INTERNSHIP REPORT

Muhammad
Muhmmad
Abdullah
Uzair Aslam
Mohsin

Mechanical Industrial
Engineering Manufacturing
Department Department

Third Year Engineering, NED UNIVERSITY

PRODUCTION INTERN, 28-May-18 to 22-June-2018

Submitted to: Col. Retd. Sarwar

Shamim

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 PREFACE

Engineering profession is adopted to serve the mankind in all possible

manners. The study of getting innovative and smart enough to build the new
horizons not completed until the practical knowledge is obtained by engineers.
Engineering internships is providing a great opportunity to get the best of their
curriculum in the vacations. NED University is making it easier to link with
industries though Directorate Industrial Liaison Department. Atlas Engineering
Pvt Ltd giving beneficial and tremendous source of practical guidance from
main engineering subjects specially Manufacturing, Machining, Heat Transfer
etc. internship program gives an idea of what happening in real world and how
to serve the humans in great way after graduating.

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What is Atlas Group?
ATLAS GROUP OF COMPANIES
The Atlas group was laid in 1962, with the establishment of Shirazi Investments
Limited. Currently, Atlas group consist of fifteen companies in the fields of
engineering, financial services and trading.
Following are the list of companies included in the
Atlas Group:
1. Atlas Honda Limited
2. Atlas Battery Limited
3. Atlas Power Limited
4. Atlas Engineering Limited
5. Honda Atlas Cars Pakistan
6. Atlas Insurance Limited
7. Atlas Asset Management Limited
8. Shirazi Investment (Private) Limited
9. Shirazi Trading Company (Private) Limited
10. Honda Atlas Power Product (Private) Limited
11. Atlas Hitec (Private) Limited
12. Atlas Worldwide
13. Atlas Global FZE
14. Atlas Venture Limited
15. Atlas Autos (Private) Limited
16. Atlas Metals (Private) Limited
17. Atlas Die Casting (Private) Limited
18. Atlas Aluminum (Private) Limited

ATLAS INDUSTRIAL PARK

Atlas Engineering Private Limited is located in Atlas Industrial Park. The Atlas
Industrial Park comprised of many group companies of Atlas Group shown
below:

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ABOUT ATLAS ENGINEERING

Atlas Engineering Private Limited (formerly Allwin Engineering Industries

Limited) was established in 1951.
Atlas Engineering is one of the largest and oldest manufacturers of automotive
parts and components in the private sector in Pakistan.
The Company has state-of-the-art facilities to process pig iron and aluminum
alloys into high precision automotive components.

PRODUCTS OF AEL

The products of AEL are distributed in three sections; Cast Iron Products,
Aluminum Products and Radiators. The chart of Products is shown below.

ATLAS ENGINEERING
LTD

Cast Iron Aluminum

products products

Radiators

Cast Iron Products:

This is done CI Foundry and cylinder machining shop. First pig iron melts then
comes to form the cylinders using molds. This obtained product then machined
and finishes into final products.

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Aluminum Products:
Pistons of bike engines manufactured here, raw material melts and move to
dies where it takes the shape of molds. After that aluminum machining shop
finishes the pistons at high quality.

Note: Radiator department is where we appointed as production internee.

Radiators:
Engines are producing power and lost a reasonable amount of energy in the
form of heat. Heated engine decreases the efficiency of its system. So cooling
is done through RADIATOR which is basic component in cooling.

Working of radiator:
Water or any anti-freezing liquids used to cool down the temperature. They
are passing the radiator tubes coming from engine. The fins takes their heat
and air through the fins takes the heat to environment. Hence the system
cools down by 8-10⁰C.

Introduction to Radiator Assembly Shop:

There are more than 350 sizes radiator formed here. There are 9 main sections
including:

Press and shearing section, tube and fin forming section, jig filling, baking of
core, washing and testing, assembly attachments, paint section, inspection and
dressing, and packing.

Pressing and shearing Section:

It includes the punching, sharing and drawing the brass sheet for header plates
and bottom plates. They also punch the upper and lower tanks. The size of
radiator mentioned on strip embossed in die in this section.

