Bachelor of Technology in Department of Mechanical Engineering

A
SUMMER TRAINING REPORT

ON
KEC INTERNATIONAL LIMITED, JAIPUR
Submitted
In partial fulfilment
For the award of the degree of
Bachelor of technology
In
Department of mechanical engineering
(2018-2019)
Submitted to: Submitted by

Mr. Sandeep Jhamb Rohit soni
Head of Department 15EAIME096
Department of Mechanical Engineering
ARYA INSTITUTE OF ENGINEERING AND TECHNOLOGY,

JAIPUR
RAJASTHAN TECHNICAL UNIVERSITY, KOTA

(2015-2019)
(AIET/DOME/2015-19/SP/1)
ARYA INSTITUTE OF ENGG. & TECH.
DEPARTMENT OF MECHANICAL ENGINEERING
CERTIFICATE
This is to certify that the Training report for Study of Production Process of Angles in KEC
International, Jaipur from 10 July 2018 to 9 August 2018 is submitted by Mr. ROHIT SONI in
partial fulfillment for the award of degree of Bachelor of Technology in Mechanical Engineering has been
found satisfactory and is approved for submission.
(PTS GUIDE) (PTS INCHARGE)

Mr. Pankaj Kumar Mr. Gurmeet Singh
Assistant Professor Assistant Professor
Dept. of Mechanical Engg. Dept. of Mechanical Engg.
Mr. SANDEEP JHAMB

(Head of Department)
Dept. of Mechanical Engg.
CONTENT
Content name page no.
A. Certificate from department 1

B. Certificate from plant 3
C. Candidate’s declaration 6
D. Acknowledgement 7
E. History 9
CHAPTER 01
Manufacturing 11
-tower testing 11
-procedure of tower testing 14
CHAPTER 02 ( Plant )
-fabrication process 17
Production department 17
CHAPTER 03 (Galvanizing process ) 24
CHAPTER 04 (Quality assurance)
CHAPTER 05 (Process capability ) 26

- Measure the process 27
- Capability contemplate 28
CHAPTER 06 ( Six sigma ) 28

Process execution file 29
-Example 30
5-S System 33
O. Time check of worker 37
CHAPTER 07 ( Measuring instruments ) 38

- Vernier calipers 39
- Digital caliper 41
- Micrometer 42
- Slip gauges 44
- Accessary set 49
- Coating thickness meter 52
- Infrared thermometer 54
- Digital universal protector 56
- Profile projector 58
Q. Conclusion 59
R. Reference 60
CANDIDATE’S DECLARATION
I hereby declare that the work, which is being presented in the Seminar “Production
process of angles” in partial fulfilment for the award if degree of “Bachelor of Technology”
in Mechanical Engineering and submitted to the Department of mechanical Engineering,
Arya Institute of Engineering & Technology, affiliated to Rajasthan Technical University is
record of my own work under the guidance of Mr. Pankaj Kumar, Assistant Professor,
Department of mechanical Engineering.
ROHIT SONI
15EAIME096
ACKNOWLEDGEMENT
First of all I would like to express my whole hearted thanks and deep gratitude to our parents
who have always been my source of inspiration for any challenging work, project or
assignment.
I whole heartedly acknowledge the intellectual stimulation of my esteem Project Guide, Mr.
Sunil jangir (Sr. Production Engineer) for his continuous help and guidance throughout the
project duration in spite of his busy schedule. My faculty Guide for giving necessary
instruction and guidance on how to pursue this summer project. I really found your guidance
extremely helpful at every step of the research and in analyzing the various facts and figures.
Finally in this chain I am also thankful to Mr. Rajeev (HR department) for providing Extra &
useful knowledge, which helped me to have a deep insight of the Theoretical aspects of the
report and all the officers and Staff of KEC, without their help my training report, would not
have been successfully completed.
PREFACE
The objective or main motive of this practical training is to getting a true practical
knowledge about the industries, that how their industrial setups are held, and their
techniques used in industry technologies to be made or used in the environment.
This report is presented on the basis of practical training acquired at KEC International
Limited, Jaipur. This report is on Plant Engineering Process with relevant diagrams & by
their proper description & explanation.
In spite of all my best efforts some unintentional errors might have eluded, it is requested to
abrogated them.
HISTORY
Fig. no. 1
GLOBAL PRESENCE:-
Fig. no. 2
CHAPTER 01
Manufacturing - Technical Capability
Tower & Steel Structures Production facilities
KEC today, brags of the biggest generation limit on the planet for pinnacle assembling of
around 150,000 MTs for each annum spread more than three cutting edge producing offices
in the deliberately invaluable areas of Jaipur in Rajasthan, Nagpur in Maharashtra and
Jabalpur in Madhya Pradesh. In these offices, the organization fabricates steel structures
required for transmission and appropriation lines, telecom and railroads foundation. It
likewise has close relationship with five Value Added Partner Manufacturing offices (VAPs)
who give select limit of in excess of 60,000 MTs for each annum. All the assembling units
are overseen autonomously and are bolstered midway by acquirement, coordinations, QA,
arranging and business capacities at Supply Chain. It is likewise connected with in excess of
400 sellers and more than 25 coordinations specialist organizations. The organization has as
of late gone into 4PL Partnership with Kuehne+Nagel. The organization provided over 2.5
million metric huge amounts of towers till date, for developing more than 85,000 kms of
transmission lines all inclusive.
A portion of the highlights of these offices are:
•State of Art Manufacturing innovation with all around built spread out
•In-house created exceptional reason flat cum vertical bowing press for twisting the
distinctive segment sizes
•Capability of taking into account zinc coat thickness in the scope of 65 to 130 microns
according to client prerequisite
•Strong Steel sourcing capacity
•Common ERP System over all Supply Chain producing offices
•Fully Integrated Planning framework – Order to Delivery
•Capability of obliging pinnacle astute packaging necessity of the client to empower capacity
and simple supply of pinnacle to the ideal areas.
Fig. no. 3
Tower Testing Facilities-
KEC has four of Asia's most advanced Tower Testing stations, fit for testing towers of up to
1200 kV Transmission Line. These testing stations serve the target of fulfilling clients about
structure parameters of pinnacle by exposing Proto-Towers to different test stack conditions.
KEC has set up the Asia's (India) biggest Transmission Line Tower Testing Station at
Butibori close to the current Tower Manufacturing Factory.
PROCEDURE OF TOWER TESTING:-
The galvanized test tower complete with required extensions will be erected on rigid foundation are of
testing station. The loads are applied as per data sheets, which are submitted for approval before tower
test.
In the design calibration Ultimate, Transverse, Vertical & Longitudinal loads for cases are give. Tower is
tested for loading cases indicated in the test data sheet.
These loads will be applied in following steps for all load cases:
50% of Ultimate load 75% of Ultimate
load 90% of Ultimate load 95% of
Ultimate load 100% of Ultimate load
In the event of failure at less than 95 % of the specified design load, the failed components are modified &
structure will be rested to 100% of the specified design load.
In the event of failure b/w 95% & 100% of the specified design loads. Support shall be modified & rested.
In the event of failure at100% of the specified design loads but less than 1 min. in to the holding period,
the client may accept the support without modification.
All the load cells to be used for testing will be calibrated before starting the test with the help of UTM in
the presence of the engineer. The test loading shall be applied as per calibration result.
PROCEDURE OF LOADING:-
The longitudinal, transverse & vertical loads are applied to tower wire ropes using electrical winches.
Now transverse, vertical & longitudinal loads will be applied as per data sheet. Applied loads are measured
by dial indicators connected to the load cell inserted b/w tower & wire ropes. The gradually
increment of loads is 50%,90%, 95%, 100% of the specified loads. Holding period for load stages
below 100% shall be 1 min for 100% load stages.
After completing all the design loads test as required by the purchaser, tower will be subjected to destruction test
under normal condition by applying loads in step of 105%, 110%, 115%, 120% ultimate failing occurs.
Jaipur Jabalpur Vashi New Test Bed Butibori
Testing Capacity 400 kV 800 kV 800 kV 1200 kV and above
Rectangular
up to 18m Square/Rectangular/Monopoles/Guyed
Base Configuration Square 800 kV
Square up to towers
24m
Height of Mast
45m,48m 50m,58m 60m,60m 90m,90m
Transverse longitudinal
Maximum
compression/uplift per 250 M/T 450 M/T 500 M/T 1250 M/T
Leg
Electrical Electrical Electrical Electrical Winches with Variable
Load Application
Winches Winches Winches Frequency Drives and SCADA
CHAPTER 02 (PLANT):-
Tower Packing Factory Qualified Re-

