details about various processes in nbc

1. NATIONAL BEARING CORPORATION

2. Introduction
 National Engineering Industries Limited (NEI) is the flagship company of the CK Birla Group, a
conglomerate with a turnover of US$ 1.6 billion. NEI was founded in 1946 by the renowned
industrialist, Shri B M Birla, under the name of ‘National Bearing Company Limited’. The company
commenced manufacturing in 1950 with an annual production of 30,000 bearings in 19 sizes. With
increasing activities and grant of industrial licenses for other vital industries and manufacturing, the
name of the company was changed in 1958 to ‘National Engineering Industries Ltd.’ retaining its
original trade mark NBC.
 Over the past 60 years, NBC, has grown to be the leading and fastest growing bearings brand in India
and currently produces over 100 million bearings in more than a 1000 sizes every year. It has the
capacity to develop bearings from 10 mm bore to 2000 mm outer diameter. The product range
includes ball bearings, tapered roller bearings, double row angular contact (DRAC) bearings,
cylindrical and spherical roller bearings. The company has specially equipped facilities to manufacture
axle boxes for railway applications, cartridge tapered roller bearings, large-diameter bearings for
industrial applications and allied engineering products.

3. Introduction
 Three production plants at Jaipur, Newai (both in Rajasthan), and Manesar (in Haryana),
boast of world class manufacturing and process technology. A fourth plant - a green field
project at Savli in Gujarat – will ship out its first bearing in November 2013, ramping up
the total production capacity to 150 million bearings per year once the Savli plant is fully
operational
Newai Plant Jaipur plant Manesar

4. History

5. History

6. NEIL Network

7. Product Information
(Roller Bearings)

8. Product Information
(Ball Bearings)

9. Customers
 Rolling Stock: -
TEXMACO
Hindustan Motors Ltd.
Maruti Udyog Ltd.
Mahindra & Mahindra
 Automobiles-LCV: -
Ashok Leyland
Force Motors
Eicher Motors
Tata Motors

10. Purpose and roles of a bearing

11. Components of a Ball bearing
1. Outer race
2. Inner race
3. Cage
4. Balls

12. Bearing Designation

13. Manufacturing process of Ball Bearing
Ball forging
Tube extrusion
Heat
Treatment
Ball
manufacturing
Race
Grinding
assembly
Finished goods
Warehouse &
Shipping
Bought out
component
Turning
Vendo
r

14. Heat treatment plant
Raw material Stamping Hardenin
g
Tempering Hardness
checking
carburizatio
n
Row material is low carbon
steel containing
Steel upto 0.15%

15. Carburization
 Gas Carburizing Process is a surface chemistry process, which improves the
case depth hardness of a component by diffusing carbon into the surface
layer to improve wear and fatigue resistance.
 Initially the low carbon row material contains around 0.15% carbon. During
carburization the carbon % is increased up to 1.2%. The process takes place in
Gas Carburizing Furnace where the row material comes into contact with CP
mixture at 940º to 980ºc for about 9 to 10 hours. i.e. for adding 0.9% carbon the
row material is exposed to the gas mixture for 8 + 1 hours for the last 1 hours the
gas mixture is lean.
 There are total 7 GC machines 2 out of which are automatic. Blowers are used
to cool down the carburized material.

16. Carburizing process:
Cone loading
in
Basket
manually &
load in GC by
crane.
Carburizing
process
At 950 C for 8+1
hrs. at c.p = 1.40%
After complete
carburizing
process
cooling in
furnace till
temp 550 C
Take out from
GC by crane.
Put basket in
pit for fast
cooling
Takeout from
cooling pit and
unload

17. Process flow:
race is loaded
manually in ROTARY
HEARTH FURNACE
Austenisation
Manually taken out from
furnace and oil quenched
in BEMCO PRESS.
Cooling in chiller
unit and tempered
for 2.5 hrs.
Manually unloaded
from tempering
furnace in basket.

