A

REPORT

Of

INDUSTRIAL VACATIONAL TRAINING

At

KIRLOSKAR FERROUS INDUSTRIES LIMITED, SOLAPUR

- SUBMITTED BY -

RANGREJ SOMNATH PRAKASH B.E. (MECHANICAL ENGINEERING)

DIV-A ROLL NO-49

- UNDER THE GUIDANCE OF -

PROF. P.P Kate

MECHANICAL ENGINEERING DEPARTMENT

N. K. ORCHID COLLEGE OF ENGINEERING AND TECHNOLOGY, SOLAPUR.

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2012-2013

CERTIFICATE

This is to certify that,

The under mentioned student has completed his training during the period of 25th May to 9th June 2012

Mr. RANGREJ SOMNATH PRAKASH B.E. (MECHANICAL ENGINEERING)

At

KIRLOSKAR FERROUS INDUSTRIES LIMITED, SOLAPUR

This is in partial fulfilment for the award of Degree of Bachelor of

Mechanical Engineering of Solapur University, Solapur.

Prof. P. P. Kate Prof. B. K. Sonage (Guide) (H. O. D.)

(Mechanical Engg. Dept.)

Prof. Dr. J. B. Dafedar(Principal)

N.K.ORCHID COLLEGE OF ENGINEERING AND TECHNOLOGY, SOLAPUR.

2012-2013

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MECHANICAL ENGINEERING DEPARTMENT

REPORT APPROVAL SHEET

It is certified that the industrial vocational training report completed by Mr. RANGREJ S. P. of class B.E.(MECHANICAL ENGINEERING , DIV-A, ROLL NO-49 is a bonafide work done by him during the academic year 2012-2013.

This is in partial fulfilment for the award of Degree of Bachelor of Mechanical Engineering of Solapur University, Solapur.

Prof. P.P.Kate Prof. B. K. Sonage (Guide) (H. O. D.)

(Mechanical Engg. Dept.)

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ACKNOWLEDGEMENT

I am very thankful to the management of Kirloskar Ferrous

Industries Limited, Solapur for allowing me to undergo implant

training during my Mechanical Course. I am grateful to Mr. H. Kulkarni

who granted for the training and guided me for this training session.

I would like to express my sincere gratitude to our Principal

Dr. J. B. Dafedar and Prof. B. K. Sonage (Head of Mechanical

Engineering Department) for giving me the opportunity to widen our

knowledge and project Guide Prof. P.P. Kate for giving much of their

valuable time, precious guidance and constructive criticism for bringing

out this report. Their moral support and kind co-operation enabled us to

bring out, this report successfully.

- RANGREJ S. P.

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INDEX

Sr. no. Title Page no.

1. Introduction

1.1 History

1.2 Company Profile

1.3 Company Location

1.4 Symbol Of Kirloskar

1.5 Present Status

1.6 Mission, Values & Policy

1.7 KFIL Journey

1.8 Organizational Structure

1.9 Products Of Company

1.10 Costumers Of Company

7

7

7

8

8

8

9

10

11

12

13

2. Layout Of KFIL 14

3. Departments In KFIL

3.1 Manufacturing Department

3.2 Administrative Department

15

15

17

4. Plants In KFIL

4.1 Foundry (B-plant)

4.2 HPML

4.3 Machine Shop

19

19

19

20

5. Area Of Work - Machine Shop

5.1 Machining section

5.2 Tool room

5.3 Gauge room

5.4 Assembly section

20

21

22

22

22

6. Management System Of KFIL 23

7. Conclusion 25

8. Bibliography 26

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List Of Figures

Fig Number

Name Of Figure Page Number

1 Symbol Of Kirloskar Organization 8

2 Cylinder Block 12

3 Cylinder Head 12

4 Crankcase 12

5 Gearbox Casing 12

6 Cylinder Liners 12

7 Clutch Housing 12

8 Castings Sales Distribution 13

9 Layout Of KFIL 14

10 Machine Shop Layout 20

11 Machine Shop 21

1. INTRODUCTION

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1.1 HISTORY:-

The Kirloskar story starts with Laxmanrao Kirloskar, the Founder. A

man who believed that an understanding of one’s environment and reality is

essential to the manufacture the path breaking industrial implements. From

this steadfast belief was born the iron plough, the first Kirloskar product.

Originally intended as an essential aid to agriculture, the plough soon

became an icon of reform and revolution. A highlight of the early history

of the group is Kirloskarwadi, India's first industrial township.