Tested of towers stuffing and validatio
More in single/ of experien n of
than 1100 multi contain- c-ed man proto
numbers. tower ers. -power. assemb
configur- -lies.
ation.
CHAPTER 03 (Fabrication Process):-
Fig. no.4
PRODUCTION DEPARTMENT:-
Creation deptt. Comprises creation shop I and II. All the task is performed in a grouping in
this deptt. On crude material. The fundamental point of this deptt. Is to deliver the creating
right quality and amount. Directions are given to this deptt. By arranging deptt. This deptt.
Issues M.I.R. to crude yard and crude material originates from crude yard at the premise of
M.I.R. In this deptt. Move in control takes participation report of men assets and as
indicated by it work designation Is finished by him.
The processes which are performed on various m/c are following.
A . Straightening
B . Shearing
C. Stamping
D. Punching
E . Notching
F. Chipping
G. Drilling
H . Grinding
I . Bending
PROCESS FLOW DIAGRAM (CNC SHOP)
STAMPING
PUNCHING
SHEARING
NOTCHING
BENDING
CHIPPING
GRINDING
HANDLING OVER TO GALVANISING SHOP
A. STRAIGHTENING:-
The straightening m/c is utilized for points to fix them if there is any default in them. The
edge goes between two rollers which are inverse to one another and turn by electrically
implies. The lower roller is settled and turns about a fix hub however upper roller is versatile
and its position can be changed by hand wheel. Weight is balanced physically. Consequently
the crude material is fixed on this machine.
fig. no. 5 : Straightening M/C
B. SAWING MACHINE:-
This m/c is utilized for cutting the points of substantial area. A belt saw is utilized in this m/c
and amid cutting procedure a cutting liquid is additionally utilized for cooling reason. The
maximum. Substantial segment 250X250X35 is utilized for cutting edges which have their
area above 150X150XX15.
C. STEPPING MACHINE:-
The letters, numbers and different figures are embellished on part no. , type no., venture
no.etc. This helps us in get together shops. If there should arise an occurrence of twisting
of parts the stepping is done in the wake of bowing. As a matter of course, in the event that
there wrong stepping happens, re stepping is finished.
Stepping is done as:- H717S2397
This speaks to: H-High elastic steel 717S-Project no. 2397-Member no

