JBM-NMPL TRAINING REPORT,GURGAON

I
A REPORT
ON
UNDERSTANDING THE JAPANEESE 5S, PPAP DOCUMENT
AT
JBM GROUP, GURGAON
BY
PRANJUL PAL
131MC00219
AT
IP-2 STATION: NMPL, JBM GROUP, GURGAON,
HARYANA
An Internship Program-2 station of
ICFAI TECH SCHOOL
(June, 2017)

II
A REPORT
ON
UNDERSTANDING THE JAPANEESE 5S, PPAP DOCUMENT
AT
JBM GROUP
BY
PRANJUL PAL 131MC00219 MECHANICAL
Prepared in partial fulfillment of the
IP 2 Internship Program –2 Course
AT
NMPL, JBM GROUP, GURGAON
An Internship Program-2 station of
ICFAI TECH SCHOOL
(June, 2017)

III
ICFAI TECH SCHOOL
Internship Program Division
Station: NEEL METAL PRODUCTS LTD. Center: JBM GROUP
Duration: 6 Months Date of Start: 15th
JANUARY 2017
Date of Submission: 15th
JULY 2017
ID No./Name/ 131MC00219/ PRANJUL PAL/ MECHANICAL
Discipline/of
the student:
Name and
Designation Mr. VINEET AWASTHI
of the expert: Deputy Manager in Sheet Metal Department

JAY BHARAT MARUTI LIMITED
A dissertation submitted to
ICFAI TECH SCHOOL
Towards The Partial Fulfillment of The
Requirement For
The Award of the Degree of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted By
PRANJUL PAL
131MC00219
Under The Guidance of
MR. VINEET AWASTHI

IV
ACKNOWLEDGEMENT
It is indeed a great pleasure and privilege to present this report on training at NMPL,
JBM GROUP, GURGAON.
I am extremely grateful to my ICFAI UNIVERSITY, HOD, FACULTY and
Placement Officer for issuing a Training letter, which made my training possible at
NMPL, JBM GROUP, GURGAON.
First, I thank The HR Head, MR. ABHAY KRISHNA for considering my potential
in doing this training and providing this wonderful opportunity.
I would like to express my gratitude to MR. VINEET AWASTHI for his invaluable
suggestions, motivation, guidance and support throughout the training. His
methodology to start from simple ant then deepen through made me to bring out this
project report without anxiety.
Thanks to all other JBM officials, operators and all other members of JBM, yet
uncounted for their help in completing the project and see the light of success. I am
very thankful to friends, colleagues and all other persons who rendered their
assistance directly or indirectly to complete this project work successfully.
Dated- JUNE 2017
PRANJUL PAL

V
PREFACE
If one has to succeed in life, one has to keep pace with changing times this saying
holds good in every field of life be it general or professional. Being the student of the
professional courses we have to keep a constant vigil on rapidly changing
environments. Is Indian Industry a protected one? Except some strategically important
industries, every field is thrown to global competition, liberalization and globalization
combined with the privatization of existing public sector companies is the new mantra
of Indian economic policies. So in this era of tough competition only fittest will
survive. Industries spend a lot of capital in making the best out of the availability and
improving the present scenario every time.With the purpose of getting myself abreast
improvement management I done with the new trends in my training at “NEEL
METAL PRODUCT LIMITED” On the basis of what I have learn in the company I
am here by submitting a report.

VI
TABLE OF CONTENTS
1. INTRODUCTION...................................................................................1
1.1 About Company:.............................................................................1
1.2 Overview:........................................................................................1
1.3 Customer:........................................................................................2
2. NEEL METAL PRODUCTS LIMITED.................................................4
2.1 Certifications:..................................................................................4
2.2 Vision:.............................................................................................4
2.3 Core Values:....................................................................................4
2.4 Divisions Of JBM:..........................................................................5
2.5 Alliances:........................................................................................ 5
2.6 Departments in Neel Metal Products Limited, Gurgaon:.............. 6
3. TECHNOLOGY......................................................................................7
4. HEALTH, SAFETY & ENVIRONMENT............................................. 7
5. PRODUCTION........................................................................................8
5.1 Types Of Production Procedure:.................................................... 8
5.2 Factors that can affect the Production Process:..............................9
6. PRESS SHOP:....................................................................................... 10
6.1 Hydraulic Presses:........................................................................ 12
6.2 Mechanical Presses:......................................................................13
7. WELD SHOP:........................................................................................15
7.1 Types Of Welding:....................................................................... 15
7.2 Spot Welding Process:..................................................................16
7.3 Projection Welding:......................................................................18
8.WELDING FIXTURE:...........................................................................19
9. QUALITY DEPARTMENT:................................................................ 19
9.1 JBM Quality Goals:......................................................................20
10. DIE MAINTAINENCE DEPARTMENT:......................................... 21
10.1 Dies and It’s Types:....................................................................22
11. WORKING METHDOLOGY:........................................................... 25
11.1 The 5S:........................................................................................25