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Tubes and Fins forming section:
There is a Brass coating process in which it is coated with soldering materials
which are lead and tin for this particular process. 2 strip tanning machines are
being used for this process. The temperature for the tanning is 360°C .The
more the temperature the less the thickness of the coat. Currently the
thickness of the coating on brass strip is 12-13 microns. It’s done for coils of
brass getting into tube machining. There are 2 machines for complete tube
forming and bending. It forms required sizes on demand. The basic material is
brass coil either coated with soldering or simple.
There are 7 fins forming machines. 2 of them are flat pins forming while 1 is
classic Allwin forming machine, there are 4 zig zag pins forming machines out
of them 1 is for 8 mm thickness while 3 are for 10 mm thickness. They work on
principle of metal forming. The basic raw material is copper coil.

Jig Filling Section:

There are 8 flat pin core jig filling fixtures in the assembly area and 7 zigzag
core jigs including pneumatic and screw driven. Skilled labor inserts the tubes
in fins which are fixed at jigs. At zigzag they put tubes on zigzag fins one by
another up to the size and fixed the header plates.

Baking Section:
Before baking etching is done on core to have proper melting of soldering on
tubes so the fins attach to them properly. Etching is done by chemical include
ZnCl, HCl and water. After etching there are 4 furnaces for baking the cores.
The temperature of the furnace is 380°C. The capacity of each furnace is 6-7
cores per batch. The timer setting for the furnace varies from zig zag core to
flat pin core. For zigzag core it is 10 minutes per heat while for the latter one it
is 6-7 minutes per heat. The cores are given a time of 10 minutes to cool down
before further processing.

After cooling of cores then they go for 340 ° C solder filling cores for complete
joining of upper and lower plates known as dipping process

Testing and washing sections:

100 % testing is done for the leak test by passing the air at 2 bar pressure
through cores which dipped in water so water bubbles gives the idea of

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leakage. After testing cores goes for washing in different chemicals such as
sodium cyanide NaCN, Caustic soda NaOH. Then they pass through distilled
water, anti-cutting/ lubricating oil and sea fall for shining effect.

Assembly section:
In assembly area following parts are being assembles together with soldering
rod (tin + lead) by oxyacetylene flame,
i. Core
ii. Tank ( top & bottom )
iii. Hose pipe ( outlet and inlet pipe )
iv. Holding and mounting frame
v. Drain nut
vi. Pouring neck and overflow pipe

Three washing tanks are present for washing of the assembly and cores after
the process of grinding is completed.

Paint section:
100% drying off the products is done to make sure no moisture is present in
the parts. Drying is done at 115 ° C for 15 minutes in baking oven placed at
assembly area. 20-25 small parts can be loaded at a time.

Painting is done on the assemblies, assemblies are loaded into trolleys and
then passed to oven at 105 C for 5-10 minutes, 8-10 parts per batch for
painting so the paints get dried.

Inspection and dressing sections:

Fins are combed on the cores of radiators as well as assemblies just to make
smooth touch. Final Inspection of the radiators done at the end with naked
eyes; specifically tubes are re-checked, if any issue arise then radiators are sent
back to the reworking.

Packing:
The last step is packing. It includes stickers pasting according to various sizes
and packing into card boxes and silver spray if any mark remains on brackets,
and then dispatched.

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Radiator Department Product:

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 Assignments

 Main Assignment is time and motion study of assembly shop and

recommendation for assembly shop keeping in view of 5S and Kaizen.

 Time and motion study of jig filling

 Acceptance and rejection data of radiator testing

 Recommendation of paints which are acid resistant

Through all these projects we are guided by every single of shop, starting from
top management the support provided by HOO Col. Retired Sarwar Shamim,
the information sharing of Mr. Anwar (Manager) and Mr. Imtiaz (Assistant
Manager) is remarkable. Hafiz Fashi ur Rehman (Assistant Manager) gives us so
many ways of thoughts and skillful learning is worth-full. Mr Iqbal Usman and
Mr Asad (Production Supervisor) always there to help us in all technalities.
During projects worker provide us all necessary information and it proves Atlas
culture is remarkable.