In January 1910, when the Kirloskar were being ousted from

Belgaum to make room for a new suburb, they found themselves in dire

need of a place to live and work. Sensing this need, the Raja of the

princely state of Aundh, who admired and respected Laxmanrao

Kirloskar, offered the latter all the land he needed in Aundh state. Driven

by his faith in human ability, Laxmanrao bonded together 25 workers and

their families and succeeded in transforming the barren expanse into his

dream village.

1.2 COMPANY PROFILE:-

“Kirloskar Ferrous Industries Limited” is one of the oldest

concerns in Kirloskar group of industries which was established at 4 th

April 1900. In the beginning it had produced vices, agricultural

implements, brass and copper sheet metal utensils as their soul product.

In 1997, it was restructured to remain competitive in changing

circumstances and merged with KOEL, Pune in 2000. Then it was called

as “Kirloskar Oil Engine Limited (K.O.E.L.) (Casting Division)”. But in

2007, it is also known as “Shivshahi Plant”.

1.3 LOCATION:-

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It is situated about 7km from Solapur City on the way to Hotagi,

Southern Solapur.

Total Area: - 318,000 sq. m (54 acre)

1.4 SYMBOL OF KIRLOSKAR ORGANIZATION:-

1.5 PRESENT STATUS:-

Gross Fixed Asset Over 28 Crores

Turn Over 6-6.25 Crores Per Month

Casting Produced: Gray & S.G. Iron Castings

Total Employees 590

1.6 MISSION:-

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To seek global market leadership.

Development and growth in oriented firms will be our

focus.

To continue to create a winning culture, operating in the

highest standards of ethics and values.

Strive for excellence in customer service, quality and

R&D.

VALUES FOR ACHIEVING MISSION:-

Customer orientation

Vendor development

Development of human resource (Trust, Positive attitude, concern

for quality cost , kaizen, continual improvement and result

oriented)

Responsible corporate neighbour.

QUALITY POLICY:-

Company’s motto itself tells us about the company’s attitude towards

quality.

The motto is:-

“Discipline-Cleanliness-Continuous Improvement”

1.7 KFIL JOURNEY:-

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1900 Manufacturing of household utensils & brass ware

1934 G.I. Foundry started

1941 Manufacturing of vices, exports to USA , Australia

1951 Manufacturing self priming pump

1980 I C plant in collaboration with Hitchner INC USA

1993 Started ceramic moulding technology at I C plant

2000 Merged with KOEL , Pune

2001 ISO 9001 certification through BVQI

2005 Synergy with KFIL & restructuring

2007 Merged with KFIL

2008 Recommended for TS & EMS,HPML plant, completed oracle

11i

1.8 ORGANIZATIONAL STRUCTURE

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CHAIRMAN

Mr. Atul Kirloskar

MANAGING DIRECTOR

Mr. R. V. Gumaste

CHIEF

EXECUTIVE

OFFICER

Mr. Mujumdar

CHIEF

EXECUTIVE

OFFICER

Mr. S. L. Kulkarni

General Manager & Deputy General Manager

H.R.

Mr. Vaidya

(G. M.)

R & D

Mr. Ramrao

(G. M.)

FOUNDRY

PLANT

Mr. Kolkur

(G. M.)

MACHINE

SHOP

Mr. Gore

(G. M.)

HPML

PLANT

Mr. Rao

(G. M.)

1.9 COMPANY PRODUCTS

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Cylinder Block Cylinder Head

Crank Case Gearbox Casing

Cylinder Liners Clutch Housing

1.10 COMPANY CUSTOMERS

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Casting Sales Distribution

Names of the Customers.......

1 K.O.E.L. 8 Swaraj Mazda

2 Mahindra & Mahindra 9 KBSA South Africa

3 Tata 10 DLW- Waranasi

4 Toyota 11 Ashok Leyland

5 Indian Railway 12 Bajaj Tempo, Pune

6 H.M.T. Tractor 13 Kerala Agro Machinery

7 Escorts 14 Bharat Earth Movers, Banglore

2. Layout of KFIL

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3. DEPARTMENTS IN KFIL-S

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Administrative Department

Personnel Department

Finance Department

Purchase Department

Marketing Department

Security Department

Manufacturing Department

Research Development Department

Production Department

Quality Control Department

Maintenance Department

3.1 ADMINISTRATIVE DEPARTMENT

Personnel Department

This dept is meant for employee development. It organized

various activities like training, placement, recruitment and skill

development to enhance the skills of employee in the industry.

