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Industrial

Visit
2004

NAME OF COMPANY
PADGILWAR ELECTRICAL INDUSTRIES
TYPE : Small scale
MANAGEMENT : Partnership
TYPE OF PRODUCTION : Job order production.
LOCATION5

1. It is placed in M.I.D.C. AKOLA, Phase No. - II


2. This company has got perfect situation exactly nearer to highway No. 6. So ease
of transportation.
3. From the nearby city company can get technicians and engineers easily.
4. No problems of electricity, water and man power.
5. In this region farming is the main business. Since company’s orientation is
agriculture based , company can get customers easily.

ORIENTATION :-
~ Mainly agriculture based products.
~ Now company is entering into seed processing industry and making products that
are used by seed processors.
~ Company’s aim is AUTOMATION IN INDIAN AGRICULTURE.
~ Products manufactured by this company has very bright future in all over the
world.

COMPANY BACKGROUND :
~ Company has started by manufacturing THRESHERS in 1954 which are used for
cleaning of wheat grains from impurities.
~ Then company started manufacturing of POWER SPRAYERS. Now company
has reached the stage where it is second largest manufacturer of power sprayers.

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~ Now company is manufacturing many technically advanced machines like


AUTOMATIC WEIGHING MACHINES, AUTOMATIC SEALING MACHINES,
GRAVITY SEPARATOR, MIST-O-MATIC SEED THREATER ETC.
FUTURE :
Now company is entering into seed treating industry by making COTTON SEED
DE-LINTING PLANT. It is fully automatic, safe and convenient to use than
traditionally used delineating plants. It is based on German technology and can be
fully controlled by one person. It has very high perspectives of export because of its
muck lesser cost.
PLANT LAYOUT :
Plant layout is a very important feature in today’s industries. It is arrangement of the
desired machinery and equipment of a plant established in the way which will permit
the easiest flow of material at lowest cost and with the minimum handling in
processing the product from the receive of raw materials to the dispatch of the
finished product.
PADGILWAR ELECTRICAL INDUSTRIES has process layout.

DEPARTMENTS OF COMPANY :
1. Research and development department.
2. Machine shop.
3. Store department.
4. Sheet metal and fabrication department.
5. Production planning & control department.
6. Inspection department.
7. Assembly section.
8. Coloring and packaging department.
VALUED CUSTOMERS :
~ Maharashtra Biyani Mandal &
~ Others seed processing units.

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INTRODUCTION TO DEPARTMENTS
RESEARCH AND DEVELOPMENT DEPARTMENT:-
It is very important department since it develops new ideas improves
continuing process. Now a days it plays an important role in advancement of
company. They are being very necessary in the environment of tough competition.
In PADGILWAR the employees of R & D department keep themselves always busy
in modifying the products and making them more convenient and more advanced.
Small scale industries like PADGILWAR have very limited sources of R & D. But
still employees of this department tries to give the best. They always try to maintain
close tolerances with maximum production. Everyday they discuss about the product
and make necessary changes.

MACHINE SHOP :
Machine shop includes various production machines. Different
assemblies and sub-assemblies are manufactured in this shop.
Following machines are placed in machine shop.

1. Lathe machine
2. Drilling machine
3. Nibbling machine
4. Grinding machine
5. Electric are welding machine

STORE DEPARTMENT :
The finished and non finished parts, raw materials, in process
inventories etc. are stored in store departments. To be precisely, functions of stores
are as follows :
1. To maintain record of incoming and out going materials from store.
2. To maintain record of issued materials, equipment etc.

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3. To prevent materials from erosion or any other such type of fatigue.


4. To keep record of quantity of materials remaining; and from this record, to inform
purchase department that which goods need to be purchase.

SHEET METAL AND FABRICATION DEPARTMENT :


In sheep metal shop sheets are cut or bended according to design
considerations. Because of PADGILWAR machines are made of different sheet
metals, this department plays an important roll. The complete bodies of various
machines are manufactured by this section. Channels, panels, angles of small
sections can be manufactured by various machines like nibbling machine, bending
machine etc.

PRODUCTION PLANNING & CONTROL :


Advanced planning of flow of materials, operations to be performed on
raw material, material handling maintenance, are made on the charts, tables and
graphs. By using these charts, tables, graphs various operations are performed.
It results in saving of time, easy control of production, prevention from
breakdown of machines. Due to this systematic method required processing time is
reduced. It causes increase in production rate as well as profit.

INSPECTION DEPARTMENT :
It is the main department in all manufacturing companies. Inspection is
necessary to maintain quality and close tolerances. The method of inspection
depends upon method of manufacturing. For assembly line production in line
inspection is used. But it is not possible in job order production. PADGILWAR also
has job order production. So it is impossible to have in line inspection. So
inspection is done in machine shop while manufacturing.