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Assignment: Time and motion study of jig filling

Atlas Engineering Private Limited

15th Mile, National Highway Landhi, Karachi-75120

Plant: Radiator Assembly Supervisor Name: Faseeh ur Rehman Advisor: Mr Anwar

Jig Filling Airway and Flat Fin Shakeel Sb

Area: Technical Head: Incharge: Syed Iqbal
Cores Imtiaz Sahab

Time And Motion Study Sheet

Sheet: 1
Objective: Time and motion study of Jig Filling Airway and flat Fin cores
Date: 06-02-18

Characterstics Time: (in sec)

Mean Time:( in sec) Remarks:
Size: Rows:
S.No: Type: FPI: 1st Cycle 2nd Cycle 3rd Cycle
1 Zig Zag 11.75 x 13.75 315 330 310 318.3333333
2 Zig Zag 24 x 255/8 4 850 815 875 846.6666667
3 Flat 17.5 x 17.5 5 6 879 890 900 889.6666667
4 Flat 18.5 x 15 4 6 770 780 775 775
5 Flat 24.5 x 25 5 7 1350 1319 1322 1330.333333
6 Flat 19 x 205/8 5 6 1185 1190 1200 1191.666667
7 Flat 29 x 217/8 5 7 1495 1450 1500 1481.666667
8 Flat 31.5 x 31.25 5 7 2220 2250 2150 2206.666667
9 Zig Zag 12x151/4 4 305 280 245 276.6666667
10 Zig Zag 13x23 6 320 350 355 341.6666667

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Assignment: Recommendation for acid resistant coating

Materials of Coating:
1)
Epoxy Metal Coatings
Epoxy Coatings & Air Dry Epoxy
Coatings
Air dry epoxy coatings are self-priming, high gloss, corrosion resistant coatings
that are recommended for use where a high performance, chemically resistant
coating is desired. These coatings offer single coat corrosion protection at 4-6
mils thickness, as well as very good abrasion resistance. It may also be used as
a 2 or 3 coat system for use in industrial environments including offshore oil
and gas.

Epoxy Coating Statistics

Color many options available

Thickness .004" - .006" per coat

Use Temperature 300°F max

Adhesion (ASTM D4541) 1933 psi

Salt Spray Resistance (ASTM B117) 4000 hrs

Hardness (ASTM D3363) >8H

Chemical Resistance (ASTM D543) Excellent

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 Protection from acids on any surface
Acid proof coating is designed especially for industrial environments which
frequently deal with acids in forms of immersion or occasional contact. The
applications take place for instance in acid storage areas on walls and floors,
and in acid containers internally and externally. There are different coatings
suitable for many substrates either on large surfaces or smaller objects such as
machinery parts. The most common substrates include metals (e.g. steel and
aluminium) and concrete. If you are looking for an acid resistant coating
system, make sure to know your project and provide the supplier with
sufficient information. Here you will discover what the coating options for your
substrate are, and what you should know before making the coating choice!
Acid resistant paint can be applied to:
 Cargo and storage tanks
 Packaging
 Battery rooms
 Acid storage areas
 Garages

Give acids no chance by using acid proof coating

Steel is a material which often needs protection from acids of different kinds.
The acid proof paints for steel are applicable on all surfaces including small
objects and large substrates such as walls, floors and doors. The following
table introduces the coating types and gives an idea of their acid resistance. All
these coatings are applicable on steel; but some of them are also suitable for
other substrates such as concrete.

ACID PROOF PAINT RESISTANCE NON RESISTANT TO..

Moderate; require fast

removal of stains and
Epoxies spills Nitric and sulfuric acids

Excellent; the only nitric

and sulfuric acid resistant
Epoxy novolac epoxy –

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Vinyl esters Good; most acids Propionic acids and nitric acid fumes

Moderate; only mild acids;

require fast removal of
Polyurethanes stains and spills Aggressive acids

PTFE Good Fuels and oils

Good; most acids such as

Strongly oxidising substances such as nitric,
PSS (polyphenylene phosphoric and sulfuric
sulfide) acids hydrochloric and peroxy acids.