The normal limit of stepping m/c is 20MT per move. In this m/c the power is given by
substantial wrench.
Capacity to wrench is gotten by a substantial engine with flywheel and apparatus system.
Stepping edges are put on the machine with the assistance of supporting table and
administrator utilized the foot switch by which wrench, takes its underlying position for
next stepping or to process proceed.
D. SHEARING MACHINE:-
In the business the crude material comes as vast edges. The points are sliced by the
prerequisite by utilizing this m/c. this m/c takes a shot at the standard of water powered
weight. Cutting device and kick the bucket are utilized for cutting. Cutting instrument is
made of HSS. The normal limit of this m/c is 20MT per move.
E. PUNCHING MACHINE:-
The primary capacity of this m/c is to deliver openings on points at different separations. The
points which have thickness up to 12mm are punched. This m/c depends on water driven
weight rule. KECIL utilizes seven punching m/c. The normal limit of this m/c is 5MT per
move.
F. DRILLING MACHINE:-
The angles which have their thickness above 12mm are drilled. For this purpose
there are six radial arms drilling m/c. This m/c is rounded at 360. The average capacity of
this m/c is 2.25MT per day. This drill is made of HSS. The m/c is operated manually.
G. CHIPPING MACHINE:-
This m/c is used for hell grinding. When we want to joint two angles. Then hell
grinding is done for eliminating the interference between angles clot. Achiness’s tool is
used for this purpose. This m/c is operated manually and works on pneumatic pressure
principle. The average capacity of this m/c IS 1MT per shift.
H. GUSSET SHOP:-
Gusset shop is the sub shop of FAB-I where the work is done only on the plates. The
plate type parts of tower are manufactured here.
I. NOTCHING M/C:
The little cuts are made on the spines of points at any edge by this m/c scrap is gathered in
boxes and after that send to store. There are five machines to this procedure. These work on
water powered weight standard. The normal limit of this m/c is 5.5MT per move.
1. F-cut
2. B-cut
3. C-cut
4. Notch
J . BENDING MACHINE:-
There are two methods of bending for angles:
1. Cold bending
2. Hot bending
In cold bending the angles is bended by using hammer. Templates are used to check them.
Cold bending is done for those angles which have their thickness below 6mm.
The angles which have their thickness above 6mm are bended by hot bending process.
For hot bending there is an oil furnace and a bending m/c which works on hydraulic
principle.
Firstly the angles are heated on oil furnace and then it is put along the bending die and
pressure is applied by ram. So the angle bends according to the shape of die. Then the
angle is checked with the help of templates. The average capacity of this m/c is
2.25MT per shift.
CHAPTER 04 ( Galvanizing Process)
Fig. no. 6
Fig. no. 7
CHAPTER 05
QUALITY ASSURANCE
DEPARTMENT
DEPARTMENTAL ACTIVIES:-
• Steel and Accessories Inspection at KEC and at Vendors
• Quality Management System (ISO – 9001:2008)
• Environment Management System (ISO-14001:2004)
• Process Monitoring and Audits (Fabrication and Galvanizing)
• Client Inspection/Finish Material Inspection
1. Examination at KEC and at Vendors:-
- Vendor Assessment
- Verification of accepting material
• Offer from sellers
• Purchase arrange
• Daily receipt
- Inspection of accepting Material
• Purchase Order - - Visual Dimension Inspection
(Determined measurements and visual deformity according to significant particular)
• Relevant Specification - Mechanical Testing (according to important determination)
- Yield pressure, Ultimate tractable, %of extension &impact test for steel and Wedge
stack, evidence stack, shear quality, head soundness &hardness on screw and nut.
• Sampling Plan - - Chemical Testing (according to applicable detail)- % of

Carbon, Sulfur, Phosphorous, Silicon, Manganese and so on.
• Approved/Relevant Drawing - Inspection Report/Material Inspection

Clearance Certificate - Inspection Summary
• Okay - Release of GR note
• Not Okay - Rejected or acknowledged after revamp or arranging
• Feedback to provider for development
2. Quality Management System (ISO-9001:2008):-
Internal Audits
Customer Complaint Analysis
Product Audit
Updation and Distribution of Standards and codes
Implementation of QMS (ISO-9001:2008)
Updation of Departmental Procedure/System in accordance with
ISO-9001:2008 for its adequacy
Coordination with MR and QMS
3. Condition Management System (ISO-14001):-
Improving natural execution
Green and clean condition
Internal review
Compliance of lawful prerequisites
Ensure wellbeing and wellbeing
Conservation common assets
Coordination with MR and QMS
4. Process Inspection (Fabrication and Galvanizing):-
- Calibration of estimating apparatus/gadgets
- Process Qualification (Galvanizing and Welding)
- Verification of LOT for online assessment
• LOT containing course sheet, draw examination report and so on.
- Inspection of material amid process
• Route sheet and Inspection report - Visual and Dimensional Inspection
(Determined measurements and visual imperfections according to applicable particular

and portray)
• MR noticed &Company's standard - LOL amount according to course sheet
• Customer's standard - Galvanizing covering on pinnacle parts
• Sampling plan - - (according to applicable determination)
• Approved portrays - Inspection reports/nonconformance reports
- Inspection rundown
• Okay - Release of further preparing
• Not alright - Rejected or modify capable
• Analysis for non-accommodating material for underlying driver and

coercive/preventive activity
• Feedback to concern looks for enhancements
5. Customer Inspection and Finish Material Inspection:-
Inspection of bundling material in Gen. Stores
(Pressing strips, seals, invar, wooden catch/boxes and so on.)
Inspection offer rundown
Customer details
Bundling Specifications
Company's Standards
Proper stockpiling of complete material in indicated zone.
PROCESS CAPABILITY :-
A procedure is a novel mix of apparatuses, materials, techniques, and individuals
occupied with delivering a quantifiable yield; for instance an assembling line for machine
parts. All procedures have intrinsic measurable inconstancy which can be assessed by
factual strategies.
The Process Capability is a quantifiable property of a procedure to the particular,
communicated as a procedure ability file (e.g., Cpk or Cpm) or as a procedure execution
record (e.g., Ppk or Ppm). The yield of this estimation is typically outlined by a histogram
and computations that foresee what number of parts will be delivered out of determination
(OOS).
Process ability is additionally characterized as the capacity of a procedure to meet its

