damage in pin hole the pin will not operate properly.

2.7.12 Step In Pin Hole

If there is step in pin hole, it will reduce the pin hole diameter and the pin will not be inserted in
the pin hole.

2.7.13 Compression Height

Compression height is another parameter which has an important role in the working of the
piston.taken from cener of pin hole to the crown of piston.
If the comp. height is more than the tolerances than it will surpass the T.D.C and will touch the
cylinder head and damage it. Whereas, if the comp. height is less than the tolerances than more
fuel will start entering the assembly which will result in lesser mileage and efficiency.

2.7.14 Cavity
Cavity is another parameter of piston as according to drawing. The main function of the cavity is
to properly burn the mixture of air and fuel because if the fuel drops at the centre of the cavity then
the force is exerted mainly on the piston.
Whereas, if the fuel is distributed equally inside the chamber than the force is exerted equally in all
the directions and only a part of the force is exerted on the piston which produces lesser power.

22
2.7.15 Circlip Groove
Circlip groove is a groove in the pin hole which is provided for the locking of the pin. If the groove
is not correctly made than the pin will not stay at its place and connecting rod may move out of the
assembly and seize the engine.
2.7.16 Cracks
These refer to the cracks which are present on the piston surface.

2.7.17 Total Height

Total height refers to the length of the piston from top to bottom.
Whereas, if the height is increased from the top, it will touch the top of the cylinder .

2.7.18 Roughness
The roughness which is provided on the piston surface helps in retaining the oil film

2.7.19 Groove Angle

Groove angle should always be positive so that when the pressure is exerted from the top the ring
is sealed.
Whereas, if the groove angle is already negative, the pressure exerted will further increase the
angle and result in more space and leakage of gases will be there accompanying further
consequences.

2.7.20 Groove Waviness

Waviness of the groove flank is checked. If there is waviness the ring will rest on lesser surface
area and will press the flank resulting in more space, which will result in leaking of gases.

2.7.21 Concentricity
If the chamfer of the skirt is not concentric, the piston will move in a tilted position in the engine
which may result in eroding of the cylinder lining.

2.7.22 Open Bore

To regulate the weight of The piston, open boring is done on some of the casting pistons. A cut as
per the requirement is made on the boss.

23
3. PROCESS FLOW

Figure 3: Process Flow

3.1 Casting
The molten aluminum alloy is poured with the help of a spatula manually into the runner. Each
worker had 2 machines with split dies which would make 2 pistons at a time as in figure 3.1.

Figure 3.1: Casting

3.2 Machining
In this process the blank piece obtained from foundary is made according to needed dimensions by
removing extra material that is present on the piece during casting process.
24
3.3 Surface Treatment
In this process the final product obtained after machining process is the sent for surface treatment
these processes are are used to provide extra life to the pistons. There are different types of surface
treatments are done on pistons . In this process a coating is provided on the outer surface of piston
which works as self lubricant.Coating is basically defined as a covering that is applied to the
surface of an object, usually referred to as the substrate. In many cases coatings are applied to
improve surface properties of the substrate, such as appearance, adhesion, wet ability, corrosion
resistance, wear resistance, and scratch resistance. Coatings may be applied as liquids, gases or
solids. In industry we studied about various coatings like graphite coating, tin coating, molycoat
and anodizing.
And for this process various methods are used:

3.3.1 Tin Coating

Titanium nitride (TiN) (sometimes known as Tinite or TiNite or TiN) is an extremely hard
ceramic material, often used as a coating on titanium alloys, steel, carbide, and
aluminiumcomponents to improve the substrate's surface properties.

3.3.2 Moly Coating

Moly" is molybdenum disulfide, a dry powder, high temperature lubricant. Moly coatings are a
combination of molybdenum disulfide lubricant and high performance resins. Molybdenum
coatings are thermally cured and thoroughly bonded to the base metal of the coated part.

3.3.3 Graphite Coating

Graphite coating is a combination of graphite and thinner applied on the material for its coating.
The ingredients used for graphite coating are graphite pigment, amino resin and aromatic
hydrocarbons.

3.3.4 Anodizing
Anodizing is an electrolytic passivation process used to increase the thickness of the natural oxide
layer on the surface of metal parts. The process is called "anodizing" because the part to be treated
forms the anode electrode of an electrical circuit.