Excellent; also high

FEP (fluorinated ethylene concentration in
propylene) temperatures up to 100°C –

Excellent; most acids,

Kynar PVDF including acid fumes Fuming sulfuric and nitric acids

Excellent; most acids, also

High concentration nitric and
high concentration in high
Halar ECTFE temperatures picric acids in high temperatures

The best protection from sulfuric acid

Sulfuric acid is an acid highly corrosive to metals; it additionally causes damage
on many other materials. Therefore, objects and surfaces which might be in
touch with sulfuric acid, require a special protective coating. The acid is used
for example in:
Lead acid batteries
 Domestic acidic drain cleaners
 Chemical industry: mineral processing, fertilizer manufacturing,
wastewater processing, chemical synthesis etc.
 Production of sulfuric acid
To protect from the acid, surfaces can be treated either with sulfuric acid
resistant sealant or paint. As a floor coating, (more about: floor coating)

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epoxy novolac is recommended; it is the most acid resistant floor coating,
and the most durable epoxy. It can also endure exposure to sulfuric acid for
several days before cleaning up.

2)
Specially Formulated Polymer Systems

Specific grades offer outstanding resistance to various concentrations of

selected acids such as: Sulfuric acid, nitric acid, hydrophiloric acid etc.

Most Popular Acid Resistant Polymer Systems

EP21ARHT
Serviceable from +400°F. Exceptional acid
resistance. Cures at room temperature. Good flow
properties. 100% reactive. Low shrinkage upon
cure.
Withstands 1,000 hours 85°C/85% RH. Reliable
electrical insulator. Adheres well to metals, glass,
ceramics, rubbers and plastics. Shore D hardness
80-90.

EP62-1HT
Superior resistance to harsh chemicals, particularly
to acids. Two part epoxy has long pot life at
ambient temperatures. High bond strength
properties. Ideal for bonding and coating. Good
flow. Reliable electrical insulator. Serviceable from
-60°F to +450°F. Tg 150-160°C. Shore D hardness
80-90.

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 EP62-1BF
Cures rapidly at moderate elevated temperatures.
Superior resistance to harsh chemicals. Two part
epoxy has long pot life at ambient temperatures.
High bond strength properties. Reliable electrical
insulator. Serviceable from -60°F to +500°F. Tg 170-
175°C. Shore D hardness 80-90.

3)
Multi-Functional - Highly Chemically
Resistant Novolac Epoxy Coating -Flooring
Resin

DESCRIPTION
Epoxy.com Product #633 Novolac Epoxy - Highly Chemical Resistant Epoxy
Coating is a 100% solids epoxy Novolac coating ideal for harsh chemical and
solvent resistant applications. Epoxy.com Product #633 Novolac Epoxy - Highly
Chemical Resistant Epoxy Coating is used in secondary containment, solvent
storage, pump pads, trenches, and other high exposure areas.

Epoxy.com Product #633 Novolac Epoxy - Highly Chemical Resistant Epoxy

Coating is ideal for use as a protective coating for concrete and steel in the
extremely corrosive areas of chemical plants and pulp mills secondary
containment areas, water and waste treatment, and gas and electric
utilities. Epoxy.com Product #633 Novolac Epoxy - Highly Chemical Resistant
Epoxy Coating is commonly used as a seal coat for Epoxy.com MORTAR
SYSTEMS where chemical resistant performance is required.

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ADVANTAGES
 Exhibits excellent resistance to strong acids, alkalis, and most industrial
chemicals and solvents

 Can be applied in cool damp conditions

 Can be re-coated in 4 to 6 hours

 Can be applied in occupied facilities

 Forms a virtual moisture barrier

CONSIDERATIONS
 Concrete substrate to receive Epoxy.com Product #633 Novolac Epoxy -
Highly Chemical Resistant Epoxy Coating must be free of dirt, waxes,
curing agents, and other foreign materials.

