TRAINING REPORT

NAME Dinesh Kumar

ROLL NUMBER 6914035

COMPANY NAME Kamla Dial & devices Ltd.

TRAINING PLACE Parwanoo (Solan)

TRAINING PERIOD 30th June to 12th August 2017

GOALS OF THE TRAINING:-
1. To learn the different kinds
of processes for preparing the dials in the company.

2. To check the quality parameters at every stage of processes.

3. To work as a team to achieve a goal.

 PROCESS OBSERVATIONS

Types of Dials:-

o APPLICATED DIALS

o PRINTED DIALS

o PRESS PATTERN DIALS

o MOP

STAGE 1ST
BLANKING: -
It is a process in which we cut a specified shape from a metal
strip by using tool and die.

Quality Parameters:-

o Outer dia.

o Centre hole

o Eccentricity

o Thickness

o No dent or scratches

o Flatness
STAMPING: -
It is a process in which we generate a design on the dial by
stamping tool. This operation is done by passing the dials many times from
oven till it does not match with sample.

CHECKING PARAMETER:-

o Match with sample

o Thickness

o Outer diameter

o Centre hole

o Visually ok

o Flatness

FEET STICKING:-
It is the process in which we are sticking the feet on the dial
or ring by passing the electric current.

It can be of two types:

o Direct feet sticking

o Solo feet sticking

Direct feet sticking:-
It is the process in which feet are sticking on the dial by
passing the D.C. current from the feet.

Solo feet sticking: -

It is the process in which feet stick on the dial by
giving a shock of current. After that the dials are passing through the oven
then the solder layer come from the feet and sticks between the feet and
height of feet is increased. In this way feet stick by the dial.

Checking Parameter:-

o Length of the feets.

o Diameter of the feets.

o bending

o no feet marks

o feet position

o Melting.

o burr

o feet strength (hardness)

Window Piercing: -
 It is an operation in which we cut a specified shape like
square, rectangle, circle, for producing the window.

Checking parameter:-

o Window length

o Width

o Position

o No burr inside the window

o Flatness

WINDOW CHEMPFERING:-
It is the operation in which we give a desired
shape on the window like beveled, scoop etc.

Checking parameter:-
o Window size.

o Chamfering size

o Position

o Burr

o Flatness

o Visually ok
Record Turning:-
It is the operation in which we cut a specified circle
up to a specified depth which has a specified distance from the centre of
centre hole

Checking parameter:-

o Diameter of the record

o Depth

o Pitch of the thread

o Chattering

o No extra marking

o Match from the sample

o Visually ok

PUNCHING:-
It is the process in which we cut holes on the dial for fixing the
pins or the indexes in a single punch.

o Checking parameter:-

o Dia of the holes

o Position of the holes

o Visually ok.

o Match from the sample.

 o Flatness

CNC DRILLING:-
It is the process in which we are doing drilling on the dial
on CNC drilling machine.
CHECKING PARAMETER:-
o Diameter of the holes

o Position

o Shape of the holes

o Visually ok

o Slant.

APPLIED PARTS:-
The parts which are applied on the dial for giving a
different look to the dial are known as applied parts.
o Rings

o Window frames

o MOP

RINGS:-
This is the circular part which are use on the dial are known as
ring.

Ring Parameter:-

o Shade cut
 o Outer diameter

o Inner dia

o Back side cut

o Back side cut depth

o Thickness

o Back side slot

o Visually ok

o Fitting on the dials is ok.

Window Frame: -
The frame which are used on the window for giving the
different look to the window.

Checking parameter:-
o Size of the window frame

o Thickness

o Feet position

o Visually ok

MOP: - “Mother of Perl”.

It is made up from the Perl and gives a different look to the
dial. It is divided in to the four categories depending upon the color.
o Snow white

o Pure white

o White
 o Iridescent white

CHECKING PARAMETER:-
o Color of the MOP.

o Size of the MOP

o Thickness

o Dent scratches or broken

o Visually ok

HARDNESS OF THE BRASS:-

Before doing the blanking operation hardness of the
metal strip is checked on the hardness checking machine.

o Soft Brass:- 80-100

o Hard Brass:- 170-200

(STAGE – 2ND)

This stage is divided into five parts:-

o Base finish.
 o Electro plating
o Lacquering
o Lapping
o QC STAGE –IInd

Base Finish:-
In this department we create base of the dial
according to customer requirements. The following operations are
done:-
o Disk poncage
o Manual poncage
o Vertical brushing
o Sunray
o BDL
o Buffing
o Centre hole, back side, outer side cleaning
o Acetone washing
o Decabba
o Etching
Disc Poncage:-
It is a process of base rubbing by using 2000
grid size wheel.