3.4 Inspection
In this after all the processes including surface treatment the pistons are sent for final inspection
where all the parameters are checked by electronic devices and are checked to very minute level.
In inspection the machining of piston blanks, acidic tin coating, Moly coating, screening, final
inspection, and packing of pistons to be done. Piston blanks from Foundry shop are brought at
PMS in trolleys with identification tags on them. There is provision for the 13lines in the shop.
Each line includes different machines and every operation from rough machining to finishing of
the piston is done within theline. After this piston goes to Washing & Coating section and then
come to the final inspection section. In final inspection piston parameters, critical thickness are
being checked by equipments & after inspection Pistons after packing are ready.
After carrying out the various processes final inspection is done in order to check any kind of error.
During the final inspection following points are taken care of:
25
 a.) Sound check: Piston being used is first made to do sound check so that it does not produce
any kind of noise while working.
b.) Eye visual: Manual check is done in order to detect any defect.
c.) Pin testing: Pin testing is done to check the fitting of the pin in bore .
d.) Pin hole/ compression height check: Pin hole or compression height is checked with the
help of gauge.
e.) Middle point/ angel: Middle point or angle at which the piston is to be installed is checked
with the help of gauge to check its accuracy.
f.) Pin hole dia and outer dia: These are checked by using circular gauge.
g.) Groove check: In groove check groove dia, groove depth and groove width are checked.
h.) Lock pin depth: Lock pin depth is checked when the ring is not rotating.
i.) Grading: Grading is done in order to rank the equipment quality or standard of work done.
j.) Stamping: Stamping includes a variety of sheet-metal forming manufacturing processes,
such as punching,grooving etc.It is a process in which we code the piston according to thire
defects .For machining defects,coding is done in accordance with the standard codes.

3.5 Packaging
The final product obtained after all the machining processes and inspection is then packed in the
packing room and then sent to the customers.

26
4. PISTON MACHINE SHOP DOMESTIC (PMS D)
In Piston machine shop domestic there are 16 lines in which different pistons are made .These
pistons are of different sizes and are of different vehicals .
The pistons manufactured are of
i) Two wheeler
ii) Three Wheeler
iii) Four Wheeler

The pistons may vary according to the type of fuel used. These are
i) Diesel pistons
ii) Petrol Pistons
iii) C.N.G pistons

The Pistons also vary according to

i) Ring Carrier
ii) Non- Ring Carrier

4.1 Different Type Of Processes For Different Pistons In Piston Machine Shop
Domestic

4.1.1 For Ring Carrier Pistons

a) Blank Piece From Foundry
b) Plung Cut
c) Riser Cutting
d) Fixture Seat Machining
e) Rough Overturning and Pre Grooving
f) Oil Hole Booring
g) Fininsh Aluminium Grooving
h) Finish Caste Iron Grooving
i) Finish Outer Diameter Turning
j) Finish Pin Hole Booring
k) Finish Crown Cavity
l) Valve Seat machining
m) Circulip Grooving
n) Rooling and cleaning
o) Surface Treatment
p) Inspection
q) Packaging

4.1.2 For 4 Stroke Bi- Wheeler Piston

a) Blank Piece From foundry

27
 b) Fixture Seat Machining
c) Rough Over Turning
d) Pre Grooving
e) Oil Hole Drilling
f) Finish Grooving
g) Finish pin Hole
h) Circulip Grooving
i) Finish Outer diameter Turning
j) Finish Crown
k) Rolling and cleaning
l) Surface Treatment
m) Inspection
n) Packaging

4.1.3 For Passanger Car Pistons

a) Blank piece From Foundry
b) Fixture Seat Machining
c) Rough Over Turning
d) Oil hole Drilling
e) Finish Aluminium Grooviing
f) Finish Pin Hole Booring
g) Circulip Grooving
h) Finish Outer Diameter Turning
i) Finish Crown
j) Pin Hole recess
k) Rooling
l) Cleaning
m) Surface Treatment
n) Inspection
o) Packaging

4.2 Various Types Of Codes Of Machining Defects

A1 Surface treatment
A2 Step on ground
A3 Groove width
A4 Groove Diameter
A5 Weight
A6 Oil holes
A7 Skirt size
A8 Step on skirt
A9 Milling/slot
A10 Pin hole diameter
28
A11 Pin hole squareness
A12 Pin hole offset
A13(A) Bore Unclear Defect
A13(B) Deep Living defect
A13(C) Chips Pressing Defect
A13(D) Other Reasons
A14 Compression height
A15 Cavity
A16 Circlip groove
A17 Lock pin
A18 Chamfer/ PH radius
A19 GR ground eccentricity
A20 GR plane inclination
A21 Transport scrap
A22 Cracks
A23 Serrations
A24 Total height
A25 Wall thickness
A26 Bending
A27 Edge breaking
A28 Oxidation