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ASSEMBLY SECTION :
PADGILWAR has special assembly section for making assemblies of
POWER SPRAYERS. Various parts of power sprayers made in other shops are
collected in this section. Since there are number of screws and nuts used in power
sprays the tightening and unscrewing caused mental fatigue to human being. So
pneumatic tightening and unscrewing is provided for such type of work. Other
products like Delineating plant, seed treater, gravity separator, weighing machines
etc. are assembled in this section.

COLORING AND PACKAGING DEPARTMENT :


After assembling machines they are send to the coloring department.
In this department painting sprays are used for painting the machines. Painting
prevent the product from corrosion at the same time it makes product attractive.
Then packaging is done.

COMMENTS :
We find this industrial visit very interesting and informatic. We come
to know about how a small scale industry works. To know about how the limitations
of small scale industry can be over come is very necessary for an engineer.
PADGILWAR is a nice example of such type of industry. We also come to know
about how engineering can be related with other fields like agriculture.

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2004

PADGILWAR ELECTRICAL INDUSTRIES


INTRODUCTION:
The seed was won way back in 1954 when PADGILWAR started
manufacturing manual and semiautomatic farm machinery.
Even today PADGILWAR is a named i.e. synonymous with quality and
excellence in farm machinery separator. Automatic sealing machine, etc.
The fiery enthusiasm to venture into unexplored areas, the capability to overcome
hurdless and transform the odds into opportunities, the over whelming desire to excel
in every endeavor these are the indefinable qualities that are manifest in every
machine manufactured by PADGILWAR.
The two plants of PADGILWAR at Akola are equipped with some of
the world’s best machines and excellent testing facilities enabling them to
manufactured range of machines that stand out as import substitutes, at par with
world renowned machines.
The export award by Government of Maharashtra for PADSONS RICE
MILL and the best industry award from department of Industries are testimonies to
the international standards of PADSONS machines.
From simple nuts and bolts to bearings and sheet metals only the best in
the world go into the market is making of PADSONS machines.
At PADGILWAR, the selling of machine is not the end, but the
beginning of an enduring relation. It is the prompt and efficient after sales service
that has contributed to the reputation of PADGILWAR as muck as the quality and
performance of their machinery. And this tradition for excellent service continuous
to be the forte at PADGILWAR.
The confidence PADGILWAR has earned from their reputation gives
them the inspiration and strength to look forward to the future with hope and
determination.

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Now the company has introduced cotton Seed delineating Plant the first
of its kind and among the best few in the world.
With quality and performance at per with the worlds best machines and
technical services that can be matched by few, PADGILWAR is all set to blaze a new
trial in Seed Processing Plants.

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* AUTOMATIC GAS BASED COTTON SEED DE-LINTING PLANT *


INTRODUCTION :
Cotton seed delineating plant is the latest product manufactured by the
PADGILWAR Industries. It is technically very advanced fully atomized with the
help of German technology. This plant is only of its kind in Asia.
Delineating of cotton seeds is the process removal of fuss (lint) from
the linted cotton seeds.
Delineating of seeds is essential to facilitate further processing of seeds
on automatic machines and results in faster and higher percentage of germination.
Conventionally delineating of cotton seeds is done by use of wet acid,
which is hazardous, layout intensive and creates pollution. This conventional process
is not adaptable for atomization and calls for large floor space. Extensive handling
also deteriorates the quality of seeds and reduces percentage of germination.
This plant eliminates all the disadvantages of conventional method and
offers many advantages, like fast germination, ease of sowing, grinding, cleaning and
treating of seeds.

OPERATION :
All the operations in this plant is controlled by PLC (Programmable
Logic Control).
With the help of conveyor, cotton seeds with lint is fed into trolley
which is placed on weighing platform. Then required weight of seed is fed into the
delineating drum with the help of trolley. In this drum cotton seed is treated by
required amount of chlorine gas, which removes the lint. Then by the bucket elevator
acidic seeds are fed into buffer where it is treated by ammonia gas which neutralizes
the seed. This makes the seed able to germinate with the help of centrifugal blowers
seeds and lints gets separated. Lints are passed to cyclone separator. Seeds are taken
out through discharge hoppers. From cyclone separator lints are collected in a tank.

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The polluted gases are forced in to scrubber which is partially filled with water which
makes gases safe. The gases are thrown to the atmosphere with the help of chimney.

AUTOMATIC GAS – BASED COTTON SEED DELINTING PLANT

SPECIAL FEATURES :
1. The cotton seed is in dry state through out the process needs no water in process.
Plant is designed in such a way that it is not needed to clean the plant after each
lot.
2. All the operations are carried out absolutely automatically and hence no chance of
any human error. Substantial savings on labour cost.
3. Minimum handling of seed, hence quality of seed and germination percentage of
seed is very high.

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4. The powerful fumes extractor and scrubber ensure pollution free environment.
5. Any lot size of seed from 50 kg to 200 kg can be fed which is one of the
important requirements for hybrid cotton seed.
6. Adequate precaution is taken to ensure safety for people working in this plant.

