A

MINI PROJECT
REPORT ON
MANUFACTURING OF YUVO STAR FUEL TANK
SUBMITTED IN PARTIAL FUFILMENT OF THE REQUIREMENT
FOR THE AWARD OF THE DEGREE OF
BACHELOR OF TECHNOLOGY
IN
DEPARTMENT OF “MECHANICAL ENGINEERING”
SUBMITTED BY
MD. SHAHNAWAZ KHAN 21RE1A0303
M. NARSIMLU 21RE1A0304
C.SHIVA KUMAR 22RE5A0303
Under the guidance of
MR. A RAJINIKANTH
Asst. professor

MNR COLLEGE OF & TECH ENGINEERING

(Approved by AICTE and Affiliated to JNT University, Hyderabad)
MNR NAGAR , FASALWADI. SANGAREDDY - 502294
 DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
This is to certify that the project work entitled “ MANUFACTURING OF YUVO STAR
FUEL TANK” submitted by “ MD.SHAHNAWAZ KHAN 21RE1A0303 , M.
NARSIMULU 21RE1A0304, C. SHIVA KUMAR 22RE5A0303 “ in partial fulfilment of
the requirement for award of the degree of Bachelor of technology in MECHANICAL
ENGINEERING , by Jawaharlal Nehru Technological university hyderabad during the
academic year 2024-2025 is a Bonafide record Of the work carried out under my
guidance and supervision at MNR COLLEGE OF ENGINEERING & TECH,
SANGAREDDY.

Internal Guide Head of the Dept

MR. A RAJINIKANTH MR.N. KIRAN KUMAR
Assistant professor Assistant professor

External Examiner
 Acknowledgement
We would like to express my sincere gratitude to all the individuals who have
supported and guided me during my internship project
First and foremost, I would like to extend my heartfelt thanks to the Vice
Chairman, Mr. M. Ravi Varma Sir, for providing me with the opportunity to be
part of this institution and for his continuous encouragement and support.
We Are deeply thankful to the Principal, Dr.E.L.Nagesh, for his visionary
leadership and for creating a conducive learning environment that facilitated my
growth and learning throughout the internship.
A special thank you to the Head of the Department, Mr. N. Kiran Kumar, whose
guidance and valuable insights helped me in understanding the core aspects of my
project and internship tasks.
We would like to express my sincere gratitude to my Project Guide, Mr. A
Rajinikanth, Assistant Professor, Mechanical Department, for his constant
support, mentorship, and for providing me with the opportunity to work on a
project that significantly enhanced my skills and knowledge.
Lastly, I would like to extend my appreciation to all the faculty members and staff
who have helped me in various ways, making this internship experience truly
rewarding.
Thank you all once again for your unwavering support and encouragement.

In all sincerity,
MD. SHAHNAWAZ KHAN 21RE1A0303
M. NARSIMLU 21RE1A0304
C. SHIVA KUMAR 22RE5A0303
 DECLARATION

We hereby declare that the Dissertation entitled “MANUFACTURING OF YUVO

STAR FUEL TANK” Which is being submitted in partial fulfillment of the
requirement of the course leading to the award of the “B.tech in MECHANICAL
ENGINEERING” in MNR COLLEGE OF ENGINEERING TECHNOLOGY.

The result of the dissertation is carried out by our team, under the guidance and
supervision of MR . A RAJINIKANTH, Assistant professor. We further declared
that we have not previously submitted this to any institution/university for any
other degree.

MD. SHAHNAWAZ KHAN 21RE1A0303

M.NARSIMLU 21RE1A0304
C. SHIVA KUMAR 22RE5A0303
 INDEX

Contents page no.

CHAPTER-1 {INTRODUCTION}

1.1 About CIE AUTOMOTIVE INDIA LTD 1

1.2 CIE AUTOMOTIVE INDIA LTD STAMPING ZAHEERABAD 3

CHAPTER-2 { MANUFACTURE OF YUVO STAR FUEL TANK}

2.1 Operation 05 - cleaning 5

2.2 Operation 10 - spot welding 6

2.3 Operation 20 – seam welding 9

2.4 Operation 30&40 – mig welding 11

2.5 Operation 50 – leak test 14

2.6 Operation 60 – powder coating 16

2.7 Operation 70 – diesel flushing 17

2.8 Operation 80 – final inspection 18

2.9 Operation 90 – packing and dispatch 20

CHAPTER-3 { TYPES OF RESISTANCE WELDING}

3.1 spot welding 21

3.2 seam welding 23

3.3 CO2 welding 27

CHAPTER-4 { 7 QC TOOLS}

4.1 Fishbone diagram 32

4.2 check sheet 34

4.3 control chart 36

4.4 histrogram 38

4.5 Pareto chart 41

4.6 scatter diagram 43

4.7 Flow chart 45

LIST OF FIGURES
Fig.1.1.CIE Branches in India 10

Fig.1.2.CIE Products 11

Fig.2.1. Spot gun weld 13

Fig.2.2 . Seam welding 16

Fig.2.3. Leak Test 20

Fig.3.1 resistance spot welding 26

Fig.3.2 seam welding line diagram 28

Fig.4.1. Fish bone Diagram 34

Fig.4.3. Control chart 41

Fig.4.4. Histogram 42

Fig.4.5. Pareto chart 45

Fig.4.6. Scatter diagram. 46

List of Tables
Table.3.3 34

Table 4.2 38

CONCLUSION 50

REFERENCE 51
 ABSTRACT

The internship project at CIE Automotive India Ltd. revolved around the
manufacturing of the Yuvo Star fuel tank, a crucial component in the automotive
industry. The primary objective was to gain insights into the mechanical
engineering aspects of the fuel tank’s production process, from design and material
selection to assembly and testing. The project involved a detailed study of the
fabrication techniques used, including injection molding, welding, and the
application of surface treatments to ensure durability and safety. A significant
portion of the work focused on analyzing the efficiency of the manufacturing
processes, identifying potential improvements, and exploring ways to optimize
material usage, reduce costs, and improve overall product quality. The project also
examined the integration of automation and lean manufacturing principles to
streamline operations and enhance production timelines. Hands-on exposure to the
latest manufacturing technologies and methods allowed for a comprehensive
understanding of the challenges and opportunities within automotive component
production.
 CHAPTER-1
INTRODUCTION

CIE Automotive India Limited produces and sells automotive components to

original equipment manufacturers and other customers in India, Europe, and
internationally. It offers forgings, such as crankshafts, CV joints, knuckles, diff
crowns, and spindles; gears, including gears and shafts, e-drive components,
flanges/end yokes, and clutch hubs; composites comprising front lid, wind shield-
electric-3WH, electric box top tray, crash-shields fuel tanks, and front bumper; and
crankcase, pump housing, turbo cover, and brake panel aluminum products. The
company also provides iron castings, such as differential, turbine, and axle housings,
as well as gear carriers; hard and soft magnets; and stampings, including chassis and
structural parts, BIW panels and assemblies, cross car beam, safety assemblies, and
fuel tanks. In addition, it offers stub axle as forged and machined, steering shaft,
wheel hubs, steering yokes, constant velocity joints, steel metal stamping,
components and assemblies; turbo chargers housing; axle and transmission parts;
and engine gear, timing gear, and drive shafts. The company provides its products
for use in cars, utility vehicles, light commercial vehicles, tractors, medium and
heavy commercial vehicles, off road vehicles, and two-wheelers. The company was
formerly known as Mahindra CIE Automotive Limited and changed its name to CIE
Automotive India Limited in June 2023. The company was incorporated in 1999 and
is based in Pune, India. CIE Automotive India Limited is a subsidiary of
Participaciones Internacionales Autometal
ABOUT CIE AUTOMOTIVE INDIA LTD
CIE Automotive India Ltd is a part of the CIE Automotive Group, a global company specializing in the
manufacturing of automotive components and systems. CIE Automotive, headquartered in Spain, is known
for its expertise in producing components for various automotive sectors, including body-in-white,
powertrain, and suspension components, among others.

