1. INDUSTRIAL TRAINING REPORT
ROCKMAN INDUSTRIES LIMITED
A-7, PHASE 5, FOCAL POINT, LUDHIANA
Submitted in Partial Fulfilment
for award of Degree of
Bachelor of Technology
ADESH INSTITUTE OF TECHNOLOGY, GHARRUAN
SUBMITTED TO SUBMITTED BY
H.O.D KUL BHADHUR
BALWINDER SINGH ROLL.NO. 1536346
2. CANDIDATES DECLARATION
I hereby certify that the work which is being presented in the Report entitle
―Six Months Industrial Training Report in partial fulfillment of the‖
requirements for the award of the degree of Bachelor of Technology
(Mechanical Engineering) submitted in the Department of Mechanical Adesh
institute of technology college of Engineering and technology an Autonomous
body is an authenticate record of my own work carried out during a period
from 4 January 2018 to 4 may 2018 under the H.O.D.( NHMCL) of Mr.
Parveen Singh . The matter presented in this Training Report has not been
submitted by me in any other University/Institute for the award of any degree.
Univ . Roll no.:
This is to certify that the above statement made by the candidate is true to the best
my knowledge and belief .
Industrial Training is meant to expose the students of engineering to the actual
Industrial Processes about which we have been studying in detail for the last seven
semesters. I have spent the last three and half years in gaining theoretical
knowledge of various manufacturing processes. The six months training has
exposed me to the actual application of the various studies. The training period has
being very interesting wherein I got to know how the final product comes to the
market after going through the various processes like drilling, casting, grinding,
milling etc. Each product undergoes a number of qualit y control tests to bring in
uniform it y and quality. Each field requires skillful handling and this training will
help me in the long run .
I would like to express m y sincere thanks to m y Project Guide, Mr. Parveen singh
for his guidance and support throughout m y training at ROCKMAN
INDUSTRIES LIMITED, LUDHIANA. His calm demeanor and willingness to
teach has been a great help to me for successfull y completing the project . I also
acknowledge heartfelt gratitude to Mr. sunil verma, Mr. aman singh , who made
available tons of information required for m y project . Finall y, I thank my
institute adesh insititute of technology for making this experience of Industrial
training in an esteemed organization likes ROCKMAN INDUSTRIES LIMITED .
6. SYNOPSIS ON INDUSTRIAL TRAINING
For the period 04-01- 2018 to 4-05-2018
Name of the Industry & Address Rockman Industires Ltd.
(A-7, Focal Point, Ludhiana-141010)
Department Non-HMCL Quality
Training timings 9:00 am to 5:30 pm
Training Manager‘s name & Designation Parveen singh(H.O.D)
Company contact no 01612670701-704
No. of training days in a week 6 days a week
Off Days Sunday
8. Title page
Chapter -1: Introduction to Company
1.2 Major Components
a) Facilities and services
b) Engineering & Designs
1.4 Customers of Rockman on Non-HMCL
1.7 Plant layout
1.8 Organization Structure
Chapter -2: Detailed Study of Quaulity Department
2.1 Introduction to Department
2.1.1 Objectives of Production Planning Control
2.1.2 Production Planning and Control Functions
2.1.3 Steps in Production Planning and Control
2.2 R&D Department
Chapter - 3: Training Given
3.1 Training Detail
3.1.1 Process Study
3.1.2 Study of Processes of Major Components
23 Time study
24-25Training Given about on Quality system
3.2.1 What Is QUALITY?
9. 3.3 Training Given on Quality
Chapter - 4: Study of Major
a) Pressure Die casting ( ZITAI)
) Vertical Machining Centre (VMC)
c) Special Purpose Machine (SPM)
Chapter - 5: Projects
10. 1.1 INTRODUCTION TO ORGANIZATION
Rockman Industries Ltd, was set up in 1960 by Late. Sh.Brijmohan Munjal, with
production of bicycle chains in India. In 1996, with the help of Japanese
Technology, the plant was expanded for the manufacture of automotive chains.
Subsequently, in 1999, its operations were expanded to manufacture Aluminium Die
Casting, Machined, Painted and Sub Assembled Components. 2008 Started Low
Pressure and Gravity Casting in Haridwar. Current Rapid growth in volume and
variety. An in-house modern tool room. Present production level 12 million
motorcycle chains per
annum and 20 million
motorcycle hubs per
annum. World largest
producer with exports to over
30 country globally.