 Steel surfaces to receive Epoxy.com Product #633 Novolac Epoxy - Highly

Chemical Resistant Epoxy Coating must be free of grease and oils. Abrasive
blast to SSPC-SP5.

COMPOSITION
 100% solids, modified amine adduct cured epoxy Novolac resin.

R-Recommended for continuous service L-Limited recommendation, occasional

spills.

PERFORMANCE PROPERTIES
Tensile Strength ASTM-D-638 10,400 p.s.i

Adhesion to concrete ACI Committee 403 300 p.s.i - 100% concrete failure

Hardness ASTM-D-2240 86 Shore D

Abrasion Resistance ASTM-C-501 CS-17 Wheel 30 mg lost

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Service Temperature MIL- D-3134F Up to 180-325 degrees F. Dry Heat

Elongation 2.5%

SUPPLIERS IN PAKISTAN:
1.

CHEMPROCK
Manufacturer and Supplier
Superior chemical resistance to 98% sulfuric acid, 37% hydrochloric acid, 50%
nitric acid, 20% chromic acid, 85% phosphoric and glacial acetic acid etc. As
well as 50% caustic, wet/dry chlorine, most solvents and petroleum-based
derivatives etc.
For any enquiry and further detail information, please feel free to contact us.
Contact Person:

Mr. Sarfraz Ahmed

Address:

411, E-II, M.A.Johar Town, Lahore, Pakistan. Contact Number:+92 42

35221241

2.
3M™ Scotchkote™ Epoxy Coating 162CR

Two component 100% solids coating designed to protect steel and concrete
surfaces including water tanks, bund walls and concrete subject to chemical
attack.

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3M™ Scotchkote™ Epoxy Coating 162CR, 5L
Two component 100% solids coating designed to protect steel and concrete
surfaces including water tanks, bund walls and concrete subject to chemical
attack. 5L: 1.66L activator, 3.34L base-Mixed 2.33 parts base to 1 part
activator.

3M Pakistan (Pvt) Ltd.

Islamic Chamber of Commerce Building

ST-2/A, Block 9, KDA Scheme 5,
Clifton, Karachi 75600. Telephone: 9221 111225536 Fax: 9221 35877865

3.

PROTECTIVE COATING &

LINING

EXTERNAL COATINGS : When pipes are left uncoated they are exposed and left
subject to corrosion which causes leaks and spillages leading to serious
consequences to both life and the environment. In 1992 CSAPL was the first to
offer multi layer coatings on line pipes in Pakistan and continue to provide
Single and Multi Layer coatings in controlled environments. Through
technological advancements we have been able to consistently produce
premium quality pipe coatings.

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MULTI LAYER POLYOLEFIN COATING: Multilayer Polyolefin coatings encompass
steel pipelines with high mechanical strength and greater adhesion to steel.
Spiral pipes produced at CSAPL employ the side extrusion process, an
advanced coating system, to produce strong, reliable, stable and age resistant
coatings. High standards of quality are achieved at our coating facility by
maintaining a controlled and clean environment.

FUSION BONDED EPOXY: Fusion Bonded Epoxy coating is a one-part heat

curable thermosetting epoxy resin powder, used for in-ground coatings. By
using heat to melt and adhere to metal substrates it provides excellent
adhesion and results in a smooth chemical and abrasion resistant finish. FBE
coatings increase pipeline durability by protecting and reinforcing steel against
corrosion at extreme temperatures.
ANTI-CORROSION EPOXY COATINGS: Epoxy coatings are a form of Internal Anti
Corrosion Epoxy coatings which are thinner than Cement coatings. Pipes of a
smaller size can be used which reduce the bulk and weight during handling and
pipe installation. The smooth hard coating reduces friction, decreases energy
costs and decreases investments in installed pumps or compressors. At CSAPL
internal coatings are applied to the AWWA C210 international standard.