Overview of CIE Automotive India Ltd :

Industry: Automotive Parts and Components

Products and Services: CIE Automotive India manufactures a wide range of automotive components,
including structural parts, transmission systems, and other precision-engineered parts used in both
commercial and passenger vehicles. They focus on creating value through innovative, high-quality products,
supporting both domestic and global OEMs (Original Equipment Manufacturers).

Operations: The company has production facilities across India, which are strategically located to cater to
both domestic automotive manufacturers and international markets. These plants utilize advanced
manufacturing technologies and employ practices such as lean manufacturing to ensure efficiency and
quality.
Key Areas of Expertise:

Forging and Casting: The company is involved in the production of forged and cast parts, which are crucial
for high-strength automotive applications.

Tooling and Assembly: CIE Automotive India also specializes in designing and manufacturing complex
tooling solutions for automotive applications, as well as assembling large parts and modules for vehicle
manufacturing.

Automation and Robotics: The company adopts advanced technologies like automation and robotics in its
production processes, ensuring precision and optimizing production efficiency.

Global Presence: CIE Automotive is a global player in the automotive supply chain, with operations not just
in India, but also across Europe, North America, and other regions. This global reach provides CIE
Automotive India Ltd with significant exposure to international markets, allowing it to support multinational
automotive companies.Growth and Innovation: The company focuses on continuous improvement and
technological innovation to meet the evolving demands of the automotive industry. This includes efforts
toward producing lighter, more fuel-efficient components and supporting the growing trend of electric
vehicles (EVs) and other advanced mobility solutions.

Parent Company – CIE Automotive:

CIE Automotive, established in Spain in the 1950s, is a prominent name in the global automotive supply
chain, providing a wide array of engineering solutions and manufacturing capabilities. With more than 40
production facilities worldwide, it serves some of the biggest names in the automotive industry, including
Volkswagen, General Motors, and Ford.
Manufacturing Facilities :

CIE Automotive India operates multiple manufacturing plants in different parts of India. These facilities are
equipped with advanced machinery, robotics, and quality assurance systems to ensure the precision,
reliability, and performance of automotive parts. The plants adhere to international quality standards and
are ISO certified.

Carrier in CIE automotive India LTD :

CIE Automotive India encourages employees to take charge of their careers by providing them with
customized development action plans, resources, support, and training

CIE AUTOMOTIVE INDIA LTD BRANCHES :

1. Chakan (Pune) - Automotive components, body-in-white parts, powertrain components.

2. Bawal (Haryana) - Structural components, press parts, welded assemblies.

3. Ranjangaon (Pune) - Transmission components, forged and cast parts.

4. Hosur (Tamil Nadu) - Suspension and chassis parts.

5. Nashik (Maharashtra) - Powertrain and drivetrain parts.

6. Kolkata (West Bengal) - Structural and chassis parts.

7. Coimbatore (Tamil Nadu) - Forged components for suspension and powertrain.

8. Raigad (Maharashtra) - Forged and stamped parts.

9. Bangalore (R&D) - Product development for electronics and automotive technologies.

fig . 1.1
 CIE AUTOMOTIVE INDIA LTD STAMPING IN ZAHEERABAD:
CIE Automotive India Ltd is a part of CIE Automotive, a global supplier that focuses on providing advanced
automotive components and systems. The company has a significant presence in India, with its
manufacturing operations in various locations, including Zaheerabad, which is in the state of Telangana.

In Zaheerabad, CIE Automotive India Ltd specializes in the manufacturing of **stamping** components,
which are critical for the automotive industry. Stamping refers to the process of shaping or cutting metal
sheets into specific forms using stamping presses. The company primarily produces **metal stamped parts
for the automotive sector, such as chassis components, body panels, and other structural components, which
are essential for vehicle assembly.Zaheerabad's location is strategic for the company's operations due to its
proximity to major automotive manufacturing hubs and supply chain routes in India. The plant in
Zaheerabad is equipped with advanced stamping technologies that enable the production of high-quality,
precision-engineered parts for both domestic and international automotive companies.

I. Press Capacity: The Zaheerabad plant has 10 presses ranging from 1200T (hydraulic) to 40T
capacity.

II. Roll Forming Technology: The plant uses roll forming technology for cargo assembly production.

The Zaheerabad plant is part of CIE India's extensive stamping capabilities across its seven plants, which
have a total installed capacity of 185,000 tons per year.

III. Press Line Automation: The plant focuses on automating press lines to enhance efficiency and
minimize rejection rates.

IV. Robotic Welding and Assembly: They utilize robotic systems for welding and assembly processes
to ensure high accuracy and productivity.

V. Material Capabilities: The plant works with both high-strength steel (up to 980 MPa) and mild steel..

VI. Roll Forming Technology: The facility uses roll forming technology for cargo assembly

VII. Certifications: The plant is certified with IATF 16949, ISO 9001, ISO 14001, and OHSAS 18001,
ensuring high standards of quality and safety.
VIII. Market Segments: They serve multiple market segments such as passenger vehicles, utility vehicles,
commercial vehicles, tractors, and three-wheelers.

Assembly lines :
• Cargo assembly

• NST/CRE 4DI

• Druv fender

• STA/LCA

• Cabin

• Jeeto fuel tank

• M – star

• Yuvo star
 • Yuvo star fender

• Yuvo star hood

• LT fender

• Front grill

• Roll forming

CIE PRODUCTS:

Fig. 1.2

CIE PRODUCTS
 CHAPTER-2

Manufacturing process Of Yuvo star fuel tank

Operation 05 – cleaning:
To prevent rust on metal surfaces, oil is often used as a protective barrier.

In Yugo star fuel tank the oil will be applied to rear half panel and front half panel

1. Oil as a Protective Layer

How it works: When applied to metal, oil forms a thin layer on the surface, which prevents water, air, and
other corrosive elements from reaching the metal.

❖ Types of oil : RP 72 oil

RP 72 oil is a rust preventive oil that protects metal objects from corrosion. It can be applied to ferrous and
non-ferrous metals by dipping, brushing, or spraying. The oil creates a protective film on the metal that
prevents moisture and oxygen from causing rust.

Here are some specifications for RP 72 oil :

Colour: Amber clear

Viscosity: 13 at 40°C

Specific gravity: 0.889 at 60°F

Flash point: 160°C

Volatiles: 1% by weight

Film thickness: 2–4 microns

Pour point -66°C

Saponification value: 5.0–7.0 mg KOH/gm

Salt spray protection: 72 hours +

Operation 10 -spot welding:

Spot welding is a type of resistance welding used to join two or more metal pieces together by applying heat
and pressure at specific points, known as "spots."

Where in this case the rear half panel and front half panel are assembly by using IT GUN ( Integrated
Transformer Gun in spot welding refers to a welding system where the transformer and the gun (welding
electrode assembly) are integrated into a single, compact unit. This design is typically used in automated or
robotic spot welding applications,
such as in the automotive industry, to improve efficiency, reduce complexity, and ensure consistent, high-
quality welds) were to assembly the two panel’s total ‘20' spots are required

Capacity of the gun – 44 KVA

Tip force - 430 kgf

Gun weight - 84 kg

Fig. 2.1

Spot welding cause and control :

1.Poor Weld Quality

Causes:
o Insufficient current or welding time.

o Incorrect electrode force.

o Dirty or contaminated work pieces.

o Poor contact surface between the materials.

Control:

o Adjust welding parameters such as current, time, and force according to material thickness and type.

o Clean the work pieces to remove oxides, rust, or oils before welding.

o Use proper electrode design and material for the job.

2. Electrode Wear and Damage

Causes:
 o Overheating or excessive pressure on the electrodes.

o Incorrect electrode material or shape.

Control:

o Regularly inspect electrodes and replace them before they wear down excessively.

o Use high-quality electrode materials that are resistant to wear and heat.

o Properly set the electrode force to prevent damage.

3. Burn-Through or Overheating :

Causes:

o Excessive heat generation, often due to too much current or too long a welding time.

o Thin materials that can't dissipate heat effectively.

Control:

o Optimize welding parameters (current, pressure, and time) to suit the material and thickness.

o Ensure proper heat dissipation and use of proper electrode cooling if necessary.
o Perform tests and adjust the process for thin or heat-sensitive materials.