motivation as overseen by an association's administration and process definition
structures ISO 15504.
Two sections of process ability are: 1) Measure the inconstancy of the yield of a procedure,
and 2) Compare that fluctuation with a proposed determination or item resilience.
• Measure the procedure
The contribution of a procedure for the most part has no less than at least one quantifiable
attributes that are utilized to indicate yields. These can be investigated measurably; where
the yield information demonstrates an ordinary dispersion the procedure can be portrayed by
the procedure mean (normal) and the standard deviation.
A procedure should be built up with suitable process controls set up. A control graph
examination is utilized to decide if the procedure is "in factual control". In the event that the
procedure isn't in factual control, capacity has no significance. Thusly the procedure ability
includes just normal reason variety and not exceptional reason variety.
A clump of information should be acquired from the deliberate yield of the procedure.
The more information that is incorporated the more exact the outcome, anyway a gauge
can be accomplished with as few as 17 information focuses. This ought to incorporate the
typical assortment of creation conditions, materials, and individuals simultaneously.
With a made item, usually to incorporate no less than three distinctive generation
runs, including new companies.
The procedure mean (normal) and standard deviation are determined. With an ordinary
appropriation, the "tails" can expand well past in addition to and short three standard
deviations, however this interim ought to contain about 99.73% of generation yield. In
this manner for a typical appropriation of information the procedure capacity is frequently
portrayed as the connection between six standard deviations and the required particular.
• Capability contemplate
The yield of a procedure is relied upon to meet client prerequisites, determinations, or item
resiliences. Designing can lead a procedure ability concentrate to decide the degree to which
the procedure can meet these desires.
The capacity of a procedure to meet determinations can be communicated as a solitary number

utilizing a procedure ability list or it tends to be surveyed utilizing control graphs. Either case
requires running the procedure to acquire enough quantifiable yield with the goal
that designing is sure that the procedure is steady thus that the procedure mean and
inconstancy can be dependably evaluated. Factual process control characterizes strategies to
legitimately separate between stable procedures, forms that are floating (encountering a long
haul change in the mean of the yield), and procedures that are developing progressively
factor. Process capacity records are important for procedures that are steady (in a condition
of measurable control).
For Information Technology, ISO 15504 indicates a procedure capacity estimation structure
for surveying process ability. This estimation system comprises of 5.5+0.5 dimensions of
process ability from none (Capability Level 0) to streamlining forms (CL 5). The estimation
system has been summed up with the goal that it very well may be connected to non IT
forms. There are at present two process reference models covering programming and
frameworks. The Capability Maturity Model in its most recent rendition (CMMI constant)
likewise pursues this methodology.
CHAPTER 06
SIX SIGMA
The Six Sigma procedure is all around established in insights and factual science.
Realize why six standard deviations is beneficial for your association to gauge
What is being "Six Sigma"? Six Sigma at numerous associations just means a
proportion of value that takes a stab at close flawlessness. In any case, the factual
ramifications of a Six Sigma program go well past the subjective annihilation of
client distinguishable deformities. It's an approach that is very much established
in arithmetic and insights.
The target of Six Sigma Quality is to diminish process yield variety so that on a long
haul premise, which is the client's total involvement with our procedure after some
time, this will result in close to 3.4 deformity Parts per Million (PPM) openings (or
3.4 Defects Per Million Opportunities – DPMO). For a procedure with just a single
particular limit (Upper or Lower), this outcomes in six process standard deviations
between the mean of the procedure and the client's detail limit (thus, 6 Sigma). For a
procedure with two detail limits (Upper and Lower), this means marginally in
excess of six process standard deviations between the mean and every particular
limit to such an extent that the aggregate imperfection rate compares to likeness six
process standard deviations.
Numerous procedures are inclined to being affected by unique and additionally

assignable causes that affect the general execution of the procedure in respect to the
client's determination. That is, the general execution of our procedure as the client sees it
may be 3.4 DPMO (relating to Long Term execution of 4.5 Sigma). Be that as it may,
our procedure could without a doubt be equipped for creating a close impeccable yield
(Short Term ability – otherwise called process qualification – of 6 Sigma). The
distinction between the "best" a procedure can be, estimated by Short Term process
ability, and the client's total understanding (Long Term capacity) is referred to as Shift
portrayed as Zshift or sshift. For a "normal" process, the estimation of move is 1.5; in
this way, when one catches wind of "6 Sigma," intrinsic in that announcement is that the
momentary capacity of the procedure is 6, the long
haul ability is 4.5 (3.4 DPMO – what the client sees) with an accepted move of 1.5.
Regularly,
when reference is given utilizing DPMO, it indicates the Long Term ability of the
procedure, which is the client's understanding. The job of the Six Sigma proficient is
to measure the procedure execution (Short Term and Long Term ability) and
dependent on the genuine procedure privilege and process move, build up the
correct technique to achieve the set up execution objective
As the procedure sigma esteem increments from zero to six, the variety of the
procedure around the mean esteem diminishes. With a sufficiently high estimation of
process sigma, the procedure approaches zero variety and is known as 'zero
deformities.'
Process execution file
In process enhancement endeavors, the procedure execution record is a gauge of

the procedure capacity of a procedure amid its underlying set-up, before it has been
brought into a condition of factual control.[1]
Formally, if the upper and lower details of the procedure are USL and LSL, the
evaluated mean of the procedure is , and the assessed inconstancy of the
procedure (communicated as a standard deviation) is , then the procedure
execution file is characterized as:
is evaluated utilizing the example standard deviation. Ppk might be negative if the
procedure mean falls outside as far as possible (in light of the fact that the
procedure is creating an expansive extent of flawed yield).
A few details may just be uneven (for instance, quality). For details that just have a
lower limit, ; for those that just have a furthest limit, .
Specialists may likewise experience , a metric that does not represent process
execution that isn't actually focused between as far as possible, and subsequently is
deciphered as what the procedure would be equipped for accomplishing in the event
that it could be focused and settled.
• Example
Consider a quality trademark with focus of 100.00 μm and upper and lower
determination breaking points of 106.00 μm and 94.00 μm separately. On the off
chance that, after painstakingly observing the procedure for some time, it creates
the impression that the procedure is crazy and delivering yield capriciously (as
delineated in the run outline underneath), we can't genuinely assess its mean and
standard deviation. In the precedent underneath, the procedure mean seems to float
upward, agree to a while, and afterward float descending.
If and are estimated to be 99.61 μm and 1.84 μm, respectively, then
Index
KEC International Limited , Jaipur
Process capability Studies ON CNC m/c s
MACHINE AXIS Cp Cpk SECTION LENGTH

