MEPL Report
MEPL Report
Report
By
Hrushikesh Ajit Chavan
201103003
[2023-24]
Internship (Industry) Report
In partial fulfilment of requirements for the degree of
Bachelor of Technology
In
Mechanical Engineering
Submitted By
[2023-24]
The Shirpur Education Society’s
CERTIFICATE
This is to certify that an Internship (Industry) Report (Semester-VIII) submitted
by Hrushikesh Ajit Chavan (PRN:201103003) under the supervision of Mr.
Prasad Kulkarni in partial fulfilment of the requirement for the degree of
Bachelor of Technology in Mechanical Engineering of R. C. Patel Institute of
Technology, Shirpur affiliated to Dr. Babasaheb Ambedkar Technological
University, Lonere during the academic year 2023-24.
Date:
Place: Shirpur
List of Figures…………………………………………………..2
List of Table…………………………………………………….3
Chapters
1. Introduction………………………………………………………….04
2. Product Gallery……………………………………………………...08
3. Safety………………………………………………………………..10
4. Departments…………………………………………………………11
6. Consumable Material………………………………………………..21
7. Spot Data……………………………………………………………22
10. Conclusion…………………………………………………….38
11. Reference……………………………………………………...39
ABSTRACT
Mungi Engineers Pvt Ltd Nashik this company is a Vender Company supply
and manufactures sheet metal components Mahindra and Mahindra Nashik,
Chakan, Kandivali, etc. This company is manufacturing different-different
sheet metal components and small and big parts. This company provides to
100% accuracy for the customer’s requirement and delight them. My
organization is an extremely efficient and quality-focused organization. We
value all our assets & ensure that we use the effectively & maintain them in
immaculate condition. We value human beings working with us & also
associated with us (in all areas) and ensure that all of them are happy &
continuously increase their value. This plant is probably the largest cargo
manufacturing plant in the country today where roll formed panels, pressed
parts and subassemblies are all under one roof. The plant's product portfolio
consists of floors, front doors, back doors, fenders, and load body cargo
production. The semi-automated process boosts the production process in the
Light and Heavy press shop. This is a pressing and assembly unit where we
manufacture door sash, which is the most critical sheet metal part that goes into
assembling a car. It requires top-notch sheet metal roll forming, stretch bending,
welding, and highly skilled metal finishing under close tolerance.
1
List of Table
Tablse 9.1 Week Wise Work Sheet………………………………………………………….36
2
Chapter 1
Introduction
Since our inception in 1984, we have been manufacturing high quality
engineering products for OEMs. From a modest start with 4 presses, 4 men and
Rs. 4 lacks as our turnover, today we have grown many folds to have achieved a
turnover of over $200 million USD (1500 cores INR). As we march ahead with
time and trust, we look forward to increase our reach and conquer bigger markets
globally.
3
Praful Mungi (C.M.D.)
Leadership Team
Santosh Kulkarni (President)
Kirankumar Aher (Sector Head)
Milind Waghode (Chief Operating officer)
Prakash Jaisinghani (Head Business Development Strategy)
Vidita Mungi (Director)
Deepak Kukawalkar (GM HR and Group IR Head)
Sandeep Purkar (Chief Financial Officer)
Infrastructure
Fig. 1.2[Infrastructure]
4
Certifications
Quality Policy
We at Mungi group are committed to manufacture and supply sheet metal,
machine & fabricated components to meet “customer satisfaction.”
We shall achieve this by following quality management system confirming to
ISO/TS 16949:2002 with emphasis on Improvement in quality by doing right at
the first time through team work and training to employees.
Vision
To be a preferred supplier among domestic and international customers, while
adhering to our core values and helping build and support sustainable
communities.
Mission
We supply world class quality engineering products at a competitive price, by
committing to on time deliveries to domestic and international customers.
5
Core Values
Entrepreneurship Integrity
Innovation
6
Chapter 2
Product Gallery
2
Fig. 2 [Product Gallery]
7
8
Chapter 3
Safety
9
Chapter 4
Departments
Fig. 4 [Departments]
10
Chapter 5
Cargo Assembly Line
This is cargo assembly line use in bolero car for the loading purpose. Cargo
transport is mainly for commercial purpose for onboard. It refers to goods or
produce being transported frame one place to another place This line is large line
here total 51 Spot Guns and 15 Co2 machines are use in on line. Total 39 stations
are there in the line.
Mainly there are two processes performed on the line which are as follows:
11
A. Spot Welding:
12
sheets of metal are welded together without the use of any filler material. The
material melts, fusing the parts together at which point the current is turned off,
pressure from the electrodes is maintained and the molten “nugget” solidifies to
form the joint.
1. Current = 10-12 KA
2. Force = 400-500 KGF
3. Cycle = 17-20 Cycle
In the CO2 welding a gas cylinder is used for the supply of the active gas.
However, it is also possible to weld CO2 by means of a gas filled welding
wire. During welding, a welding wire is fed by means of a welding torch
towards the weld pool of the workpiece to be welded. The welding wire
melts and melts together with the molten pool that is created during
welding. The molten pool is actually the molten metal. Partly created by
the melting of the starting material, the material that is being welded.