4. Cracking or Fractures :

Causes:

o Rapid cooling due to excessive heat input or poor welding parameters.

o Material properties that are prone to cracking (e.g., high-carbon steels or brittle alloys).

Control:

o Control the cooling rate by adjusting welding parameters.

o Use pre- or post-weld heat treatment if necessary.

o Choose materials with compatible properties for spot welding.

Causes:

o Excessive heat at the electrode tip, causing rapid wear.

o Incorrect electrode pressure or alignment.

Control:

o Adjust the welding time and pressure to minimize electrode damage.

o Ensure proper electrode shape and material.

o Maintain proper electrode cooling mechanisms.

Material s used :
 ➢ Electrodes: Copper or copper alloys (e.g., copper-chromium, copper-tungsten).

➢ Frame and Arms: Steel (typically carbon or stainless steel).

➢ Cooling Systems and Other Parts: Materials like aluminium for lightweight or corrosion-resistant
components.

Parameters :
Current – 10 to 13 KA

Electrode force - 350 to 450 kgf

Weld time – 11 to 13 cycle

Electrode force – 350 to 450 kgf

Spot welding nugget dia formula : ( 5* t1/2 )

Operation 20 – seam welding :

Seam welding is a type of resistance welding used to join two or more pieces of metal together by applying
heat and pressure through a series of overlapping spot welds along a continuous line (the seam). The process
involves passing an electric current through the work pieces while they are held together under pressure by
rotating seam wheel the seam wheel rotates using knurling wheel. After every 30 parts seam wheel dressed.

Continuous Seam Welding: The electrodes rotate continuously to create an uninterrupted seam. This is ideal
for applications where a tight, continuous joint is needed, such as in the manufacture of tanks, containers,
and automotive parts

Fig.2.2
Common Failures in Seam Welding :
1) Porosity: This is when small holes appear in the weld due to trapped gas. Think of it like bubbles trapped
in chocolate when it melts—except in welding, these bubbles can weaken the joint.

2) Cold Welds: This happens when the metal isn’t heated enough to form a good bond. It’s similar to trying
to glue two surfaces together without applying enough pressure or heat, causing the bond to be weak
and ineffective.
3) Overlapping: This is when the molten metal spreads out too much, creating a messy, weak weld. It’s like
trying to paint a wall, but the paint spills over the edges instead of staying within the lines.

4) Burn-Through: This occurs when too much heat is applied, causing the base metal to melt through. It’s
akin to leaving a hot iron on a piece of fabric for too long, causing it to burn.

5) Cracking: Cracks can form in the weld due to thermal stress or improper cooling rates, much like how
a frozen water bottle cracks when it expands.

Control methods :
1) Electrode Pressure Control: Just like pressing the keys too hard on a piano can distort the sound,
applying too much or too little pressure can impact the weld quality. Adjusting the pressure ensures
consistent contact between the wheels and the material.

2) Current Regulation: Think of the electrical current like water flowing through a pipe. Too much current
is like turning on the faucet too high—this could cause burning or melting. Too little is like a trickle,
which might not heat the metal enough. Maintaining the right balance is key.

3) Speed Adjustment: The speed of the welding process needs to be just right. If the wheels move too fast,
the weld might be incomplete. If too slow, it could overheat the material. It’s like walking a dog—if you
walk too fast, the dog can’t keep up; too slow, and the dog might lose interest.

4) Cooling Control: Rapid cooling can lead to cracking, so controlled cooling rates help avoid this. This is
similar to how ice cubes might crack if they cool too quickly in boiling water.

5) Regular Maintenance: Just as a car needs routine checks to run smoothly, seam welders also require
maintenance to prevent issues like electrode wear, misalignment, or electrical problems.

Parameters :
Heat – 80 to 83%
Heat – 75%

Hold time -15 cycle

Weld time -1. 2 to 2.4 cycle

Cool time – 1.2 to 2.4 cycle

Seam width – 5.8 mm , seam length – 218 mm
Operation 30 & 40 -MIG Welding :
MIG Welding (Metal Inert Gas Welding), also known as GMAW (Gas Metal Arc Welding), is a popular and
versatile welding process that uses a continuous, consumable wire electrode and a shielding gas to join
metals. It is widely used in various industries due to its speed, ease of use, and ability to weld a wide range
of materials.

Child parts :
i. Reinef brkt for fuel tank neck

ii. Harness NTG

iii. Strainer plate

iv. Tube bottom fuel tank

v. Fuel filler neck for tank lock

vi. MTG spacer

vii. Fuel tank return line pipe

viii. Fuel tank drain plug

ix. Outlet adapter

Common MIG Welding Failures and control methods :

1. Porosity
Cause: Porosity occurs when gas bubbles get trapped in the weld pool, resulting in holes or voids in the
weld. This can be caused by contaminants like rust, oil, or moisture on the work piece or electrode, improper
shielding gas coverage, or incorrect welding settings.

Control Methods:

• Ensure that the work piece and filler wire are clean and free of contaminants.
• Use appropriate shielding gas and ensure proper gas flow to protect the weld pool from contamination.
• Avoid welding in windy conditions or in areas with drafts, as this can blow the shielding gas away.
• Adjust welding parameters (current, voltage, travel speed) to maintain proper arc stability.
2. Inconsistent or Spatter-filled Welds

Cause: Excessive spatter, where small droplets of molten metal are ejected from the weld pool, can occur
when welding settings (voltage, wire feed speed, gas flow) are not properly adjusted. Spatter can cause a
rough surface and negatively affect weld quality.

Control Methods:

o Adjust the voltage and wire feed speed to ensure proper arc stability and minimize spatter.
o Use the correct shielding gas for the material and welding position (e.g., pure argon or an argon/CO2
mix).
o Maintain the correct electrode extension (distance from the contact tip to the work piece)
o to reduce spatter.
o Use a short-circuit transfer mode for thin materials to minimize heat input and spatter.

3. Lack of Fusion

Cause: Lack of fusion happens when the weld metal does not properly bond with the base material. This
can result from insufficient heat, too fast of a travel speed, or inadequate welding parameters.

Control Methods:

Ensure that the weld pool has sufficient heat to penetrate both the base material and the filler metal.

Adjust the travel speed to match the material thickness and welding process.

Use proper welding techniques, such as weaving or maintaining the correct torch angle, to improve fusion.
4. Distortion and Warping

Cause: Distortion occurs when the metal deforms due to uneven heating and cooling during welding. This
is particularly common in thin or large components.
Control Methods:

• Use a multi-pass welding technique to distribute heat evenly across the work piece.
• Weld in small sections or in a stitch pattern to control heat input.
• Preheat or post-heat large parts to reduce thermal stresses.
• Use clamps and fixturing to hold the material in place and reduce movement during welding.

5. Cracking

Cause: Cracking can occur due to excessive heat, improper welding material, or rapid cooling. It can be
seen as cracks in the weld metal or heat-affected zone (HAZ).

Control Methods:

o Control the heat input by adjusting welding parameters (voltage, amperage, travel speed) and preheating
or post-heating thick sections if necessary.
o Use filler materials that are compatible with the base material to prevent brittle joints.
o Ensure proper cooling rates to avoid thermal stresses that can lead to cracking.

6. Overlapping

Cause: Overlap happens when molten metal flows over the base material without bonding, creating a weak
and irregular joint. This is typically caused by improper technique or inadequate pressure.

Control Methods:

Use proper heat settings to ensure that the molten metal fuses well with the base material.

Adjust the torch angle to prevent excessive build-up of molten material at the weld surface.

Ensure that the weld pool has adequate penetration into the base material.
Parameters :

Current – 120 to 150 amp

Voltage – 18 to 20 v

Gas flow – 12 to 15 lpm

Operation 50 – leak test :
The fuel tank is sealed, and air is pumped inside to (four bar) pressurize it.

The tank is then monitored using sensors (such as pressure sensors) to detect any pressure drops that indicate
leaks.