29
5. PROJECT I
5.1 Phase I
5.1.1 Project Charters
5.1.1.1 Project Title: Scrap Reduction in Line 2(Ring Carrier).
5.1.1.2 Project Objectives:
To reduce the rejection of pistons from 5.23% to 3.66%
To reduce the annual COPQ (Cost of Poor Quality).
Projection completion by 30.04.2017
5.1.1.3 Problem Statement:
Rejection of Line 2 Piston is 5.23% which has the highest COPQ among all pistons from same type
of other lines.
5.1.1.4 Mission Statement:
To reduce the rejection of pistons from Line 2 from 5.23 % to 3.66%
Annual saving of 2.9 K$
Increase productivity
High morale of operator

30
5.1.2 Process flow Diagram

Figure 5.1.2: Process flow diagram

31
5.2 Phase II
5.2.1 Data collection
Rejection data from last year was collected to identify the major parameters contributing towards
the rejection of pistons from Line 2.

Table 5.2: List of total number of defects in year 2016

Sr. Description Jan. Apr. July Oct.
No. 2016 to 2016 to 2016 to 2016 to
Mar. Jun. Sept. Dec.
2016 2016 2016 2016
1 SURFACE TREAT. 353 343 252 14
2 STEP ON GR. 0 0 13 0
GORUND
3 GROOVE WIDTH 1 19 16 1
4 GROOVE DIA 38 106 81 40
5 WEIGHT 0 0 0 0
6 OIL HOLES 347 265 616 508
7 SKIRT SIZE / FORM 535 755 1913 625
8 SKIRT FINISH 116 72 108 190
9 MILLING /SLOT 0 0 0 0
10 PH. DIAMETER 163 157 121 103
11 PH SQ.NESS 12 16 14 134
12 PH OFFSET 104 128 37 79
13 PIN BORE 316 453 306 268
UNCLEAR
14 DP. LNG. IN BORE 0 2 1 0
15 CHPS. PR. IN BORE 0 0 0 0
16 BORE UN. OTHERS 0 0 0 0
17 COMP. HEIGHT 290 165 145 175
18 CAVITY 8 0 1 0
19 CIRCLIP GR. 19 14 0 4
20 LOCK PIN 0 0 0 0
21 DEB./CHAMF. 16 3 16 6
22 ECCENTRICITY 0 0 0 22
23 G.P.I 0 0 0 0
24 TRANSPORT 832 581 596 540
25 CRACKS 63 41 178 247
26 SERRATIONS 0 0 5 0
27 TOTAL HEIGHT 100 89 248 285
32
28 WALL THICKNESS 23 4 8 24
29 BONDING 0 0 0 0
30 EDGE BREAKING 92 102 148 108
31 OXIDATION 306 248 469 640
Total 3734 3563 5292 4140

5.3 Phase III

5.3.1Histogram

Scrap Percentage 2016

9

7.88
8

7 6.76
6.42
6.26
6 5.71
5.54
5.37

5 4.85

4.17 4.15 4.1

4 3.71 3.66
Percentage

Months

Scrap Percentage

Figure 5.3.1: Monthly Scrap Percentage of year 2016

33
 5.3.2 Pareto Chart

Pareto Chart

120

100

80

60

Percentage
40

20

Defects on piston

Rejection Percentage Commulative Rejection Percentage

Figure 5.3.2 : Pareto Chart for year 2016

Conclusion:
We have observed from Pareto analysis that total contribution of Skirt Size, Transport, Oil Holes,
Oxidation, and Pin Bore Unclear is 66.47% for line 2 pistons rejection. Therefore we have decided

34
to reduce this rejection, so that our objective of reducing the rejection from 5.23% to 3.66% can be
achieved.
5.3.4 Testing Theories
Team decided to test the theories based upon the data of brainstorming. Various theories tested.
Based on the improvement in the results vital few remedies were selected. These theories are
implemented on all the defect.
The main outcome of this testing theories is that we will find which the root cause of the defect is.