VII
TABLE OF FIG.
FIG 1.................................................................................................................................... 6
FIG 2.................................................................................................................................. 11
FIG 3.................................................................................................................................. 12
FIG 4.................................................................................................................................. 13
FIG 5.................................................................................................................................. 14
FIG 6.................................................................................................................................. 15
FIG 7.................................................................................................................................. 15
FIG 8.................................................................................................................................. 16
FIG 9.................................................................................................................................. 18
FIG 10................................................................................................................................ 19
FIG 11................................................................................................................................ 19
FIG 12................................................................................................................................ 21
FIG 13................................................................................................................................ 22
FIG 14................................................................................................................................ 23
FIG 15................................................................................................................................ 24
FIG 16................................................................................................................................ 24
FIG 17................................................................................................................................ 27

1
1. INTRODUCTION
1.1 About Company:
JBM Group began its journey of excellence in 1983. The organization commenced
operations as a manufacturer of LPG Cylinders for the Delhi NCR region of India.
Moving strength to strength, assisted with experience and knowledge, JBM Group
entered into the automotive industry in 1985.
In 1986, the Group signed a joint venture with Maruti Suzuki India Ltd for the
manufacturing of sheet metal components and assemblies. The journey began with a
vision to expand the business in the automotive sector by keeping abreast with market
trends and global technology.
Headquartered at Delhi NCR, JBM Group is a diversified conglomerate with presence
in automotive, engineering & design services, renewable energy and education sectors.
The organization’s commitment towards all stakeholders and community has made it
a leading manufacturing and engineering player.
The milestones and achievements of JBM Group gave the energy for diversification
and establishment of multiple business units in order to meet the needs of customers.
The organization’s management follow a unique business model to create empowered
companies that enjoy the best of entrepreneurial independence, assisted with leverage
of group-wide synergies.
1.2 Overview:
JBM Group is a focused, dynamic and progressive organization that provides
customers with value added products, services and innovative solutions. The Group
has a diversified portfolio to serve in the field of automotive, engineering & design
services, renewable energy and education sectors and has an infrastructure of 35
manufacturing plants, 4 engineering & design centres across 18 locations globally.
With turnover of USD 1.2 billion, JBM Group has broadened its horizons by focusing
on quality delivery, solutions approach, product development processes, flexible
manufacturing systems and contract manufacturing.

2
JBM Group is primarily a tier- 1 supplier to the automotive OEM industry and caters
services to esteemed clients that include Ashok Leyland, Bajaj Auto Ltd, Fiat, Ford,
General Motors Corporation, Honda, Hero, JCB, Mahindra, Maruti Suzuki, Renault,
Nissan, TATA, Toyota, TVS, Volvo-Eicher, Volkswagen and many more.
The Group has alliances with more than 20 renowned companies globally and the
associations include Arcelor Mittal, Cornaglia, Dassault Systems, JFE Steel
Corporation and many more. The organization’s structure enables each business unit
to chart its own future and simultaneously leverage synergies across its competencies.
Over the last 3 decades, JBM Group has created new benchmarks in the automotive
industry, with the manufacturing of Body-in-White, Chassis & Suspension Systems,
Die Casting, Exhaust Systems, Jigs and Fixtures, Skin Panels, Tool Rooms, Tubes
&Tubular Parts, Weld Assemblies and engineering services among many others.
The Group has a diversified portfolio to serve in the field of automotive, engineering
& design services, renewable energy and education sectors and has an infrastructure
of 35 manufacturing plants, 4 engineering & design centres across 18 locations
globally.
1.3 Customer:
CARS/ MUV:
 Ford India
 General Motors
 Hindustan Motors
 Honda Siel
 Maruti Udyog Limited
 Toyota Kirloskar
TRACTORS:
 Eicher
 Escorts
 Hmt
 L & T John Deere