AIR SCREEN SEED CLEANER


INTRODUCTION :
PADSONS Air Screen Seed Cleaner is a unique, compact and proven
design to give absolutely reliable performance. This is best suited for high output of
all types of seeds and grains. The screen boat and other structures are made of the
finest steel so that under any operating conditions, the machine should run absolutely
maintenance free.

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OPERATION :
PADSONS Air Screen Cleaner has highly efficient preliminary and
final aspiration. At first the uniform flow of material enters preliminary aspiration
where light impurities and dust are air extracted.
From there the material is passed on to the top sieve has two brusher of
screen which separates seeds and impurities. Then the material is passed to the
bottom sieve which has two layers of screen, where undesired material is separated
from good seeds. All remaining light seeds and impurities are extracted b final
aspiration to obtain high purity seeds which comprises only fully viable seeds
delivered as an output.

SPECIAL FEATURES :
1. Brush type screen cleaning for all models.
2. The screen boat made of steel in place of most commonly used plywood makes
the machine real sturdy.
3. The unique design of ball rollers makes loading and unloading of screen very
easy.
4. The stainless steel screen with chrome plated hollow pipe frames last practically
lifelong.
5. For uniform feeding, a simple flap with rack and pinion gears arrangement is
provided.
6. Variable speed drives for easy adjustment of sieve speed.
7. Unique design by which equal distribution of seeds is done on both layers of
screens for more output.
SEED CLEANER

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TECHNICAL SPECIFICATIONS

Details Padsons 100 Padsons 200 Padsons 400


Capacity (Wheat) TPH 1 2 4
Screen 0.80 × 1.16 1.0 × 1.5 1.2 × 1.845
Length (m) × Width (m) 0.928 1.5 2.214
Area for Fine Grading (m2)
Screen 0.8 × 0.415 1.0 × 0.5 1.2 × 0.615
Length (m) × Width (m) 0.332 0.5 0.738
Area for Scalping (m2)
No. of Screes for Scalping 2 2 2

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No. of Screes for Grading 2 4 6


Overall Length (mm) 2100 2700 3100
Dimensions Width (mm) 2500 3000 3500
Height (mm) 1300 1550 1800
3
Gross Volume (m ) 15.70 23.20 35.62
Gross weight (approx.) (kg) 1000 1750 2500
Electrical Drive 10.5 HP/ 18 HP/ 23 HP /
7.8 kW 13.5 kW 17.2 kW
440 V 440 V 440 V
50 Hz AC 50 Hz AC 50 Hz AC

Air delivery CFM 6000 8000 10000

APPLICATIONS
In addition to seed industry, this machine is excellent in food
processing industry like oil extraction, pulses mill, bakery, rice mill, flour mill,
breweries, etc.
GRAVITY SEPARATOR
INTRODUCTION :
PADSONS Gravity Separator is designed to separate the particles of
same size but having slightly different specific gravity (i.e. insect attacked for or
immature seeds).

OPERATION :
The material is fed continuously on the surface is covered with porous
material through which pressurized air creates a fluidized bed casing the seed
particles to instantly orient themselves according to their specific weight.
The reciprocating motion of the table deck induces the heavier particles
to migrate to the higher level of the deck. Because of fluidized state, the lighter
particles flow to the lower level of the deck.

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SPECIAL FEATURES :
1. Deck inclination in both directions (longitudinal and transverse) can be easily
adjusted when the machine is running.
2. Excellent and easy wheel arrangement for individual air control of each blower.
3. Best quality tested steel for long life.
4. Dynamically balanced blower to avoid noise and vibration.
5. For operators convenient all the controls of the machine are on one side.
6. Easily cleanable air filter panels.
TECHNICAL SPECIFICATIONS

Details PGS 3 PGS 5 PGS 7


(3 Fans) (5 Fans) (7 Fans)
Capacity TPH 1 2 4
(Wheat)
Deck Width (mm) 750 1000 1200
Size Length (mm) 1500 2100 3000
Overall Length (mm) 2400 3000 3600
Dimensions Height (mm) 1100 1300 1500
Width (mm) 1200 1600 2000
Gross Volume (m3) 4.50 7.20 11.50
Gross Weight (kg) 800 1200 1600
(approx.)
Electrical Drive 7.5 hp 10 hp 15 hp
440 V 440 V 440 V
50 Hz AC 50 Hz AC 50Hz AC

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GRAVITY SEPARATOR

APPLICATIONS
In addition to seed industry, this machine is excellent in food
processing industry like oil extraction, pulses mill, bakery, rice mill, flour mill,
breweries, etc.
AUTOMATIC WEIGHING MACHINE
INTRODUCTION :
Automatic Weighting Machine is one of the most advanced machine
manufactured by PADGILWAR. This machine is designed to facilitate the precise
weighting of seeds. This machine is fully automatic and is approved by weighing
and measurement department, Lucknow.
Capacity of this machine ranges from o to 5 kg and its speed of operation is 8 to 12
bags per minute.

