Beruflich Dokumente
Kultur Dokumente
Certificate
Certified that this is a bonafide report of the Industrial Visit done by
Sri..of Fifth semester Mechanical Engineering with
Reg No. in fulfillment for the award of Diploma in Mechanical
Engineering during the academic year 2016-2017 From the Directorate of
Technical Education, Kerala.
ACKNOWLEDGEMENT
This is a report on In-Plant training at Intimate Machines (P)
Ltd during 1st August 2016 to 12th August 2016 by 5th semester
Mechanical Engineering students of Central Polytechnic College,
Thiruvananthapuram.
We take this opportunity to express our hearty thanks to the
members of the organization who helped us a lot during this period.
Also sincerely thank our college and teachers for arranging the in-
plant training.
CONTENTS
1. Introduction
1.1 Company Profile
1.2 Origin and History
1.3 About Welbound
1.4 Vision Document The Purpose of Welbound
1.5 Mile Stones
2. Products Manufactured
3. Departmentation
3.1 Introduction
3.2 Production Department
3.3 Personnel Department
3.4 Commercial Department
3.5 Research and Development Department
3.6 Human Resource Development and Administration Dept.
3.7 Engineering Department
3.8 Finance Department
3.9 In process stores
3.10 Safety Department
4. Introduction to CNC
5. Conclusion
CHAPTER 1
INTRODUCTION
1.1 COMPANY PROFILE
Welbound Worldwide was established in 1989, by K.C
Sanjeev, a young entrepreneur, with N Kumar, a design engineer.
Their passion - developing state of the art equipment for the graphic
art industry, at affordable
prices. P Sajith, a marketing
professional joined the
Group as Director in 1991.
Welbound went on to
change the way books are
bound in India. Since then.
Welbound has developed
more than 15 products and
variants, with indigenous expertise. From folding to trimming, the
products complete the book binding cycle. The tie up with world
leaders in adhesives, Henkel Adhesives (erstwhile National Starch and
Chemicals) has helped Welbound deliver complete solutions to the
book binding industry. With their support, technical seminars and
application training sessions are hosted all over the country to
increase awareness in book binding techniques. Welbound designs
and develops majority of the products with indigenous expertise.
Welbound also has tie up with a few European manufacturers for the
production of their machines and accessories in India. A well-
established sales and service network takes care of installations and
training - on machine as well as application. Welbound has more than
2000 unique customers in India and neighboring countries. In addition
to this, Middle East Asia and Africa are the major export destinations.
Intimate Machines Pvt Ltd is the first branch of Welbound established
in 1989 in Manila Industrial Estate, Thiruvananthapuram. It is small
scale manufacturing industry. The firm consists of Research &
Development department, Manufacturing department and Assembly
department. The products of Intimate Machines are Post-Printing
equipments like Perfect Binder, Gathering Machine, Folding Machine,
Trimmer etc. Intimate Machines (P) Ltd won the Award for Quality
Products (State Level) from the President of India (for the year 1993).
The firm got ISO 9002 certification in 1999.
Products (State Level) from the President of India (for the year 1993).
Completes the construction of the new Factory (over 30000 sq.ft in
area) and modern. P&M added on.
1995 - Intimate Machines (P) Ltd, wins the National Award for Quality
Products (All India Basis) from the President of India (for the year
1989). Ties up with Hindustan Lever Ltd (Unilever Group), the largest
Corporate Entity in India, for the distribution (and for providing
Technical Support) of the adhesives manufactured by them in
Collaboration with National Starch & Chemicals, A separate company
is floated for this Activity, Impel Marketing Services, with Bombay as
the Head Office. Conducts Seminars with the help of experts from NSC,
like Tony Clark, in different parts of the country for building awareness
on Perfect Binding Technique, with the arrival of this tie up , a lot of
adhesive -- machine related Binding Problems were identified and
sorted out. Started extending technical support to competitors
installations, till then unheard of in this Industry in India, for binding
related problems. The NSC- HLL Experts trained our Service Engineers
on different models of Perfect Binders from reputed manufacturers.
1995 - Also saw unprecedented demand for WELBOUND and the
Installation Base grew to 150.