3
 M & M
 T A F E
 International Tractors
 New Holland
HCV/ LCV:
 Ashok Leyland
 Eicher Motors
 Mahindra & Mahindra
 Volvo
TWO/ THREE WHEELERS:
 Yamaha Motors India
 Piaggio India
 Tvs Suzuki
 Honda Motorcycle
OTHERS:
 Delphi – India, China, Usa
 Hal, Ifb, Samsung
 Defence
 Indian Railways
 Meritor, Usa
 Onida
 Subros
 Whirlpool

4
2. NEEL METAL PRODUCTS LIMITED
The Neel Metal Products Limited (NMPL), Gurgaon is a major vendor company of
Honda 2 Wheelers India Ltd, Honda Cars, Maruti Suzuki, Hero Moto Corp. NMPLis
the fastest growing Company of JBM Group with high-tech plants at various locations
in India. NMPL has earned a leading position in industry with facilities available in
press lines up to 1200 tons, weld lines and ED coating plant- which are not only
limited to auto world but also fitting for white goods industry.
2.1 Certifications:
ISO 9001
ISO/TS 16949
ISO 14001
OHSAS 18001
2.2 Vision:
“Expanding leadership in our business by creating an agile environment that delivers
excellence and delight to stakeholders through the power of people, innovation,
market trends and technology.”
2.3 Core Values:
We believe in...
Simplicity, by keeping a low profile externally and having clear, open and effective
communication within the organization.
Teamwork, with well-defined responsibilities and accountability.
Relationships of trust among people, through well-defined job responsibility and
authority.
According top priority to customer focus, through prompt and appropriate response.
Respect and care for all those dedicated to meeting commitments.

5
2.4 Divisions Of JBM:
 JBML GURGAON
 NEEL AUTO
 NMPL MANESER
 NMPL GURGAON
 JBM BUSSES
 NMPL GUJRAT
 NMPL PUNE
 NMPL HARIDWAR
 NMPL CHENNAI
 NMPL HIMANCHAL
 NMPL KOSI
2.5 Alliances:
 BredaMenarinibus BMB
 Arcelor Mittal India Ltd.
 CLN Group
 Comaglia Metallurgical Products India Pvt. Ltd.
 Daiwa Excel Co. Ltd.
 Dassault Systemes India Pvt. Ltd.
 Futaba Corporation of America
 Hamamatsu Pipe Company Ltd.
 Hay Consultants India Pvt. Ltd.
 Kanemitsu Pulleys Pvt. Ltd.
 Magnetto Automotive
 Maruti Suzuki India Ltd.
 Metal One corporation India Pvt. Ltd.
 Nisshin Steel Co. Ltd.
 Ogihara Company Ltd. (Thailand)
 Okamoto Press Industries Co. Ltd.
 Solaris Bus & Coach S.A.

6
 Sumitomo Corporation India Pvt. Ltd.
 Yorozu Corporation
 ISGEC Heavy Engineering Ltd.
 KOMATSU India
Fig.1 Alliances
2.6 Departments in Neel Metal Products Limited, Gurgaon:
 Paint Shop
 Weld Shop
 Press Shop
 Quality Department
 Engineering Department
 IT Department
 Finance Department
 Purchase Department
 Maintenance Department
 Safety Department
 HR Department

7
3. TECHNOLOGY
Technology, Innovation and People serve as the three key pillars of the JBM
foundation. Core to this philosophy is a constant quest for excellence by enhancing
technology, enabling innovation and empowering people, thereby, creating consistent
value for all stakeholders.
JBM Group has always kept a close watch on the dynamic needs of its customers
and continues the journey of efficiency by enhancing the technology at every stage.
The organization has collaborated with best global technology partners; possess
state-of-the-art manufacturing facilities and highly automated processes. These
advantages have established new benchmarks that have aided in providing superior
quality and flawless technical perfection to the organization's deliverables.
The continuous commitment towards excellence and consistent efforts to innovate
have brought excellent growth results for the Group. Apart from incorporating
sophisticated technology, JBM Group aims to not only exceed expectations, but to
create value through innovation. The long standing commitment to nurture research
and development has brought the organization a long way since its commencement
three decades ago.
4. HEALTH, SAFETY & ENVIRONMENT
At JBM, sustainability is the way of doing business. The Group aligned its goals for
environment, health and safety, making an impact across its value chain worldwide.
Together with the suppliers, customers and stakeholders, JBM strives to maintain
highest standards to preserve and protect the environment, as well as enhance the
health and safety of the Group’s employees and communities.