Functions of this dept includes following:-

Training, education & development of employee skill.

Maintaining adequate employee supply

Maintaining satisfactory relationship between employee &

management.

Recruitment of new employees in case of vacancies or expansion

of industry

Making management aware of employee welfare related services.

Finance Department:-

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It is one of the most important dept as it is all related to money

or economics matters of the concern. It provides finance to the industry &

audit of all activities going around. It is responsibility of finance dept to

provide maximum possible finance to dept as &when required.

Its other functions are:-

To keep account of every penny spent.

To prepare the balance sheet, maintain loss & profit account of

industry.

To prepare annual report for company.

To decide the pay structure of employee, raise the funds use part of

profit to pay & audit it.

Purchase Department:-

Purchase is one of the major tasks during the commencement

of business, Industrial working of manufacturing. Generally industry had

to purchase almost everything from the market such as raw materials,

tools, machinery & technology too. Activities performed by the dept

basically depend on 5R’s principles.

Right time

Right quality

Right quantity

Right price

Right source

Properly following these principles put the industry in more & more

efficient position & also increases its profit.

Marketing Department:

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The marketing department is mainly focus on the activities

of marketing products, pricing and promotion of products. The

company has got distribution network spread all over India in from

of dealership and also through company’s employees, the divided its

market into 7 zones

Security department:-

It is one of the important dept of industry. This dept ensures

security of available facility as well as of the goods in industry. A special

guard is hired by the industry & employed for security purpose.

Duties of this dept include:

Thorough checking & maintaining records of visitors & employees

entering or leaving the industry.

Keeping record of visitors & ensuring that they have got the

permission for visit by querying to respective concern.

3.2 Manufacturing Department

Research & Development Department

This department is most important department as far as efficient

& effective manufacturing is concerned.

Functions:-

It makes pattern design & development.

This department carry out planning of the realization

To control & maintain the customers drawing.

To control & maintain the customers drawing.

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To design equipments such as jigs and fixtures necessary for

manufacturing process.

To check properties of castings time to time.

It performs iterative design process to improve working process &

increase the productivity.

Production Department:-

KFIL has plant B which includes the foundry department in

which various treatments moulding, casting, cooling etc. This department

makes efficient plans for production process to satisfy the customer’s

requirement & delivery of product.

Quality Control Department:-

This department consist of Universal Testing Machine & well

equipped metallurgical laboratory with facilities of destructive & non

destructive test. The main function of this dept is to check thoroughly

finished products are as per required quality & as per specification.

Maintenance Department:-

This dept plays very important role to keep the industry well

functioning. Every process is at its peak point only it is properly

maintained. Thus this department works continuously for all seven days

of week to ensure high productivity. This dept responsible for all

maintenance work everything from machine to industrial premise. The

maintenance & servicing is carried out as per charts provided for each

machine or furnaces.

4. Plants in Industry

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4.1 FOUNDRY (B-PLANT)

This plant manufactures castings by pouring molten metal into the mould

& plant B is mechanized foundry. In this plant sand supply &

conditioning system is fully mechanized from shake out to condition

return. Moulding boxes for pouring are handling on rails from machines.

For large moulds, pouring of liquid metal is carried out by overhanging

cranes & ladle, while for small moulds pouring is done with shake ladles.

Section of B plant:-

Sand section

Core section

Moulding section

Melt shop

Fettling section

4.2 HIGH PRESSURE MOULDING LINE PLANT (HPML)

In December 1, 2007 KFIL set up a new plant called HPML which has

product capacity of 50,000 MT per annum. The machines in the plant are

from Germany, Italy & India. The whole plant is fully automated & work

has been carried out through industrial robotics. The process in the

HPML plant are controlled by electronic system called as “Programmable

Logic Control (PLC)”

5. Area of Work – “Machine Shop”

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Machine Shop Layout

Machine Shop

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Machine shop produces finished product from castings

manufactured in the foundry (B plant). Some preliminary operations on

castings like rough turning are subcontracted to machine shops located

near the industry. The machine shop is subdivided in following

departments;

5.1 MACHINING SECTION

Here previous operations are carried out on castings

produced in the B-plant (foundry) such as drilling, killing, boring,

turning, facing. The machines available in machining section are;

Lathe Machine – Bombay Lathe, Shimoga Lathe, Chucker Lathe

(CNC)

Drilling Machine – BFW Radial Drilling Machine

Grinding Machine – surface Grinding Machine, Bench Grinding

Machine, Universal Grinding Machine, Cutter Grinding

CNC Machine – BFW Bangalore

VMC Machine – Kirloskar made

Boring Machine – Vertical Boring Machine

Milling Machine – Horizontal & Vertical Duplex Milling Machine

(BFW)

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The machining is carried out according to process sheet.

