Lakshmi Precision Screws Ltd.

Lakshmi Precision Screws Ltd.

Summer Training
Welcome to IMEA Team

At LPS from

rd 3

July 2008

Vision 2010
MISSION
Be a globally competitive organization providing the best fastening solutions.

VISION 2010
Make LPS a Most Sought After Brand.
Achieve US $110 Million in Sales. Become a Deming Organization Expand Manufacturing to 2 more locations

Most Sought After means:

1. Fastest New Product Development time. 2. Fastest Customer Response Time. 3. Customer PPM < 100 consistently.

S Respect For People

Customer Obsession

Continuous Improvement

History & Milestones

History & Milestones

1972 - Established by Mr. B P Jain as LPS

History & Milestones

1984 - Registered as Public Limited Company
1988 - Established as Exporter 1991 to 93 - Continuously received Regional Export Award from EEPC

1993 - Established LPS Plant-II

1995 - A2LA and NABL Accreditations

History & Milestones

1996 - ISO 9002 Certification
1996 - Technical tie-up with Sunil Machinery Corp., S.Korea for Quality, Productivity & Development of Automotive Parts 1998 - Marketing tie-up with RECOIL Pty. Australia 1998 - Joint venture with BOSSARD-AG, Switzerland

History & Milestones

1999 - License to manufacture & market Torx brand of proprietary products from Textron Inc. USA 2000 - QS-9000:1998 Certification 2001 - ISO/TS 16949:1999 Certification 2001 - ISO 14001 Certification 2002 - SAP R/3 implemented

History & Milestones

2002 - Golden Peacock Environment Management Award

2003 - VOLVO Global Supplier Certification

2003 - ISO/TS16949 (Version 2002) Certification 2004 - Recommended for OHSAS 18001 Certification 2005 - License to manufacture fasteners with Doerken Proprietary Delta-Seal & Delta-Tone Finishing Technology

History & Milestones

2005 - License to manufacture & market EJOT brand of proprietary products Delta-PT & Altracs from EJOT GMBH, Germany 2005 - Marketing tie up with Wiha Werkzeuge GmbH, Germany for their Quality Tools 2006 Quality Software Sapphire implemented to integrate plant-wide Quality data and institute online traceability 2006 Winner of Silver Award for Manufacturing Excellence in the Engineering Emerging category during Indian Manufacturing Excellence Awards 2006 conducted by Frost and Sullivan

History & Milestones

2006 Certified to supply high tensile fasteners of grade 10.9 and above to Volkswagen globally 2006 Winner of 1st runner up award in North West Qualtech awards 2006 2006 Winner of

2007 Winner of 3rd prize in Kaizen Competition conducted by CII in 2007

Our Key Customers

Our Product Range

Standard Products Special Products Components

Our Product Range

STANDARD PRODUCTS
Socket Head Cap Screw Socket Counter Sunk Head Screw Socket Set Screw Knurled Cup Point Flange Bolts/ Screws Dowel pins Stainless steel Fasteners Socket Low Head Cap Screws Socket Button Head Cap Screw Hex Head Bolts/ Screws Hex Nuts Friction grip bolts

Our Product Range

SPECIAL PRODUCTS
Torx and Clamp Compressor Bolt Wheel Bolts Collar Bolts and Axles Axles Studs Pivot Pin Transmission Bolt C.R. Bolt, Hub Bolt Durlock Screw Wheel Bolt and Stud Hex Bolts

Our Products
COMPONENTS
Piston Pins Shafts Ball Pins Ball Rods Plunger Sockets Spine Shafts

Manufacturing Capabilities
Diameter Range: M3 to M30 by Cold Forging. Above M30 by Hot Forging.
Grade: JIS, ANSI, BIS, IS, DIN, ISO. Length: 6 mm to 300 mm by Cold Forging. Above 300 mm by Hot Forging.

Manufacturing Capabilities

Variety of Finishes: Dacro Coating, Zn Plating with Chrome Passivation (Black, Green, White, Bleach Yellow & Yellow)

Thermal & Chemical Blackening

Transmission / Engine Fasteners

Description of Symbol
The hexagon is a symbol of precision. When interpreted as a nut, it symbolized craftsmanship and unending productivity, the workers and the people related to LPS are represented by the view of a Hexagon nut. In the symbol, the circle represents the co -process, understanding Dedicating towards the workers work or duties in a quality circle, LPS is the name itself (LAKSHMI PRECION SCREW) in self explanatory or explaining the keenness every worker or employee to produce a precise product.

Different Process of Making Bolt

1. 2. 3. 4. 5. 6. Production of die and punch according to the bolt Forging operation- done in forging machine. And is used for making Head. Thread rolling- thread cutting is done on thread rolling machine. Heat treatment- done for improving strength, internal stress etc. Plating- plating is done by electroplating mechanism and zinc, zinc iron and phosphate plating is generally done. Final inspection and packaging

How the Process For The Bolt Making Initialize By The Company
The customer gives a description or drawing to the company as his requirement He Gave description about that product which he wants. This description firstly goes to the engineering department. They make a drawing for that product in AutoCAD 14 or in solid works. In that drawing engineer first equate the volume of the product to the area of the wire. It gives the length from which they make the given product, then from these length of wire he make calculation for the dimension of head it goes to the that engineer which make its process sheet and what type of raw material is used in making that product. Then it goes for approval that all things and process for that product is right or not.