OPERATION :
Automatic weighing machine is very simple and easy to operate. In
this operation at first, seed is fed into hopper. There is a weight balance on which
one of its side required weight is put and on the other side there is seed. When the
weight of seed is balanced with the required weight then the solenoid valve operates
and the seed is discharge through the discharge hopper into the bag. When the bag is

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taken out the bottom sensor operates and again gives signal to the solenoid valve and
the operation is repeated.

SPECIAL FEATURES :
1. Simple and easy to operate.
2. Increase productivity.
3. Glass shields provide protection to operator from powder, chemicals, etc.
4. Display screen gives information on step to step operation.
5. Electronic circuit unaffected by dusty environment.
6. Digital counter for counting of bags.

AUTOMATIC WEIGHING
MACHINE

TECHNICAL SPECIFICATIONS
Details Model WX 905

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Maximum Capacity 400 bags of 5 kg wt/hour


Overall Dimensions
Width 820 mm
Length 1002 mm
Height 1515 mm
Gross Volume 2 m3
Gross Weight 200 kg
Electrical drive 1 hp
230 V
50 Hz AC

APPLICATIONS
Ideal for accurate weighing of seeds, and any other aranular material.
AUTOMATIC SEALING MACHINE
INTRODUCTION :
PADSONS Automatic Sealing Machine offers a superior alternative to
the conventional method and introduces a revolutionary new way of sealing stitched
bags.
The seal a formed from H.D.P.E. plastic granules and the bag is sealed
automatically, once it is kept by the operator on the sealing platform. The
temperature and amount of plastic required for seal are controlled automatically by
the circuit, as per setting.

SPECIAL FEATURES :
1. Simple and easy to operate.
2. Saves time and labour.
3. Counter display screen shows number of bags sealed.
4. Electronic circuit is fully protected and unaffected by the dusty environment in
the plant.

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5. Company monograms can be embossed prominently by fixing suitable die. This


facilitates identification of brand and enhances corporate image.

TECHNICL SPECIFICATIONS
Details Model SX-900
Maximum Capacity 500 to 700 bags/hour
Overall Dimensions
Width 815 mm
Length 1020 mm
Height 1300 mm
Gross Volume 1.8 m3
Gross Weight 300 kg
Electrical drive 0.75 kW
440 V
50 Hz AC

AUTOMATIC SEALING MACHINE

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APPLICATIONS
This machine is best suited for all applications where bags or pouches
are sealed using lead seal.
SEED TREATER
INTRODUCTION :
PADSONS Mist-o-Matic seed treater ensures uniform costing of
pesticides on each individual seed grain. This is essential in order to protect the seed
against seed borne, soil borne decreases etc.

OPERATION :
This stainless steel construction makes it corrosion free and gives
longer machine life. The weight of the seed acts to mater both the seed and chemical.
In the blending chamber finest possible distribution of treating agent over the seed
surface is done. In the coating chamber the specially designed blending rods gently
tumble the seed to provide uniform film coating on all types of seed.

SPECIAL FEATURES :
1. Stainless steel construction ensures long machine life.
2. The counter weight measuring system is proven to be the most accurate one.
3. Because of minimum moving parts machine is best suitable for continuous duty.

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4. The variable speed drive synchronizes flow rates for maximum blending
efficiency.
5. High speed rotating disc to ensure uniform coating.
6. Attachment for powdered treatment available.
TECHNICAL SPECIFICATIONS
Length 3659 mm
Width 1755 mm
Height 1825 mm
Number of trays 42 Nos., 14 Rows, 3 Columns
Length of Tray 980 mm
Width of Tray 130mm
Power 23 kW, 3 Phase, 440 V, 50 Hz
Capacity 1.5 tonnes per batch

SEED TREATER

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PRE CLEANER
Padsons Pre Cleaner is the most simple and versatile machine. The
machine is developed to separate light-weight impurities in seeds by air suction.
When the seeds are fed through the inlet hopper, all impurities get
separated because of suction created by the blower. Then the seeds automatically
passes on to the sieves, where oversized and low grade are separated from good
seeds. The light seed and impurities are separated by blower suction.

SALIENT FEATURES
• Self-cleaning of screens by mean of ball cleaning.
• Simple to operate.
• Screen boat made of best quality tested steel for long life.
• Easily changeable screen for multipurpose operation.
• Magnetic separation of iron particles at outlet (optional).
• Variable speed drive for control of sieve speed.
• Can be mounted on mobile wagon with diesel engine and an elevator.