Process sheet is prepared by taking into account machining sequence, jigs

& fixtures required process sheet consist of following contents;

1) Machining sequence

2) Drawing of specified machine operation

3) Drawing number

4) Dimension of jobs after operation

5) Location points of jobs

6) Jig & fixtures

7) Tools & Gauges

5.2 TOOL ROOM

Tool room stores various tools required for machining of jobs.

This section issues & keeps account of tools used for processing of jobs.

Tools are mounted on shadow boards which help to search the tools in

short time. Various cutting tools in tool room are milling cutters,

grinders, reamer, insert, spot facer. Other auxiliary tools are spanner,

hammer, springs and gaskets.

5.3 GAUGE ROOM

It stores, issue & keeps account of various gauges required for

machining of jobs. The various gauges in the gauge room are vernier

calliper, micrometer, plug, ring, digital gauges etc.

5.4 ASSEMBLY SECTION

At this section various parts are joined to make complete

assembly of jobs. Here various parts such as core plugs, nuts, bolts &

rods are assembled together with the job to make the job ready for

packing. Then whole assembly is packed in wooden box for dispatch.

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6. Management system of KFIL

5S

Kaizen

Poka Yoke

“5S”

Japanese Term English EquivalentMeaning in Japanese

Context

Seiri Tidiness

Throw away all

rubbish and unrelated

materials in the

workplace

Seiton Orderliness

Set everything in

proper place for quick

retrieval and storage

Seiso Cleanliness

Clean the workplace;

everyone should be a

janitor

Seiketsu Standardization

Standardize the way of

maintaining

cleanliness

Shitsuke Discipline

Practice Five ‘S' daily

- make it a way of life;

this also means

'commitment'

KAIZEN:-

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Kaizen is the Japanese term that basically translates to continuous

improvement or change to become good this management concept

originated by Japanese in order to continuously effect incremental

changes for better involving everybody within organization for worker to

the manager. Kaizen is aimed at producing more & more values with less

& less waste (higher efficiency), attaining better working environment &

developing stable process by standardization.

POKA YOKE:-

Poka yoke is a quality management concept developed by a

Matsushita manufacturing engineering named Shigo to prevent human

errors from occurring production line. Poka Yoke comes from two

Japanese words “Yokeru” which means “To avoid” & “Poka” which

means “Inadvertent errors”. Thus Poka yoke more or less translate to

“Avoiding inadvertent errors.”

7. Conclusion

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There were many th ings tha t I have exper i ence and

l ea rned dur ing my Indus t r i a l T ra in ing a t KFIL . The

whole training period was very interesting, instructive and challenging.

Through this training I was able to gain new insights and more

comprehensive understanding about the real industry

Work ing  cond i t ion  and p rac t i ce . I t has   a l so  has

p rov ided  me   the oppor tun i t i e s to deve lop and improve my

so f t and func t iona l sk i l l s .

A l l o f th i s va luab le exper i ence and knowledge tha t

I have ga ined were no t on ly acqu i red th rough the d i rec t

i n v o l v e m e n t   i n   t a s k   g i v e n   b u t   a l s o   t h r o u g h   o t h e r  

a s p e c t   o f   t h e   t r a i n i n g   s u c h   a s   w o r k   obse rva t ion ,   in t e r

ac t ion  wi th   co l l eagues ,   supe r io r ,   and  o the r s   th i rd  pa r ty   r

e l a t ed   to   thecompany . F rom wha t I have undergone , I am

hundred pe rcen t ag ree tha t the indus t r i a l training program

have achieve its entire primary objective. It’s also the best ways to

prepare student in facing the real working life. As a result of the program

now I am more confident to enter the employment world and build my

future career.

8. Bibliography

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1. www.kirloskar.com

2. www.kirloskarapps.kirloskar.com

3. www.intimespectrum.com

4. www.enam.com

5. www.google.co.in

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