A REPORT ON

6 WEEKS INDUSTRIAL TRAINING AT

JAY BHARAT MARUTI LIMITED ( A Joint Venture with Maruti Suzuki India Limited)
PLOT NO. 15 & 22, MARUTI SUPPLIER PARK, SECTOR-3A, IMT MANESAR, GURGAON 122051 ( HARYANA ) E.MAIL WWW.JBM-GROUP.COM TEL : +91 9999190423, +91 9899079952
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Submitted By : GAGANDEEP ITM UNIVERSITY, GURGAON

HISTORY OF THE COMPANY

Jay Bharat Maruti Limited set up in 1987 is one of the largest joint ventures of Maruti Udyog Limited. This is a unique combination of modern Press Shop and Weld Shop capable of supplying components in Just in Sequence (JIS) meeting customers quality and quantity requirements. Manufacturing facilities at JBML also include die maintenance, dedicated facilities for manufacturing exhaust systems and in house modern tool room. JBML is rising to meet new challenges with modern equipment and higher goals of manufacturing and quality control. The period from 1988 to 1995 was a steep rise in the demand of passenger car in India. To meet this rising demand, JBML had to continually expand its manufacturing facilities. Because of space constraints a new plant (Plant-2) was set us for the manufacturing of sheet Metal parts with latest technologies like fully automatic tandem line from Rovetta of Italy, 5-axis laser cutting machine from Prima of Italy. This new plant is located approximately 14 kms from Plant-1. Space crated extra because of this new plant was being utilized by additional business of weld assemblies like front under body, rear under body for car & exhaust systems for various models of

Maruti. The net sales of the company has increased from 262.86 crores in the year 2002-03 to 414.85 crores in the year 2004-05. Driven buy a commitment to customer satisfaction and international standards of quality, JBML has not only won customer confidence but also industry recognition through several awards and accolades viz. National Productivity Award Best Performing Vendor Award, Quality Trophy etc.

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GUIDING PRINCIPLES AT JBML

MISSION
To make JBML a synonym for world class organization excelling in sheet metal technologies.

VISION
Expanding leadership in our business through people, keeping pace with market trends and technology.

HR POLICY
JBML will always keep on striving for the deployment of competent and efficient employees at all levels to create inculcate and foster excellent Working and learning environment; because it believes in nurturing strength of individuals for developing mutual trust, support and positive attitude for achieving organization goals to create a world class manufacturing organization and to remain the market leader in sheet metal components not only today but for all the tomorrows to come.

QUALITY POLICY
The policy of JBML is to achieve total customer satisfaction by delivering products and providing services that meet or exceed their exacting requirements and expectations and to do so on time and at most competitive prices in domestic and export market for our entire product range. ENVIRONMENT, HEALTH AND SAFETY POLICY Jay Bharat Maruti Limited, as a responsible manufacturer of sheet metal components, welded sub assemblies and exhaust systems for automotive applications, re-affirms its commitment to minimize the adverse impacts of its operations, products and services

on the environment, health and safety. To this end, the company endeavor to: 1Develop and maintain an Environment, Health and Safety Management System and continually monitor, set and review the environmental, health and safety objectives and targets. 2Meet all applicable legislations, regulations and customers requirements. 3Conserve natural resources and energy by constantly seeking to reduce their consumption by reducing wastages and maximizing recycle/reuse. 4Minimize/Prevent air, water, noise and land pollution generation. Maintain a system for hazard waste management. 5Establish health and safety programmes to continually reduce health and safety risks. This policy shall be communicated to all the employees of JBML and be made available to public and interested Parties on demand.

QUALITY IS COMPONENT NO. 1

More than anything else, the driving force at JBML is Quality. Stringent quality control maintained at every stage of the designing and manufacturing processes translates into zero-defects, international standard products. Rooted on the policy to achieve total customer satisfaction by delivering products and services that meet and exceed their expectations, on time and at competitive cost, JBML has developed a tradition of quality. Every personnel is positively attuned and committed to excellence. It is a corporate motto at JBM to accomplish tasks right the first time, every time. And ongoing improvement on manufacturing processes and advanced quality planning play a critical role in ensuring high standards. No wonder, globally JBML became the first company to achieve ISO/TS-16949-2002 certification. Also, concern for environment protection has brought JBML ISO 14000 certification.