REGISTERED OFFICE
E- Floor, IT Tower, 73-E/1, Hali Road, Gulberg III, Lahore
Phone: +92 42 35783801-3
Fax: +92 42 35783811

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Assignment: Acceptance and rejection of radiator on 1st
testing

Radiator Assembly Department

Testing analysis of Radiator Acceptance/Re-working/Rejection on 1st Testing
Date: 5-june-2018 Submitted to: Fasih ur Rehman
S.No:
Acceptance Re-working Rejection Remarks
1 1 tubes repair
2 1 footer plate+tubes leakages
3 1 footer plate+tubes leakages
4 1 tubes leakages
5 1 tube repair
6 1 tube repair
7 1 header plate+over flow pipe leakages
8 1 tubes+over flow pipe
9 1 1
10 1 header plate+tubes repair
11 1 tube leakages
12 1 footer plate+tubes leakages
13 1 bottom tank+tube leakages
14 1 tube and footer plate repair
15 1 tube leakages
16 1 tube and outlet pipe repair
17 1 header plate+tube leakages
18 1 1
19 1 tube repair
20 1 tube leakages
Total: Acceptance= 02 Re-working=07 Rejection=11

Note: Rejected Radiator again send to Baking Process for having many leakages to be fixed.

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Assignment: Recommendation for improving assembly area
under sight of 5S and Kaizen
RECOMMENDATIONS FOR RADIATOR ASSEMBLY LINE
1. Acid resistant paints should be used on all jigs, work holding devices,
bath tubs and other equipment.
2. Vinyl flooring should be used that can resist the effect of sulfuric acid.
3. Chimneys should be used to discharge smoke and fumes properly.
4. Surface should be made flat on ground for the ease of walking.
5. Mechanical rollers should be used for transportation between
workstations to promote quick operation.
6. At least six exhaust fans should be mounted on wall adjacent to dressing
area.
7. Bracket fans should be used instead of pedestal fans in top to tank
radiator assembling.
8. Electric igniters should be used to avoid fire hazards.
9. Rejected radiators should be removed from assembly area immediately.
10. Cupboard with sliding doors should be used for storing tanks, filling
necks, overflow pipe, side brackets and other small components to
increase storage capacity.
11. Every work table should be placed in separate cabins.
12.Fire extinguisher should be mounted on walls.
13.Separate path should be used for transporting radiator trolleys.
14.Oxygen cylinders should be placed away from assembly area to ensure
safety in case of any explosion.
15.Pneumatic clamps should incorporate sensors to ensure fool proofing.

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Assignment: Time and motion study of Assembly line

Atlas Engineering Private Limited

15th Mile, National Highway Landhi, Karachi-75120

Plant: Radiator Assembly Supervisor Name: Faseeh ur Rehman Advisor: Mr Anwar

Jig Filling Airway and Flat Fin Shakeel Sahab

Area: Technical Head: Incharge: Syed Iqbal
Cores Imtiaz Sahab

Time And Motion Study Sheet

Sheet: 1
Objective: Time and motion study of radiator assembly line.
Date: 2/6/2018

Characterstics Time(in seconds):

Neck
Bottom Side Inlet Outlet with
S.No: Type: Top Tank Drain Nut Total Assembly Time Remarks:
Tank Bracket Hose Hose overflow
pipe Pipe pipe
1 SUZUKI RAVI/BOLAN 158 143 65 40 35 95 45 581

2 SUZUKI ALTO VXR 123 118 105 50 65 115 35 611

3 SUZUKI CULTUS 186 178 110 80 103 140 54 851

4 SUZUKI MEHRAN 88 120 60 30 55 80 44 477

5 TRACTOR 330 289 200 130 150 190 98 1387

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 Conclusion:

Atlas Engineering ltd give us motivation and satisfaction related to our

academics. This summer internship program is really a great opportunity for
future endeavors to make their ideas better and better. Recommendations and
all learning objective of our beneficial days at radiator assembly shop will help
us in future engineering studies. We hope that the engineering culture develop
here will spread and benefits our Country and honored us more. At the end of
internship we admire to say that:

THANKYOU ATLAS

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