The machine typically includes a control panel to monitor pressure levels and the duration of the test. The
primary goal of the machine is to identify leaks in fuel tanks that could lead to fuel loss, contamination, or
hazardous situations. The tests check the tank’s ability to maintain a proper seal, whether the tank is under
pressure (for pressure testing) or submerged in water (for water immersion testing).

Fig.2.3

Failures and it’s solutions :

1.Air Leak or Pressure Drop :

Cause: A drop in pressure during the dry leak test indicates an air leak, which means there is a crack or hole
in the fuel tank that allows air to escape.

Defects:

▪ Improper sealing of joints.

▪ Pinholes or cracks in the tank body.

▪ Faulty welds or seals.

Solution:

▪ Inspect the fuel tank for visible damage or misalignment.

▪ Use a leak detection spray or foaming agent to identify pinholes or cracks.

▪ Rework or replace damaged seals or faulty welds.

▪ Ensure the machine's pressure regulation and sealing components are functioning properly.
2.Inconsistent or Low Test Pressure
Cause: A test pressure that is too low or fluctuates during the test can lead to false negatives, where leaks
are not detected.

Possible Defects:

▪ Faulty pressure regulator or sensor.

▪ Blockages or leaks in the testing setup.

▪ Solution:

▪ Calibrate the pressure regulator and sensors regularly.

▪ Check all connections for leaks or blockages.

▪ Maintain the air supply or pressure sources to ensure consistency.

3.Inaccurate Measurement or Detection

Cause: Inaccurate leak detection could occur due to poor calibration of sensors or faulty detection systems.

Possible Defects:

▪ Incorrect readings from pressure gauges or flow meters.

▪ Software or machine calibration errors.

▪ Solution:

▪ Regularly calibrate and maintain testing instruments.

4.Inconsistent or Uneven Distribution of Test Fluid

▪ Cause: In a wet leak test, uneven distribution of the test fluid may result in incorrect conclusions about
the presence of leaks.

Possible Defects:

▪ Faulty spraying or fluid application system.

▪ Air bubbles or improper fluid circulation.

▪ Solution:
▪ Ensure uniform fluid application using calibrated nozzles or spray systems.

▪ Check for air pockets or blockages in the fluid line.

5.Contamination of Test Fluid

▪ Cause: If the test fluid becomes contaminated (e.g., through dust, oil, or foreign particles), it may affect
the accuracy of the leak detection.

Possible Defects:

▪ Inaccurate readings or failure to detect leaks.

Solution:

• Regularly clean and maintain the fluid reservoir and application systems.

• Ensure proper filtration of the test fluid.

6.Sealant or Gasket Failure

Cause: The failure of seals or gaskets in the test setup can lead to test errors or the inability to achieve a
proper test seal.

Possible Defects:

• Degraded seals or gaskets.

• Misalignment during sealing.

• Solution:

• Regularly inspect and replace seals and gaskets.

• Ensure proper alignment during the test setup.

Operation 60 – powder coating :

Steps involved in powder coating

Surface Preparation :

Cleaning the Surface: Before the powder coating can be applied, the surface of the material (usually metal)
must be properly cleaned to ensure good adhesion. This step involves removing any contaminants like dirt,
oil, grease, rust, or old paint. Surface preparation can include

Powder Application:

➢ The gun sprays a fine mist of dry powder (often a mixture of pigments and resins) that is attracted to the
object’s surface due to the electrostatic charge.

➢ Types of Powder: Powders can be based on thermoplastic or thermoset materials, depending on the
intended application. Common types include epoxy, polyester, and polyurethane

Curing (Baking):

After the powder is applied, the coated part is placed in an oven and heated to a specific temperature
(typically between 160°C to 200°C or 320°F to 400°F).

Cooling :

After the curing process, the coated part is removed from the oven and allowed to cool naturally at room
temperature. During cooling, the coating solidifies, hardens, and becomes a tough, protective layer

Operation 70 – diesel flushing :

In diesel flushing process the fuel tank will filled with 4.5 lit diesel through the diesel if any dust are inside
the tank they will be cleaned

Diesel flushing failures and control methods :

➢ Improper Flushing Technique:
If the diesel flushing process is not done correctly, it may fail to fully remove contaminants like dirt, water,
or microbial growth. This can lead to the persistence of performance issues.

Control Method: Follow recommended procedures and manufacturer guidelines for flushing, ensuring
correct tools and techniques are used.
➢ Incorrect Flushing Fluid:

Using the wrong type of diesel flushing fluid can result in poor cleaning performance or even chemical
reactions that damage the fuel system.

Control Method: Always use the correct flushing fluid designed for diesel engines, and check compatibility
with your engine and fuel system.

➢ Residual Cleaning Agents:

If cleaning agents are not properly flushed out, they can mix with diesel fuel, leading to poor engine
performance or damage.

Control Method: Ensure thorough flushing of the entire system with clean diesel fuel or water to remove
any residual cleaning chemicals.

➢ Fuel Contamination Post-Flushing:

If the fuel system is not adequately sealed or if the flushing agent is not properly drained, contaminants can
re-enter the system after the process.

Control Method: Inspect the system after flushing, ensuring all flushing fluids are thoroughly drained and
that all filters are replaced.

Parameters :
Current – below 240 amp

Voltage – 15 – 18 v

Velocity flow – 10- 13 ft/s

Operation 80 – final inspection :

Final inspection is the last step in the quality control process, typically in manufacturing, construction, or
product development. It involves a thorough review or examination of a product, structure, or system to
ensure that it meets all specified requirements, standards, and regulations before being approved for delivery
or use.
Quality checking :

• Threading

• Dust particles

• Child parts

• Weld wire

• Weld lump
• Go No Go

• Shabby weld

Operation 90 – packing or dispatch :

• Packing is the process of securely placing items into packaging to prevent damage during transit
⚫ Dispatch refers to the action of sending out the packed goods.

Good packing and a streamlined dispatch process help ensure products reach customers safely and on time.
 CHAPTER-3

TYPES OF RESISTANCE WELDING

Spot welding :
Spot welding is a type of resistance welding process used to join two or more metal sheets by applying heat
and pressure to a small, localized area (or "spot"). This process involves passing a high electrical current
through the work pieces, causing them to heat up at the point of contact due to their electrical resistance.
The heated metal then melts, and the pressure from the electrodes fuses the pieces together, creating a strong
weld

Fig. 3.1

Applications of Spot Welding:

Spot welding is widely used in industries where metal parts need to be joined quickly and efficiently,
particularly for sheet metal. Common applications include:

1. Automotive Industry: Spot welding is used extensively in car manufacturing, particularly for joining
thin metal sheets in car bodies and other structural components.

2. Electronics: Spot welding is often used to join battery terminals, especially in the production of battery
packs for devices like laptops, electric vehicles, and power tools.
3. Appliance Manufacturing: In the production of home appliances like refrigerators, washing machines,
and microwave ovens, spot welding is used to assemble metal components.

4. Aerospace: Spot welding can be used in the assembly of aircraft parts, especially where high-speed,
accurate, and consistent joining of metal components is required.

5. Construction and Fabrication: Spot welding can be used in the production of structural elements or steel
frames, often in combination with other welding methods for enhanced strength.

Limitations of Spot Welding:

Despite its advantages, spot welding has certain limitations that make it unsuitable for all types of
applications:
 i. Material Thickness: Spot welding is most effective on thin materials (typically less than 6 mm thick). It
is not suitable for thicker metals because the heat generated would be insufficient to create a strong
weld, or the process might overheat and damage the material.

ii. Material Compatibility: Spot welding works best with materials that have good electrical conductivity,
such as mild steel and aluminium. Non-ferrous metals like copper and brass, or metals with poor
conductivity, may not weld effectively using this method.

iii. Limited Joint Strength: While spot welding is strong, the joint strength is often less than that of
continuous welding methods (like MIG or TIG). In certain applications, this may be a concern,
particularly in high-stress environments.

iv. Surface Preparation: The surfaces to be welded must be clean to ensure good electrical contact and
proper heat generation. Rust, oil, or dirt can interfere with the process, leading to weak or unreliable
welds.

v. Size and Accessibility: Spot welding is limited by the size of the parts being welded and the accessibility
of the joints. Complex or large parts might not be suitable for spot welding due to limitations in electrode
reach or clamping ability.

vi. Limited to Lap Joints: Spot welding is most effective for lap joints (where one sheet overlaps the other).
Other types of joints, such as butt joints, are difficult or impossible to perform using spot welding.

vii. Heat Affected Zone: While the heat-affected zone (HAZ) in spot welding is typically small, the process
can cause changes in material properties around the weld area. In some cases, this can lead to reduced
mechanical properties, like brittleness, in the vicinity of the weld.

viii. Appearance of Welds: Spot welds can sometimes be visible on the surface, which may be undesirable
for aesthetic reasons in some applications.