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MARCHING AHEAD WITH PEOPLE, THROUGH PEOPLE JBML has an image, which is transparent, fair, and customer caring. The vision of the Company and its goals are well appreciated by all our stakeholders viz. employees, suppliers, customers, shareholders and society at large. Our basic value simplicity, Teamwork, trust in people, customer focus and meeting commitment are well embodied in each and every employee of the organization Jay Bharat Maruti Ltd. honours the dignity of labor and that is the reason that one can see all JBML Employees in the same uniform right from the lowest worker to the top level of Managing Director. People from different states with different religious leanings, different lifestyle, and speaking different languages make JBML a well-knit close family. All the policies/practices are, therefore, fair do allow the principle of equal opportunities. There is absolutely no discrimination on account of age, sex, caste, creed, religion or region. Environment, health and safety are considered imperative for physical health of JBML. Besides fulfilling the legal requirements it generates a feeling of care and healthy well being towards the employees. The Company understands its responsibility towards protective, environment and is already an ISO 14001 Organization and has received OHSAS 18001 Certification. It is ensured that all processes and work are designed to take account of health and safety and are properly supervise at all times.

Business Environment
With entry of worlds leading automotive manufacturers in India the passenger car manufacturing segment found them in fierce competitive environment. The utilization of manufacturing facilities added by OEM s in anticipation of further demand, declined. Market share of Maruti dropped from 83% to 65%. JBM then started looking for other business avenues. JBML, for expanding its manufacturing scope for higher market share shifted its approach from MUL as component supplier to system supplier.

JBML believed that, for survival growth and prosperity change is must. The policies need to be reassessed and changed as needed. As a result business development was added as a key business process and a separate function and department was created for the same. This decline in profitability is due to tough competition and heavy discounts being asked by customers on regular basis.

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Customer Management
Customer focus is one of the basic values adopted by the company. Quality policy revolves around the customer satisfaction. There is emphasis on understanding the unspoken and meeting the implied needs expectations of the customer also. Customer satisfaction has been identified as one of the CSF. It is one of the business performance measures of long term plan and its improvement. Over the years based on periodic reviews various forms have been established for regular interaction with customer. Top management apart from personal meetings of middle managers regularly visits customers. The process of satisfaction surveys also provides the voice of customer for policy and strategy making. All customer complaints, customer ends non-conformances, performance of delivery, result of customer satisfaction surveys and any other need and expectation of customer is reviewed on weekly basis. Major customers are Maruti Udyog Limited, Eicher Motors Ltd. M&M Ltd., and HMSI.

Supplier Management
The definition of customer in the company is not limited to buyers of the product. The company treats all its associates as customers in one way or the other way. Various form set-ups for regular meeting, understanding, and responding to the suppliers need are maintained. Major vendors are connected through emails. The information on vendors and suppliers expectations and needs gathered through these forms are analyzed and considered by formulating policies and strategies. Day to day expectations and needs are responded through the normal communication channel of materials division, purchase department, supply chain cell as part of MX dept. Vendors and suppliers are rated and communicated the performances with respect to quality and delivery. These are reviewed for continual improvements on weekly basis. Major suppliers for bought out parts are group companies whereas raw material is arranged from leading Indian steel manufacturers and through imports. Finance Management:

Financial management system and policies are directed towards optimum utilization of financial resources. The approach has been to use the financial resources for minimizing returns to the company, and in return to the stakeholder. There is clear-cut laid down rules and regulation for its transparent monitoring and inflows and outflows of funds. There is transparent pricing system between the company and all major customers, so that prices are continuously reviewed and rationalized in view of any KAIZEN/Cost reduction/VA-VE exercise as the case may be. It is all that because of this transparent price reviewing system in existence we have passed on around 20% discounts to MUL since last five years. The other important stakeholders are banks and Finance Institutions. The financial policies are in line with the expectations and high level of commitment to them. The company ensures the timely payment to entire supply chain partners in time. The company has been rated as P1 by CRISIL(one of the best credit rating agency in India) various currency movements are monitored and accordingly risks are hedged by forward coverage. The company has been constantly working on the various financial strategies for reducing the cost of funds. Conversion of term loan to lease Transactions, Foreign currency, short term unsecured loans, inter changeability of limits etc are negotiated from time to time which has helped in bringing down its weighted average cost of funds from 13.25% in 2001 to 10% in 2002. By negotiating the L.C. charges and bank charges have been brought down to half of normal rates. No commitment charges are paid to the bank. Due to these measures, the other income on account of cash discount and interest earned has been to the tune of 221 Lac in 2004. The company has been able to manage its working capital in efficient manner. The company is continuously improving its financial system. Baan ERP System has been implemented. Decisions on all new investment are based on IRR at the pre-project analysis stage. Management of building, equipment and materials Main thrust area regarding utilization of assets has been on achieving high capacity utilization and productivity, through continual improvement in the production 9|Page