Table 5.3.4: Testing Theories for Transport

Parameter Methodology Observation Result
Non Check if Partition boxes Root cause
Availability of partition boxes are not available validate.
Partition are available or
boxes not
Improper Check whether Process flow acc. Root cause not
Process flow process flow To control plan validate.
followed or not
Cut Marks Observe the very less Root cause not
during loading worker loading negligence of validate.
and unloading the piston worker
of piston
Machine part Train the worker Non considerable Root cause not
causing about proper scratch observed validate.
detention on handling of
piston piston during
machining
Metallic Check whether worker are Root cause not
ornament of worker wore all wearing gloves validate.
operator safety gears or during machining
causing not
damage to
piston
Improper inspect handling worker carry two Root cause
handling procedure pistons with one validate.
during during hand after
machining machining machining
process
untrained verify the worker are Root cause not
operator driving ability of trained validate.

35
 worker

uneven Inspect the path vehicles move as Root cause not

passages for followed supposed validate.
transportation
Too soft Laboratory Composition is Root cause not
material inspection of acc. To validate.
piston material organization
standards

5.3.5 Cause and Effect/Fishbone Diagram

To generate the maximum number of ideas to point the problem of Transport, a cross functional
team including Production, Quality, Maintenance, R&D and all the process operators were
gathered for conducting Cause and Effect/Fishbone Diagram session the outcome of the session.

5.3.5.1 Transport fish bone diagram

36
Figure 5.3.5.1: Fish Bone Diagram for Transport

37
5.3.6 Possible Solution for Transport
Table 5.36: Solution
Root Cause Alternative Solution
Improper Handling Proper guidelines the worker about
During Machining handling of Pistons during Machining
Process

Non Availability of Addition of partition boxes in trays

Partition boxes

5.4 Result And Discussion

As project will complete on 30th June that why conclusion is missing but still we can analysis the
current report of scrap.
As per the data presented below scrap drops at considerable rate .

Table 5.4: Scrap Report up to April

Sr. Description Jan. 15 Feb. 15 Mar. 15 Up to 20th
No. Apr.
1 SURFACE TREAT. 67 172 214 286
2 STEP ON GR. 0 0 0 1
GORUND
3 GROOVE WIDTH 0 3 3 4
4 GROOVE DIA 11 90 311 358
5 WEIGHT 0 0 0 0
6 OIL HOLES 249 372 489 575
7 SKIRT SIZE / FORM 132 297 471 602
8 SKIRT FINISH 68 125 174 238
9 MILLING /SLOT 0 1 1 1
10 PH. DIAMETER 39 324 409 153
11 PH SQ.NESS 21 217 261 288
12 PH OFFSET 64 246 345 374
13 PIN BORE UNCLEAR 71 112 186 188
14 DP. LNG. IN BORE 0 0 0 0
15 CHPS. PR. IN BORE 0 0 0 0
16 BORE UN. OTHERS 0 0 0 0

38
17 COMP. HEIGHT 101 215 441 601
18 CAVITY 0 0 1 1
19 CIRCLIP GR. 1 1 0 3
20 LOCK PIN 0 1 1 1
21 DEB./CHAMF. 2 1 1 2
22 ECCENTRICITY 7 148 171 175
23 G.P.I 0 0 0 0
24 TRANSPORT 154 365 560 667
25 CRACKS 66 102 131 173
26 SERRATIONS 0 0 0 0
27 TOTAL HEIGHT 109 201 281 359
28 WALL THICKNESS 6 63 164 213
29 BONDING 0 0 0 0
30 EDGE BREAKING 20 43 72 81
31 OXIDATION 297 524 660 834
Total 1485 3623 5347 6478
Percentage 3.79 3.98 3.95 3.8

Now

39
 Figure 5.4 Transportation

6. PROJECT II

6.1 Name- Complete Knowledge OF Line Number 2

SR. NO. 1
Tool name : a) Carbon bit (H.S.S.)
M/C Name: Plunge cutting b) P.C.D Carbide
No. Of machines: 2 No. Of tools: 3
Operations: Coolant: Yes
a) Rough over turning Cycle time: 30 sec
b) Cast iron groove Production per shift: 475 pistons
c) Bottom thickness
Loading/unloading time: 12-15 sec.
Tool life:- a) Ring cut-250 pistons
b) Over turning-3000 pistons
SR. NO. 2
M/c Name: Rough crown facing Tool name: Solid carbide
No. Of machines: 1 No. Of tools: 1
Operations: Coolant: Yes
a)Rough Bottom Cycle time: 26 sec.
L/U time: 12-15 sec. P/S: 600 pistons

Tool life:- a) Carbide- 600 pistons.

b) P.C.D.- 30000 pistons.