Components :
• Welding Machine/Power Supply – Provides electrical power.

• Electrodes – Copper tips that focus current on the work pieces.

• Electrode Holder – Supports and positions the electrodes.

• Control System – Regulates the welding parameters (time, current, pressure).

• Work pieces – The metal sheets being welded.

• Pressure Mechanism – Applies pressure to keep the sheets in contact.

• Cooling System – Prevents electrodes from overheating.

• Transformer (optional) – Reduces voltage to a suitable level for welding.

Seam welding :
Seam welding is a specialized type of resistance welding where a continuous, welded joint is formed
between two metal sheets or work pieces. This process uses rotating wheel-shaped electrodes that apply
both pressure and electric current to the interface of the materials, which causes them to fuse together
along a continuous seam.

The major distinction between seam welding and other forms of welding, like spot welding, is that seam
welding results in a continuous or near-continuous weld, unlike spot welding, which creates isolated weld
points. This is particularly useful when a hermetic, leak-proof, and strong joint is required over an extended
length.

Fig . 3.2

How Seam Welding Works :

Electrode Contact: Two copper electrodes (wheels) are applied to the surfaces of the materials being welded.
These electrodes are water-cooled to dissipate heat and prevent overheating.

Current Application: An electric current is passed through the electrodes. The electrical resistance between
the two materials causes heat to be generated at the point of contact, which melts the metal and forms a
weld.

Rotating Electrodes: The electrodes rotate continuously, ensuring that the weld is formed along the length
of the joint. In some cases, the weld may consist of overlapping spot welds (a "stitch" pattern), while in
other cases, a smooth, continuous seam is created.

Pressure: The electrodes apply pressure to ensure intimate contact between the materials, ensuring the
formation of a strong bond as the metal fuses.

Types of Seam Welding :

Description: In continuous seam welding, the electrodes rotate in a continuous motion, generating a smooth,
uninterrupted weld along the entire seam. It is particularly suitable for applications requiring a completely
sealed, airtight, or watertight joint.

Applications: Commonly used in making fuel tanks, pressure vessels, and liquid containers, where a
continuous, leak-proof weld is essential.

Spot Seam Welding (also called Stitch Welding):

Description: Instead of producing a continuous weld, this method generates a series of overlapping spot
welds along the seam. It is effective for joining materials when a perfect continuous seal is not necessary,
but strength is still required.
Applications: Used for automotive body panels, light metal fabrication, and other structural applications
where a continuous joint isn't crucial but strength and consistency are still necessary.

Applications of Seam Welding :

Seam welding finds widespread use in various industries where continuous, strong, and leak-tight joints are
required. Some of its key applications include:
1) Automotive Industry:

Car Bodies: Used to weld automotive parts together, particularly for joining the metal sheets of car bodies.
It ensures both strength and resistance to external factors like corrosion.

Exhaust Systems: For joining metal pipes or components of automotive exhaust systems, where airtight and
durable seams are necessary to prevent leaks and rusting.

2) Aerospace Industry:

Fuel Tanks: In aircraft, seam welding is crucial for joining fuel tanks and ensuring that they are pressure-
tight.

Airframe Structures: It is used in some cases for joining parts of airframes and other aerospace components
requiring high strength and precision.

3) Food and Beverage Packaging:

Cans and Containers: Seam welding is a core process in manufacturing sealed food containers (like
aluminium cans), where a continuous weld is essential to maintain freshness and prevent contamination.

Pressure Tightness: In industries like oil and gas, chemicals, and pharmaceuticals, seam welding is
employed to create pressure-tight vessels, tanks, and heat exchangers, where leaks are unacceptable.

4) Electronics and Batteries:

Battery Seals: Used in the production of batteries, especially in consumer electronics, to create airtight,
leak-proof seals for lithium-ion batteries or other electrochemical cells.

5) Marine Industry:
Hull Construction: In shipbuilding, seam welding is used to join large metal panels in ship hulls, ensuring
structural integrity and preventing water leakage.

Components of a Seam Welding Machine :

A seam welding machine consists of several key components, each playing a role in the process:

Electrodes (Welding Wheels):

▪ Function: These copper wheels apply pressure to the work pieces and carry the electric current that melts
the metal to form the weld. The wheels are often water-cooled to prevent excessive heat build-up.
▪ Material: Typically made from copper because of its excellent electrical conductivity and ability to
dissipate heat.

Electrode Holder:

▪ Function: Holds the electrodes in position and applies pressure to the work pieces. It ensures that the
electrodes maintain constant contact with the materials.

Transformer:

▪ Function: Converts the incoming electrical current (usually AC or DC) to the required voltage and
current for welding. The transformer is essential for controlling the power applied during welding.

Control System:

▪ Function: The control system regulates the welding parameters, such as current, pressure, and electrode
speed. Modern systems often include automatic feedback to adjust the parameters in real time based on
the process conditions.

Water Cooling System:

Pressure Mechanism:

▪ Function: Ensures that the electrodes apply a consistent amount of pressure to the work pieces. This
pressure is necessary for good electrical contact and strong fusion of the metal.

Power Supply:

▪ Function: Provides the necessary electrical power for the welding process. This may include rectifiers,
transformers, or inverters to adjust the current to the required levels.

Drive Mechanism:

▪ Function: Moves the electrodes along the seam. The drive can be continuous or intermittent, depending
on whether continuous seam welding or stitch welding is being used.

Limitations of Seam Welding :

1. Material Thickness:

Seam welding is typically most effective for thin materials. Welding thick materials may be less efficient,
requiring higher energy inputs, and the process may not provide a strong bond.

2. Weld Strength:

The strength of the weld can be affected by the speed of the electrode wheels, the current, and the pressure
applied. Improper settings can result in weak or incomplete welds, which can be problematic for high-stress
applications.

3. Electrode Wear:

Over time, the rotating electrodes can wear out, requiring replacement. This increases maintenance costs
and can affect the quality of the welds if not properly managed.

4. Material Suitability:
Some materials, such as high-strength alloys or coated metals, may not be suitable for seam welding, as
they may not allow for effective fusion or could lead to poor-quality welds.
5. Precision and Alignment:

Ensuring proper alignment of the work pieces is critical to obtaining a uniform weld. Misalignment can lead
to inconsistent weld quality or even defects in the welded seam.

6. Cost of Equipment:

The machine is the largest cost factor. Advanced, high-capacity machines with robotic capabilities cost
significantly more than basic machines.

CO2 WELDING :
CO2 Welding, also known as Metal Inert Gas (MIG) welding with CO2 shielding gas is a type of Gas Metal
Arc Welding (GMAW) where carbon dioxide (CO2) is used as the shielding gas to protect the molten weld
pool from contamination by atmospheric gases, such as oxygen and nitrogen. In this process, a consumable
wire electrode is fed through a welding gun, where it melts and joins with the work piece under the heat
generated by an electric arc. CO2 is commonly used as a cost-effective shielding gas, especially for welding
ferrous materials like mild steel and low-alloy steels. This process is known for its high deposition rate,
good penetration, and relatively low cost, but it can produce more spatter compared to other welding
methods using inert gases like argon.Bottom of Form

Working operation :Power Supply: CO2 welding uses a constant voltage power supply to maintain a stable
arc. The power supply ensures that the arc between the wire electrode and the work piece remains consistent,
providing a steady flow of current to melt the filler wire.

Filler Material (Electrode): A consumable wire electrode is fed through a welding gun. This filler wire is
made from the same material as the base metal, and it melts during the process to form the weld pool. The
wire is typically made of mild steel or alloyed steel.

