THE MID WAY REPORT

PROJECT SEMESTER TRAINING

PREET KAMAL SINGH

101409025

MTX-1

UNDER THE GUIDANCE OF :- SUBMITTED TO :-

Mr. Kamal Kant Dr. N Harshavardhana

Deputy Manager

MSIL-M
 TABLE OF CONTENTS:-

*OBJECTIVE

*PROBLEM AND BACKGROUND

*INTRODUCTION

*WORK DONE/ CALCULATIONS

*WORK PENDING AND REMAINING TASKS

 PROJECT-1

OBJECTIVE:

REDUCE COST OF THE SENSORS PLACED IN PLANT WITH THE

HELP OF COMMONISATION TECHNIQUE.

AND

DESIGN OF A PHOTOELECTRIC SENSOR SUCH THAT IT ADDS TO

INCREASED EFFICIENCY OF AN EXISTING SENSOR.

PROBLEM AND BACKGROUND:-

There are a variety of photoelectric sensors used in our plant which are not
properly commonized. Ie. A sensor which cost less with same characteristics to be
used as an alternate for expensive one. Hence, it just adds to increased cost of
working sensors and also the sensors placed as backup stock in stores.

Usage of sensors in our plant have significantly increased with time. Firstly only
mechanical limit switches were used. But now with advanced technology, more
precise and efficient sensors have over took the mechanical counterparts.
Photoelectric sensors, proximity sensors etc. are widely used in automation
industry because of its features. There are a number of photo sensors placed in our
industry with different properties for different tasks. We need to find out common
characteristics sensors which can be best suited for other ones keeping the cost
factor in mind.
INTRODUCTION:-

Over the past 30 years, vehicle electronic systems have changed significantly.
Mechanical systems are continued to be controlled with Automotive Electronics.

The evolution of microcontroller and sensor technology is allowing automobile

industry to create complex systems that can provide higher levels of vehicle
control and safety.

Sensors are sophisticated devices that are frequently used to detect and respond to
electrical or optical signals. A Sensor converts the physical parameter (for
example: temperature, blood pressure, humidity, speed, etc.) into a signal which
can be measured electrically.

Without the use of sensors, there would be no automation !!

FACTORS ON WHICH SENSORS APPLICATION DEPENDS:-

Mostly used sensors in our plant industry are:-

1.) Photoelectric sensors (mostly used)

2.) Proximity sensors

3.) Limit switches

4.) Other sensors (area sensors etc.)

PHOTOELECTRIC SENSORS:-

*An industrial photoelectric sensor is a device composed of a light transmitter and

light receiver.

*Light is directed towards the object by the transmitter.

*The receiver is pointed towards the same object and detects the presence or
absence of reflected light originating from the transmitter.

*Detection of light generates and output signal for use by an actuator, controller or
computer.

*The output signal can be analogue or digital and is often internally modified by
timing logic.

* A photoelectric sensor is a semiconductor component that reacts to light or emits

light. The light may be either in the visible range or the invisible infrared range.
 WORK DONE:-

DETAILS OF CORRESPONDING PHOTO ELECTRIC SENSORS USED IN

OUR INDUSTRY ARE:-

SIMILARLY, PROXIMITY SENSORS USED IN THE PLANT ARE:-

OUTCOMES :-

*Studied and learnt about the sensors used in the plant.

*Collected the data related to all photoelectric sensors and proximity sensors.

*Obtained data sheets of all the photoelectric sensors.

*EZZ-LT61-2M and E3X-NA11-2M are the mostly used PE sensors.

*Talked to Omron industry officials to help with this project and they provided
reasonable data regarding the placement of sensors in plant.

*Collected necessary parts for sensor making.

REMAINING TASKS

*To study all the data sheets of photoelectric sensors and based on their properties,
find out in terms of cost, which sensor can be the best alternate for other to replace
with, such that the sensor properties remain same under the similar external
conditions.

*Requested plant head for implementing that sensor in industry in real time to
check for its practicality and feasibility.