13
Fig. 5.4 [CO2 Welding Machine]
14
Line Detailed Study
Line Production Capacity for 12 Hours = 250
Line Production Capacity for 24 Hours = 500
Manpower Requirement on Line 12 Hours = 96
Manpower Requirement on Line 12 Hours = 192
15
Line Process Flow According to Station wise Floor Line:
16
Fig. 5.7 [Front and Rear Re-spotting 1&2]
17
Fig. 5.9 [Side Panel and Front Panel]
18
Fig. 5.11 [Ready for Dispatch]
19
Chapter 6
Consumables Required on Cargo Line
1. COTTON GLOVES 12”
2. COTTON TAPE 12”
3. TEFLON TAPE
4. SPOT WELD TIP 008
5. SPOT WELD TIP 3228
6. ELECTRODE TIP 1762
7. ELECTRODE 08-234
8. ELECTODE MOV CG 123×50
9. CO2 WELDING WIRE 0.8 MM
10. CONTACT TIP 0.8 MM
11. NOZZLE MB 25AK
12. WELDING GLASS BLCK
13. WELDING WHITE GLASS
14. SANDER WHEEL 60×5
15. CO2 GAS
16. FLAP DISC 125×22
20
Chapter 7
Spot Data
Gun and Machine Wise Required Spots on Cargo:
A. Welding Shop
CA/SW/33 = 12
Pedestal 13 =30
SPM/7 =34
Total No. of Spots = 76
CA/SW/25 = 6
CA/SW/26 = 8
SPM/03 = 16
Pedestal 68 =22
Total No. of Spots = 52
CA/SW/110 = 18
CA/SW/132 = 27+33
Total No. of Spots = 78
21
B. Floor Line
4. Seam Welding
M1 = 31
M2 = 31
M3 = 42
Total No. of Spots = 104
CA/SW/80 = 16
CA/SW/84 = 16
Total No. of Spots = 32
8. Re-spotting 2
CA/SW/143 = 29
CA/SW/144 = 29
CA/SW/01 = 34
CA/SW/04 = 34
Total No. of Spots = 126
9. Inversion
CA/SW/38 = 29
CA/SW/130 = 33
CA/SW/10 = 20
CA/SW/11 = 24
Total No. of Spots = 106
22
C. Front Panel
23
E. Side Panel
24
Fig. 7.1 [Poka-Yoke Fixture]
POKA-YOKE fixture has master sample part this part is given to pink colour.
And, we have to check the fixture it is ok or not ok. On the fixture part will check
and some part to be checked by using some sensors to detect the part position or
missing part. Poke- yoke is one of the Japanese word this sensor is avoid the
human error of working time. They are providing one indicator box for mention
the fig. this box indicates the sensor is working or not. Poka-yoke means “avoid
the unexpected surprises” essentially a poka-yoke is a safe guard the prevents a
process frame proceeding to the next step until the proper condition have been
met. Poka-Yoke is a lean manufacturing tool that refers to “mistake proofing” or
“error- proofing” a process.
25
Following are Total Poka-Yoke Fixture on Cargo Line:
1) MB/FB/08: (Cross Member Tacking and Re-spotting)
Provide the buzzer for detection of cross member m6 nut missing.
2) MB/FB/F/O7: (Front and Rear Tacking)
To detect component of hole position.
3) MB/FB/F/14: (Front Panel Spotting)
To detect the nut plate missing on the fixture.
4) MB/FB/37: (Side Panel Tacking)
To detect current hole position and nut plate missing.
5) MB/FB/04: (Tail Gate Re-spotting 1&2)
To detect hat section wrong position on tail gate.
6) MB/FB/F/37A: (Side Panel Welding &Finishing)
Encloser nut plate missing LH & RH and also wrong position of
encloser.
7) MB/FB/02: (Side Panel Tacking)
To avoid wrong z section
8) MB/FB/05: (Side Panel Tacking)
To avoid the wrong position of the part
9) MB/FB/F/12: (Tail Gate Fitting)
To avoid assembly of kit lock rod.
10) MB/FB/F/16: (Hat Section Tacking)
To avoid shifting of skid bracket position.
11) MB/FB/F/18: (Front & Rear Tacking)
To avoid shifting of skid bracket position.
12) MB/MPV/05: (Hat Section Tacking)
To detect the wrong cross member.
13) MB/FB/F075/34: (Floor & Side Sill Spotting)
To detect the mud flap nut plate, to ensure of side sill spotting.
26
Fig. 7.2 [Pedestal Welding Machine]
This a pedestal welding this machine used in small parts welding for using
machine. Two pieces are welded together due to the pressure exerted by the two
electrodes which are connected to the lower and upper arms, where the upper arm
is movable and the lower arm is stationary.