8
5. PRODUCTION
“Production is defined by the Webster online as “to make into a product suitable to
use.”
The action of manufacturing from components or raw material or the process if
being so produced.
Production is a process of combining various material inputs and immaterial inputs in
order to make something for consumption. It is the act of creating output, a good or
service which has value and contributes to the utility of individuals. Economic
well-being is created in a production process, meaning of all economic activities that
aim directly or indirectly to satisfy human needs. The degree to which the needs are
satisfied is often accepted as a measure of economic well-being.
5.1 Types Of Production Procedure:
Casting Process: This type of procedure required liquid material. This is the only
process which uses liquid material. This is oldest procedure of production in which
the molten metal is poured into refractory mould cavity and allowed to solidify. The
object from the cavity removed after the solidification.
Forming Process: This solid state production process involving minimum amount of
material wastage. In this process the metal may be heated to a temperature, which is
slightly below the solidus temperature and then large force is applied such that
material flows and takes the desired shape.
Customers
 Households
 Other
Product
Company
(Production)
Suppliers
 Material
 Energy
 Capital
 Service

9
Fabrication Process: It essentially, involves joining pieces either permanent or
temporarily so that they would perform necessary function. The joining can be
achieved by either or both of heat and pressure or joining through material. It is
secondary manufacturing procedure.
Material Removal Process: This is also a secondary procedure where the additional
unwanted material is removed in the form of chips from the blank material by a
harder tool so as to obtain the final desired shape.
Production Line: A production line is defined as an arrangement in a factory in
which a thing being manufactured is passed through a set linear sequence of
mechanical or manual operations. The production line is required to produce products
fast. As well the market demand is getting increase as well we need more products
also with more in quantity. This concept reduces the production time up to a mark and
exponentially increases the profits.
5.2 Factors that can affect the Production Process:
Supplies: Many manufacturing depends on raw material supplied from outside
sources. Some of the factors that can delay or hamper a regular delivery schedule
include a glitch at the site of a supply source, problem with transportation or
inclement weather. If supplies are not forthcoming as needed, the potential for
shutdown in the manufacturing process can result. Alternatively a smooth supply
operation and well managed inventory promote production as scheduled.
Equipment: When a manufacturing process involves complex machines to complete
production, a temporary malfunction or a breakdown in an intricate piece of
equipment can affect the production. Identifying means of improving efficiency of all
working parts of production promotes a continual and more efficient operation.
Positioning of equipment and the personal required to operate machine can also affect
production.

10
Factory overhead: Production depends on utilities to power machines, cool
equipment and light the work space in their factories. Even a temporary shutdown of
the power supply or lack of a steady water source can impact production, thus
affecting the production process. In addition management style can have a significant
impact on production in both negative and positive ways.
Need of special Parts: In the textbooks “Operation Management” professor R Dan
Reid of the University of New Hampshire and Nada R. Sanders of Lehigh University
posit “Conformance to specification” as one definition of quality in production. They
cite as an example the situation of machine parts being built to specs. Here an
unforeseen change in made to order parts can have significant impact on production,
especially if the parts are shipped over long distance from offsite. Disparities in
qualities may require multiple orders for the same inventory, resulting in delays and
temporary slowdowns or shutdowns of the production.
People who work at all points: The workforce especially “touch labour”, the
workers directly involved in the production can affect that process in many ways. For
example: sick days and vacations taken by key personal must be figured into
production to prevent a negative impact on production. An intangible factor that
affects the production process and is dealt with after the fact is human error.
Alternatively, human inside a production leading to more labour-efficient and
cost-effective methods of production can affect in a positive way.
6. PRESS SHOP:
The press represents a specific type of machine tool, essential in the performance of
industrial manufacturing processes. Presses deliver energy through a force that acts
over a distance or stroke.
Press machines are also the primary machine tool used in metal extrusion and sheet
metal fabrication processes. Hydraulic and mechanical presses are employed during
sheet metal forming to the extent that sheet metal processes, in general, are often
referred to as press working. Presses may be used in the manufacture of plastic parts.
Machining operations, such as broaching, may also require presses.