TECHNICAL SPECIFICATION

Details Model Model Model


PC 2 T PC 5 T PC 10 T
Capacity TPH
Wheat 2 5 10
Screen Width (mm) 600 1000 1200

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Size Length (mm) 800 1500 1850


Overall Length(mm) 1500 2800 2800
dimensions Height (mm) 1700 2500 1700
Width (mm) 700 1400 1300
3
Gross volume (m ) 3.5 8.16 12.00
Gross weight (kg) 750 1400 1800
(approx.)
Electrical drive 6 hp 7.5 hp 10 hp
440 V 440 V 440 V
50 Hz AC 50 Hz AC 50 Hz AC

PRE CLEANER

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APPLICATIONS
In addition to pre-cleaning of seeds PADSONS Pre Cleaner is also best

suited in all kinds of food processing industries like oil extraction, pulses mill, rice
mill, flour mill, breweries etc.
POWER SPRAYER
This is most efficient motorised Knapsack Spraying Machine.

SPECIAL FEATURES :
1. The blowers delivers air at high velocity causing fine automation of all pesticides.
2. Due to fine automation optimum utilization of pesticides.
3. The flexible pleated hose makes spraying easy.
4. Extremely comfortable due to high quality shoulder and back cushion.

JAYANT / PUSPHPAK POWER SPRAYER

SPRAYING

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TECHNICAL SPECIFICATIONS
Engine : Rallis L-35 or Greaves L-34
Fuel : Petrol or Kerosene
Tank Capacity : 11.9 litres
Total weight : 11.5 kg
Air Discharge : 0.175 m3 / second
THRESHERS
PADGILWAR THRESHER - APT 83 :
This is the most popular multi crop thresher. Best suitable for Jower
(Sorghum). The compact size makes it truly mobile. It has excellent cleaning and
threshing efficiency. This machine is good source of income for rural youth.
SPECIAL FEATURES :
1. Extremely safe to operate.
2. Conforms to is : 9020
3. The lower fan cleans the dust in the grains very efficiently.
4. Can be operated by electric motor and diesel engine.
PUSHPAK THRESHER - PT 1 :
The specially designed threshing drum for this multicrop thresher
makes it best suitable for soyabean crop.

SPECIAL FEATURES :
1. Sturdy and well balanced drum structure.
2. Low feeding height makes it efficient and convenient to use.
3. Adjustable air flow for optimum cleaning efficiency.
Model APT-83 Pushpak PT-1

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Drum width (mm) 356 356


Drum type Spike tooth Raspbar
RPM 720 720
Dimensions L×W×II (mm) 1530 × 950 ×1450 1900×980×1460
Threshing capacity (kg) -- --
Jower 950 850
Soyabean -- 250
Wheat 350 300
Power required (hp) 5 5

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PADGILWAR THRESHER – APT 83

PUSHPAK THRESHER – PT-1

BULLOCK-DRIVER SPRAYER : ‘BRAMHA’

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Only one of its kind, not only in India but also in whole world.

 One of the first of its kind Sprayer in World driven by bullock power.
 Tank having 200 liters of storage capacity.
 A pressure of 4 to 5 kg/cm2 pressure can be developed with 100 feet travel
of bullocks.
 Due to the absence of horizontal axel in BRAMHA, a good spraying can be
done on crops having 4 feet of height from the ground.
 Distance between the two wheels of BRAMHA can be adjusted.
 Excessive pressure is released due to special provision of safety - valve.
 Spray-Nozzles does not get checked, as special non-corrosive plastic fitter in
BRAMHA.
 Structure of BRAMHA is best suited to local atmosphere and Indian
conditions.
 Spraying action is continuos inspit of slow down in bullock speed.
 One person and two bullocks are enough for spraying of 15 acres of land in
a day.
 After opening special projections provided on both the sides, spraying action
can be obtained in a strip of 20 feet width.
 Nozzles for spraying can be changed as per the requirement of crops.
 Nozzles can be changed with guns. This enables spraying on trees upto 20
feets of height.
 Nozzles can be adjusted in vertically upward and downward direction in
range of 9” to 8 feets from the ground.

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BULLOCK – DRIVER SPRAYER : ‘BRAMHA’

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Name of Company
JADHAV GEARS INDUSTRY
TYPE : Small Scale
MANAGEMENT : Individual
TYPE OF PRODUCTION : Job Order Production
PLANT LAYOUT : Process Type Layout
LOCATION : JADHAV INDUSTRIES
W-27, STREET NO: 5
MIDC AMRAVATI – 444605
MAHARASHTRA, INDIA.
MANAGEMENT :-
1) Production Manager :- Mr. Vijayrao Deshmukh.
2) Managing Director :- Mr. Sanjay Jadhav.
3) Q.C.C.Manager :- Mr. Mahure
4) Marketing Executive :- Mr. Deshmukh

OBJECTIVES OF QUALITY CONTROL


The main objectives of a quality control program conducted in an industry are:-
1. Evaluation of quality standards of incoming material, product in the actual manufacture,
and of outgoing product.
2. Judging the conformity of the process to the established standard and taking suitable
action when deviations are noted.
3. Developing methods for effective utilization of scrap materials in minimum handling.
4. To improve quality and productivity by process control and experimentation.
5. Developing procedures for good employer – employee relations.
6. Developing quality consciousness both within and outside the organization.

