INTERNSHIP REPORT

PREPARED BY

VINEETH M BHAT

01FE15BME235

At

Aequs Aerospace private limited

No: 437/A, Hattargi Village,

Hukkeri Taluk, Belagavi District,

Karnataka - 591243

This report is submitted to

School of Mechanical Engineering

K L E Technological University, Hubballi

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 LIST OF CONTENTS

Chapter No Title Page No

1 INTRODUCTION 1-3

1.1 Introduction 1

1.2 Industrial training objective 2

1.3 The important of industrial training to student 3

2 COMPANY BACKGROUND AND ORGANIZATION 5-8

STRUCTURE

2.1 Organization chart 5

2.2 Company logo 8

3. WEEKLY JOBS SUMMARY 9-11

3.1 Weekly Jobs Summary 11

4 TECHNICAL CONTENTS 15-25

4.1 Details of machines, equipments & technology used etc. 15

5 FINDINGS AND RECOMMENDATIONS 25

6 CONCLUSIONS 30

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 LIST OF TABLES

Table no Title Page no

1.1 Description about table --
1.2
1.3

LIST OF FIGURES

Figure no Title Page no

1.1 Description about figure -- .
Note: 1.2 Table
1.1 1.3

indicates about the table no 1 of chapter no 1

Note: Figure 1.1 indicates about the figure no 1 of chapter no 1

guideline: please do not include the colored texts (are for examples) in report

School of Mechanical Engineering

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 CERTIFICATE

Certified that the Internship work carried out by Mr./Ms. ………………….………………..,

USN…………………..………, a bonafide student of …………………………….in partial
fulfillment for the award of Bachelor of Engineering /Bachelor of Technology in
………………………………………….……… of the K L E Technological University,
Hubballi during the year ……………………… It is certified that all corrections/suggestions
indicated for Internal Assessment have been incorporated in the Report deposited in the
departmental library. The Internship report has been approved as it satisfies the academic
requirements in the said Degree.

Name : Name: Name:

Signature: Signature: Signature:
(Internal Guide) (Coordinator, SME) (Registrar)

External Viva
Name of the examiners Signature with date
1
2.

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 (Certificate issued at the Organization where the internship work carried out)*
(On a separate sheet)*
NAME OF THE INDUSTRY / ORGANIZATION
(Address with pin code)

CERTIFICATE

Certified that the Internship work carried out by Mr. VINEETH M BHAT USN
01FE15BME235 a bonafied student of KLE Technological University in partial fulfillment
for the award of Bachelor of Engineering in Mechanical engineering of the K L E
Technological University, Hubballi during the year 2018-2019 It is certified that, he has
completed the internship satisfactorily.

Name: Name:
Signature: Signature:
(Industry Guide/Mentor) (Head of organization)

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Chapter 1
INTRODUCTION

As a partial fulfillment of the requirement for the award of degree in Mechanical

Engineering, the student must at least take one session of Industrial Training or practical at an
organization relevant for the field of mechanical engineering. Industrial Training will be
progress for five weeks. (This chapter briefs about the organization and the products/ services
that it provides to the customers)

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Chapter 2

COMPANY BACKGROUND & ORGANIZATION STRUCTURE

2.1 Organization Background

Aequs is India’s fastest growing precision engineering company, specializing in forging &
heat treatment, precision machining, sheet metal fabrication, surface treatment and structural
assemblies for the aerospace and other allied industries. It is headquartered within the Aequs
Special Economic Zone in Belagavi, India’s First Notified Precision Engineering &
Manufacturing SEZ.

Aequs operates several manufacturing facilities in India, US and France. They are located in
Aequs SEZ, Belagavi (Karnataka, India), Houston (TX, USA), Paris (TX, USA), Aubigny
(France), Cholet (France) and Besancon (France).

