SUMMER TRAINING PRESENTATION

By,Akshay jangidDepartment:- Maintenance

-:TABLE OF CONTENTS:-Company profile Different learning areas in JBM.My area of interest.My work experience with maintenance team.Awareness training material.Conclusion.Appreciation.

Company profile:-JBM Auto Ltd. was originally set up in the year 1990, mainly to manufacture Tools, Dies and Moulds at Faridabad. In the year 1993, the Company established a Press Shop for manufacturing Sheet Metal Components and Welded Sub-assemblies to meet the growing stringent quality requirements of automobile industry. The company went for its first public issue in March 1994.

Plant Particulars•Faridabad Plant -Press shops suitable for manufacturing components for car, tractor and truck industry. Current product range includes BIW parts and sub-assemblies for cars, skin panels and axles for tractors & body components, bumpers, axles and suspension components for trucks. Components are being also exported to various truck manufacturers in Europe. The Company’s philosophy of corporate governance is based on integrity, respect for the laws & compliance thereof and transparency & accountability in all facets of its operation. The Company believes that good governance brings sustained corporate growth and enhances returns to all its stakeholders viz. customers, suppliers, shareholders, employees and government agencies including society of which the Company is an integral part.

FARIDABAD JBM AUTO LIMITED, PLANT-I

GLOBAL PARTNERS OF JBM GROUP :-

CUSTOMERS;- PRODUCTS:-•Air tank•BIW parts and assemblies•Buses•Chassis and suspension parts•Cross car/truck beam•Cross members•Engineering•Fabrication•Fuel filter•Fuel tanks•LPG/CNG cylinders•Oil sump•Shaped blanks•Steel fasteners•Tailor welded blanks•Skin panels•Tools,jigs and fixtures•Wheel assembly•Tubes and tubular manipulations

Different Learning Areas In Jbm-

•Press shop •Weld shop•Tool shop•Quality

•Dispatch•Other areas

PRESS SHOP-

.

•Heavy Press Shop:Components for which heavy tonnage is required for most of their processes are worked upon in this shop. These processes include blanking, flattening, draw operation, forming, flanging, trimming, piercing, bending etc.

•Light Press ShopComponents for which heavy tonnage is not required for most of their processes are worked upon in this shop. These processes include flanging, trimming, piercing, bending etc.

WELD SHOP-

•Weld Shop 1:Spot welding and MIG welding on various components are carried out in this shop . •Weld Shop 2:After being worked upon in weld Shop 1, the components are sent to Weld Shop 2 for denting, deburring, grinding, buffing, sanding etc. Besides these processes MIG welding, Arc Welding, Spot Welding etc. are also carried out on components for some customers, in this shop.

TOOL SHOP- Tool shop is the area in which tools, dies ,jigs and fixtures. are prepared upto finish using a series of operations. Design section is the main part in tool shop .The process starts with the design making of which pattern is made ,this pattern is inspected and send out for casting .After casting is brought ,it is machined under 2d and 3d operations on CNC machines .Additional manual operations are performed for further inspection and finishing including grinding,drilling etc.Dies are inspected under spotting press for colour test and pieces are made. If fine, dies are declared ready for use.

QUALITY-Quality department is the area where product’s quality is checked,whether the produt has achieved its required dimensions and other physical properties. Process of quality check is divided in to three steps namely –•Incoming quality control•In process quality control•Finished product quality controlInspite of these three, customer complaint handling is also done.

DISPATCH-This department deals with the releasing of stock as per customer’s requirement. As per ppm schedule the dispatch team distribute targets to different shops . and finally the stock is packed and dispatched as per packaging standards. Dispatch also takes care of inventory and customer’s remarks .

Other areas-Other areas include-•Marketing(takes care of the social approach and customer’s relations)•Store(takes hold of the inventory and incoming vendor stock)•HR(concerned with training and development matters and recruitment )•SAP(red bin analysis and product design)

Area of interest-Maintenance:-WHAT IS MAINTENANCE:-

WHAT IS THE ROLE OF MAINTENANCE DEPARTMENT IN JBM:-Their chief role is to achieve continuous sustained condition of the whole plant whether it is a machine or some fitting work. Team maintenance includes works as given under :- •Mechanical job(concerned with internal functioning and fitting work of machines)•Electrical job(concerned with plant electrical supply including fans ,ac ,compressors etc. And panel problems related with machines )•Plumbing work.•Other maintenance of plant.