ZA 0.6 0.43 HT 150×150×15 4315
ZB 1.04 1.02 HT 120X120X10 2000
ZC 0.57 0.55 HT 150×150×12 5002
CP-03
YA 0.48 0.21 HT 150×150×12 5002
YB 0.84 0.27 HT 120X120X10 2000
YC 0.46 0.23 HT 150×150×12 5002
ZA 1.942 1.274 HT 150×150×12 546
ZB 1.42 1.13 90×90×7 3649
ZC 1.387 1.179 MS 250 60×60×4 2214
CP-04
YA 1.42 0.86 MS 250 60×60×4 2214
YB 1.13 0.97 90×90×7 3649
YC 1.572 1.274 HT 150×150×12 546
ZA 1.01 0.89 HT 80×80×6 350
ZB 0.974 0.552 HT 130×130×10 6000
ZC 2.19 1.01 HT 350 75×75×6 5792
CP-05
YA 1.32 0.98 HT 80×80×6 350
YB 1.798 1.681 HT 350 130×130×10 6000
YC 1.36 1.02 HT 350 75×75×6 5792
Y1 0.886 0.807 50X50X5 110
CP-02
Y2 1.014 0.716 50X50X5 110
NO. 1 0.8 0.7 50X50X5 1919
NO. 2 1.369 0.875 80×80×6 4655
CP-01
NO. 5 0.757 0.651 75X75X6 7000
NO.6 0.99 0.83 75X75X4 5188
X
AXI
S 2.511 2.295 HPE350×10 442×105
P 81
Y
AXI
S 2.652 1.629 10 MM PLT 442
NATURE
SR
OF WHY 1 WHY 2 WHY3 WHY4 ACTION FREQUENCY RESPONSIBILITY
NO.
PROBLEM
Hold Bent
check
1 Hold down down material material after receiving Operator
LEG loose guide bolt feed in visually each MIR
broken machine
before
feeding
material check
Angle does not no 100% material
after receiving
struck hold undergo straightening visually Operator
each MIR
down leg 100% capacity before
straightening feeding
hold down
shaft
housing
because of
bolt, check
continuous no checking
floating included in monthly PM team
hitting standard
arm monthly PM
attachment operation
found
loose
pincher
supporting
pincher because of check
plate hit no checking
supporting continuous included in weekly PM team
from hold standard
plate loose working monthly PM
down leg
slot
runtime
after
Replacemen
which t
Hold no
replacemen
2 down LEG rework is t frequency weekly PM team
worn out to be done standard set to 6
is not months.
defined or
captured
lock pin
Undesired
included in
clearance clearance
trolley,C
in lock pin in piston
3 support to weekly PM team
of hold rod C
be checked
down support
in weekly
assembly
PM.
Because of check
reference
mounting impact alignment
Reference plate
bolt
4 plate loose mounting became loading and on both daily Operator
bolt loose lose continuous sides by
use rope
-S-SYSTEM:-
TIME CHECK OF THE WORKERS
Fig. no. 8
Column1 Column2 Column3 Column4 Column5 Column6 Column7 Column8 Column9
Time
Motion
Study
11
June,2012
Time In
Time of Performing Start End Lead
S. No. Item No. Arriving S. No. Operation Operation Time Time Time
A187-DD- Back Mark
1 9:08 9:12 AM 10:05 34 Mins.
547R 1 Measuring 6 Mins.
Pieces
2 Arrangement 28 Mins.
Grinding
3 (Filing) 10 Mins.
Grinding
4 (Machine) 3 Mins.
A187-DA- Initial
2 9:39 9:41 10:49
122X 1 Measuring 4 Mins.
Pieces
Back Mark 9 Mins. 30
3 Measuring Secs.
5 Mins. 30
4 Grinding Secs.
5 Coloring 10 Secs.
A187-DA- Initial
3 10:33 10:38 12:49
221 1 Measuring 3 Mins.
Pieces
Back Mark 7 Mins. 30
3 Measuring Secs.
4 Grinding 8 Mins.
Lunch
Time
11:00 to
4 11:30
A187-DA- Initial
5 12:35 12:38 1:48
126X 1 Measuring 6 Mins.
Pieces
Back Mark
3 Measuring 6 Mins.
4 Grinding 13 Mins.
Tea Time
01:10 To
6 01:15
A187-DB- Pieces
7 9:40 9:50 12:47 39 Mins
421 1 Arrangement 26 Mins.
2 Grinding 9 Mins.
Bending
3 Check 5 Mins.
Initial
4 Checking 23 Mins.
Back Mark
5 Measuring 18 Mins.
A187-DD- Pieces
8 9:45 9:50 12:20
113L 1 Arrangement 23 Mins.
Initial
2 Measuring 5 Mins.
Back Mark
3 Measuring 7 Mins.
4 Coloring 15 Secs.
A187-DD-
9 9:50 9:59 12:21
266S 1 Grinding 5 Mins.
2 Stamping 2 Mins.
Pieces
A187-DC- Initial
10 12:35 12:56 13:55
11 1 Measuring 4 Mins.
Pieces
Back Mark
3 Measuring 10 Mins.
12
June,2012
A187-DA- Initial
11 196 10:53 1 Measuring 8 Mins. 11:40
A187-DC- Back Mark
12 17 10:50 1 Measuring 4 Mins. 11:59
Fig. no. 9
CHAPTER 07
Instruments used for measurements in KEC