processes, technological up-gradation and higher levels of productivity. Other thrust areas has been improvement in space utilization. This has been achieved by systematic review of all layouts and production flow sequence, balancing of production lines, improvement in method of material storage, inventory reductions and internal logistics. The materials constitute 70% of the sale value. Therefore material utilization has been another thrust area. The material yield, which is ratio of weight of finish product to the weight of total weight of raw material consumed, has been continually improved by reducing the material going to scrap. A committee called as VA/VE has been reviewing this exercise in a planned and systematic manner. The various approaches adopted in VA/VE are blank size reductions, using off cuts changes in blanking layouts. Raw material inventories have been reduced drastically. Predictive maintenance and TPM concepts are applied to maintain the equipments. Detailed checklist developed one for each process equipment is used for preventive maintenance as per the maintenance dept plan developed yearly and reviewed monthly. Minimum and minimum levels of spares have been defined for keeping low inventories and to avoid stockpot. History cards are maintained for each equipment and tooling. Uninterrupted electric power is supplied through own D.G. sets to save any damage to delicate electronic parts and mechanism of equipment. Technology Management In line with vision the company is continually upgrading the technology to world-class level. Visiting collaborators plants, visiting exhibitions and regular interaction with customer and different forums gather the information of new technology. The company has one fully automated tandem press line, fully automatic laser cutting machine etc. Latest IT technologies are being used like Baan ERP is used for managing companies business. Integrated communication system is developed. Knowledge management system has been developed to share improvements and good practices adopted in the organization.

Shareholders Management Annual shareholder s meeting and board meetings provide useful information on needs and expectation on them. A shareholders grievance committee has been formed at director s level. Grievances are reviewed in board meetings. Shareholders views are captured in one to one communications, letters also. The company has been giving dividend to share holders continuously.

Regulator Management All the laws and regulations applicable to the operations are taken care off. The company has been consciously and proactively ensuring compliance to all such applicable laws and regulations. There has never been any challan from authorities concerned with respect to labor laws and factories act. The company has been rated "good" during the audits conducted by central excise department during the year 1999 to 2003. The sales tax and income tax returns have always been satisfactorily assessed and no penalty was imposed. Company is actively involved in various industries and association, which interact with government agencies. Society Management The environmental policy has been prominently displayed at the entrance of the company. Company s policies and practices ensure equal opportunities to all. It does not discriminate on the basis of caste, creed and religion, sex language and province etc, during recruitment, supply and service contracts, employing casual labor, allowing visitors inside the plant. Company is continually generating directly and indirectly higher employment opportunities. Preferences are given to local residents. Large no of local suppliers, vendors, contractors are developed thus boosting the local economy. MX DEPARTMENT MX Material transaction department deals with supply chain. This department is a 11 | P a g e

combination of raw material & consumable store, PPC, and Dispatch. JBM P2 supply materials to JBM Plant 1, Maruti Udyog Ltd., Eicher Motor Ltd., Mahindra & Mahindra, Honda Motorcycle & Scooters Pvt. Ltd. along-with job work for JBM Auto components Ltd. There are two types of components supplied by JBM P2, one is in house production and other is job work by subcontractors to fulfill the requirement of customers. The components manufactured by subcontractors the raw material is supplied by JBM P2. MX department monitor & control the whole supply chain of subcontractors, raw material for production at JBM P2. The customers of JBM P1 are JBM P2, MUL, EML, M&M, HMSI and JBM Auto. All customers have given their production plan and schedule for dispatch of material. MUL communicate daily schedule on their WEB SITE for vendors. In the MUL daily schedule and time of deliveries is also indicated. This is to control inventories at MUL. All other customers give their schedule on weekly basis. App. 70% of the total components manufactured by JBM P1 is of Maruti Vehicles and remaining 30% are for other customers. For the purpose of raw material planning JBM P1 consider the production of vehicles per day at customer end and the requirement of our components for manufacturing these vehicles MUL communicate their production plan in advance so every vendor should plan production and purchase of raw material. To bring the planning on one plate form a Daily Status Report (Annexure No.1) is generated by PPC department. On the basis of DSR raw material planning is done by raw material store and a schedule is raised to suppliers. Daily consumption of steel at JBM P1 is app. 70-100 tons and for feed the lines of JBM P1we have to purchase the same quantity of material per day. Therefore to avoid criticalities we should have the material, which is required in next 3 days. In making schedule for raw material (Annexure No.02) first we check the status of the material, secondly requirement of material in the week for which schedule is generated and third, material requirement date and forth, minimum loading plan. First, status of material, status tells us about the finished goods inventory and seconds the coverage. Coverage means the material in finished goods cover the requirement of number of days. It is counted on the basis of production levels of our customers. For example, If