1996 - 2 more products (prototypes) were demonstrated to the
Industry, TRIDENT - A stand-alone Three Knife Trimmer & WELBOUND
2000 - A five Clamp Perfect Binder. WELBOUND becomes the Industry
standard for Perfect Binding in India. Adhesive Sales grow by 200%.
Installation base reaches 230 machines.
1997 Installation base reaches over 300 machines. Plant geared up for
a production of 10 machines per month.
1998 - The group takes over a Unit engaged in the manufacture of CNC
Machines in Chengannur, Kerala. This plant gets allocated for the
manufacture of higher end machines.
1999 - In print Pack 99, New Delhi, a Modular Signature Gatherer
called PickWell was unveiled. INTIMATE MACHINES Private limited is
conferred ISO 9002 certification, thereby making it one of the very few
companies in Graphic Art Industries in India to achieve the same.
2000 - Ties up with NATIONAL STARCH & CHEMICAL As an Exclusive
Agent for their Hot Melt Adhesives (Book Binding Grades) for India.
The installed base of Welbound has grown over 800 machines.
CHAPTER 2
PRODUCTS MANUFACTURED
SINGLE CLAMP PERFECT BINDER
WELBOUND BLUE
MULTY CLAMP PERFECT BINDER
WELBOUND 2000
WELBOUND 3600
GATHERING MACHINE
PICKWEL
FOLDERS
DIPLOMA 4Z3X
DOCUMENT BINDERS
MICROBINDER 330
STITCHER WITH ONLINE TRIMMER
SWITCHWEL COLT
OFFLINE THREE KNIFE TRIMMER
TRIDENT3
Salient Features
6 book clamps traveling in
an oval shaped path,
where the spine is in line
with the crucial binding
station.
Calibrated book clamps
with thickness indicators;
single knob adjustments.
Easy job change over.
Continuous flow of clamps to the feed-in station with "No book-No
cover" system.
Special type milling cutter which removes paper in "strips" form
(which has commercial value) and avoids generation of paper dust.
Three roller gluing system with reverse spinner; calibrated head & tail
end cut-offs to avoid adhesive squeeze out.
Separate side gluing station with tank & gluing discs. A thin & even
layer of glue is spread along the side adding value to the book finish.
Automatic, pile type cover feeder with on-line creasing attachment.
Salient Features
Calibrated book clamps with 'thickness indicators'. Single knob
adjustments leading to easy job change over.
"No book-No cover" system.
Two milling stations- One with "strip" cutter and other with
"roughener" (user selectable) for better spine preparation.
Dial indicators provided to measure depth of milling.
2.4 FOLDERS
2.41 DIPLOMA 4Z3X
AUTOMATIC PAPER FOLDING MACHINE
Salient Features
PLC controlled with soft touch display
Various folding formats up to 4 parallel and 3 cross folds
Digital sheet to sheet distance regulation
Easy job change-over with the help of digital position indicators
Creasing / perforation / slitting attachments before each knife
Electronically controlled folding knives with independent servo
motors
Third knife (or final fold) mobile type unit
Ready to be upgraded with attachments and add-ons
Salient Features
Two feeding stations are provided which can be used
simultaneously.
Both stagger and straight stitching possible.
In case there is no signature under the stitching head it is sensed
and the stitching head will not be activated.
Easy machine set up.
On line trimming - Trims one book at a time for superior quality.
Each knife has its own built-in clamp, which actuates prior to
trimming.
Books can be deflected after stitching for off line trimming
ADMINISTRATIVE DIAGRAM OF
INTIMATE MACHINES
CHAPTER 3
DEPARTMENTATION
3.1 INTRODUCTION
Departmentalization is the efficient and effective grouping of jobs into
meaningful work units to coordinate numerous jobs-all the expeditious
accomplishment of the organizations objectives. This creates Flexibility,
Adaptability and unit of action within the firm. The various departments in
Intimate Machines Pvt Ltd are as follows:
Production Department
Personnel Department
Commercial Department
Financial Department
Research and Development Department
Engineering Department
Human Research Development and Administration Department
Safety Department
4. Performance Appraisal
Performance appraisal a systematic evaluation of present potential
capabilities of personnel by their superiors. It is the process of estimating
or judging value status of a person. The main objectives of performance
appraisal are
To provide systematic judgment to back up salary increments,
transfers etc.