VERNIER CALIPER
Fig. no. 10
Purpose of Use
A variation to the more traditional caliper is the inclusion of a vernier scale; this makes it
possible to directly obtain a more precise measurement.
Vernier calipers can measure internal dimensions (using the uppermost jaws in the picture at
right), external dimensions using the pictured lower jaws, and depending on the
manufacturer, depth measurements by the use of a probe that is attached to the movable
head and slides along the centre of the body. This probe is slender and can get into deep
grooves that may prove difficult for other measuring tools.
The vernier scales may include both metric and inch measurements on the upper and
lower part of the scale.
Vernier calipers commonly used in industry provide a precision to a hundredth of a

millimetre (10 micrometres), or one thousandth of an inch.
DIGIMATIC CALIPER
Fig. no. 11
MICROMETERS
A micrometer some of the time known as a micrometer screw check, is a gadget utilized
generally in mechanical building and machining and most mechanical exchanges for
exactness estimation, alongside other metrological instruments, for example, dial
calipers and Vernier calipers.
The first ever micrometric screw was imagined by William Gascoigne in the seventeenth
century, as an improvement of the Vernier; it was utilized in a telescope to gauge precise
separations between stars. Its adjustment for the exact estimation of handheld articles was
made by Jean Laurent Palmer of Paris in 1848.
Parts & Operating Principles:-
Fig. no. 12
A micrometer is made out of:
Edge
The C-formed body that holds the blacksmith's iron and barrel in steady connection to
one another. It is thick since it needs to limit flexion, extension, and constriction, which
would twist the estimation.
The edge is overwhelming and thusly has a high warm mass, to anticipate significant
warming up by the holding hand/fingers. Usually secured by protecting plastic plates
which further decrease warm transference.
Clarification:
on the off chance that you hold the edge sufficiently long with the goal that it warms up by
10°C, at that point the expansion long of any 10 cm straight bit of steel is of extent 1/100
mm. For micrometers this is their run of the mill exactness go.
Micrometers normally have a temperature indicated, at which the estimation is right.
Iron block
The sparkly part that the axle pushes toward, and that the example leans against.
Sleeve/barrel/stock
The stationary round part with the straight scale on it. Once in a while Vernier markings.
Bolt nut/bolt ring/thimble bolt
The knurled part (or switch) that one can fix to hold the shaft stationary, for example,
when quickly holding an estimation.
Screw
(Not seen) The core of the micrometer, as clarified under "Working standards". It is inside
the barrel. (No big surprise that the typical name for the gadget in German is
Messschraube, truly "estimating screw".)
Shaft
The gleaming tube shaped part that the thimble causes to push toward the blacksmith's iron.
Thimble
The part that one's thumb turns. Graduated markings.
Ratchet stop
(not appeared in outline) Device on end of handle that limits connected weight by slipping
at an aligned torque.
Working standards:-
Micrometers utilize the standard of a screw to intensify little separations that are excessively
little to quantify specifically into extensive revolutions of the screw that are sufficiently huge
to peruse from a scale. The exactness of a micrometer gets from the precision of the string
structure that is at its heart. The fundamental working standards of a micrometer are as per
the following:
1. The measure of revolution of a precisely influenced screw to can be specifically

and absolutely associated to a specific measure of pivotal development (and the other way
around), through the steady known as the screw's lead (/ˈliːd/). A screw's lead is the
separation it pushes ahead pivotally with one finish turn (360°). (In many strings [that is, in
all single-begin threads], lead and pitch allude to basically a similar idea.)
2. With a proper lead and significant width of the screw, a given measure of pivotal
development will be intensified in the subsequent circumferential development.
For instance, if the lead of a screw is 1 mm, yet the real distance across (here, external
measurement) is 10 mm, at that point the outline of the screw is 10π, or about 31.4 mm. In
this manner, a pivotal development of 1 mm is intensified (amplified) to a circumferential
development of 31.4 mm. This intensification permits a little contrast in the sizes of two
comparable estimated articles to correspond to a bigger distinction in the situation of a
micrometer's thimble.
In more established micrometers the situation of the thimble is perused straightforwardly

from scale markings on the thimble and shaft. A Vernier scale is normally included, which
enables the situation to be perused to a small amount of the littlest scale check. In more up
to date advanced micrometers, an electronic readout shows the length carefully on a LCD
show on the instrument.
SLIP GAUGES
A check square (otherwise called a gage square, Johansson measure, slip measure, or Jo square)
is an accuracy ground and lapped length estimating standard. It is utilized as a source of
perspective for the setting of estimating gear utilized in machine shops, for example,
micrometers, sine bars, calipers, and dial markers (when utilized in an assessment job.
Fig. no. 12 Slip Gauge Box
Depiction
Gage square is an accurately shaped instrument to pass judgment on separations between

contradicting faces. Regularly, gage squares come in sets that comprise of squares of
different sizes, alongside two wear squares. , with the base number of squares. The wear
pieces are incorporated at In use, the squares are expelled from the set, cleaned of their
defensive covering (oil jam or oil) and wrung together to frame a heap of the required
measurement each finish of the stack at whatever point conceivable as they give assurance
against harm to the lapped countenances of the primary pieces. After utilize the squares
are bothered or lubed to shield their countenances from consumption.
Wringing:-
Fig. no. 13
36 unique Johansson measure squares wrung together, held together exclusively by
the attachment of their to a great degree level surfaces. 1907.
Wringing is the way toward sliding two squares together with the goal that their appearances
softly bond. At the point when joined with a light film of oil, this activity rejects any air from
the hole between the two squares. The arrangement of the ultra-smooth surfaces as such
allows sub-atomic appreciation for happen between the squares, and structures an extremely
solid bond between the squares alongside no perceptible adjustment to the stack's general
measurements. Measure squares, when appropriately wrung, may withstand a 200 lb. (890
newton) pull. The itemized material science in charge of this marvel stays indistinct.
Conceivable causes that have been proposed are: environmental weight, sub-atomic
fascination, a moment film of oil, or a blend of these elements.
Fig.no.14
Accessory set:-
Fig.no. 15 Gauge Block Accessory Set
The envisioned frill give a lot of holders and apparatuses to broaden the convenience of
the check square set. They give a methods for safely clipping substantial stacks together
alongside reference focuses and scribers.
Slip measures are produced using a select review of carbide with hardness of 1500
Vickers hardness. Long arrangement slip checks are produced using superb steel having
cross area (35 x 9 mm) with gaps for clipping two slips together.
Evaluations:- They are accessible in different evaluations relying upon their proposed use.
• reference (AAA):
little resilience (±0.05 μm or ±0.000002 in) used to set up principles
• calibration (AA): (resistance +0.10 μm to −0.05 μm) used to align assessment