we take a component no. PPC58120 it is used in manufacturing of Maruti 800, on any day its finished goods is 800 nos. and Maruti 800 production per day is 600 nos. PPC58120 is required one component per vehicle so the coverage is 800/600 = 1.3 days. To feed the line of MUL we have to take loading of this material of the same day or next day. Second, when we get the per-day requirement of material and status of raw material then we can calculate requirement of material per week. Third, on which date of the week material will be required for take loading, it is calculated by the coverage of material and schedule for dispatch. For example: If any day, coverage of PPC58120 is zero and there is no schedule in next two days then this material required today because of coverage is zero. Fourth, and very important, to control the loss time in die changing, minimum loading for every component is standardized.

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ACCOLADES AND RECOGNITIONS

MERIT CERTIFICATE FOR PRODUCTIVITY BY NPC AWARD FOR PRODUCTIVITY BY ACMA BEST VENDOR AWARD BY CUSTOMER (MUL) BEST VENDOR AWARD BY CUSTOMER (MUL) ISO 9002 ACCREDITATION BY RWTUV (GERMANY) MERIT CERTIFICATION FOR PRODUCTIVITY BY ACMA BEST VENDOR AWARD BY CUSTOMER (MUL) MERIT CERTIFICATION FOR PRODUCTIVITY BY NPC AWARD FOR QUALITY BY ACMA QS 9000 ACCREDITATION BY UL AWARD FOR QUALITY BY ACMA SAFETY & WELFARE AWARD BY GOVT. OF HARYANA MERIT CERTIFICATE FOR QUALITY BY ACMA AWARD FOR PRODUCTIVITY BY ACMA ISO 14000 ACCREDITATION BY UL ISO/TS 16949:2002 ACCREDITATION BY UL OHSAS 18001 ACCREDITATION BY UL OUTSTANDING OVERALL PERFORMANCE TROPHY BY MUL CERTIFICATE BY MUL FOR COST REDUCTION THROUGH (1) VA / VE (2) YIELD IMPROVEMENTS (3) KAIZENS CII-EXIM BANK AWARD FOR BUSINEES EXELLENCE & 2003-04 2003-04 2003-04 2003-04 1993-94 1993-94 1994-94 1994-95 1994-95 1996-97 1996-97 1996-97 1997-98 1997-98 1998-99 1999-00 1999-00 2000-01 2001-02 2002-03 2003-04 2003-04

STRONG COMMITMENT TO EXCEL

2004-05

JBM MILESTONE BRICK BY BRICK COMPANY INCORPORATED

COMMERCIAL PRODUCTION COMMENCED 03-89
EQUITY HOLDING MUL S.K. ARYA & ASSOCIATES PUBLIC PLANT 2 COMMISSIONED WITH UPGRATION OF PRODUTION TECHNOLOGY FORAY INTO EXHAUST SYSTEM SUPPLIES FOR MUL VEHICLES SYSTEM SUPPLIER CONCEPT STARTED FOR MUL FENDER ASSEMBLY BAAN IV SOFTWARE SYSTEM IMPLIMENTED EXHAUST SYSTEM OF ALTO AND WAGON-R WITH EMMISSION NORMS COMPLIANCE COMMENCED SYSTEM SUPPLIES FOR CAR UNDER BODIES STARTED VERSA LINE COMMISSIONED 5-AXIS LASER CUTTING MACHINE COMMISIONED 15 | P a g e 01-02 03-04 00-01 99-00 98-99 97-98 96-97 29.30% 29.30% 41.40% 95-96