18. Inner Race Grinding
Face
Grinding
Track
Grinding
Flange
Grinding
Bore
Grinding
Track
Honning

19. Face Grinding
 Two grinding wheels rotating in opposite directions with same speed so that both the
faces can be grounded simultaneously.
 ROWLAND MACHINE having grinding wheels with horizontal spindle Fine Face
Grinding
 DISCUSWERKE MACHINE having grinding wheels with vertical spindle
 A diamond point tool is used for dressing the grinding wheel as it wears out due to
continuous working and looses its shape. A coolant is used to prevent the heat
generation due to grinding.
Centreless Face Grinding

20. Inspection View of Centre less Face Grinding

21. Track Grinding
 IZUMI KN 312 is used for track grinding of inner race. A large diameter grinding wheel,
having proper shape for track grinding, rotates at high speed. Inner race is fed through a
channel in the machine and clamped in magnetic chuck. Grinding wheel then moves
towards the race and grounds it. After grinding, grinding wheel moves back and race
comes out through another channel.
 Grinding on surface is maintained through a MARPOSS GAUGE. A skilled operator sets this
electric gauge according to the required finished size. It consists of a thin resistance wire
which is connected to a diamond point tool. After rough grinding of the job surface, this
tool comes automatically in surface contact. As the metal is removed continuously by
grinding wheel, this diamond point tool moves in the direction of “Depth of Cut” and this
movement increases the length and resistance of wire as well, related to the number
appeared on the screen, shows the limit of grinding. Machines are connected with PLCs
for automatic control.
Cone Track Grinding Using Noritake
Wheel

22. Flange Grinding

23. Bore Grinding
 The bore of the inner race is also grounded in the similar fashion. The diameter of grinding
wheel is slightly less than that of bore. Rest is similar to outer race track grinding.
Bore Grinding

24. Track Honning
 It is the process super finishing the surface of the tracks. Types of
stones are used for rough and final finishing. They are made of
aluminium oxide and chromium oxide respectively. These stones rub
the surface of the track giving it a polished look.

25. Outer Race Grinding
Face
Grinding
Outer
Diameter
Grinding
Track
Grinding
Track
Honning

26. Face Grinding
 Two grinding wheels rotating in opposite directions with same speed so that both the
faces can be grounded simultaneously.
 ROWLAND MACHINE having grinding wheels with horizontal spindle Fine Face
Grinding
 DISCUSWERKE MACHINE having grinding wheels with vertical spindle
 A diamond point tool is used for dressing the grinding wheel as it wears out due to
continuous working and looses its shape. A coolant is used to prevent the heat
generation due to grinding.
Centreless Cup Face
Grinding

27. Outer Diameter Grinding
 centreless grinding machines
 The job is held against the face of grinding wheel by the combination of supporting
rest and a regulating wheel. Both wheels rotate in the same direction, but the speed
of regulating wheel is very less than grinding wheel. Grinding wheel rotates about its
horizontal axis during working process. The work piece is supported on a work rest
blade and regulating wheel which hold it against the horizontal force of action
controlling its size. Relational and longitudinal feed are given to the races. The edge
of the work rest blade is beveled, so it makes a “v” formation with the regulating
wheel, when races are set. A roller of very small diameter compared to its length is
provided for loading of the races. This rotates at very slow speed in the same
direction of rotation to that of regulating wheel. Work pieces are loaded manually
on this roller.
Centreless Cup Face
Grinding

28. Track Grinding
 CINCINNATI MILACRON machine consists of a grinding wheel smaller in
diameter than outer race track diameter. Initially, race is clamped in a chuck
through a channel and then wheel enters into race according to feed. Race
is supported by bush and backing plate. Now wheel reciprocates along the
direction of its axis.

29. Track Honning
 It is the process super finishing the surface of the tracks. Types of stones are used for rough
and final finishing. They are made of aluminium oxide and chromium oxide respectively.
These stones rub the surface of the track giving it a polished look.