The electrode is fitted in electrode holder and electrode is fitted to the upper arm
with cotton tape insulation. The upper arm is connected to pedal by means of
connecting rod the spring connected to the connecting rod so that is makes the
upper arm to move up and down. In this machine we have to small part or child
part welding on the large part means in short to say that to main part and child
part with assemble part to joint and welding together. In this welding machine
does not use to any filler material.
27
Fig.7.3 [Pneumatic Sander Machine]
This line also used in sander machine for finishing purpose and also using the
orbital machine for the shining purpose.
28
This is a Pneumatic sander machine using the air pressure. Sander machine
purpose is finishing the product and part.
Wheel Dimension- 60×4” or 60×5”
Sander machine RPM is between 8000 to 11000 (rpm is depend on pressure
range.) This a Pneumatic orbital machine using the air pressure. Orbital machine
purpose in shining the product or part. Also used in pneumatic sender machine
for purpose is finishing and remove the spot burr. Sander wheel diameter is 60×4”
& 60×5”
Also used in Pneumatic orbital machine for purpose is clear finishing and shining
for.
Orbital wheel diameter is 80×5”
Wheel Dimension – 60×5”
Orbital machine rpm is 8000 to 10000 (rpm depend on pressure range.)
On the line orbital and sander machine also use the purpose of finishing scratches
on the part and also spatters on the parts are also finishing the buffing marks.by
using the sander machine and orbital machine on line to finishing the part and
makes the quality part.
29
Chapter 8
Front Door Line
Front door is the project of manufacturing driver side and co-driver side doors of
Mahindra Bolero. There is total 10 models of doors.
In this line there are 3 CO2 welding machines, 5 spot welding guns in which 1
Spot gun is IT and 4 guns are Non-IT.
30
There are 3 Projection welding machines in front door line. This is use for welding
the M6 nut to panels and fixing of hinge to lid cover of fuel tank of Mahindra
Bolero.
31
Poka-Yoke
There are total 5 Poka-Yoke in front door line. Two Poka-Yoke are at Stage-II
which is given for detection of missing nut plate, missing slot and piercing hole
and channel shift with gun interlock. One Poka-Yoke is given at Stage-IV for
avoiding wrong assembly of inner and outer panel. Two Poka-Yoke are given at
Stage-V which is clinching stage. Among two Poka-Yoke one is for avoiding bad
clinching. The guns used for clinching is pneumatic control. So, when the air
pressure is less than 5 kg/cm2 then the lights in the clinching room are turned off
automatically. So, the operator can come to know that the air pressure is reduced
and due to this clinching will not be done properly and they stop working
immediately. Another Poka-Yoke is for cleaning for clinching block. So, after
every 15 jobs the alarm sounds and operator clean the clinching block.
32
Deburring
In this stage the burr is removed on outer and inner panel. During the processes
in press shop the burr is present on the edges of panels. This burr is removed by
using pneumatic sanders, pneumatic orbiters, electric orbiters.
Tapping
Tapping is done in finishing stage. It is done for removing burr in internal
threads of nuts. The machine which is used for tapping is pneumatic.
33
Clinching
In this stage the inner panel is fixed with outer panel by pressing the flange of
outer panel on inner panel. This is done by pneumatic clinching gun.
34
Chapter 9
Week Wise Work Sheet
35
To monitor and maintain safety – PPE
Weak 8 8:30 to 5:00
zero accident on the shop floor.
To have knowledge of station wise
Weak 9 8:30 to 5:00
spots, Co2 welding of product.
To learn preventive maintenance of
Weak 10 machine and fixture. To understand 7:00 to 3:30
cycle time of operation on line.
Learn to maintain system and process
requirement through. 1- Poka-yoke
Weak 11 7:00 to 3:30
Sensor. 2- Contingency Plan. 3- Process
Validation.
To ensure knowledge of Control Plan,
Weak 12 7:00 to 3:30
SOP
36
Chapter 10
Conclusion
37
Chapter 11
References
1] Puschner, P., Kölzer, G., Geisler, F. Neuartige Schweißsystem für eine flexible
Fertigung. Tagungsband 21. DVS-Sondertagung "Widerstandsschweißen 2010";
2010 May 05-06
2] Mikno et al. describe a new control system and the results of its operation,
particularly visible in projection welding. Mikno et al. present a new control
system used during the welding of sheets with an embossed projection.
3] Deen, M.J., & Basu, P.K. (2012). Silicon Photonics: Fundamentals and
Devices.
4] Moses, M., Yamaguchi, H., & Chirikjian, G.S. (2009). Towards cyclic
fabrication systems for modular robotics and rapid manufacturing. Robotics:
Science and Systems.
5] Aguilar, J., Zhang, T., Qian, F., Kingsbury, M., McInroe, B., Mazouchova, N.,
Li, C., Maladen, R.D., Gong, C., Travers, M.J., Hatton, R.L., Choset, H.,
Umbanhowar, P., & Goldman, D.I. (2016). A review on locomotion robophysics:
the study of movement at the intersection of robotics, soft matter and dynamical
systems. Reports on progress in physics. Physical Society
38