How the Process For The Bolt Making Initialize By The Company
Then it goes to the production planning and control department. Where they decide that this product goes to various machines for production and in in what time interval this Product will goes to another machine for next step. After that this description goes to the Production department. Then this description and design goes to the supervisor of the tool room. They make dies and punch for that product as in the description and drawing given by the supervisor. Then dies, punches are made on different machines. Like lathe, drilling, wire cut, drilling machines etc. then these dies and punches and ready and goes in the tool store room for checking. These checkings are done in pore gauge, hole gauge etc.then the die and punch for checking goes to projector profile machine which check the under collar radius in the die and head angle given in the punch and die. .

Heat Treatment
Heat treatment is an important operation in the manufacturing process of machine parts and tools. It may be defined as an operation of heating and cooling of metals in the solid state to induce certain desired properties into them. Heat treatment can alter the properties of steal by changing the size and shape of the grains of which it is composed, or by changing its micro constituents. It is generally employed for the following purposes: Advantages: To improve machinability To change or refine grain size To relieve the stresses of the metal induced during cold or hot working. To improve magnetic and electrical properties. To increase resistance to wear, heat and corrosion.

Most Commonly Used Operations Of Heat Treatment Are

1) 2) 3) Annealing Hardening Tempering

4)

Carburizing (case hardening)

Annealing
It is one of the widely used operations in heat treatment of iron and steel and is defined as the softening process in which iron base alloys are heated above the transformation range in the furnace itself. Alternatively, the steel may be transferred to another furnace at about 6500c, and held there until the austenite has transferred into pearlite (final cooling can be done in still air). The success of annealing depends upon controlling the formation of Austenite, and the subsequent transformation of the austenite at high sub critical temp. Various types of any annealing treatments are:

Hardening
According to A.S.M.T. it is defined as the heat-treatening process in which steel is heated to 200c above the transformation range, soaking at this temp. for a considerable period to ensure through penetration of the temp. inside the components, followed by continuous cooling to room temp. by quenching in water , oil or brine solution. The rate of cooling is controlled by quenching medium. These solutions are: Solution of salt or caustic soda, high flash point/clean water from grease of soap, blast by dry air.

Tempering

According to A.S.M.T. it is defined as the reheat process, reheating being carried out under subcritical temp. Such a reheating permitting the trapped martensite and relieve the internal stresses. Toughness and ductility are improved at the expense of hardness and strength. It is an operation used to modify the properties of steel hardened by quenching for the purpose of steel hardened by quenching for the purpose of increasing its usefulness.

Case Hardening or Carburizing

This process is used to produce a high surface hardness for wear resistance supported by a tough shock resisting core. It is the process of carburisation such that saturating the surface layer of steal with carbon to about 0.9% or some other process by which case is hardened and core remains soft. The carburised steel is then heated and quenched, so that only the surface layer will respond, and the core remaining soft and tough since,its carbon content is low.

Project on Simulation

Objective: To calculate stresses acting on the tools (die and punch) while cold forging so to prevent tools from failure and to ensure a longer life for a given forging sequence.

Given: Forging sequence for given bolt, simulation software (Nagsim 2d), drafting software (AutoCAD).

Project on Simulation

Simulation: It implies an approach in which a virtual (computational or on computer) but similar to existing system is designed to predict the actual application parameters. Medium can be a computer or a prototype. Here the step by step simulation in Nagsim gives the prevailing stress values at different points of the tool which would be applicable as if the tool were actually operated on the forging machine. Thus without any actual operation on the machine we can have an insight of the stresses acting on the tools and can design the tools to withstand those stresses with a longer life.

Procedure Of Doing Simulation

1. A step by step tooling as per the given forging sequence is drafted with the help of AutoCAD. The tooling is drafted such that the cut-off length is inserted once in the first step because the same will be transferred to further steps in deformed shape. The simulation software (Nagsim) will automatically transfer the deformed blank step by step. A new project file is created in the simulation software. Now the step by step tooling drawing of AutoCAD is imported in the software. The materials for the blank, die, punch are chosen from among the listed ones.

Procedure Of Doing Simulation

Here; the material of die is tungsten carbide, to ensure good fatigue and wear strength provided by high hardness. Material of punch is alloy of HRC 60 or carbide (58-60 HRC), which also provides good wear strength. Material of the blank is given by the customer and is chosen to have almost same properties with respect of percentage of major elements like carbon. 5. Now the first stage simulation is run by providing tool displacement (usually 200 steps), where in each step refers to a tool displacement of .01 mm. As soon as simulation starts running the punch moves downward thereby deforming the blank material as per the die shape. The simulation is stopped as the material takes the desired shape.

Process Of Doing Simulation

6. Now the deformed shape will automatically be transferred to second stage. Again the simulation is run and further deformation of blank material starts. Simulation is stopped as soon as the required shape is achieved.

7.
8.

Similarly the final stage simulation is performed, thereby giving the final bolt shape.
Now the stress values acting on the tools in different stages are checked by reading the results. The results in the form of animation are recorded by the software and can easily be obtained by clicking the result button and selecting the stage.

Result Of Simulation
The results are shown in the form of animated figures with different colors. A sided scale defining stresses corresponding to different colors is referred to find the point of maximum stress. In this way the maximum prevailing stresses in each of the three stages are recorded. Now the recorded value is compared with the yield strength of the material and taking a factor of safety greater than 1.3 in to consideration, we can decide whether the tool is capable of withstanding the acting stresses or not. If not than an alternate solution is found such that changing the material of tool or increasing the diameter of cut-off.

Result Of Simulation
1st Station

Result Of Simulation
2nd Station

Result Of Simulation
3rd Station

Thank you