*Design of a photoelectric sensor that can be most efficiently modified such that it
adds to increased efficiency of that sensor.
 PROJECT II

OBJECTIVE:-

TO PREVENT LEAKAGE DURING BRAKE OIL FILLING IN THE CAR

WHILE ON LINE.

PROBLEM AND BACKGROUND:-

The brake oil filling process is one of the most critical and essential part of the
assembly line process. Sometimes, during the brake oil filling, the gun(as shown in
fig.) doesnt fit in properly to the brake oil tank of the car, hence causing leakage
of brake oil, which adds to improper amount of brake oil filling, which eventually
results in decreased car performance. This is a major issue being faced by the
company.
 INTRODUCTION:-

PRINCIPLE OF OPERATION: -

The Brake Fluid Filling Machine works on the principle of Evacuation and
pressurized oil filling &leveling the volume in the bowl.

BASIC SEQUENCE OF OPERATION: -

EVACUATION
LEAK TEST
PRESSURE FEEDING
FLUID LEVELLING

The components of the system are:

1. BASIC SYSTEM UNIT WITH CONSOLE
2. FILLING ADAPTOR OR GUN

FILLING ADAPTOR OR THE GUN: -

This is the important component of the system, which comes directly in

contact with the brake system. This adaptor is mounted on the bowl
of the brake system and all operations i.e. evacuation, filling are operated through
this adaptor.
This adaptor is connected to the various lines (vacuum, filling) through flexible
piping.
* Connect the Gun to the Reservoir Tank
*Push the Cycle Start button on the Gun
Pre Vacuum and Vacuum
Leak Test (Major and Minor)
Filling of Brake Fluid
Re-suction and Leveling
*Completion of cycle will be indicated by Buzzer and Lamp
*Press Gun remove acknowledgement button on the Gun
* Remove the Gun
* Park the Gun on the gun stand provided on the Machine
CONNECTION OF GUN TO CAR
BRAKE OIL FILLING CONSOLE

WORK DONE
Till now, I have studied the basics of the brake oil filling module, which is highly
complex structure. The whole process of brake oil filling is studied.
The brake oil filling machine does the following Vaccum error This is the major
problem that every process automobile industry comes across. Vacuum error is
vaccum test machine as a leak in the system. As brake oil filling leak test machine
has its own constrain to have a vaccum oil filling pressure of 1.1 to 1.6 Torr.

Hence , it has been discussed to provide sensors to the brake oil filling gun which
detects the perfect tightening of the gun so prevent leakage.

Failure modes and effects analysis is discussed which will be studied and
implemented.
 WORK PENDING

Check for feasibility of putting sensor into the gun.

FMEA implementation.

PROJECT 3

OBJECTIVE:-
To study and implement line balancing technique for more efficient
production of the plant.

PROBLEM AND BACKGROUND:-

There are many different lines in our assembly system. Every line is not working at
its full efficiency and capacity. So, we have to detect any line where we can apply
the line balancing technique and increase the efficiency and hence productivity of
that line.

INTRODUCTION:-
The strategy is to make the production line flexible enough to absorb external and
internal irregularities. For this task, there are a number of calculations involved
which will be carried out. The Takt Time should be optimized. In this project, the
leveling of Workload across all processes in a line will be done to remove
Bottlenecks and excess capacity

WORK DONE:-

*Studied the previous data sheets related to cycle time, takt time, time cycles of
various lines for our pant.

*Detected the line where line balancing technique ought to be applied.

*Detected the parts where time can be minimized so as to decrease Takt time.

*Current Takt time of our plant is 1min/car.

*5S policy which is very helpful for increased productivity.

Ie. Seiri, Seiton, Seiro, Seiketsu, Shitsuke

*TIMWOOD (7 WASTES which needed to be minimised) :-

Transport
Inventory
Motion
Waiting
Over-processing
Overproduction
Defects
*Technique and broad process for line balancing is shown in fig.
REMAINING TASKS:-
*Time study of that line.

*Calculate cycle time, load rate, line efficiency.

*Decrease bottleneck processes.

*Hence, finally reduce the takt time.