squares and high accuracy checking
• inspection (A):
(resistance +0.15 μm to −0.05 μm) utilized as device room guidelines for setting
other checking devices
• workshop (B):
substantial resilience (resistance +0.25 μm to −0.15 μm) utilized as shop models

for accuracy estimation
fig. no. 16 ( coating thickness meter )
COATING THICKNESS
Coating thickness is a vital variable that assumes a job in item quality, process control, and
cost control. Estimation of film thickness should be possible with a wide range of
instruments. Understanding the gear that is accessible for film thickness estimation and
how to utilize it is helpful to each covering task.
TYPES:-
Attractive FILM THICKNESS GAGES:-
Attractive film gages are utilized to nondestructively gauge the thickness of a

nonmagnetic covering on ferrous substrates. Most coatings on steel and iron are estimated
along these lines. Attractive gages utilize one of two standards of activity: attractive draw
off or attractive/electromagnetic enlistment.
1. Attractive Pull-off:-
Attractive draw off gages utilize a lasting magnet, an adjusted spring, and a graduated
scale. The fascination between the magnet and attractive steel pulls the two together. As the
covering thickness isolating the two expands, it winds up simpler to pull the magnet away.
Covering thickness is controlled by quantifying this draw off power.
More slender coatings will have more grounded attractive fascination while thicker movies
will have similarly less attractive fascination. Testing with attractive gages is delicate to
surface unpleasantness, bend, substrate thickness, and the cosmetics of the metal
combination.
Fig. no. 17 Pencil-type magnetic pull-off thickness gauge.
Pencil-type models utilize a magnet that is mounted to a helical spring that works oppositely
to the covered surface. Most pencil-type pull-off gages have huge magnets and are intended
to work in just a single or two positions, which somewhat make up for gravity. A
progressively exact adaptation is accessible, which has a modest, exact magnet to gauge on
little, hot, or difficult to-achieve surfaces. A triple marker guarantees precise estimations
when the gage is pointed down, up, or evenly with a resilience of ±10%.
Fig. no. 18 Roll-back dial magnetic pull-off thickness gauge
Rollback dial models (PosiTest appeared in Fig 2) are the most widely recognized type of
attractive draw off gage. A magnet is appended to one end of a turning adjusted arm and
associated with an aligned hairspring. By pivoting the dial with a finger, the spring builds
the power on the magnet and pulls it from the surface. These gages are anything but difficult
to utilize and have a reasonable arm that enables them to work in any position, autonomous
of gravity. They are sheltered in hazardous situations and are regularly utilized by painting
temporary workers and little powder covering tasks. Regular resilience is ±5%.
Attractive and Electromagnetic Induction:-
Attractive acceptance instruments utilize a changeless magnet as the wellspring of the attractive
field. A Hall-impact generator or magneto-resistor is utilized to detect the attractive motion
thickness at a shaft of the magnet. Electromagnetic enlistment instruments utilize a rotating
attractive field. A delicate, ferromagnetic bar twisted with a loop of fine
wire is utilized to create an attractive field. A second loop of wire is utilized to recognize
changes in attractive motion.
Fig. no.19 Electronic magnetic induction thickness gauges
These electronic instruments measure the change in attractive motion thickness at the
surface of an attractive test as it nears a steel surface. The size of the transition thickness at
the test surface is specifically identified with the separation from the steel substrate. By
estimating motion thickness the covering thickness can be resolved.
Elcometer 345 Coating Thickness Gauge
Fig. no. 20 Elcometer 345 Coating Thickness Gauge
The Elcometer 345 Coating Thickness Gauge is an inconceivably flexible measure. With a
scope of tests in both basic or separate test renditions for covering thickness estimations
on Ferrous (F), Non Ferrous (NF) or both Ferrous and Non Ferrous (FNF) Substrates, the
Elcometer 345 will have a measure for your necessities. The check is anything but difficult
to utilize and has been structured in light of the administrator. Client quantifiable
straightforward insights enables the client to see normal, standard deviation, number of
readings, most extreme and least thickness readings. These insights Can be printed out.
• Key lock™ highlight to keep away from coincidental recalibration
• Switchable between microns or mm and mils
• Bigfoot™ for security on fundamental models
• Ideal for level, bended and impacted surfaces
• Fast perusing rate
• Two point alignment
• Switchable between microns or mm and mils
• Bigfoot™ for security on fundamental models

• Ideal for level, bended and impacted surfaces
• Fast perusing rate
• Two point alignment
Fig. no. 21 INFRARED THERMOMETER
Item Description:- The 370 arrangement are non-contact temperature analyzer with laser
locating to affirm the objective . They are anything but difficult to utilize and fir easily in
client's grasp. All have worked in K-type thermocouple contribution for discretionary
contact temperature estimation.
Fig. no. 22
Highlights:
• Temperature Range: 0° to 1,832°F