19-03-87
01-

REAR AXLE LINE COMMISIONED PROPOSED PT-CED PAINT SHOP AXLE LINE OF MODEL YN4 COMMISSIONED 04-05 COMMENCEMENT OF COMMERCIAL PRODUCTION OF MODEL YN4

04-05 04-05

05-06

COMPANY PROFILE
JBM group began its engineering activity in 1983 with the establishment of Gurera gas cylinder limited and entered the auto component industries in 1985 with the inception of SUZUKI AUTO INDIA. JBML is a multi- unit, multi-product group with extensive and diversified interest in engineering and precision tooling, dies and facilities spread over different parts of the country. The JBML engineering groups deals in brand range of sheet metal assemblies, die casting components and forging for the domestic and export markets.

Jay Bharat Maruti Ltd.

An ISO/ITS 16949:2002/iso- 14001/ohsas-18001-

company setup in 1987 is the largest joint venture of Maruti Udyog ltd. In collaboration with Suzuki motors company of Japan. The plant worth Rs.1210 million, and is equipped with state of art technology, in metal forming and welding. This is a unique combination of modern press shop and weld shop capable of supplying components in JUST-IN-TIME (JIT) meeting customers quality and quantity meeting customers quality and quantity. The working at JBML is based on Japanese system of manufacturing. Flawless on quality and reliability, these products have won the confidence of industry leaders. Manufacturing facility at JBML includes die maintenance, dedicated facilities for manufacturing exhaust systems, in house modern tool room and a talented design team. JBML is rising to meet new challenges with modern equipments and higher goals of manufacturing and quality controls.

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JBMS PRODUCT RANGE:

JBM nicely diversified their business by starting manufacturing not only sheet metal components but also started manufacturing other automobile components and tools. PRESENT MANUFACTURING RANGE: Skin panels (unpainted) for driver cabin of LCV and MCV. Underbody parts / assemblies (unpainted) for passenger cars, e.g., Front and rear underbodies Fenders Aprons Cross members Floor tunnel

Rear axle (painted) for passenger cars. Fuel neck pipe (electroplated) Exhaust systems for Passenger cars in SS / coated steel, and Two wheelers in painted condition

JBMS MAIN PRODUCTS:

1Sheet Metal Stamping. 2Welded Sub Assemblies. 3Chassis and Suspension System. 4Jigs and Fixtures. 5Exhaust System. JBM manufactures a range of specialized components for front ranking OEMs.

Flawless on quality and reliability these products have won the confidence of industry leaders.

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Production Volume:(Approximate) Products per day 32,000 assemblies of 203 types Made up of about 2,00,000 pressed parts 20,00,000 spots 1,20,000 hardware

JBMS QUALITY GOALS:

1Zero defects. 2First time right, every time right. 3No quality control, only quality assurance. 4Reduced process variance. 5100% customer satisfaction. 6Reduction in the cost of product. 7Not 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.

TODAY, JBM ENJOYS A COMPETITIVE EDGE IN THE MARKET. SOME OF THE REASONS FOR THIS ARE:
1A unique combination of modern press shop and weld shop. 2The capacity of supplying components on a just in time (JIT) basis. 3Indigenisation and system engineering to manufacture complex automobile exhaust systems. 4Flexible manufacturing systems. 5Support of modern tool room facilities available within the group.

FEATHERS ADDED IN THE CAP JBML: National productivity councils Certificate of merit 1993-94&1996-97. ACMA productivity award 1993-94. Best performing vendor award in the technology group largest sheet metal components-category A from MUL for four consecutive years, 1993-97. Certificate of recommendation from Haryana state pollution control board in recognition of environment friendly industry 1994-95 Certificate of merit for excellence in products of automotive components from ACMA 1996-97 Award for quality ACMA1997-98 QS 9000 accreditation by UL 1997-98 Award for quality ACMA 1998-99 Safety and welfare award by Government of Haryana 1999-2000 Merit certificate for quality by ACMA 1999-2000 Award for productivity by ACMA 2000-01 ISO 14000 Accreditation by UL 2001-02 21 | P a g e

Recommendation by UL for ISO/TS

-- 16949 certificate

The prestigious QS-9000 CERTIFICATE by KPMG Peat-Marvic, the Quality Register of India, representing Peat- Marvic, USA, has also awarded the company.