CO2 as Shielding Gas: Carbon dioxide is used as the shielding gas, which helps protect the molten weld
pool from contamination by atmospheric gases like oxygen and nitrogen. CO2 is less expensive than other
shielding gases (like argon or mixed gases), but it also causes more spatter and requires higher heat input.
Arc Formation: The welding torch creates an electric arc between the wire electrode and the base metal.
The heat generated by the arc melts both the electrode and the base material, creating a molten pool of metal
that solidifies to form a weld once the torch moves along the joint.

Shielding Action: CO2 gas, when ionized in the arc, forms a plasma that shields the molten pool and the
weld zone from contaminants. While CO2 provides adequate shielding, it produces more spatter compared
to other gases like argon or a mixture of argon and CO2.

Applications of CO2 Welding :

CO2 welding is commonly used in various industrial sectors due to its efficiency and cost-effectiveness:

1. Automotive Industry:

Ideal for structural steel fabrication and welding, particularly in large-scale projects like bridges, buildings,
and pipelines.

Suitable for heavy-duty welding tasks involving thicker sections of steel.

2. Shipbuilding:

Used in shipyards to weld steel plates, hulls, and other structural components.

3. Fabrication and Maintenance:

Widely used in manufacturing and repair work, especially where speed and cost-effectiveness are critical.

Common in the repair of metal equipment and machinery.

4. Railways:
Used for joining rail tracks, rails, and other railway components, where the welding needs to withstand high
stresses and wear.

Limitations of CO2 Welding:

A. Higher Spatter:
CO2 welding tends to produce more spatter compared to other shielding gases like argon or argon-CO2
mixtures. This can lead to a need for additional clean-up and can affect the quality of the weld bead.
B. Lower Quality Welds:
While CO2 provides good shielding, it can lead to lower-quality welds compared to using pure argon or
argon-CO2 mixes. This is due to the higher heat input and the potential for oxidation, which can result in
more porosity or cracks.

C. Increased Heat Input:

CO2 welding generally requires a higher heat input compared to other welding processes. This can lead to
issues such as warping, distortion, or burn-through on thinner materials.

D. Limited to Steel:
While CO2 is an effective shielding gas for welding ferrous metals, it is not as suitable for non-ferrous
metals like aluminium, copper, or titanium, which require specialized shielding gases like argon.

Components of CO2 Welding Setup:

1) Welding Power Supply:
The power supply unit provides a stable current to maintain the welding arc. Typically, a constant voltage
(CV) power source is used for CO2 welding.
2) Welding Gun (Torch):

The welding torch is used to feed the filler wire to the weld pool while maintaining the arc. It also directs
the shielding gas (CO2) to the weld area. The gun is equipped with a trigger to control the wire feed and the
gas flow.

3) Wire Feed System:

The wire feeder mechanism pushes the filler wire through the welding gun. It can be either a spool gun or
a push-pull system, depending on the wire thickness and type.
4) Shielding Gas Supply:
The CO2 gas is stored in a cylinder and fed to the welding gun through a regulator. The gas flow rate is
typically controlled by a valve on the torch or through a separate flow meter.

5) Electrode:

The electrode is the consumable filler wire that melts to join the base material. The diameter and type of the
wire depend on the base material being welded.

6) Ground Clamp:

A ground clamp is connected to the work piece to complete the electrical circuit. The clamp ensures that the
welding machine operates safely by grounding the current.

Safety equipment is essential to protect the welder from sparks, spatter, UV radiation, and heat. A welding
helmet with an auto-darkening lens, gloves, apron, and other protective gear is used.

Table. 3.1

Advantages of CO2 Welding:

o Cost-Effectiveness:

CO2 is an inexpensive shielding gas compared to other alternatives, making the process more affordable for
high-volume and industrial applications.

o Good Penetration:

The higher heat input allows for deep penetration, which is useful for welding thicker materials.

o High Speed:

CO2 welding allows for high deposition rates, making it efficient for large-scale production and thick
material welding.

o Versatility:

It is suitable for welding mild steel, low-carbon steel, and some alloyed steels, providing good adaptability
for different applications.
 CHAPTER-4

7 QUALITY CONTROL TOOLS

In identifying, analyzing, and resolving quality issues in various settings. Below is a detailed explanation
of each of the seven quality control tools:

a) Fishbone diagram :
Cause-and-Effect Diagram (Fishbone or Ishikawa Diagram): A visual tool used to identify, explore, and
display the possible causes of a specific problem. It helps in brainstorming potential sources of issues.

Purpose:

This tool is used to identify, explore, and visually display the possible causes of a problem. It helps team
members brainstorm potential reasons behind an issue by categorizing causes into main groups like people,
processes, materials, equipment,

Fig . 4.1

Components of a Fishbone Diagram :

o Effect (Problem):
This is the head or the “effect” of the fishbone diagram. It represents the issue or problem that needs to be
analysed and resolved. It is placed at the “head” of the diagram, and all causes will be traced back to this
central problem

o Main Categories (Major Bones):

The large branches (main bones) represent the main categories of potential causes that could be contributing
to the problem. These categories are typically broad factors that could influence the issue. Common
categories include

o Subcategories (Smaller Bones):

These are smaller branches connected to the main bones, representing more specific causes within each
category. They provide more detailed insights into the contributing factors. The subcategories break down
the broad categories into more precise causes.

o Minor Causes (Tiny Branches):

These are the smaller branches extending from the subcategories, representing more specific or granular
causes. The goal is to explore these in-depth to uncover the root cause(s).
o How to Build a Fishbone Diagram ;
Define the Problem: Start by clearly defining the problem or effect you’re analysing. Place it at the “head”
of the diagram.
Identify Major Categories: Choose the major categories (main bones) that are most relevant to the problem.
These are typically based on your industry, process, or area of focus.

o Brainstorm Causes: Under each category, brainstorm potential causes of the problem. Use team
discussions, data, or observations to identify as many potential causes as possible.

Drill Down: For each cause, break it down further by identifying sub-causes or specific details that could
contribute to the issue. Continue this process to ensure all possible causes are considered.

Analyse and Prioritize: Once the diagram is complete, analyse the causes and prioritize the most likely or
impactful ones to investigate further.

Benefits for using fishbone diagram :

▪ Structured Problem-Solving
The Fishbone Diagram provides a clear and organized approach to identifying the causes of a problem. It
breaks down a complex issue into smaller, manageable parts, helping teams systematically explore different
potential causes across categories (people, process, materials, equipment, etc.).

▪ Identifies Root Causes

One of the biggest benefits is that it helps identify the root causes of a problem rather than just focusing on
symptoms. By drilling down into the causes and exploring sub-causes, the Fishbone Diagram helps uncover
deeper issues that may not be immediately obvious.
▪ Improves Communication and Documentation

The diagram can be easily shared among team members and stakeholders, fostering better communication
and ensuring everyone is aligned on the causes of the problem. It also serves as a useful tool for documenting
the analysis, which can be referenced later for problem resolution or future process improvements.
The structured categories of the Fishbone Diagram ensure that all possible causes are explored. This reduces
the likelihood of overlooking key factors, helping to ensure a more thorough investigation into the problem.

▪ Simplifies Complex Problems

For complex or multifactorial problems, the Fishbone Diagram provides a straightforward way to break
down the problem into its constituent parts. This helps teams focus on specific areas and avoid feeling
overwhelmed by the complexity of the issue.

▪ Works Across Industries

The Fishbone Diagram is versatile and can be applied in a wide range of industries, including
manufacturing, healthcare, service industries, and more. Its flexibility in categorizing causes makes it useful
for any situation where problem-solving and process analysis are required.

b) Check sheet :
Collects data in a structured format, often in a tally sheet, to identify patterns or trends in quality-related
issues.