Q.CHECK ASPECTS:-

o No dent scratches on the base.

o Round off
o Thickness of the dial

Manual Poncage:-
The poncage is done by the use of brush
and 130 no. powder. This process is also done on the stamped dials.

Vertical brushing:-
It is a process in which we produce
vertical lines by the use of brass brush. It is also known as V SATIN.
Q.check parameter:-
o Lines are matches according to the sample.
o The lines should be straight.
 o Pitch of lining should be same.
o Visually ok.

Sunray:-
It is the process in which we produce sunrays on the
dial by sunray machine.

Q.check:-
o Match from the sample
o Uniform sunray
o Pitch
o Visually ok.

BDL:-
It is a process in which we are doing base dull by sand blasting.
The material is used in BDL is Aluminum Oxide. Depending on the pressure of
the Aluminum oxide on the dial it is of two types:-
o Light BDL

o Full BDL

Q.CHECK:-
 o Base as per sample
o No variation in the BDL
o No stain
o Visually ok.

Buffing: -
This process is used for doing the extra shining to the
dial. Two types of wax are used in buffing.
o Red wax
o Green wax

OD cleaning:-
This process is used for removing the extra
material from the outer diameter of the dial. This operation is done
by two types:-
o On belt for the shaped dials
o By emery paper for circular dials.

CENTREHOLE CLEANING:-
 This process is used for removing
the extra material from the center hole by drilling machine.

Backside cleaning:-
In this extra material is cleaned from
the backside by using knife manually.

ETCHING:-
It is a metal cutting process by using ferric chloride.
First a protection lacquer is done on the dial after that masking is done then
the dial is dipped in the chemical by timely. In this way etching is done.

DECABBA:-
This operation is done for reprocessing the
plating and matt dials by the use of HLC.

ACETONE:-
This operation is done for reprocessing of
printing and lacquer dials.
ULTRASONIC:-
It is a process in which removing of gress or oily
particles by the use of US4000+VIBRATION at 60-70 *C.
LAPPING:-
It is a process in which dial is rubbing between
the two surfaces in the presence of abrasive. It is done by three
steps:-
o Stone lapping.
o Semi finish lapping
o Fine lapping
By the use of polypla of 103 no. and 103A*

Q.CHECK ASPECTS:-
o Base clean
o No dent or scratches
o Peel off
o Round off
o Thickness

ELECTROPLATING:-
It is the process for doing the platting on
the dials by passing the electric current in the presence of
electrolyte.
Types of Bathes:-
o Normal nickel
 o Black bath
o Gold 2N
o Rhodium bath
o Shiny nickel
o Gold 3N
o Potassium Cyanide
o Blue bath
o Slat gray bath
o Bright silver

Q.CHECK ASPECTS:-

o No dent, scratches after electroplating.

o Uniform colors.
o Color should be match with the sample.

(Stage- 3RD)
PRINTING:-
It is the process in which printing is done on the dial with
the help of printing ink and machine. This can be of two types:-
o Pad printing.

o Screen printing.

PAD PRINTING:-
This printing is done by the help of pad and clicheé s.

SCREEN PRINTING:-
This printing is done with the help of screen . In this
process ink is spread on the screen.

There is a use of clothe in screen that is:

o Cloth no. 43

o Cloth no.77

o Cloth no. 140

Q.C.ASPECTS:-

o Printing should be dimensionally correct.

o No dust particles.

o No cut marks.
 o No spreading of the ink.

o Match with the sample.

FIXING OF INDEX:-
The indexes are fixed on the dial with the help of twiger.
After that gluing is done from the backside of the dial. After that inspection is
done for missing.