SR. NO.3
M/C Name: KD Machine Tool name: a) Carbide bit
No. Of machines: 1 b) P.C.D.
Operations: No. of tools: 2
a) Fixture sheet Coolant: No
b) Internal depth centre Cycle time: 32 sec.
L/U time: 12-15 sec. P/S: 600 pistons

Tool life:- 600 pistons

SR. NO.4
M/C Name: M8R Tool name: Solid Carbide bit
40
 No. Of machines: 1 No. Of tools: 3
Operations: Coolant: Yes.
a) Rough grooving Cycle time: 25 sec.
L/U time: 12-15 sec.(8-12 sec.) P/S: 600 pistons.

Tool life:- 600 pistons

SR. NO. 5
M/C Name: WFI Tool name: Solid Carbide(Drill)
No. Of machines: 1 No. Of tools: 2
Operations: Rough pin hole Coolant: Yes
L/U time: 12-15 sec. Cycle time: 14 sec.
P/S: 600 sec.

Tool life:- 600 pistons

SR. NO. 6
M/C Name: Finish Groove Machine Tool name: P.C.D
No. Of machines: 2 No. of tools: 3
Operations: Coolant: Yes
a) Groove cutting Cycle time: 49 sec.
b) Chamfering P/S: 750 pistons
L/U time: 12-15 sec.

Tool life:- 30,000 piston

SR. NO. 7
M/C Name: Cast iron
Grooving Machine
No. Of machines: 2
Operations: Cast iron grooving
L/U time: 12-15 sec.
Tool name : Carbide bit
No. Of tools: 2
Coolant: Yes(kerosene)
Cycle time: 59 sec.
P/S: 600

Tool life: 250 pistons

41
SR. NO. 8
M/C Name: TAKISAWA Tool name: b) Carbide bit for cut iron ring
No. Of machines: 2 a) P.C.D for finishing
Operations: Outer dia finishing No. Of tools: 2
L/U time: 12-15 sec. Coolant: Yes.
Cycle time: 47 sec.
P/S: 700 pistons

Tool life: 150 pistons (carbide)

4000 pistons (P.C.D)

SR. NO. 9
M/C Name: ZA4 Tool name: a) P.C.D(rough)
No. Of machines: 2 b) Diamond for finishing
Operations: Finish pin hole No. of tools: 2
L/U time: 12-15 sec. Coolant: Yes
Cycle time: 1 min.
P/S: 700 pistons

Tool life:- 2000-3000 pistons

SR. NO. 10
M/C name: ACE & FEMLO Tool name: a) Carbide bit(rough)
No. Of machines: 2 b) P.C.D(finish)
Operations: Finish No. of tools: 2
L/U time: 12-15 sec. Coolant: Yes
Cycle time: 1 min. 5 sec.
P/S: 700 pistons

Tool life: 300 pistons (carbide)

30,000 pistons (P.C.D)

SR. NO. 11
M/C Name: Pin hole chamfer machine Tool name: Solid carbide
No. Of machines: 1 No. Of tools: 1
Operations: Chamfer on outside in pin Coolant: No
L/U time: 8 sec. Cycle time: 9 sec.
P/S: 1200 pistons

Tool life: 500 pistons

42
SR. NO. 12
M/C Name: C.G Machine
No. Of machines: 1
Operations: Circlip grooving
L/U time: 8 sec.
Tool life: 500 pistons
Tool name: Solid carbide
No. Of tools: 1
Coolant: No.
Cycle time: 9 sec.
P/S: 1200 pistons
43
7. CONCLUSION
Being the student of B.Tech Mechanical I thank the FEDERAL-MOGUL GOETZE INDIA for

imparting six months training in a renounced and reputed organization. The training was fruitful

and I have developed maximum knowledge and gained so many new things which will be useful

for me in the future. Last but not the least I thank the management for their act of kindness and

cooperation they have given to me during training.

I wish every success of FEDERAL-MOGUL GOETZE INDIA in future.

Jashanpreet Singh

1302560

8M2

44