Aequs offers a fully capable manufacturing ecosystem that effectively meets the wide-
ranging demands of customers around the world. Aequs currently has three multinational
joint ventures to provide increased value-add capabilities within the SEZ; they are with
Aubert & Duval SAS of France (ERAMET Group) for forging, Magellan Aerospace of
Canada for Surface treatment and Saab AB of Sweden for Assemblies. Aequs customers
include global industry leaders such as Airbus, Boeing, Safran, Dassault, Collins Aerospace,
Eaton, Honeywell, SAAB and GKN Aerospace to name a few.

Figure 2.1 Map showing Aequs Aerospace

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MISSION – VISION – VALUES of the company :

Mission : To deliver increasing value to our stakeholders – employees, customers, suppliers,

shareholders and community – through innovative, efficient, global ecosystems.

Vision : To be a preferred global partner in every market we serve.

Values : Aequs values serve as guiding principles – What we fundamentally believe and shall
not compromise. These are the values that we demonstrate day in and day out. They guide us
in our decisions, resolve issues and make it a part and parcel of our work culture. They act as
a framework to define the scope of how we do our business.

Transparency
 We will be ethical, open, and honest in every action.
 We will set clear expectations and communicate them to all
stakeholders.

Trust
 We will foster an environment of trust.
 We will say what we do and do what we say.

Respect
 We will uphold mutual respect without exception.
 We will value our resources and deploy them judiciously.

2.2 Organization Chart

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 Figure 2.3 organization structure

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Chapter 3
WEEKLY JOBS SUMMARY

The knowledge was gained in different fields like programming, production planning,
production, quality during the internship training period. The knowledge gained are
summarized weekly as follows.

Table 3.1 weekly activities

Date Activities
 Report to the internship guide.
 7 QC tools.
21/01/2019-  Maintaining 5S.
26/01/2019  5S red tag.
 8 forms of waste.
(week 1)  Safety precautions.
 EDM and wire cutting operation.

28/01/2019 –  Specifications of different types of CNC machines.

02/02/2019  Input – Process- Output.
(week 2 )  Different process involved in order to convert Raw
material to finished products.
 Various documents involved in the control of a
process or manufacturing raw material.
 Information about FIFO (First In First Out) (effective
utilization of the inventory).
04/02/2019 –  Raw material storage.
09/02/2019  Different types of tools (boring, reaming, turning,
(week 3) milling etc).
 Finishing and roughing tools.
 Tool wear.
 Tool, holders, insert nomenclature.
 Different types of holders.
 Types of coolant and checking the concentration of
the coolant.
11/02/2019 –  Quality inspection of parts.
16/02/2019  Different quality instruments.
(week 4)  Callibration of different instruments.
 Different stages of inspection (first off, inprocess and
final inspection).
 Internal pressure test of baker hughes part in AFCD
lab.

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  Engineering drawing reading.
 Dimensions and tolerances.
18/02/2019 –  GD&T parameters.
23/02/2019  TD Diagram.
(week 5)  Angle of projections.
 Concentricity measurements.
 Checking parameters using 2D linear height gauge.

25/02/2019 –  Basics and importance of 6 sigma lean manufacturing.

02/03/2019  Introduction about Statistical Process Control.
(week 6)  Normality curve.
 First off turn back project introduction.
 Deburring introduction.

Chapter 4
TECHNICAL CONTENTS

4.1 Personal Protective Equipment (PPE) :

The most important part of the manufacturing industry is the safety of the worker. The
various safety equipment known as Personal Protective Equipments (PPE) are :
1. Helmet.
2. Earplug.
3. Safety goggles.
4. Face mask.
5. Hand gloves.
6. Tucked in shirt.
7. Safety shoes.

4.3 Introduction to ASYM :

The ASYM Department manufactures parts related to aerospace and oil & gas industries. The
major customers of the ASYM are :
1. UTAS.
2. MOOG.
3. HONEYWELL.
4. Bharat Defense Limited (BDL).
5. Airbus.
6. SAABCA.
7. SAAB.
8. EATON.