30. Assembly
 INSPECTION AND CHECKING PROCESS: - The inner and outer races of bearing job
are inspected by the respective automation control machine for outer diameter,
track (inner and outer diameter). After this process the outer and inner parts of
bearing are matched properly and inner is placed inside the outer part of the
bearing.
 BALL FILLING PROCESS: - The balls are filled in between the inner and outer part of
bearings by a ball filling machine.
 CAGE ASSEMBLING:- During this process the plane and RI is assembled with the help
of riveting machine
 DEMAGNETIZATION OPERATION: - The bearing so obtained is passed through a
demagnetor which reduces the magnetic effects of the job.
 WASHING PROCESS: - The bearing is washed with white kerosene oil washing
machine.
 CHECKING OF VISUAL FAULTS: - The berating is now checked for defaults like black
face, bad riveting, double stamping, pin missing etc.
 REWASHING PROCESS: - The bearing is again washed with white kerosene oil so as
two removed the dust particles.
 ITCHING OPERATION: - The tag or name of company can be printed by the itching
machine through laser light.
 LUBRICATING PROCESS: - The bearing is now lubricated with grease.
 PACKING PROCESS: - Finally the bearing is packed with some poly material.

31. Transportation

32. SIZE CHECKING OPERATION
 SIZE CHECKING
 Bore checking
 Outer diameter checking

33. AUTO RING PAIRING
 AUTOMATIC FILLING OF ROLLES

34. RADIAL CLEARANCE TEST

35. NOISE/VIBRATION TESTING

36. LASER MARKING MACHINE

37. GREASE FILLING AND STEAL FITTING

38. ANTI RUST OIL COATING

39. PACKAGING
Finally the bearing packed with some Poly Material

40.  WHAT IS “5-S “-
 Many people think house keeping should be done by house wives at
home and cleaners at the workplace. They do not realize that they too
play an important role in keeping their houses/workplaces clean. More
importantly, they do not know how much they can gain themselves by
just practicing, good house keeping. The “5-S” extra the virtues of tidiness
orderliness and cleanliness at all times and at every place. These account
for the clinically clean shop floors and also in their personal habits. It is the
practice of good house keeping.
 The term “5S” represents 5 Japanese words
 1. Seiri
 2. Seition
 3. Seiso
 4. Seiketsu
 5. Shitsuke
“5-S” PLAN

41. “5-S” PLAN
 Let us look at each word, understand what it means, and how it can apply to us.
SEIRI Take out unnecessary items and throw them away.
SEITON Arrange necessary items in a proper order so that they
can be easily picked up for use.
SEISO Clean your work place completely so that there is no
dust anywhere
SEIKETSU Maintain a high standard of house keeping and work
place organization at all times
SHITSUKE Train people to follow good house keeping disciplines
independently.
The factory is very much planned. All sections can work independently by with the unmark
able mutual co-operation.

42. What We Learned……
 MAINTENANCE & ELECTRICAL
 The name of this section itself suggests that the purpose of this is to maintain the
machines in the proper running position. In this section, damaged or broken parts are
either repaired or replaced by new ones produced in the shop itself. For this purpose
section is equipped with various types of machines. For making any part of machine
first blue prints are made and then experienced skilled persons manufacture it on
these machines.
 The various types of maintenance are as follows –
 Preventive maintenance
 Running breakdown maintenance
 PREVENTIVE MAINTENANCE
 It is general checking of the machine in which all defects of the machine, due to which it is
not running properly, are eliminated.
 The following defects of the machine are observed –
 Cleaning
 Lubrication – Oil level, lubrication line to check and repair, oil line to all points
 Pneumatic system – air filter to be cleaned, lubrication to be checked
 Checking of brakes, slides, gears, belts etc.
 RUNNING BREAKDOWN MAINTENANCE
 When any machine stops suddenly, it is required to eliminate the defect instantly, and for this
purpose running breakdown maintenance is done.

43. Learnings In Industrial Training
 Industrial Training is definitely a place where we learn things that will
prepare us for working life.
 How to apply what we have learned in practical terms.
 We learn soft skills and people skills too.
 Learn to handle people and work pressure.
 Learn to cope the daily routine working lifestyle.
 We think that we really need to learn to shut up and speak only of
the necessary
 We met to the people from the company and what do the
conversations revolve around? Work work work.