With a team of designers with over two decade of experience in designing, Rockman
combines together the latest technologies/platforms and rich experience. Once the
tool design is complete, the design data is converted into machining data using
11. software‘s and this data is transferred directly to High Speed and High Precision
Machining Centers. We can produce tools up to a weight of 5 tons . Rockman also
designs complex machining fixtures for CNC Machining of components.Rockman
has over 20 years of experience of exporting to the Global customers in Europe
including Germany, UK, Latin America, USA, etc.
13. (a) Facilities & Services
High Pressure Die Casting
Assemblies and Modules
(b) Engineering & Designs
Tool Design and Development
Simulation and Analysis
(a)Production Planning And Control: Production Planning And Control (PPC) is
area that plays a very important role in an industry. The ultimate objective of
production planning and control, like that of all other manufacturing controls,
is to contribute to the profits of the enterprise. As with inventory management
and control, this is accomplished by keeping the customers satisfied through
the meeting of delivery schedules.
(b)Pressure Die Casting (PDC): The plant has 35 machines out of which 23 fully
automatic die casting machines equipped with Auto Sprayer and Auto Ladle
& Auto extractors to produce consistent high quality castings.
730 Ton (ZITAI)
14. (c)Machine Shop Department: There are 32 VMC machines, 24 CNC machines
and 47 SPM machines. In this shop different machining operation performed
by the machines on the product. There are different types of machine are as
I. CNC Turning
centres II. Vertical
III. Judicious mix of standard SPM & CNCs.
V. Machining in close tolerance.
(d)Paint Shop: Rockman has modern paint shop with complete pre-treatment line
& electrostatic guns to produce components of the highest quality standard.
Fully pressurized shop ensuring zero dust environments. Environment friendly
process with zero discharge. Powder coating plant in Ludhiana by Dec 09.
(e)Standard Room: In standard room calibration has been done of the measuring
instruments time to time and different type of hardness test has been done
there. There different types of machines are:
CMM (Co-ordinate Measuring Machine)
Micro hardness testing machine
Surface Finish tester
(f) Tool Room: One of the biggest strength of Rockman is the state of the art tool
room & design facilities, to provide high precision quality components. Latest
high-speed vertical CNC machining centers like Deckle Maho, Acma &
Harford are the back bone for the accurate tool manufacturing. Tool room also
has wire-cut machine from Fanuc & Sodick, EDM & Spark Erosion machine.
15. (g)Assembly Shop: In house development of SPMs for the higher productivity.
Daily production of over 25000 assemblies. Assemblies of higher critical
safety like Brake Drum, Brake Panel Assembly and Wheel Hub Assemblies
16. 1.4 CUSTOMERS OF ROCKMAN INDUSTRIES LTD
HERO MOTO CORP(GURGOAN ,
AUTOFIT (HARIDWAR, DHARUHERA)
IWIS MOTOR SYSTEM (GERMANY)
These are the customers of rockman industries ltd of all branches. The parts here are
sub-assembled and then exported.
3.2.1 What Is Quality?
In manufacturing, a measure of excellence or a state of being free from defects,
deficiencies and significant variations. It is brought about by strict and consistent
commitment to certain standards that achieve uniformity of a product in order to
satisfy specific customer or user requirements
What is the role of a quality department?
Quality management ensures that an organization, product or service is consistent. It has
four main components: quality planning, quality assurance, quality control and quality
improvement. Quality management is focused not only on product and service quality,
but also on the means to achieve it.
19. What is 5S?
5S is a system for organizing spaces so work can be performed efficiently, effectively,
and safely. This system focuses on putting everything where it belongs and keeping the
workplace clean, which makes it easier for people to do their jobs without wasting time or
The term 5S comes from five Japanese words:
20. • Seiri
In English, these words are often translated to:
• Set in Order
21. 3.3.2 KAIZEN
Kaizen means improvement, continuous improvement involving everyone in the
organization from top management, to managers then to supervisors, and to workers.
In Japan, the concept of Kaizen is so deeply engrained in the minds of both
managers and workers that they often do not even realize they are thinking Kaizen as
a customer-driven strategy for improvement. This philosophy assumes according
Imai that ‗‘our way of life – be it our working life, our social life or our home life –
deserves to be constantly improved‘‘
24. CHAPTER – 04
STUDY OF MAJOR MACHINES
a. Pressure Die casting ( ZITAI):- Die casting is a metal casting process that is
characterized by forcing molten metal under high pressure into a mold cavity. The
mold cavity is created using two hardened tool steel dies which have been machined
into shape and work similarly to an injection mold during the process. Most die
castings are made from non-ferrous metals, specifically zinc, copper, aluminium,
magnesium, lead, pewter and tin based alloys. Depending on the type of metal being
cast, a hot- or cold-chamber machine is used.