Quality parameter:-
o Index should be straight
o see well formation
o No scratches on the index.
o No lifting of the index.
o 5 no index missing
o color of the index match by the sample card

Back side:-
In this following operations are done:

o Backside cleaning by knife

o Flatness
o Feet straighten
o Feet cutting
o Washing
o Inspection
FIXING OF EDDY: -
It is the process of fixing the eddy on the
dial with the help fixing tool.

QUALITY PARAMETER:-

o No shifting
o No cut mark on the eddy
o No gluing around the eddy
o Color should be matched with the sample card.
o No dust particles under the eddy.
o No missing

Fixing of the diamond:-

It is the process in which diamond or
stone with bushing is fixed on the dial after that gluing operation is
performed then inspection about the tilting and then baking at tend to
15 minutes at 100* C.

QUALITY ASPECTS:-
o Well formation
o Diamond should be straight after gluing process
o No missing of the diamond
o Fit of the bushing according to the diamond
o Match from sample card

GLUING:-
It is the operation by which we stick index or
diamond on the dial.

QUALITY PARAMETER:-
o No extra gluing around the index
o Check viscosity of the glue
o No missing of the index
o Index should be straight
o No mark or scratch on the dial
o Baking at tend to 15 minutes at 100 * C.

LUMIONS METHODS:-
o By screen printing
o By pad printing
o By pen
 INDEX
INDEX:-
These are the small implicated part which is used
on the dial with the help of it. The indexes can be of two types :->
1. Blank Index
2. Shield Index

Further Index Following Type:-

1 APIN -> Implicated index
2 APRJ -> Implicated Roman Joint
3 APRS -> Implicated Roman Split
4 APAS -> Implicated Arabic Split
5 APSI -> Implicated Special Index
5.1 APSI: Honey Drop
5.2 APSI: Arrow
5.3 APSI: Capsule
5.4 APSI: Drum
5.5 APSI: Pentagon
5.6 APSI: Pins
5.7 APSI: Rhombus
5.8 APSI: Trapezium
5.9 APSI: Shoulder
 5.10 APSI: Square
5.11 APSI: Thumb
5.12 APSI: Triangle
5.13 APSI: Angular Trap

FACET:-
It may be defined as the shape of the index from the
top side the facet is of following type:
GA ,GB,GC,DA,DE,DH,DC,AA,CD

VISUALLY INSPECTION:-
In visually inspection following
fault are not accepted on the index:
Points, Scratches, Shift, Burr, Chattring, Patch, Dent, Milky, Line,
Hight and Thickness

INDEX PLATING:-
It is a process of plating on the index
by the passing of electric current in the presence of electrolyte.

PASSIVATION:-
It is the process of making a protection
layer on the indexes for the protection of oily particles.

SPECIAL TEST FOR INDEXES:-

1. Sulphide Test
 2. Thyoactimide Test

PLATING BATH:-
1. Gold plating
2. Nickel Plating
3. Rhodium Plating

FINAL QUALITY CONTROL

It is the department where final dial is to be inspected visually
and dimensionally.

DIMENSIONALLY CHECKING PARAMETERS:-

1. Outer Diameter.
2. Thickness.
3. Thickness with ring
4. Central Hole Diameter
5. Record Turning Diameter
6. Record Turning Depth
7. Shifting
8. Printing Dimension
9. Ring Outer Diameter
10. Ring Inner Diameter
11. Index Outer Diameter
 12. Index Height

VISUALLY CHECKING PARAMETER:-

1. Dent
2. Scratch
3. Burr
4. Lifting and Tilting Of The Indexes
5. Peel Off
6. Round Off
7. Well Formation
8. Colour Variation
9. Match With Sample Card

SPECIAL TEST:-
1. Tape Test:- In this a 3m scotch tape is used for the
checking the peel off lacquer , printing and eddy
2. Dynamo Test :- This test is done for busing in this one
neuton force is apply from the back side of busing is
remove from the dial then it is not accepted
3. Drop Test: - This test is done for indexes in this dial is
dropped from the height of 35 cm if indexes are
removed or lift then it is not accepted.
BENEFIT OF THE TRAINING:-
1. I learn the every process, which is used for preparing
the dial during the training period.
2. I learn the quality parameter at every stage.
3. It increases my self confidence.
4. It also increases my interest in dial industry.
5. It increases my knowledge.
6. I also learn how to work in a team.