11
Press machine tools vary in size and in the amount of force they can output. The
energy from a press is often used to do work requiring a tremendous amount of force,
such as a large amount of plastic deformation of a sizable piece of metal. The method
and nature by which a press machine will deliver its energy will vary, dependent on
its type. JBM has largest pressing shop of Asia and have total of 10 different lines of
pressing machines. The plant has total ten lines comprising of different forging
machines of different tones. The main reason why JBM is developing very fast is
because of innovative technology they are using in their industries which are totally
automatic and are less dependent on human power. All pressing machines are
imported from Japan companies like KOMATSU, ISGEC etc.
Out of all 10 lines only one line has Hydraulic pressing machine and rest 9 are
mechanically pressing machine. Hydraulic pressing is very slow process and is used
for component which require large bending.
Fig.2 600 Ton ERFURT Press Line

12
6.1 Hydraulic Presses:
Hydraulic presses are a powerful class of machine tools, they derive the energy they
deliver through hydraulic pressure. Fluid pressure, in a particular chamber, can be
increased or decreased by the use of pumps, and valves. Sometimes devices and
systems may be used to increase the capacity of the pumps in more powerful presses.
These presses can operate over a long distance and at a constant speed. Hydraulic
presses are generally slower relative to other press machine types. This involves
longer contact with the work, therefore the cooling of the work can be an issue when
hot forming a part with hydraulic force. Hydraulic presses are capable of being the
most powerful class of presses. Some may be as large as buildings, and can deliver
awesome pressure. The largest hydraulic presses are capable of applying 75,000 tons
of force. The hydraulic press shown is being used to manufacture a metal forging.
Extrusion is also a very common use for such a press, although extrusion is often
performed horizontally.
Fig.3 600 Ton Hydraulic Press Line

13
Working-Principle: The basic working principles of the hydraulic press are simple,
and rely on differences in fluid pressure. Fluid is pumped into the cylinder below the
piston, this causes the fluid pressure under the piston to increase. Simultaneously,
fluid is pumped out of the top channel, causing the fluid pressure above the piston to
decrease. A higher pressure of the fluid below the piston than the fluid above it causes
the piston to rise. In the next step, fluid is pumped out from below the piston, causing
the pressure under the piston to decrease. Simultaneously, fluid is pumped into the
cylinder from the top, this increases the fluid pressure above the piston. A higher
pressure of the fluid above the piston, than the fluid below it, moves the piston
downward.
Fig. 4 Hydraulic Press Working Principle
6.2 Mechanical Presses:
Mechanical presses belong to a class of machine tools that encompass a wide range of
different machine types. Primarily, the mechanical press transforms the rotational
force of a motor into a translational force vector that performs the pressing action.

14
Therefore, the energy in a mechanical press comes from the motor. These types of
presses are generally faster than hydraulic or screw presses, (actually the screw press
may also be classified as a mechanical press). Unlike some presses, in a mechanical
press, the application of force varies in both speed and magnitude throughout the
distance of the stroke. When performing a manufacturing operation using a
mechanical press, the correct range of the stroke is essential.
Presses are chosen based on the characteristics of the manufacturing process.
Mechanical press machine tools are commonly used in metal forging manufacture,
and sheet metal working. The desired application of force will dictate the type of
machine required. Extrusion will often necessitate a more consistent force over a
longer distance. However, a mechanical press may often be a good choice for impact
extrusion, since a fast, quickly repeatable application of force, over a limited distance
is what is needed for that type of manufacturing process. The most powerful
mechanical presses in modern manufacturing industry will have a press capacity of
about 12,000 tons.
Fig.5 400 Ton ISGEC-1 Press Line

15
7. WELD SHOP:
Welding is fabrication process that joins materials, usually metals or thermoplastics,
by causing fusion, which is distinct from lower temperature metal joining techniques
such as brazing and soldering, which do not melt the base metal. In addition to
melting the base metal, a filler material is typically added to the joint to form a pool of
molten material that cools to form a joint that is usually stronger than the base
material. Pressure may also be used in conjunction with heat, or by itself, to produce
weld. JBM Group have most advanced Robotic welding line in plant for every
different types of process.
Fig.6 Robotic Welding Fig.7 Robotic Welding
7.1 Types Of Welding:
Resistance Welding:
Resistance welding is a welding process which join the metals with the heat obtained
from resistance offered by the work to the flow of electrical current through the parts
being joined.
A pair of copper alloy electrodes conducts electrical current through the two sheets
pressed between the interface. The two sheets offer maximum resistance to the flow
of current, this generates heat, the interface melts and consequently solidifies under
the pressures of the two electrodes, thereby joining the two sheets at the spot that was
under the two electrodes.