Fig. 4(a) Pressure Die casting M/C
The selection of a material for die casting is based upon several factors including the
density, melting point, strength, corrosion resistance, and cost. The material may
also affect the part design. For example, the use of zinc, which is a highly ductile
metal, can allow for thinner walls and a better surface finish than many other alloys.
The material not only determines the properties of the final casting, but also impacts
the machine and tooling. Materials with low melting temperatures, such as zinc
25. alloys, can be die cast in a hot chamber machine. The melting temperature also
affects the tooling, as a higher temperature will have a greater adverse effect on the
life of the dies. Material use in this process is Aluminum alloy.
b. Vertical Machining Centre (VMC) : Toshiba Machine Tool offers the highest
quality in the today market. This provide dual opening front door. This ensures easy
and complete access for front loading or overhead loading of stock.
Every VMC machine is designed from the casting up with all of the customer
desired features engineered as standard equipment.
Standard Feature of VMC
High speed control system
High speed axis motor
Automatic tool changer
10,000 RPM, 20 HP continuous, spindle system
High speed rigid tapping
Dual front door
Dual coolant pumps
Fully enclosed, sound absorbing machine cabinet
26. Programmable wash down
Spindle load meter
Τhis machine has been designed to carryout Leakage test on component body
by air-to-air method.
· Facility of water leakage checking for defective component is
· All component passages are checked in the same fixture using
suitable electro-pneumatic logic.
· Replaceable fixture arrangement is provided to check multiple component
in the same machine by using Quick connectors.
· Testing pressure 2 Bar
· Pneumatic/Hydraulic Cylinder Sealing and dipping arrangement .
· All wet parts fixture , tank , dipping plat form are of SS 304.
· Locating dowels and resting pads are provided for exact location of test
·Digital leakage indicator with facility of indicating leakage rate, filling time,
stabilization time , testing time , number of cycles , OK-NOT OK parts , pressure
graph , filling time calculation etc.
· Two hand safety push button is provided to start the cycle.
· Machine can be operated in two modes (a)Auto (b)Manual Mode
28. CMM – (COORDINATE MEASURING MACHINE)
The affordable CONTURA G2® is ideal for small and mid-sized companies wanting the
benefits of high-speed scanning. VAST® scanning technology enables form
inspections at maximum speed with high-quality measuring results. Process
changes are detected at an early stage, high production quality is ensured and
rejected parts are reduced
Zeiss Contura G2:-Mechanical probe Used
• Works on the basis of Universal co-ordinate system(UCS).
• Calypso software is being used by the machine for inspection results.
• Least count = 1 Mili-micron
• Dimensional Measurement .
• Profile Measurement.
1. Angularity or orientation.
2. Depth Mapping.
3. Digitizing or Imaging.
4. Shaft Measurement.
5. Cad model comparison.
6. Easy to Inspect Geometrical Dimensions
30. CONTRACER MACHINE
what is contracer machine ?
Contour Measuring Machine Contracer CV-100. ... Mounted on a jig, the device can be
manually taken to very large workpieces that do not fit into stationary measuring stands.
Using a Contour Measuring Machine customers are able to perform dimensional
measurements such as angle, radius, and distance measurements, the contour tolerancing
function for evaluating “form” and the report creation function for
outputting measurement results in a specific format are provided as standard, measuring
both ease of operation and powerful analysis capabilities. Contour measurement using a
contracer machine is a powerful system for automatic high-volume measurement. Event
with greater precision in all axis for difficult stationary contour testing in production
environment or in the test room.
Z1 axis (detector unit): ± (0.8 + | 2H | /100) μm
H = Measurement height from the horizontal position (mm)
X axis (drive unit): ± (0.8+0.01L) µm *1
L = drive length (mm)
what is measurement in countracer
3. Profile. etc)
32. POKA YOKE
WHAT IS POKA-YOKE:-Poka-yoke is a technique for avoiding simple human error in the
workplace. Also known as mistake-proofing, poka-yoke is simply a system designed to
prevent inadvertent errors made by workers performing a process.
33. 7 QC TOOLS
WHAT IS 7 QC TOOLS:-
It is a designation given to a fixed set of graphical techniques identified as being most
helpful in troubleshooting issues related to quality.