There are 32 machines in ASYM .The different machines in the ASYM are :

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4.2 Documentation :

There are different documents followed by the company to ensure that the company is
working in order. and the system becomes transparent. The different documents followed by
the company are :

1. Manufacturing Outline (MO) :

Manufacturing Outline contains information about the customer, raw material,
No of operations, tools to be used, information about each operation.

2. FIFO tracker :
This document helps in processing the first in Raw material to process first
helping in minimizing the inventory to a large extent.

3. Route Card :
This document contains information about the customer, the shop order no and
QM no, the condition of raw material, revision no of documents, the route or
machine no that should be followed in next operations.

4. Process Flow Diagram (PFD) :

PFD indicates the flow of the process, this document contains the operation no
and exactly does each operation.

5. Preparedness Chart :
This document is check list to make sure that fixture is mounted properly, the
documents are upto date, etc.

6. NC setup sheet :
This documents focuses on the production aspect, this consists of the tool
offset, work offset, work zero, butting face, clamping method, tool used,
insert, and many other things.

7. TD diagram :
This is standard engineering drawing as per the customer, having special
Tear Drop so that the quality inspection could be done easily.

8. Inspection plan :
This document is related to quality and is prepared in order to check the
different dimensions of the part is as per the dimensions mentioned by the
customer and assure the quality of the part.

9. Daily production report :

As the name indicates this document helps in maintaining the daily production
report per shift. And compare the part production in each shift thus knowing
the idle time of the machine.

10. Tool life checklist :

This document helps in maintaining the life of tool, previous time that the tool
was used so that the parts can be machined without being damaged.

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4.3 8 Forms of waste :

Waste is any step or action in a process that is not required to complete a process (called
“Non Value-Adding”) successfully. When Waste is removed, only the steps that are required
(called “Value-Adding”) to deliver a satisfactory product or service to the customer remain in
the process.

The 8 forms of wastes are :

1. Defects
2. Overproduction
3. Waiting
4. Not-Utilizing Talent
5. Transporting
6. Inventory
7. Motion Waste
8. Excess Processing
Defects are a great example as to why it is imperative to choose the right product the first
time. Improper deployment of tools, poor specifications, and poor quality can require a lot of
time and money to resolve an issue.
Overproduction is when a company produces more products than the market demands.
Overproduction is one of the largest types of waste that contribute to increased inventory
holding cost, labor, and facility cost.
Waiting involves a delay of the production flow process. Delay can happen through
unplanned downtime, which can occur through malfunctioning of poor quality materials,
waiting on appropriate materials to complete a task, or unbalanced workload that can
bottleneck the workflow.
Not-Utilizing Talent takes place when personnel is idle while waiting for a process to be
completed by another staff member or process, or when they are not utilized effectively based
on their knowledge or skill-set.
Transporting materials through long or complicated routes between operations can
exponentially increase handling costs.
Inventory Excess increases manufacturing costs by consuming extra floor space required to
maintain excess inventory, and the people obligated to handle it. Lean manufacturing works
off of a pull system that produces product at a time when customers need it. Doing so will not
put a company in a predicament of trying to figure out how to sell the excess product when
there is no demand for it.
Motion Waste is excess movement that can put workers’ safety at risk, possibly resulting
in overexertion injuries. Overexertion injuries can cause a significant reduction in employees’
productivity. Employing a new hire will cost time and money to properly train the new
employee to make up for the delay. Also, reassigning an existing employee to cover the
injured employee’s position does not alleviate the fact that the workforce is still down a
person.
Excess Processing happens when operation depends on surplus labor because of poor
maintenance, excess operational capability for production requirements and/or fulfilling
redundant processes that stand in the employees’ way of being optimally productive.

5S Methodology :

5S is frequently viewed as an element of a broader construct known as visual control visual

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workplace or visual factory. Under those terminologies, Western companies were applying
underlying concepts of 5S before publication, in English, of the formal 5S methodology.