Canteen
intimate Machines directly running and industrial canteen to cater
the needs of the employees at free or subsidized rates functions inlet
the control of personal department, works round the clock is headed by
canteen Superintendent, A flat rate system has been introduces and
deduction is made from salary/wages of the employees.
To develop good suppler relationship which will ensure the best terms
of supply of materials.
To serve as an Information Centre on the materials knowledge
relating to price, source of supply, mode of delivery etc.,
To make continuous availability of materials so that there may be
uninterrupted flow of materials for production.
To make purchase in reasonable quantities to keep investment in
materials at minimum.
3.5 RESEARCH AND DEVELOPMENT DEPARTMENT
Research is an ongoing process. For the development of any
organization, research is a prime factor. So in any reputed organization,
there is a special wing for research and development. Intimate also has a
well-equipped and efficient R & D Manager concerned with Quality control
and Pollution monitoring, Technical services, Research and pilot plant
respectively. The department was concerned with the research or study of
new processes or techniques for the company. By the findings of these
departments, the company was able to find long-term solution to certain
problems of process and quality. The R & D Manager was responsible for
guiding, directing, initiating and executing all the jobs in the department.
The ISI analysis of the products and raw materials also came under this
department. Research and Development activities are concerned with raw
material substitutions, usage norms, surface coating, development of new
products and pollution control. Intimate gave prior importance to the
quality of product. Their product was well known for its quality. Intimate
has a well-established Quality Policy is as follows.
Taking samples at various stages starting from raw material till the
end product.
Analyzing the samples, finding the variance in production.
Studying the variance.
To improve the quality as well as quantity of products.
Monitoring the plant performance and pollution.
Maintaining quality at all stages of products.
Providing service to customers.
RECORDS
Copy of WO (ERP file)
Store request
NC reports (file)
NC register
REPORTS
Stock statement (monthly).
Pending stock taking more than 15 days (weekly)
Pending WO more than one month (monthly).
Non-moving items more than three months (monthly).
NC register cum status report (weekly).
Protective Equipments
Helmet For head
A Goggles For eyes
A Mask For face
Respiratory Apparatus for Breathing
Gloves For Hand
Apron For Body
Safe Shoe For Foot
CHAPTER 4
INTRODUCTION TO CNC
DEFINITION
Computer Numerical Control (CNC) is one in which the functions
and motions of a machine tool are controlled by means of a prepared
program containing coded alphanumeric data. CNC can control the
motions of the work piece or tool, the input parameters such as feed,
depth of cut, speed, and the functions such as turning spindle on/off,
turning coolant on/off.
APPLICATIONS
The applications of CNC include both for machine tool as well as
non-machine tool areas. In the machine tool category, CNC is widely used
for lathe, drill press, milling machine, grinding unit, laser, sheet-metal
press working machine, tube bending machine etc. Highly automated
machine tools such as turning center and machining center which change
the cutting tools automatically under CNC control have been developed.
In the non-machine tool category, CNC applications include welding
machines (arc and resistance), coordinate measuring machine, electronic
assembly, tape laying and filament winding machines for composites etc.
ELEMENTS OF A CNC
A CNC system consists of three basic components
1. Part program
2. Machine Control Unit (MCU)
3. Machine tool (lathe, drill press, milling machine etc)
Part Program
Spindle speed, S
Programmed in rev/min, it is expressed as RPM or by a three-digit code
number that is related to the RPM.
Toolword, T
Consisting of a maximum of five digits, each cutting tool has a different code
number. The tool is automatically selected by the automatic tool changer
when the code number is programmed in a block.
Miscellaneous Function, M
Consisting of two digits, this word relates to the movement of the machine
in terms of spindle on/off, coolant on/off etc shown in Table 2.
EOB
The EOB character is used at the end of each block to complete a line.
CHAPTER 5
CONCLUSION
The Intimate Machines Pvt Ltd is a well reputed, profit making
Indian Company. The major asset of this company is skilled staff.
Moreover the efficient management of the resources have helped them
to overcome the slump in the sales over the last few years. Through this
In-Plant training it was able to fulfil the objective of our study. Detailed
study on the processes was made possible by giving emphasis on the
practical side of the theory. All together it was a good experience to see
the company and various processes carried out in the plants and the
various functions of the company.