ST OF 7 QC TOOLS:-
1. Check sheet
2. Cause & Effect diagram
3. Graph & control chart
5. Pareto diagram
6. Scatter diagram
34. Eight Disciplines (8D)
what is 8D ?
Problem Solving is a method developed at Ford Motor Company used to approach and
to resolve problems, typically employed by engineers or other professionals. Focused on
product and process improvement, its purpose is to identify, correct, and eliminate
D0: Preparation and Emergency Response Actions: Plan for solving the problem
and determine the prerequisites. Provide Emergency response Actions
D1: Use a Team: Establish a team of people with product/process knowledge.
D2: Describe the Problem: Specify the problem by identifying in quantifiable terms
the who, what, where, when, why, how, and how many (5W2H) for the problem.
D3: Develop Interim Containment Plan: Define and implement containment
actions to isolate the problem from any customer.
D4: Determine and Verify Root Causes and Escape Points: Identify all applicable
causes that could explain why the problem has occurred. Also identify why the
problem was not noticed at the time it occurred. All causes shall be verified or
proved. One can use five whys or Ishikawa diagrams to map causes against the
effect or problem identified.
D5: Verify Permanent Corrections (PCs) for Problem will resolve problem for the
customer: Using pre-production programs, quantitatively confirm that the selected
correction will resolve the problem. (Verify that the correction will actually solve
D6: Define and Implement Corrective Actions: Define and Implement the best
D7: Prevent Recurrence / System Problems: Modify the management systems,
operation systems, practices, and procedures to prevent recurrence of this and
D8: Congratulate main contributers to your CAR team: Recognize the collective
efforts of the team. The team needs to be formally thanked by the organization.
35. LEARING AND KNOWLAGE
Training: The International Standards Organization acts as a bridge between
the public and private manufacturers. Its primary purpose is to find a consensus
between the needs of the marketplace and the requirements of private businesses.
Quality control inspectors must be familiar with the international guidelines and
regulations established by the ISO; therefore, most distance learning quality
control programs will include extensive coursework covering these guidelines and
Statistical Quality Control: Statistical quality control is a technique by which
quality control inspectors examine a statistical sampling of the units produced by a
production process. These units are examined for flaws and inconsistencies, and
inspectors work to gauge the percentage of flawed products in comparison to the
total output and pinpoint where in the process these flaws occur. Since this is a
crucial part of quality control inspection, most distance learning programs will
include a course that covers this process.
Nondestructive Testing (NDT): Nondestructive Testing is a group of techniques
used to evaluate various components of a product without causing damage to it.
Methods of testing include the use of sound, electromagnetic radiation, and X-rays.
NDT is a meticulous and tedious process that requires a great deal of hands-on
training; however many distance learning programs provide a detailed
informational groundwork for the aspiring quality control inspector.
Quality Improvement: This course focuses on customer service components of
quality. Students will study the way that each piece of an organization contributes
to the overall quality of the service or product provided. They will also discover
various techniques to monitor and improve quality.Page 35
36. Interpretation of Technical Documentation: Those in quality control need to be
able to read the technical engineering documents of their products. This course
teaches the common conventions, symbols, and formatting found on these
Value-Based Quality: Quality is often a value-based assessment. In this course,
the perceived value of a product by the customer is used as the basis on which
quality control can establish a management system
37. Quality Glossary :
Auditing is the on-site verification activity, such as inspection or
examination, of a process or quality system, to ensure compliance to
requirements. An audit can apply to an entire organization or might be
specific to a function, process, or production step.
Types of audits
• Product audit – An examination of a particular product or service (hardware,
processed material, software) to evaluate whether it conforms to
requirements (that is, specifications, performance standards, and customer
• Process audit – A verification that processes are working within established
limits. It evaluates an operation or method against predetermined
instructions or standards to measure conformance to these standards and the
effectiveness of the instructions. Such an audit may:
o Check conformance to defined requirements such as time, accuracy,
temperature, pressure, composition, responsiveness, amperage, and
o Examine the resources (equipment, materials, people) applied to
transform the inputs into outputs, the environment, the methods
(procedures, instructions) followed, and the measures collected to
determine process performance.
o Check the adequacy and effectiveness of the process controls
established by procedures, work instructions, flowcharts, and training
and process specifications.