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AIM OF THE PROJECT


The project has been undertaken keeping in view establishing an assembly
shop, which supports continuous assembly line thus replacing the existing assembly practice
of job type for “Auto feeder” at Jadhav Gears, M.I.D.C. Amravati.
The company was facing a problem of not meeting the delivery dates in the
peak season. A that time the production rate was 6 Auto feeders per shift of 8 hours. Thus
to fulfill the demand they have to use 3 shifts. So it was decided that instead of batch wise
production, a systematic approach towards continues production should be adopted. This
necessitates the need for assembly line and assembly shop. The target production rate was
fixed at 20 Auto feeders per shift.
PROFILE OF INDUSTRY
“JADHAV GEARS” is a manufacturer of all types of reduction gear boxes,
gears, conveyors spares, is located at M.I.D.C. Amravati.
The company is mainly involved with cotton processing systems, for which
they produce following products on demand.
* Ginning machine.
* Micro feeder
* Lint opener
* Lint conveyors
* Cotton pre-cleaner.
* Cotton baling press.
* Raw cotton suction system.
* Pneumatic cotton -seed conveyor
* Screw conveyor for raw cotton and cotton- seed.
Apart from above-mentioned products, there is regular production of AUTO
FEEDER, a machine for feeding the cotton in the ginning machine. The company motto, “
Excellence is not a destination, it is a continuous journey that never ends,” has a very
positive attitude towards the quality of its products. In a very short future, it has received
ISO 9002 certification; giving a self-identity to its products in the market.

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A company, which believes in thought “We have not arguments with


competitors who charge less. But we realizes what their product and service is worth.”
Majority of the parts of Auto feeder are been produced at “Jadhav Gears” and
its sister concerns viz. “Jadhav Steel Alloys”, “ Jadhav Agro Pvt. Ltd.” etc. So in this sense,
the company is self-sufficient.
In this company, near about 150 workers with quality consciousness produce
quality products to provide best services to the customer.

PLANT LAYOUT
Plant layout is a very important feature in today’s industries. It is the
arrangement of the desired machine and equipment of a plant established in a way which
will permit the easiest flow of material at lowest cost and with the minimum handling in
processing product from the receive of raw materials to the dispatch of the finished product.
Jadhav Gears Industries has the Process Type Layout.
DEPARTMENTS OF COMPANY
The company is comprised of several departments, which work all together
with good co-ordination.
* Machine Shop
* CNC Machine shop.
* Design and drafting section.
* Assembly shop.
* Quality Control Department.
* Warehouse department.
* Account Section.
* Sales marketing section.

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INTRODUCTION TO VARIOUS DEPARTMENTS


ASSEMBLY SHOP BUILDING
A. CNC MACHINE SHOP: -
CNC machine shop includes mainly two semi-automatic operated CNC
machines. These are listed as below: -
1. CNC - I
On this machine, the ginning machine pin is finished and trued. The single
point cutting tool is clamped automatically on turret head provided with eight tool stations.
Once the tool is set to proper position, it works automatically.
The loading and unloading of work piece (ginning pin) is done manually. As
being semi-auto operated, only one worker is required to operate the machine nicely and to
get completed 1 job in 5 minutes.

2. CNC – II
The required work piece - tool position is set as above.
On this machine, the swing lever clutch is trued as shown in figure. This
machine is capable of having 12 tools for different operations.
B. ASSEMBLY SHOP:-
This shop includes various production sections. It comprises the production
and assemblies of various parts of ginning machine.
1. This shop includes the assembling of ginning machine and various products of the
company:
The body of the ginning machine is placed on the rail conveyor. This is then
proceeded further by attaching the various parts of the machine i.e. frame, roller, screw
conveyor, motor, gear box, blower, etc.
The Product Type Layout is in working superiously .
2. In this shop two production machines are placed:
i) Hydraulic shaping/Bending Machine.
This machine is employed to cut or bend different shapes of angles, flat
strips, bars, etc.

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ii) Hydraulic Press Fitting Machine:


This machine is used to press fitting of needle bearings into the hub. The
loading and unloading of the hub is done manually. The raising and lowering of press stamp
is totally manual.
3. The Assembly Shop is associated with many material-handling equipments.
The various material handling devices are:
* Fork lift truck: - It is widely used for stacking the materials. Similarly it is used for
carrying the scrap sheet metals, bars, and angles throughout the various departments.
The company has the two medium-sized truck.
* Jib Crane: - This crane is used for lifting and displacing the heavy objects like steel bars,
plates, dies, etc. within the shop.
For a smooth and continuous work of assemblies and sub-assemblies; three
jib cranes are employed in the assembly shop. The crane has the oscillating movements.
* Overhead Crane: - This crane has both transverse and longitudinal movements. The crane
hook thus moves in a rectangular area and can reach to any part of rectangular floor or yard.
It is used for displacing and lifting the frames, steel rolls of ginning machine within the
shop.The one overhead crane is employed in assembly shop.
* Rail lines: - A very small rail line is installed within the shop for conveying the ginning
machine through the various sub-assemblies sections of assembly shop.
C. MACHINE SHOP – I: -
This shop includes various production machines. Different assemblies and
sub-assemblies are manufactured in this shop. Various operations like facing, turning,
drilling grinding, etc. are performed in this department.
Following machines are placed in the machine shop.
1. Centre lathe machine.
2. Drilling machine.
3. Grinding machine.