(18° to 1,000°C)
• Non-contact and K-Thermocouple input
• Laser Pointer
• 8:1 Distance to Spot Ratio
• Record Function
• Display Data Hold Function
• °C and °F Selectable Temp
• Gun-Type Compact Design
• Back Light
• Operation Lock Function
• Trigger Switch
• Carrying Holster
• 9V battery and delicate pocket are incorporated
All items discharge an imperceptible infrared vitality. This instrument detects the surface
temp and showcases it quickly on the LCD. No test required. The discretionary laser
locating takes you to the correct hot or chilly spots instantly.
Temperature Probes:
Browse a total line of tests for your interesting activity task Contact or
surface Gas, Air, Flame High Temp Immersion Semi Frozen Product
Fig. no. 23
DIGIMATIC UNIVERSAL PROTRACTOR
Fig. no. 24
Fig. no. 25
PROFILE PROJECTOR
It is otherwise called an optical comparator, or even called a shadowgraph, a profile

projector is an optical instrument that can be utilized for estimating. It is a helpful thing in
a little parts machine shop or generation line for the quality control investigation group.
Working:-
The projector amplifies the profile of the example, and presentations this on the implicit
projection screen. On this screen there is ordinarily a matrix that can be pivoted 360
degrees so the X-Y hub of the screen can be lined up with a straight edge of the machined
part to analyze or gauge. This projection screen shows the profile of the example and is
amplified for better simplicity of ascertaining straight estimations. An edge of the example
to look at might be agreed with the lattice on the screen. From that point, straightforward
estimations might be taken for separations to different focuses. This is being done on an
amplified profile of the example. It tends to be less complex and in addition lessen mistakes
by estimating on the amplified projection screen of a profile projector.
The normal strategy for lighting is by diastolic enlightenment, which is lighting from behind.
This sort of lighting is additionally called transmitted brightening when the example is
translucent and light can go through it. On the off chance that the example is dark, the light
won't experience it, yet will frame a profile of the example. Estimating of the example
should be possible on the projection screen. A profile projector may likewise have episcopic
brightening which is light sparkling from above. This helpful in showing exhausts or inner
regions that may should be estimated.
Conclusion
In the corporate world a technocrat is judged not only on the basis of technical knowledge but
also on his problem solving efficiency planning & ability to work in a team exposure of
technical knowledge to real world problems makes a man professional conversant with the
complexities involved in a job. In view of such benefits, practical training has been made
an integral part of my curriculum.
The weeks of my first practical training were full of wonderful experiences. Training has
made me well acquainted with the necessities & the problems that engineers a1ctually face
during their jobs. It has also helped me a lot to adapt myself to actual working
environment & working co-ordination with other team members.
This training helped me a lot in exchanging my inter and personal skills there by
furnishing my attitude, skills, & knowledge. Further the guidance, support, co-operation
and assistance provided by my colleagues & members at the bank helped me a lot
in developing the project.
Reference
The main source of reference for me during my training period have been the
people here working for the company since the company started its production.
They were the only source of information based on which I have
formulated the departments sections and camp to know about the lacunas existing
in the company. Though the presence of the company website cann’t be ignored
which acts as a good platform to compare their product range with the same
category. The following are the sources of information:
1.www.kecrpg.com
2.Kec project and planning manual.
3.R.K. Jain ……. 17th edition june 2009

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A

SUMMER TRAINING REPORT

Submitted to: Submitted by

Department of Mechanical Engineering

ARYA INSTITUTE OF ENGINEERING AND TECHNOLOGY,

RAJASTHAN TECHNICAL UNIVERSITY, KOTA

(PTS GUIDE) (PTS INCHARGE)

Mr. SANDEEP JHAMB

A. Certificate from department 1

CHAPTER 03 (Galvanizing process ) 24

CHAPTER 04 (Quality assurance)

CHAPTER 05 (Process capability ) 26

CHAPTER 06 ( Six sigma ) 28

CHAPTER 07 ( Measuring instruments ) 38

Manufacturing - Technical Capability

Tower & Steel Structures Production facilities

A portion of the highlights of these offices are:

•Strong Steel sourcing capacity

•Common ERP System over all Supply Chain producing offices

•Fully Integrated Planning framework – Order to Delivery

Tower Testing Facilities-

Tower Packing Factory Qualified Re-

CHAPTER 03 (Fabrication Process):-

The processes which are performed on various m/c are following.

PROCESS FLOW DIAGRAM (CNC SHOP)

HANDLING OVER TO GALVANISING SHOP

fig. no. 5 : Straightening M/C

This speaks to: H-High elastic steel 717S-Project no. 2397-Member no

• Steel and Accessories Inspection at KEC and at Vendors

• Quality Management System (ISO – 9001:2008)

• Environment Management System (ISO-14001:2004)

• Process Monitoring and Audits (Fabrication and Galvanizing)

• Client Inspection/Finish Material Inspection

1. Examination at KEC and at Vendors:-

- Verification of accepting material

• Offer from sellers

- Inspection of accepting Material

• Purchase Order - - Visual Dimension Inspection

(Determined measurements and visual deformity according to significant particular)

• Relevant Specification - Mechanical Testing (according to important determination)

• Sampling Plan - - Chemical Testing (according to applicable detail)- % of

• Approved/Relevant Drawing - Inspection Report/Material Inspection

• Okay - Release of GR note

• Not Okay - Rejected or acknowledged after revamp or arranging

2. Quality Management System (ISO-9001:2008):-

Customer Complaint Analysis

Updation and Distribution of Standards and codes

Implementation of QMS (ISO-9001:2008)

Updation of Departmental Procedure/System in accordance with

ISO-9001:2008 for its adequacy

Coordination with MR and QMS

3. Condition Management System (ISO-14001):-

Improving natural execution

Green and clean condition

Compliance of lawful prerequisites

Ensure wellbeing and wellbeing

Conservation common assets

Coordination with MR and QMS

4. Process Inspection (Fabrication and Galvanizing):-