• System audit – An audit conducted on a management system. It can be
described as a documented activity performed to verify, by examination and
evaluation of objective evidence, that applicable elements of the system are
appropriate and effective and have been developed, documented, and
implemented in accordance and in conjunction with specified requirements.
38. FINDING AND SUGGESTION
A WASTE HEAT RECOVER
A waste heat recovery unit (WHRU) is an energy recovery heat exchanger
that transfers heat from process outputs at high temperature to another part
of the process for some purpose, usually increased efficiency. The WHRU is a
tool involved in cogeneration. Waste heat may be extracted from sources
such as hot flue gases from a diesel generator, steam from cooling towers, or
even waste water from cooling processes such as in steel cooling.
Regenerative Thermal Oxidizer (RTO) Systems use a process of applying very
high heat to purify dangerous exhaust air toxic compounds, by oxidizing the
exhaust and destroying the gaseous hydrocarbons and waste volatile organic
compounds (VOCs) at 1500 F and greater oxidation temperatures.
Our Adwest brand RETOX Regenerative Thermal Oxidizer systems are cost-
effective and custom-designed to delivery maximum performance, reliability, and
efficiency. Our RTO systems boast several unique features, including our Large
Flow Capacity (LFC) series, which provides a compact low profile alternative to
traditional large flow abatement equipment with rapid field assembly up to
100,000 scfm flow rates. All Adwest RTO have Flameless NGI-Natural gas
injection for NOx-Free operation that utilizes a fraction of the gas that burner firing
We can also custom design your system with special metallurgy for acid gas and
corrosive process applications, ensuring that your Regenerative Thermal Oxidizer
39. system fits all of your required specifications. Typical applications include:
• Paint spray and industrial finishing
• Print and web converting
• Flexible packaging & printing
• Food processing, bakery ovens, fryers & roasters
• Metal litho, foil and coil coating
• Ethanol, biofuels and food processing
• Composites, fiberglass and EPS styrene
• Carbon Fiber, Laminating & Treating
• Chemical, oil and gas processing
• Rubber and tire production
• Microelectronics and wafer FAB
• Air strippers and soil vapor extraction (SVE)
• Mineral processing and kilns
• Halogenated and acid gas processes
• Wood & forest products, resin plants
• Landfill, wastewater off-gas and biogas
• Low Total Cost of Ownership - energy, maintenance & life cycle capital cost
• Energy-efficient – up to 97% RTO thermal efficiency for ultra-low energy
usage and virtual NOx free operation
• High quality and high value, with our 5 year extended warranty – no
complex rotary valves to adjust/maintain
• Easy simplified maintenance with our low profile RTO modules
• Cost-effective, custom-design systems
• Systems ranging from 1,000 scfm to 100,000 scfm with single shop
• Flameless natural gas injection (NGI) - requires 30-55% less natural gas than
burner and combustion air blower operation
• Flameless NGI also procies NOx-Free operation with virtually zero nitrous
oxide byproducts of combustion = low carbon footprint
40. Two Module 124,00 scfm RETOX RTO System with common Exhaust Stack
ETOX Regenerative Thermal Oxidizer - Fume & Odor
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42. PROJECT REPORT
1. Our line of work.
2. Specification of problem.
3. Define the problem.
5. Root cause.
43. OUR LINE OF WOK
ROCKMAN INDUSTRIES LIMITED
A-7, PHASE 5, FOCAL POINT, LUDHIANA
(Quality department non-HMCL)
LINE = BROSE
PART NAME = ITA Hosing
MACHINE NO = VMC -66
SPECIFICATION OF PROBLEM
PROBLEM = Concentricity variation problem.
TOLRRANCE = 0.035mm.(microns)
DEFINE THE PROBLEM.
concentricity is a complex tolerance used to establish a tolerance zone
for the median points of a cylindrical or spherical part
feature.Concentricity is generally reserved for high-precision parts, and
only when there is a need to control median points
46. (RCA) ROOT CAUSE ANALYSIS
FINDING OUT ROOT CAUSE
WHY 1 WHY 2 WHY 3
LIFE OF PIPE
CAUSE AND EFFECT DIAGRAM
47. DEVELOPMENT OF SOLUTION
SR. NO. ROOT CAUSE SOLUTION
1 CHIPS PRESENT ON THE FIXTURE
PROVIDE A COOLANT PIPE TO
CLEAN THE CHIPS
2 AIR PRESSURE LOW PROVIDING THE SAFETY COVER ON PIPE
3 BLACK LASH Y AXIS POSITION SET ON PROGRAMING