There are five 5S phases. They can be translated from the Japanese as "sort", "set in order",
"shine", "standardize", and "sustain". Other translations are possible.
1. Sort (Seiri)
Seiri is sorting through all items in a location and removing all unnecessary items
from the location.

Goals :
 Reduce time loss looking for an item by reducing the number of items.
 Reduce the chance of distraction by unnecessary items.
 Simplify inspection.
 Increase the amount of available, useful space.
 Increase safety by eliminating obstacles.

2. Set In Order (Seiton)

Seiton is putting all necessary items in the optimal place for fulfilling their
function in the workplace.
Goals :
 Make the workflow smooth and easy.

3. Shine (Seiso)
Seiso is sweeping or cleaning and inspecting the workplace, tools and
machinery on a regular basis.
Goals:
 Prevent deterioration.
 Keep the workplace safe and easy to work in.
 Keep the workplace clean and pleasing to work in.
 When in place, anyone not familiar to the environment must be able to
detect any problems within 50 feet in 5 sec.

4. Standardize (Seiketsu)
Seiketsu is to standardize the processes used to sort, order and clean the
workplace.
Goal:
 Establish procedures and schedules to ensure the repetition of the first three
‘S’ practices.
 Develop a work structure that will support the new practices and make it part
of the daily routine.

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  Ensure everyone knows their responsibilities of performing the sorting,
organizing and cleaning.
 Use photos and visual controls to help keep everything as it should be.
 Review the status of 5S implementation regularly using audit checklists

5. Sustain/Self-discipline (Shitsuke)
Shitsuke or sustain the developed processes by self-discipline of the workers.
Also translates as "do without being told".
Goal:
 Ensure that the 5S approach is followed.
 Organize training sessions.
 Perform regular audits to ensure that all defined standards are being
implemented and followed.
 Implement improvements whenever possible. Worker inputs can be very
valuable for identifying improvements.
 When issues arise, identify their cause and implement the changes necessary
to avoid recurrence.

4.2 Different Departments of Production Industry :

There are various departments in converting a drawing provided by the customer into a
finished product. These departments have to work closely together in order to complete the
part and send it to the customer on time.

The various aspects of production are:

1. Project management (PM).
2. Manufacturing Engineering (ME).
3. Production Planning & Control (PPC).
4. Production Department.
5. Quality Assurance.
6. Supply Chain Management (SCM).

1. Project management;
The project management involves in finalizing the deals and deciding the cost
estimation of the part.The project management focuses on maintaining a
healthy relationship with its customer. They are the part of the company which
will be in continuos touch with the customer.

2. Manufacturing Engineering (ME) :

ME is involved in deciding the number of operations that will be taken to
process the Raw material to finished part. They also design the fixture for
every operation. They write the NC program for every operation. They are
also responsible for specifying the tolerances. The designing is done using
CATIA tool.

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 3. Production Planning & Control (PPC) :
The PPC department is involved in plan the dates for the launch of the parts
and deciding the machines on which the parts are to be runned. The PPC also
acts as a link between the production and SCM. They notify the SCM if ther is
shortage of ant raw material.

4. Production Department :
The Production is involved in processing raw material to finished part as
required by the customer. They are closely related in controlling the parts
within the specified tolerances.

5. Quality Assurance :
The QA is responsible for verifying weather the products manufactured is
within the specified tolerances as provided by the customer. Quality check is
done for every operation of every part. And if the part does not meet the
required specification the QA department reject the part and tag the part as
Non conforming (NC tag).

6. Supply Chain Management (SCM) :

The SCM department looks after the supply of raw materials to the company
from the supplier and supply of finished parts from the company to the
supplier.

4.4 The production Engineering :

The production department is involved in

4.5 Tools, Inserts and Holders :

4.5 7 QC Tools :

The 7 QC Tools are simple statistical tools used for problem solving. These tools were either
developed in Japan or introduced to Japan by the Quality Gurus such as Deming and Juran. In
terms of importance, these are the most useful. Kaoru Ishikawa has stated that these 7 tools
can be used to solve 95 percent of all problems. These tools have been the foundation of
Japan's astonishing industrial resurgence after the second world war.