Sustaining the achieved result is maintenance.ORIt is the continuous effort to keep a system in its useful condition.

Fault occurs Fault is examined Corrective action is taken

Machine or system is brought to sustained working condition .

Fault is rechecked and assured by the operator.

Preventive action is taken So that the fault will not In future.

PROCESS OF MAINTENANCE:-

main derive shaft problem

mounting bolt problem

cushion problem slide adjustment problem

0

500

1000573 412

17 6

BREAKDOWN TIME VS CAUSES:-

WORKING ON PRESS 400 TON :-Mechanical press 400 ton is one of the oldest presses in jbm auto ltd. The press is of “H frame” and is used for low tonnage operations mostly hole making ,flanging etc. The machine dumped suddenly and maintenance team was informed . after being checked , it was found that the slide has jammed due to improper working of gear. The worm gear was damaged(as shown in pics ) and was need to be replaced by a new one. The slide was opened and the damaged gear was removed out .Proper cleaning was done . After the new gear has brought and fixed ,the machine was reassembled. Required oiling was done by the fitters for proper lubrication. Up and down movement of the slide was checked also whether the piece was made right or not? After it all operator and supervisor were called for assurance. And the machine was ready for production .

MY EXPERIENCE WITH MAINTENANCE TEAM:-

MOSTLY OCCURRED BREAKDOWN REASONS FOR PRESSES:-•Air leakage .•Over motion provided to the slide .•Lack of lubrication.•Clutch gap increment.•Shaft damage.•Panel problems.

SHAFT FAILURE

AWARENESS TRAINING MATERIAL:-TPM5 S WHISTLEBLOWER POLICY

•WHISTLEBLOWER POLICY:-•The policy empowers employees to report to the management of any malpractices that are taking place in any organization .The person who raises a concern about a wrong doing is known as whistleblower•Whistleblower’s identity is not revealed and is provided protection.•The complaint can be made considering:-

Abuse of authority.Breach of contractCriminal offenseManipulation of company data and records.Wastage of company funds /assets etc.

5 ‘S’ THE BASE OF TOTAL QUALITY CONTROL:-पहचानें और गैर

आवश्यक वस्तुओं की छटाई करना SEIRI

सुव्यवस्थाSEITON

सफाईSEISO

मानकीकरणSEIKETSU

अनुशासनSHITSUKE

आवश्यक वस्तुओ को उनके निनर्धाा(रिरत स्थान पर व्यवस्थिस्थत

करना 

काय( के्षत्र को रु्धाल और गंदगी से मुक्त रखना रखना 

निनयमिमत देखभाल द्वारा काय( के्षत्र को सुंदर रखना 

निनयमो का पालन करना  निनयम

1-11-21-31-42-12-22-32-4

‚R-‚P3-23-33-44-14-24-34-4

5-1 5-25-35-4

2-2

छटाई 

TOTAL PRODUCTIVE MAINTENANCE:-•This policy implies effective way of maintenance in order to eliminate loss and increase productivity.•Having eight pillars as shown below.

CONCLUSION:-Doing this summer training I come to know about many new things which I haven’t studied in my college .I have gathered the “In field work process” of a multi national company. Along with maintenance, i have gained knowledge of other departments also including quality, tool shop, dispatch etc. I have learned here what is the complete procedure on which a production plant works. I have also learned about teamwork. And study of numerous machines which are used in this plant has increased my technical knowledge a lot.

APPRECIATION:-I t was a great experience working with team maintenance in these 45 days . I am thankful to the company authorities for allowing me for the training. This summer training has given me experience in my working zone and also has increased my technical knowledge. I even wish to work here in future .

Thank you!!

Signature:-•HOD (MAINTENANCE)……………..

•HR…………………………

•TRAINEE…………………….

DATE OF SUBMISSION:-