16
Principles Of Process: Amount of heat generated in work pieces depend upon the
magnitude of current, resistance offered through conducting surfaces and the time for
which the current is made to flow.
Therefore :
H=I*Vt H α I
H = I (IR) t H α t
H = I2Rt H α R
Where:
H = Heat generated in Joules.
I = Current in Amperes.
R = Resistance in Ohms.
t = Time of current flow in seconds.
Fig.8 Spot Welding
Advantages Of Resistance Welding:
 Fast rate of production
 No filler rod is needed
 Less skilled workers can do the job
 Both similar & dissimilar metals can be welded
 High reliability & reproduction are obtained.
Disadvantages:
 The initial cost of equipment is high.
 Skilled persons are needed for equipment's maintenance & it’s controls.
 Large thickness cannot be welded.
7.2 Spot Welding Process:
Spot welding is a process in which contacting metal surfaces are joined by the heat
obtained from resistance to electric current flow. Work-pieces are held together under
pressure exerted by electrodes. Typically the sheets are in the 0.5 to 4 mm thickness
range. The principle of spot welding- in which a transformer core is having primary
and secondary winding. One end of the secondary winding is connected to the upper

17
electrode carried in the movable copper or bronze arm A and the other end to the
lower electrode mounted on the fixed arm B.
In operation the metal sheets S1 and S2 are held and pressed between the electrodes
and a strong current at low voltage is switched on. Due to the resistance offered by the
sheet metal to the flow of this current the temperature at the contact surfaces rises to
fusion point and the weld is completed under the contact pressure of the electrodes.
spot welding is used because of low voltage (4-15V) operated therefore it is not
hazardous to person as this supply of current 4.5KA .
Squeeze time: Time required for the electrode to close on metal and apply proper
pressure. It varies with the gap between the electrodes.
Weld time: Time required for peak current to flow and heat the metal.
Down slope time: Time taken for the current to cut off i.e from peak to zero.
Up Slope time: Time taken for the current to reach from zero the peak value.
Hold time: Time taken by the electrodes to hold the sheets together after the current.
flow stops. Pressure still applied to allow the molten metal to solidify.
Off time: It is the time between the end of one spot sequence to start of next spot
sequence.

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7.3 Projection Welding:
Projection welding is a type of resistance welding. In this welding only the projected
portion is melted and joined to the base metal. Projection nut and Projection stud of
standard specification can be welded.
Fig.9 Projection Welding
Advantage Of Projection Welding:
 A number of welds can be made simultaneously through one stroke.
 Projection welding electrodes posses longer life than spot welding because of less
maintenance resulting from fusion and overheating.
 Show sides of the jobs can be produced with no electrode marking
Disadvantages Of Projection Welding:
 Metals not strong enough to support projection , can not be projection welded ( ex.
Copper, brasses )
 For proper welding, all projections must be of same height.

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8.WELDING FIXTURE:
A fixture is a production tool that locates, holds and supports the work securely in a
fixed orientation with respect to the tool so that the required operations can be
performed.
Fig. 10 Fixtures
9. QUALITY DEPARTMENT:
This department has very crucial as well as very important role in company’s
development. A small defect in product can cause big loss economically.
The whole system work as- suppose company get an order of 1 lakh pieces of patch
pieces then the first product from the machine is verified by engineers by “panel
checker” and if it is found accurate then all other product are only visually checked by
workers. Engineers have all the basic data about product like dimensions, distance
between holes etc , which help them in verifying the product on panel checker.
Fig. 11 Panel Checker

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9.1 JBM Quality Goals:
 Zero defect.
 First time right, every time right.
 No quality control, only quality assurance.
 Reduced process variance.
 100% customer satisfaction.
 Reduction in the cost of product.
 Not only functional quality but also competitive commonly expected and
attractive quality.
 To stick to these goals, the company has successfully implemented the
Enterprises Resource Planning (ERP) software i.e. Baan-IV a system application
to support the manufacturing, finance and sales & distribution functions.
.
In JBM they follow the following Process:
In Process Quality – Engineers check the first piece by panel checker.
Their main motto is to check:
 Whether the gap between sample and panel checker is continuous or not.
 Distance between holes and position of hole.
 Any trimming of extra part is required or not.
FOA(First of approval):
After the first inspection all others product are only visually checked by workers.
They are provided with a type of “defect album” in which the possible types of
defects that can occur are written. Therefore the duty of worker is to visually check
only that area which have the possibility of any type of defects. Main motto of this is
to check any type of crack, flange, dent, wrinkle, hole shift etc.

