Industrial Case Study Report a

Industrial Case Study Report at: AGROFAB MACHINERIES PVT. LTD

CASE STUDY:

* PROBLEM I & ITS SOLUTION
* PROBLEM II & ITS SOLUTION
INTRODUCTION:
AGROFAB MACHINERIES PVT. LTD. is a reputed industry in MIDC area at Higna Road Nagpur. The main outputs of the industry are machined parts for tractors of Mahindra & Mahindra tractors located at Nagpur. Over the years company has successfully provided the required tractor assembly parts to the company and is continuing their good streak in manufacturing industry. The company has been able to get accreditation of ISO 9001:2000. The various products under its manufacturing hood are:
a) C. V. Cylinder Head
b) Differential Gear Housing
c) Distributor Housing
d) Valve Body

The company has very high quality CNC machines from AMS synchronized with Distributed Control System from FANUC. With this quality of machines hardly there are any mistakes that could happen during manufacturing. Though we have tried to take an effort and found out some problems that could be solved by certain easy measures, thus helping factory to save time and labour.

Let us know more about industry and work carried under it.
ORGANISATION STRUCTURE:
The structure of organization is primarily hierarchical. The organizational structure of the industry is given as follows:

PROCESSES UNDERTAKEN:

* Inspection of raw material: Here temporary inspection of raw material is done. Just by finding any visual defects.

* Facing: It is operation of moving the cutting tool at right angles to the axis of rotation of the rotating workpiece.

* Spot Facing: It is a machining operation where material is removed from a surface to make it flat and smooth, usually for a fastener or bearing.

* Drilling: It is used to remove material from the inside of a workpiece.

* Reaming: It is used to create an accurate sized hole.

* Threading: It is the process of creating a screw thread.

PROCESS FLOW CHART:
NOTE: INSPECTION IS DONE AT ALL STAGES.
MACHINES USED:
Different kinds of machines from conventional drilling to CNC’s both kind of machines can be found in this plant.
Some of those machine are stated and their purpose is explained below:
CNC LATHE:
The machine is controlled electronically via a computer menu style interface; the program may be modified and displayed at the machine, along with a simulated view of the process. The setter/operator needs a high level of skill to perform the process, however the knowledge base is broader compared to the older production machines where intimate knowledge of each machine was considered essential. These machines are often set and operated by the same person, where the operator will supervise a small number of machines.
CNC MILLING:
Most CNC milling machines are computer controlled vertical mills with the ability to move the spindle vertically along the Z-axis.CNC machines can exist in virtually any of the forms of manual machinery, like horizontal mills. The most advanced CNC milling-machines, the multiaxis machine, add two more axes in addition to the three normal axes (XYZ). Horizontal milling machines also have a C or Q axis, allowing the horizontally mounted workpiece to be rotated, essentially allowing asymmetric and eccentric turning. The fifth axis (B axis) controls the tilt of the tool itself. When all of these axes are used in conjunction with each other, extremely complicated geometries, even organic geometries such as a human head can be made with relative ease with these machines. But the skill to program such geometries is beyond that of most operators. Therefore, 5-axis milling machines are practically always programmed with CAM.

Milling Machine:
A milling machine is a machine tool used to machine solid materials. Milling machines are often classed in two basic forms, horizontal and vertical, which refer to the orientation of the main spindle. Both types range in size from small, bench-mounted devices to room-sized machines. Unlike a drill press, which holds the workpiece stationary as the drill moves axially to penetrate the material, milling machines also move the workpiece radially against the rotating milling cutter, which cuts on its sides as well as its tip.Workpiece and cutter movement are precisely controlled to less than 0.001 in (0.025 mm), usually by means of precision ground slides and leadscrews or analogous technology.

INSPECTION & SAMPLING:
An inspection is, most generally, an organized examination or formal evaluation exercise. It involves the measurements, tests, and gauges applied to certain characteristics in regard to an object or activity. The results are usually compared to specified requirements and standards for determining whether the item or activity is in line with these targets. Inspections are usually non-destructive.
In this industry various types of gauges to maintain accuracy and precision at various stages of machining are performed. Each stage involves checking of dimensional accuracy. The commonly used gauges at plant are:
a) Go-Nogo gauge
b) Calipers ( inside caliper, vernier caliper )
c) Micrometer screw gauge
d) Pneumatic gauge

i) INSPECTION USING PNEUMATIC GAUGE ii) GO-NOGO GAUGES

PACKAGING & TRANSPORTATION:
The final product after going through inspection & sampling is oiled for protection against corrosion. And then product is finally packed inside a plastic bag. Thus the final product is ready to be transported to other industry.

CASE STUDY:
* The case study was carried out at AGROFAB MACHINERIES PVT. LTD., MIDC, Hingna Road, Nagpur.
* The raw material was provided by Mahindra & Mahindra procured from casting unit at Chennai.
* Various machining processes were carried out to make castings fit to use.
* The plant runs 24 hours a day. The production work is carried out in 4 shifts and each shift consists of 6 hours.
* The production rate of the industry is 800 parts per day.
PROBLEMS:
PROBLEM 1: Blind boring
A through bore was sunk across the thickness of the part.

SOLUTION:
The bore was required only upto a certain depth.That process was unnecessary and was consuming more time, power and labour.
This could be overcome by just attaching a stopper with drill bit at the optimum required length. This will reduce time, save labour & avoid unnecessary wearing of tool.
PROBLEM 2: Chip disposal
SOLUTION:
Centralized chip disposal system can be suggested over this problem. We suggest that the disposal of chips can be carried out by using a conveyor disposal system. This system will run periodically to carry chips to disposal area.