CRISIL, (in famed credit rating agency) has assigned P-1 rating to company for its commercial paper program. JBM, under the guidance of Prof. Y. Tsuda of Japan, Quality M management Adviser, is working in close conjunction with a cluster of companies. Together they will march towards TQM.

ION has initiated a major drive to improve the production process by the implementation of KAIZEN (continuous improvement in small steps) in the various areas of operations, resulting in a phenomenal improvement in JBML.

OHSAS 18001 Accreditation By UL 03-04. Outstanding overall performance trophy by MUL Commendation certificate for strong commitment to TQM by CII EXIM BANK 03-04.

The company has also been awarded by the prestigious QS-9000 certificate by KPMG Peat-Marvic, the Quality Register of India, representing Peat- Marvic, USA. CRISIL, (in famed credit rating agency) has assigned P-1 rating to company for its commercial paper program. JBM, under the guidance of Prof. Y. Tsuda of Japan, Quality Management Advisor, is working in close conjunction with a cluster of companies. Together they will march towards TQM. Furthermore, SUZUKI MOTOR CORPORATION has initiated a major drive to improve the production process by the implementation of KAIZEN (continuous

improvement in small steps) in the various areas of operations, resulting in a phenomenal improvement ISO 14000 Accreditation by UL 2001-02nt in JBML.

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WORK CULTURE AT JBML:

1COMMON UNIFORM. 2ATTENDANCE BONUS. 3TRAINING (EXTERNAL AND INTERNAL). 4OPEN AND TRANSPARENT APPRAISAL.

JBMS MAJOR CUSTOMERS:

5MARUTI UDYOG LIMITED. 6ASHOKA LEYLAND. 7DEFENCE. 8DELPHI. 9EICHER. 10ESCORTS. 11HINDUSTAN MOTORS. 12HONDA SCOOTERS. 13MAHINDRA & MAHINDRA. 14YAMAHA MOTORS INDIA L.T.D.

JBML`s GROUP COMPANIES

15JAI BHARAT MARUTI LTD-PLANT -2 16JBM AUTO COMPONENT LTD 17NEEL METAL PRODUCT LIMITED 18JBM INDUSTRIES LIMITED 19JAI BHARAT BREEDS LIMITED 20NEEL INDUTRIES PRIVATE LIMITED 21JAY BHARAT EXHAUST SYSTEM LTD 22THYSSENKRUPP JBM PRIVATE LTD 23NEEL ENGINEERING SOLUTIONS 24JAICO STEEL FASTENERS LTD

JBMS GLOBAL ALLIANCES:

25BELLSONICA COMPANY, JAPAN. 26MARUTI UDYOG LIMITED. 27SUZUKI MOTORS COMPANY. 28NAGATA AUTOPARTS CO. LTD., JAPAN. 29HAMAMATSU PIPE COMPANY LTD., JAPAN.

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WELDING DEPARTMENT
INTRODUCTION Welding is the process of permanently joining two or more metal parts, by melting both materials. The molten materials quickly cool, and the two metals are permanently bonded.

TYPES OF WELDING DONE IN THIS PLANT 1SPOT WELDING. 2MIG WELDING.

SPOT WELDING
Spot welding is primarily used for joining parts that normally upto 3 mm (0.125 in) thickness. Spot-weld diameters range from 3 mm to 12.5 mm (0.125 to 0.5 in) in diameter.

MATERIALS 1Low carbon steel is most suitable for spot welding. Higher carbon content or alloy steels tend to form hard welds that are brittle and could crack. This tendency can be reduced by tempering 2Low carbon steel is most suitable for spot welding. Higher carbon content or alloy steels tend to form hard welds that are brittle and could crack. This tendency can be reduced by tempering.
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3Aluminums can be welded using high power and very clean oxide free surfaces. Cleaning the surface to be oxide-free, adds extra costs (that can be avoided with low carbon steel). 4Dissimilar materials cannot be spot welded due to different melt properties and thermal conductivities. Plated steel welding takes on the characteristics of the coating.

MANUFACTURING CONSIDERATIONS
1Thickness of the parts to be welded should be equal or the ratio of thick nesses should be less than 3:1.