Table 4.2

Components of a check sheet :

• Title: The name or description of the data being collected (e.g., “Defect Type Check Sheet” or “Daily
Production Errors”).
• Date and Time: The period for which data is being collected (e.g., date, shift, or specific time frame).
• Category/Item List: A list of categories, events, defects, or items that are being tracked (e.g., different
types of defects or causes of delays).
• Tally Column: A column where data is recorded, often in the form of tally marks or checkboxes to
indicate occurrences of specific items or events.
• Total or Count: A section that provides a total count of occurrences for each item or category after the
tallying process is complete.
• Remarks/Comments: A space for additional notes, observations, or explanations (optional but helpful in
some cases).
• Name of the Person Responsible: Optional, but often included to track who is responsible for the data
collection.

Benefits for using check sheet :

• Easy Data Collection: It provides a straightforward way to collect data in a structured format. The
simplicity of a check sheet ensures that team members can easily track events or occurrences without
requiring complex training.
• Organization: A check sheet helps in organizing information systematically, allowing for quick and
efficient data review. It helps to categorize occurrences, such as defects, errors, or any other significant
data points, for analysis.
• Real-Time Monitoring: Check sheets are ideal for tracking data in real time, making them useful in
ongoing processes or inspections. For example, they can track defects on a production line or monitor
specific operational parameters.
• Identifying Problems and Trends: When used consistently, check sheets can reveal recurring problems
or trends over time, allowing for proactive problem-solving and continuous improvement efforts.
• Promotes Consistency: Using a check sheet standardizes data collection processes, ensuring that data is
recorded consistently across different times, teams, and locations.

c) Control chart :
Plots data points on a graph over time and shows upper and lower control limits to detect whether the process
is in control (stable) or out of control (unstable). It helps in understanding process stability.

Purpose: Used to track how a process performs over time and identify variations.

Components of control chart :

• X-axis (Horizontal Axis):
Represents time or sequence of data points. This axis shows the time intervals or the order in which the
data is collected, such as days, shifts, or production cycles.
• Y-axis (Vertical Axis):
Represents the measured variable or characteristic being monitored (e.g., product dimensions, weight,
temperature). This axis shows the values of the data points
• Data Points:
These are individual measurements collected from the process and plotted on the control chart.
Each point represents a sample taken from the process at a specific time or interval.

• Central Line (CL):

 The central line represents the mean or average of the data, indicating the expected performance of the
process when it is in control. It helps to compare the actual data with the target or ideal value.
• Upper Control Limit (UCL):
This is the upper threshold or limit beyond which the process is considered out of control. It is typically
set at three standard deviations above the central line. Data points above this limit signal that something
may be wrong with the process.
• Lower Control Limit (LCL):
This is the lower threshold or limit beyond which the process is also considered out of control. Like the
UCL, it is typically set three standard deviations below the central line. Data points below this limit
indicate potential problems.
• Trend or Pattern:
A control chart can also reveal trends (e.g., consistent upward or downward movement) or patterns (e.g.,
cycles or runs), which can provide insights into process behaviour and help detect special causes.

Fig . 4.2

Benefits for using control chart :

o Monitors Process Stability
Benefit: A control chart helps identify whether a process is stable and predictable over time, or if it is
influenced by abnormal variations.

Impact: This helps ensure that the process is under control and consistent, leading to more reliable products
and services.

o Provides Objective Data for Decision Making

Benefit: The data presented on control charts is based on statistical analysis and objective measurement.

Impact: This ensures that decisions about process improvements and corrective actions are data-driven,
reducing reliance on guesswork or subjective opinions.
o Facilitates Continuous Improvement

Benefit: Regularly monitoring processes using control charts helps track ongoing performance and identify
areas where improvements are needed.

Impact: By continuously reviewing control charts, organizations can ensure they are making incremental
improvements, leading to overall long-term quality enhancement.
o Enhances Predictability and Forecasting
 Benefit: A stable process, indicated by control charts, enables better prediction of future performance.

Impact: Organizations can plan with greater confidence, optimize resources, and make accurate forecasts
regarding output and quality.

o Supports Standardization

Benefit: Control charts help ensure that processes are consistently operating within the defined limits,
promoting standardization.

Impact: This ensures uniformity in product quality, which is critical for industries requiring high standards,
such as manufacturing or healthcare.

Control charts provide a visual and statistical method for tracking, analysing, and improving processes.
They help organizations ensure consistency, identify problems early, and foster continuous improvement—
key aspects of effective quality management in the 7QC tools.

d) Histogram :
A Histogram is a graphical representation of the distribution of data. It is used to visually summarize the
distribution, frequency, and spread of a set of data points.

A histogram is a type of bar chart that visually represents the distribution of data. It helps in understanding
the frequency and distribution of values, and can highlight patterns or variations in the data that may need
attention

Fig . 4.3

How it works:
Data is grouped into intervals or bins.

The height of each bar represents the frequency of data points in each interval.
Purpose: Histograms provide insights into the underlying distribution of data, helping identify patterns,
outliers, or variations in the process that need attention.

Components of histogram :
I. X-axis (Horizontal Axis):

Represents the range of values or categories for the data being measured. This axis shows the intervals (bins)
or ranges into which the data is grouped. For example, it could represent time periods, measurements (e.g.,
weight, height, temperature), or any other measurable quantities.
 II. Y-axis (Vertical Axis):

Represents the frequency or count of data points that fall into each bin or interval. This shows how many
observations or data points fall within each range.

III. Bars:

The bars in the histogram represent the frequency or count of data points in each bin. The height of each bar
indicates how many data points fall within that specific range of values. Taller bars mean more data points
in that range, while shorter bars represent fewer data points.

The X-axis is divided into intervals or “bins” that group data points within a certain range. The choice of
bin size can affect the appearance and interpretation of the histogram. Too few bins may obscure details,
while too many bins can make it harder to see overall patterns.

IV. Data Distribution:

The overall shape of the histogram reflects the distribution of the data. Common distributions include
normal (bell curve), skewed, uniform, or bimodal distributions. The pattern helps in identifying trends,
outliers, and variations in the data.

Benefits for using histogram :

o Visualizing Data Distribution

A histogram provides a clear, visual representation of how data is distributed across different ranges. It helps
identify patterns, trends, and the shape of the distribution (e.g., normal, skewed, bimodal), which can inform
further analysis

o Identifying Variability:

Histograms reveal the spread and variability of data. By showing where most data points fall, it helps in
understanding the consistency of a process or product. This is particularly important for identifying variation
in manufacturing, quality control, and other processes.

o Spotting Outliers:

Outliers are data points that fall far from the rest of the dataset. A histogram makes it easy to detect these
anomalies, which can be critical for identifying errors in the process, equipment malfunctions, or unusual
events that require attention.
o Facilitating Comparison:

When comparing multiple datasets or time periods, histograms allow you to quickly visualize and compare
differences in data distributions. For example, comparing production performance before and after a
change in the process or comparing different production lines.
By highlighting trends and variations, histograms support informed decision-making. For example, in a
manufacturing setting, if a histogram shows that most products fall within acceptable tolerance levels,
management can focus on maintaining or improving the process.

o Simplifying Complex Data:

Large datasets can be overwhelming, but histograms simplify data into digestible intervals, making it easier
to see patterns, draw conclusions, and communicate findings with others, such as team members or
stakeholders.
o Predicting Future Trends:

Histograms help in understanding the distribution of past data, which can inform predictions about future
trends. For example, if the histogram of defects shows a normal distribution with a few outliers, adjustments
can be made to reduce variability and improve quality in the future.

o Monitoring Process Stability:

In quality control, histograms are used to monitor process stability. If the data consistently forms the same
distribution over time, the process can be considered stable. Significant changes in the histogram can
indicate shifts in the process that may require corrective actions.

o Setting Performance Standards:

Histograms help establish performance benchmarks by illustrating the range and distribution of acceptable
values. This aids in setting quality standards and determining thresholds for acceptable variations.

e) Pareto chart :
A Pareto chart is a bar graph that shows the relative frequency or size of problems in descending order. It is
based on the Pareto principle, which suggests that 80% of problems often come from 20% of causes. This
helps prioritize which problems to address first.

Purpose: A bar graph that shows the frequency of problems in descending order. Based on the Pareto
principle (80/20 rule), it helps identify the most significant issues to address first.

Fig . 4.4
Components of pareto chart :
o Bars (Categories):

The bars represent different categories or issues (e.g., defects, problems, or causes). Each bar’s height
corresponds to the frequency or magnitude of the issue.