21
Different Types Of Defects:
 Crack
 Flange cut
 Dent
 Wrinkle
 Burr
 Hole shift
10. DIE MAINTAINENCE DEPARTMENT:
A die consist of two parts one is the female part on which steel plate is to placed. The
male part apply force on the sheet metal plate and transfer it in the required shape.
Fig. 12 Die
The main work under this department is to insure that formation of die is such that the
part form is exact same as the required. Because a very small error can make very
high loss to company.
Depend on the type of process ,selection of the die is to made like for cutting we have
different type and like piercing we have different . For single product we have to do
pressing, cutting, piercing, final shaping therefore approximate 8 dies are required.
For every single order from parent company, new die needs to be made and after
completion of that order that dies have no use and are sold in scrap.

22
Basically a die consist of two pairs one is called female part which is the lower part
and the other one is called male part which is the upper one.
Fig. 13 Die
Female part of a die is fixed and male part move up and down. Some important
component involved are-
Cushion Pin or Pressure Pin: A pin used in conjunction with an air cushion that
transfers pressure from the air cushion to the bottom of the die.
Air Cushion: An air-actuated press accessory that is placed below or inside die block,
which is used to increase pressure on the die using pressure pins. The air cushion can
also be used to lift the part out of the die
10.1 Dies and It’s Types:
Die: The die may be defined as the female part of a complete tool for producing work
in a press. It is also referred to a complete tool consists of a pair of mating members
for producing work in a press.
Types Of Dies: The dies may be classified according to the type of press operation
and according to the method of operation.

23
According to type of press operation: According to this criterion , the dies may be
classified as cutting dies and forming dies.
Cutting Dies: These dies are used to cut the metal. They utilize the cutting or
shearing action. The common cutting dies are : blanking dies , perforating dies ,
notching dies , trimming , shaving and nibbling dies.
Forming Dies: These dies change the appearance of the blank without removing any
stock. Theses dies include bending, drawing and squeezing dies etc.
According to the method of operation: According to this criterion, the dies may be
classified as : single operation or simple dies , compound dies , combination dies ,
progressive dies , transfer dies and multiple dies.
Simple Dies: Simple dies or single action dies perform single operation for each
stroke of the press slide. The operation may be one of the operation listed under
cutting or forming dies.
Compound Dies: In these dies, two or more operations may be performed at one
station. Such dies are considered as cutting tools since, only cutting operations are
carried out. Figure shows a simple compound die in which a washer is made by one
stroke of the press. The washer is produced by simulation blanking and piercing
operations. Compound dies are more accurate and economical in production as
compared to single operation dies.
Fig. 14

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Combination Dies: In this die also , more than one operation may be performed at
one station. It is difficult from compound die in that in this die, a cutting operation is
combined with a bending or drawing operation, due to that it is called combination
die.
Fig. 15
Progressive Dies: A progressive or follow on die has a series of operations. At each
station , an operation is performed on a work piece during a stroke of the press.
Between stroke the piece in the metal strip is transferred to the next station. A finished
work piece is made at each stroke of the press. While the piercing punch cuts a hole in
the stroke , the blanking punch blanks out a portion of the metal in which a hole had
been pierced at a previous station. Thus after the first stroke , when only a hole will be
punched , each stroke of the press produces a finished washer.
Fig.16