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D. FABRICATION SHOP AND SHEET METAL SHOP: -


In sheet metal shop sheets are cut or bended according to design
considerations. This department plays an important role since many machines are made of
different sheet metals.
The complete bodies of various machines are manufactured by this section:
(1) Channels, (2) Circular bars, (3) Panels, (4) Angles of small sections can be manufactured
by various machines like nibbling machine and bending machine. The welding machines
are used for joining the different parts of sheet metals.
MAIN STORE BUILDING: -
This building is having the following departments:
A. Machine Shop II
This shop is equipped with production machines like milling and lathe
machines.
In this section, connecting rod casting is processed. The small end of
connecting rod is drilled on milling machine. Various machining and finishing operations on
different castings are done in this department.
Following machines are placed in machine shop – II:
(i) Gang Milling Machines (3)
(ii) Centre lathe machines (3)

B. Production Shop
This shop plays a vital role in designing and manufacturing of gears. As the
company’s name suggests, this department has its own importance.
The following machines are placed in production department.
(1) Key Way Milling Machine: -
On this machine the Keyway End Mill Cutter produces slot on the ginning pin.
The parts keyed on this machine are:
(i) Eccentric shaft,
(ii) Clutch,
(iii) Gear 39T, 46T and long bars.

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(2) Slotter Machine: -


The slotting machine or Slotter has its own importance for a few particular
classes of work. This is mainly used in cutting different types of slots and it certainly
proved to be most economical, so far as this kind of work is concerned. Its other uses are in
machining irregular shapes, circular surfaces and other pre-marked profiles, both internal as
well as external.
The two slotters are placed in the production shop.
3) Planer Machine: -
Planning is one of the basic operations performed in machining work and is
primarily intended for machining large flat surfaces. These surfaces may be horizontal,
vertical or inclined. The jobs, which are almost impracticable to be machined on a shaper or
milling machine, are machined on planning machine.
In the production shop one planning machine is satisfactorily being used for
machining flat surface or rails. The material feeding is manual.
4) Grinding Machine: -
This machine is used for removing material by the abrasive action of a
revolving wheel on the surface of hardened ginning pin.
It is a finishing operation on ginning pin uses a cylindrical grinder both for
internal and external grinding.
5) Gear Hobbing Machines: -
In this process, the gear blank is rotated with a rotating cutter called hob. A
majority of involute gears are produced by this method. Spur helical and herringbone gears
and many other shapes like splines and gear sprockets etc. can be cut by hobbing process.
The four hobbing machines are placed for gear hobbing process in the
production department.
6) Gear Burnishing: -
This process used for finishing the gear teeth and is employed on gears after
cutting. The gear is mounted on a vertical reciprocating shaft in mesh with three hardened
and ground burnishing gears. These gears are power driven. The three gears are fed into the

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cut gear and rotated through a few turns in both directions. This makes the gear teeth
surfaces smooth and also imparts a little hardness to them.
The required load is provided by hydraulic means.
* After gear burnishing: The gear meshing and run out operations is done by hydraulic
means for proper alignments of gears.

C. Store department: -
The finished and non-finished parts, raw materials, in process inventories,
spare parts of machines, etc. are stored in store departments. To be precisely, functions of
stores are as follows:
1. To maintain record of incoming and outgoing materials from store.
2. To maintain record of issued materials, equipment etc.
3. To prevent materials from erosion or any other such type of fatigue.
4. To keep record of quantity of materials remaining; and from this record, to inform
purchase department that which goods need to purchase.

D. Sheet Metal or Press working: -


In this shop sheets are cut or bended according to design considerations. The
shop is associated with bending and press machines. Channels, panels, hopper for Auto
feeder, etc. are manufactured in this shop as per the required capacity and design.
The Blower of medium to large sized capacities is completely assembled in
this section

*CASTING DEPARTMENT*
This shop is located 1 km away from the Annexure building. The various
assemblies and sub-assemblies are casted with proper technique and design.
The different sub-departments of casting shop are as below: -
A) Pattern making department :-
The process of making pattern is known as pattern making. The pattern
making is a primary stage of making casting.