The Seven QC tools are :

1. Check sheet
2. Control chart
3. Stratification (alternately, flow chart or run chart)
4. Pareto chart
5. Histogram
6. Cause-and-effect diagram (also known as the "fishbone" or Ishikawa diagram)

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 7. Scatter diagram

1. Check sheet :
Check sheets are tools for collecting data. They are designed specific to the
type of data to be collected. Check sheets aid in systematic collection of data.
Some examples of check sheets are daily maintenance check sheets,
attendance records, production log books, etc. Data collected using check
sheets needs to be meaningfully classified. Such classification helps gaining a
preliminary understanding of relevance and dispersion of the data so that
further analysis can be planned to obtain a meaningful output. Meaningful
classification of data is called stratification. Stratification may be by group,
location, type, origin, symptom, etc.

2. Control chart :
Control charts was developed by Dr. Walter A. Shewhart during 1920's while he was
with Bell Telephone Laboratories. These charts separate out assignable causes.
Control chart makes possible the diagnosis and correction of many production
troubles and brings substantial improvements in the quality of the products and
reduction of spoilage and rework. It tells us when to leave a process alone as well as
when to take action to correct trouble.

3. Stratification (alternately, flow chart or run chart) :

A flowchart is a type of diagram that represents an algorithm, workflow or
process. Flowchart can also be define as a diagramatic representation of an
algorithm (step by step approach to solve a task).
The flowchart shows the steps as boxes of various kinds, and their order by
connecting the boxes with arrows. This diagrammatic representation illustrates
a solution model to a given problem. Flowcharts are used in analyzing,
designing, documenting or managing a process or program in various fields.

4. Pareto chart :
Pareto Diagram is a tool that arranges items in the order of the magnitude of
their contribution, thereby identifying a few items exerting maximum
influence. This tool is used in SPC and quality improvement for prioritizing
projects for improvement, prioritising setting up of corrective action teams to
solve problems, identifying products on which most complaints are received,
identifying the nature of complaints occurring most often, identifying most
frequent causes for rejections or for other similar purposes. The origin of the
tool lies in the observation by an Italian economist Vilfredo Pareto that a large
portion of wealth was in the hands of a few people. He observed that such
distribution pattern was common in most fields. Pareto principle also known
as the 80/20 rule is used in the field of materials management for ABC
analysis. 20% of the items purchased by a company account for 80% of the
value. These constitute the A items on which maximum attention is paid.

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 Dr.Juran suggested the use of this principle to quality control for separating
the "vital few" problems from the "trivial many" now called the "useful
many".

5. Histogram :
Histograms or Frequency Distribution Diagrams are bar charts showing the
distribution pattern of observations grouped in convenient class intervals and
arranged in order of magnitude. Histograms are useful in studying patterns of
distribution and in drawing conclusions about the process based on the pattern.

6. Cause-and-effect diagram (also known as the "fishbone" or Ishikawa diagram) :

A Cause-and Effect Diagram is a tool that shows systematic relationship
between a result or a symptom or an effect and its possible causes. It is an
effective tool to systematically generate ideas about causes for problems and
to present these in a structured form. This tool was devised by Dr. Kouro
Ishikawa and as mentioned earlier is also known as Ishikawa Diagram.

7. Scatter diagram :
When solving a problem or analysing a situation one needs to know the
relationship between two variables. A relationship may or may not exist
between two variables. If a relationship exists, it may be positive or negative,
it may be strong or weak and may be simple or complex. A tool to study the
relationship between two variables is known as Scatter Diagram. It consists of
plotting a series of points representing several observations on a graph in
which one variable is on X-axis and the other variable in on Y-axis. If more
than one set of values are identical, requiring more points at the same spot, a
small circle is drawn around the original dot to indicate second point with the
same values. The way the points lie scattered in the quadrant gives a good
indication of the relationship between the two variables.

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