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Transfer Dies: Unlike the progressive dies where the stroke is fed progressively from
one station to another. In transfer dies the already cut blanks are fed mechanically
from one station to other station.
Multiple Dies: Multiple or gang dies produce two or more work piece at each stroke
of the press. A gang or number of simple dies and punches are ganged together to
produced two or more parts at each stoke of the press.
11. WORKING METHDOLOGY:
JBM Group follows the Japanese standards to maintain the production and achieving
the quality goals.
11.1 The 5S:
In Japanese the 5S stands for:
 Seiri (Sort)
 Seition (Set in order)
 Seiso (Spic and span)
 Seiketsu (Standardize)
 Shitsuke (Self-discipline)
1.SORT:
 Remove unnecessary items and dispose of them properly.
 Make work easier by eliminating obstacles.
 Reduce chances of being disturbed with unnecessary items.
 Prevent accumulation of unnecessary items.
 Evaluate necessary items with regard to cost or other factors.
 Remove all parts or tools that are not in use.
 Segregate unwanted material from the workplace.
 Need fully skilled supervisor for checking on regular basis.
 Don't put unnecessary items at the workplace & define a red-tagged area to keep
those unnecessary items.
 Waste removal.

26
2. SET IN ORDER:
 Arrange all necessary items so that they can be easily selected for use.
 Prevent loss and waste of time by arranging work station in such a way that all
tooling /equipment is in close proximity.
 Make it easy to find and pick up necessary items.
 Ensure first-in-first-out FIFO basis.
 Make workflow smooth and easy.
 All of the above work should be done on regular basis.
3. SPIC AND SPAN:
 Clean your workplace completely.
 Use cleaning as inspection.
 Prevent machinery and equipment deterioration.
 Keep workplace safe and easy to work.
 Keep 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 secs.
4. STANDARDIZE:
 Standardize the best practices in the work area.
 Maintain high standards in workplace organization at all times.
 Maintain orderliness. Maintain everything in order and according to its standards.
 Everything in its right place.
 Every process has a standard.
5. SELF DISCIPLINE:
 To keep in proper working order.
 Also translates as “Do without being told”.
 Perform regular audits.
 Training and discipline.
 Training is goal-oriented process. Its resulting feedback is necessary monthly.

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Production Part Approval Process:
Production part approval process (PPAP) is used in the automotive supply chain for
establishing confidence in component suppliers and their production processes.
Below is the list of all 19 elements, and a brief description of them.
Fig. 17 Control Plan
Design Records:
A printed copy of drawing needs to be provided. If the customer is responsible for
designing, this is a copy of customer drawing that is sent together with the Purchase
Order (PO). If supplier is responsible for designing this is a released drawing in
supplier's release system.
Authorized Engineering Change (note) Documents:
A document that shows the detailed description of the change. Usually this document
is called "Engineering Change Notice", but it may be covered by the customer PO or
any other engineering authorization.
Engineering Approval:
This approval is usually the Engineering trial with production parts performed at the
customer plant. A "temporary deviation" usually is required to send parts to customer
before PPAP. Customer may require other "Engineering Approvals".

28
DFMEA:
A copy of the Design Failure Mode and Effect Analysis (DFMEA), reviewed and
signed-off by supplier and customer. If customer is design responsible, usually
customer may not share this document with the supplier. However, the list of all
critical or high impact product characteristics should be shared with the supplier, so
they can be addressed on the PFMEA and Control Plan.
Process Flow Diagram:
A copy of the Process Flow, indicating all steps and sequence in the fabrication
process, including incoming components.
PFMEA:
A copy of the Process Failure Mode and Effect Analysis (PFMEA), reviewed and
signed-off by supplier and customer. The PFMEA follows the Process Flow steps, and
indicates "what could go wrong" during the fabrication and assembly of each
component.
Control Plan:
A copy of the Control Plan, reviewed and signed-off by supplier and customer. The
Control Plan follows the PFMEA steps, and provides more details on how the
"potential issues" are checked in the incoming quality, assembly process or during
inspections of finished products.
Measurement System Analysis Studies (MSA):
MSA usually contains the Gage R&R for the critical or high impact characteristics,
and a confirmation that gauges used to measure these characteristics are calibrated.
Dimensional Results:
A list of every dimension noted on the ballooned drawing. This list shows the product
characteristic, specification, the measurement results and the assessment showing if
this dimension is "ok" or "not ok". Usually a minimum of 6 pieces is reported per
product/process combination.

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CONCLUSION:
Today we are essentially operating in a global market. In this area of crumbling
economic barriers, the customer reigns supreme. The successful enterprises in this
fiercely competitive economy are those which are able to ensure a high level of
consumer satisfaction and at a considerably low cost. The focus today is not on
meeting the customer’s expectations, but on exceeding them.

JBM-NMPL TRAINING REPORT,GURGAON

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