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In this section various types of pattern are made by skilled workers. Wood is
widely used because of ease of availability and being cheaper.
B) Foundry Shop :-
In this shop metallic products are formed by melting the metal into different
furnaces, poured it into a cavity known as mould and allowed it to solidity.
The various works performed in foundry shop are: -
i) Sand preparation: -
The preparation of sand includes (i) Mixing of sand, (ii) tempering of sand
(iii) sand conditioning.
i) Mixing of sand :-
It means the mixing of various moulding materials to ensure uniform
distribution of clay, moisture and other constituents between the sand grains.
The moulding sand is ordered from Kanhan Plant Dist. Nagpur Maharashtra.
ii) Tempering of Sand :-
In this process sufficient moisture is added to the moulding sand by adding
water.
iii) Sand Conditioning :-
New sand as well as used sand is properly conditioned before being used.
Proper binders and additives are added to impart strength and other properties to the sand.
Most of the conditioning of molding sand is done by hand.
Besides, a sand Muller is used for sand mixing.
ii) Moulding Procedures :-
Most of the sand moulds are made by hand. One moulding machine is
employed in large – lot and mass production of moulds. A highly skilled worker has been
appointed for making the moulds.
The moulding procedures used in Jadhav Industries is ;
i) Based on the type of material of which the mould is made is “Green Sand Moulds”.
ii) The method used in making the mould is “floor molding”.
The graphite powder (black in colour) is provided over the moulds to develop
special properties in the moulds and consequently in casting.

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It also helps to provide smooth surface on the castings. Moulds like cover
plate, frame, rails etc. are produced.
iii) Core Making: -
Core making consists of the following operation: (i) Core sand preparation
(ii) Core molding (iii) baking and (iv) core finishing.
A core is a body made of refractory materials which is set into the prepared
mould before closing and pouring it, for forming through holes recesses, undercuts, internal
cavities.
All these core-making operations are done manually.
iv) Melting: -
Various types of melting furnaces are used, depending upon the quantity of
metal to be melted at a time, and the nature of work that is carried out in the shop.
The following furnaces used for melting are:
(i) Cupola : This furnace is used in foundries for melting and refining pig iron along
with scrap.
The continuous flow cupola furnace is used and has the capacity of 3 tonnes/hour.
(II) Oiled fired furnace:
This furnace is used for mass production and has the capacity of 1
tonne/hour.
v) Casting:
Casting is the solidified piece of metal taken out of the mould.
Different castings like crucibles, frames, rails, cover plates and many others
small pieces are conventionally casted.
C. Shot Blasting :
This is the process machining and filling the cavities left in castings. This is
done by the blow of small metal balls on the castings; which are kept on the rotary table,
operated in the closed chamber.
A Double Doored shot Blasting machine is used for this purpose.
D. Surface Grinding and Primer Coating:

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After peen blasting the castings are grinded to get the more finishing. The
pneumatic grinders are used for surface grinding.
The finished castings are then shifted for primer coating. The coatings are
used for the purpose of decoration, surface protection corrosion resistance and the providing
of a hard surface.
The coated castings are then shifted to various departments for further
operations.
* DESIGN AND DRAFTING SECTION*
Design is considered as a primary key in the production by different
machines.
Advanced parameters are considered while designing any machines. Various
comments, past experiences, different results are taken into consideration to provide the best
services to both the customers and consumers. The factors like capacity of machine, cast,
ease of availability, purpose, handling and maintenance, etc. is considered before designing
and drafting of machine. All these are recorded by means of charts, tables, CD’s, floppy’s
etc.
It helps to meet customer satisfaction and to improve quality of products.
It adds to the company’s status to be longer.
*PRODUCTION PLANNING AND CONTROL SECTION*
Advanced planning of flow of materials, operations to be performed on
raw material, material-handling maintenance are made on the charts, tables and
graphs. By using these charts, tables, graphs various operations are performed.
It results in saving of times, easy control of production, prevention from
breakdown of machines. Due to this systematic method, required processing time is
reduced. It causes increase in production rate as well as profit.
*INSPECTION DEPARTMENT*
It is the main department in all-manufacturing companies. Inspection leads
to improvements in metallurgy and raw material manufacturing due to demands of high
accuracy and precision. Inspection has also introduced a spirit of competition and led to

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production of quality products in volume by eliminating tooling bottlenecks and better


processing techniques. The method of inspection depends upon method of manufacturing.
For assembly line production in line inspection is used. Similarly in casting
department in line inspection is used.
But in line inspection is not possible in job order production. Because of
being job order production the inspection is done in different shops while manufacturing.

PLANT LAYOUTS

SHEET METAL
MACHINE SHOP - I
SHOP

ASSEMBLY SHOP
STORE
( RAW,
FINISHED
MACHINE)
CNC SHOP

ASSEMBLY SHOP BUILDING

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SHEET METAL
SHOP

MAIN STORE

STORE
(RAW) PRODUCTION
SHOP
MACHINE
SHOP-II

SECURITY OFFICE

MAIN STORE BUILDING

TOILET
SURFACE
PEEN BLASTING GRINDING &
COATING STORE
SECTION SECTION (CASTING )

STORE
PATTERN (PATTERN)
STORE
MAKING
SECTION OFFICE
FOUNDARY
(BINDERS

SHOP BAGS, SAND)

CASTING DEPARTMENT

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