The bars are typically arranged in descending order, from the highest to the lowest, to emphasize the most
significant problems.

o Y-Axis (Frequency or Count):

The vertical axis typically represents the frequency or number of occurrences of each issue or category, or
sometimes the cost or impact of the problem. This is measured in absolute terms (e.g., number of defects,
time spent, or cost incurred).
o X-Axis (Categories or Causes):

The horizontal axis represents the different categories or specific causes of the problem. These could be
defect types, failure modes, or any other factors contributing to the issue being analysed.

The categories are listed in order of their frequency or impact, starting with the most significant on the left.
o Cumulative Line (Cumulative Percentage):

This is a line graph that typically appears overlaid on the bar chart. It shows the cumulative percentage of
the total frequency or impact.

The y-axis of the cumulative line is often represented as a percentage (ranging from 0% to 100%).

o Cumulative Percentage Scale (Right Y-Axis):

The right vertical axis is typically used to plot the cumulative percentage. This axis shows the accumulated
percentage of the total impact as each issue is added.

It helps to identify which categories contribute to the majority of the problem (usually 80% of the total
impact, as per the Pareto principle).

Benefits for using pareto chart :

o Prioritization of Issues: By focusing on the “vital few” causes (usually the 80/20 rule), the Pareto chart
helps prioritize issues or problems that will have the greatest impact if addressed.
o Visual Clarity: The chart provides a clear and easy-to-understand visual representation of data, making
it simpler for teams to grasp the most critical issues quickly.
o Data-Driven Decision Making: It helps managers and teams make informed decisions based on the data,
rather than gut feelings or assumptions. It shows where to focus efforts for the highest return.
o Identification of Root Causes: By displaying the frequency of different issues or defects, the Pareto chart
helps identify the root causes of problems, which is essential for effective problem-solving and
continuous improvement.
o Facilitates Communication: A Pareto chart can be used in meetings to communicate complex data in a
straightforward, understandable format. It helps align teams on where to focus improvement efforts.
o Helps with Resource Allocation: By identifying the most frequent problems, organizations can allocate
resources (time, money, effort) more efficiently to address the most impactful issues first

f) Scatter diagram :
Scatter diagram shows the relationship between two variables. By plotting data points on an X-Y axis, it
helps identify potential correlations or patterns between variables.

Purpose

To identify relationships between two variables and understand if one affects the other.

Fig . 4.5

Components of scatter diagram :

o X-axis (Horizontal Axis):

Represents the independent variable or the variable that you want to test or predict the effect of. This is the
factor you change or manipulate to observe its effect on the dependent variable.

o Y-axis (Vertical Axis):

Represents the dependent variable or the outcome that is being affected by the independent variable. It
shows the results or values that change as the independent variable is manipulated.

o Data Points (Plotted Points):

Each point on the diagram represents a data pair (X, Y), where the value of the independent variable (X) is
plotted against the value of the dependent variable (Y). The position of each point helps visualize the
relationship between the two variables.

o Title and Labels:

The diagram should have a clear title that indicates what variables are being compared. Both the X-axis and
Y-axis should be labeled with the names of the variables and their units of measurement (if applicable).
o Gridlines (Optional):
Gridlines may be used to help with visualizing and interpreting the positions of data points relative to the
axes, making it easier to see the relationship between the two variables.

o Trend Line (Optional):

Sometimes, a trend line (also called a “line of best fit”) is added to show the general direction of the
relationship between the two variables. The trend line can indicate

Benefits for using scatter diagram

Identify Relationships: Scatter diagrams help to visually identify correlations or relationships between two
variables (e.g., positive, negative, or no correlation). This helps to understand how changes in one variable
might affect the other.
o Detect Trends and Patterns: The plot allows you to quickly spot trends, clusters, and patterns in data.
This is useful for predicting future behaviours or identifying outliers.
o Spot Outliers: Scatter diagrams make it easy to identify outliers or unusual data points that may warrant
further investigation or that could skew analysis.
o Simple and Intuitive: Scatter plots are easy to interpret, even for people without a technical background.
They provide a straightforward visual representation of data.
o Assess Linear or Non-Linear Relationships: Scatter diagrams can show whether the relationship
between variables is linear (straight line) or non-linear, which helps in choosing the right statistical
models.
o Support Hypothesis Testing: A scatter plot can be used to visually assess whether the data supports a
hypothesis, such as the existence of a relationship or the direction of that relationship.
o Helps in Data Quality Assessment: By visualizing the data, you can assess its quality, including detecting
inconsistencies, errors, or missing values that might affect further analysis

g) Flow chart :
A diagram that uses symbols (rectangles, diamonds, arrows) to represent the sequence of steps in a process.
Flowcharts help visualize how a process works and where problems might occur.

Purpose

Makes complex processes easier to understand, helps identify bottlenecks, and aids in process improvement.
 Fig . 4.6

Components of flow chart :

o Oval (Terminator):

Represents the start and end points of a process.

o Rectangle (Process):

Indicates a process or operation step, such as performing a task or action.

o Diamond (Decision):

Represents a decision point where a yes/no or true/false question is asked, leading to different branches.

o Arrow (Flow Line):

Shows the direction of flow or the sequence in which steps are carried out.

o Parallelogram (Input/Output):

Denotes the input to or output from a process, like materials or data.

o Circle (Connector):

Used to connect parts of the flow chart, particularly when the chart is split into multiple pages or sections.
Represents a document or report generated in the process.

Benefits for using flow chart :

o Simplifies Complex Processes:
Flow charts break down complex processes into manageable, step-by-step visual diagrams, making it easier
to understand how each step flows and connects.
o Identifies Process Inefficiencies:

By mapping out processes, flow charts help identify bottlenecks, redundancies, or inefficiencies, allowing
teams to target areas for improvement.

o Enhances Communication:

Flow charts provide a clear and standardized way to communicate process steps, decisions, and workflows
across teams, making it easier for everyone to understand the process.

Aids in Problem-Solving:
When used in conjunction with other QC tools, flow charts help teams trace issues back to specific steps in
a process, enabling them to diagnose the root cause of problems.

o Facilitates Standardization:

A well-documented flow chart ensures that processes are standardized, leading to consistency in how tasks
are performed, which helps maintain product or service quality.

o Improves Training:

Flow charts serve as useful training tools, helping new employees quickly understand the steps involved in
a process and the relationships between them.

o Assists in Continuous Improvement:

Flow charts provide a baseline for evaluating the effectiveness of process changes over time, supporting
ongoing efforts to optimize and improve quality.

CONCLUSION

The internship at CIE Automotive, Zaheerabad, in the Stamping Branch, provided me with An in-depth
understanding of automotive component manufacturing. Over the span of one Month, I observed and
participated in the production of Mahindra tractor and cargo Automotive parts, which are crafted using MS
HRCA and CRCA sheet metal. This Exposure offered practical insights into how raw materials are
transformed into precise Components through various stamping processes.

One of the primary learning experiences was understanding sheet metal stamping, which Involved the
operation of heavy presses and the handling of sheet metal to achieve desired Shapes. I became familiar
with critical steps like blanking, forming, and trimming, as well As the role of dies in ensuring uniformity
and accuracy in production. Additionally, I Gained knowledge of die maintenance techniques, which are
vital for maintaining Operational efficiency and reducing downtime in the manufacturing process.
Through active participation in the process, I learned about the importance of quality Checks at each stage
to ensure the manufactured parts meet industrial standards. Observing How components are inspected for
dimensions, surface finish, and material properties gave Me practical exposure to quality assurance practices
that I had studied in theory.
The internship also allowed me to witness how modern manufacturing integrates principles Like lean
practices and process optimization to minimize waste and maximize productivity.
 REFERENCES

1. "Mahindra appoints Anish Shah as the MD and CEO, effective from April 2".
2. "Annual Report 2022-23"..

3. "Indian Tractor Maker Mahindra Takes On Deere"..

4. "Mahindra & Mahindra in Fortune India list".

5. "Top Competitors for Mahindra & Mahindra Limited"..