2Spacing of welds Min. Weld to weld spacing = 10 x Stock Center of weld to edge distance = 2 x weld Weld to form distance = Bend Radius + 1 weld diameter, minimum.

3Flat surfaces are easier to spot weld due to easy access. Multiple bends impose access restrictions, and special fixtures may have to be designed to handle the parts, if access is not a problem.

WELD SPACING GUIDELINES

4Prior to finishing, the spot welds have to be sanded or ground to blend the welds with the rest of the
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surface. 5It is best to choose the same spot weld size, to minimize setups and increase throughput. 6Plating of spot welded assemblies can cause problems when the sheet metal is overlapped. This can cause plating salts to be trappedrequiring special cleaning, or potential long-term corrosion problems. By carefully designing the assembly to allow easy draining of plating solutions this can be avoided.

The mating parts can be self-jigged for easy location prior to welding. This can be done by lancing one part and locating in a corresponding slot in the other part; or by boss type extrusion, weld buttons, in part locating to a slot in the other. This type of design can often eliminate the need for external fixtures.

MACHINE DESCRIPTION
MACHINE DESCRIPTION Integrated Transformer spot welding Machine. PROCESS PART NAME Maruti models. - Spot Welding - Body parts of various

INTEGRATED TRANSFORMER GUN AND CONTROLLER DIAGRAM

MIG WELDING

Gas Metal Arc Welding (GMAW) is frequently referred to as MIG welding. MIG welding is a commonly used
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high deposition rate welding process. Wire is continuously fed from a spool. MIG welding is therefore referred to as a semiautomatic welding process.

MIG WELDING BENEFITS 1 All position capability 2 Higher deposition rates than SMAW 3 Less operator skill required 4 Long welds can be made without starts and stops 5 Minimal post weld cleaning is required

MIG WELDING SHIELDING GAS The shielding gas, forms the arc plasma, stabilizes the arc on the metal being welded, shields the arc and molten weld pool, and allows smooth transfer of metal from the weld wire to the molten weld pool The primary shielding gasses used are: 1 Argon

2 Argon - 1 to 5% Oxygen 3 Argon - 3 to 25% CO2 4 Argon/Helium CO2 is also used in its pure form in some MIG welding processes. However, in some applications the presence of CO2 in the shielding gas may adversely affect the mechanical properties of the weld. WELD DISCONTINUITIES 1 Undercutting 2 Excessive melt-through 3 Incomplete fusion 4 Incomplete joint penetration 5 Porosity 6 Weld metal cracks 7 Heat affected zone cracks

MIG WELDING PROBLEMS 1 Heavily oxidized weld deposit 2 Irregular wire feed 3 Porosity 4 Unstable arc 5 Difficult arc starting
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MIG WELDING MACHINE DESCRIPTION

1.MACHINE DESCRIPTION - MIG Welding Set PROCESS PART NAME - MIG Welding -

CONDITION Voltage 22-24 Volt Current 160-180 Amp Gas Flow As Required Wire As Required

OPERATION

1.Set part 1 & 2 on welding jig 2.Weld as per Sequence i.e. no blowholes, holes porosity etc. 3.After Welding Declaiming the part

PRESS SHOP INTRODUCTION:

PRESS SHOP LAYOUT:

PA

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MACHINE DESCRIPTION
1.MACHINE NAME - 200 Tons Hydraulic Press PROCESS NAME - Trimming PART NAME - As Per die (Fuel Tank)

SPECIFICATION OF MACHINE 1Max Load Pressure 2Set Pressure 3Brake Pressure 178 Kg / Cm2 178- 198 Kg / Cm2 2-2.8 Kg / Cm2

OPERATION
1Set Die with last component in die 2Adjust the stroke accordingly to limit collar (Yellow Pads) 3Run 3-5 Idle strokes 4Trim the component and observe 5Check component for any deformation burr and smooth disposal of scrap. 6Compare the trim component with limit sample 7Any Arability on tool maintance help and cleaning is required 2.MACHINE NAME 400 T Mechanical Press

PROCESS NAME - Parting

PART NAME DRIVEN TYPE -

Chain Case V-Belt Driven

3.MACHINE NAME

- 400 T Mechanical press

PROCESS NAME - Inner Panel Piercing PART NAME - Chain Case

4.MACHINE NAME - 200 T Press K3 PROCESS NAME Pressing PART NAME Chain Case

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