A REPORT OF INDUSTRIAL TRAINING

ON

AT

Prepared by:

 PRARIT CHAUHAN

1
 PREFACE

The Knowledge of Frame Body and Part is very useful in our day to day
life and one needs to know at least the basics of the same. The content
of this report include an overview about the whole manufacturing
processes to be followed in this category in order to obtain the final
product.
The report contains the description of various processes to be followed
and their analysis for their better understanding. The various processes
included in this report are welding process, functional line, etc. The
operation study, machine study and material information are clearly
mentioned out there.
At the end of this report I would like to thanks the people who help me
to get the things and share their knowledge about the things and the
processes are actually going on there.

2
 Acknowledgement

Before initializing the industrial report, we want to accomplish a vital

task. First of all, we would like to thanks T & P department of Gurgoan
Institute of Technology & Management to arrange such a beneficial
industrial training for us. For our under graduate career, this is the first
industrial training. It was really a fruitful campaign for us.

And I would also like to thank the crew of Metalman. The management
of the company and workers really cooperative. They gave us each and
every information that was needed and taught us the useful
fundamentals.

I would like to thanks the director of the company to permit us to get

involved in the daily routine for their production. As without their
support this training won’t be such as productive one.

3
 1.Introduction
Metalman Auto (P) Ltd. is engaged into manufacturing of Sheet Metal
and Tubular Fabricated Assemblies and Sub Assemblies with In House
Surface Treatment facilities such as Ni-Cr Plating , Cataphoresis
Electrolysis Deposition (CED Painting) , Epoxy Powder Coating &
Phosphating. We act as a one stop shop for all your fabrication needs
and are currently catering to Global Automotive OEM’s, Heavy
Fabrication & Construction Equipment Industry, Off Road Vehicles &
White Goods Industry. All our plants are ISO-TS 16949:2009 Certified
which means supplying Defect Free Parts at a Competitive Price and at
Right Time, Every Time.

We employ more then 200+ Welding Robots and we manufacture our

own Welding SPM’s for Captive Use thus implying Low Cost
Automation.

Metalman Team consists of over 250+ Engineers who ensure that we

always meet the highest standards of Quality. Our R&D Department is
capable to meet all design and prototyping demands of our customers
within a stipulated time with the support of our In House Tool Room
having state of the art Machinery to Manufacture all types of Tools,
Jigs, Fixtures and Gauges suited to our products.

4
Dharuhera Unit
This the Unit-II of Metalman Micro Turners which is being established
over an area of 4 acres. This plant has facility of frame and assessories
manufacturing along with press shop, CED paint shop. The exclusivity of
this plant this that it’s a very highly automated plant with over 50+
welding robots. This plant come in operation in august 2017.

5
 2.Functional line flow chart
AAGE

FORWARD ASSEMBLEY CELL

Stage-10&20 Steering Head & Sub Assembly

Stage-30 Centre Pipe Sub Assembly

Stage-40 Tube Down Sub Assembly

Stage-50 Tube Down Sub Assembly

Stage-60 Front Assembly

Stage-70 Front Assembly

Forward Manual Clip Welding

Forward Inspection

6
 REAR ASSEMBLY CELL

Stage-80 Rear Assembly Cell

Stage-90 Rear Assembly Cell

Stage-100 Rear Assembly Cell

Stage-110 Rear Assembly Cell

Stage-120 Frame Complete

Stage-130 Frame Complete

Manual clip
welding

Rework

Spatter
Removal

Retapping

7
Add on Gauge

Frame Visual Inspection

Boring Machine

Final Gauging

8
 AAGG

FORWARD ASSEMBLY CELL

Stage-100&110 Steering Head Sub Assembly

Stage-140 Centre Pipe Sub Assembly

Stage-120 Tube Down Sub Assembly

Stage-130 Tube Down Sub Assembly

Stage-150 Front Assembly Cell

Stage-160 Front Assembly Cell

Stage-150 Front Assembly Cell

Stage-180 Front Assembly Cell

Manual Clip Welding

Forward Inspection

9
 REAR ASSEMBLY CELL

Stage-190 Rear Assembly Cell

Stage-200 Rear Assembly Cell

Stage-210 Rear Assembly Cell

Stage-220 Rear Assembly Cell

Stage-230 Frame Complete

Manual Clip
Welding

Rework

Spatter
Remval

Retapping

10
Add On Gauge

Frame Visual Inspection

Boring Machine

Final Gauging

11
 AANP

FORWARD ASSEMBLY CELL

Stage-100&110 Steering Head Sub Assembly

Stage-140 Center Pipe Sub Assembly

Stage-120 Tube Down Sub Assembly

Stage-130 Tube Down Sub Assembly

Stage-150 Front Assembly Cell

Stage-160 Front Assembly Cell

Stage-170 Front Assembly Cell

Stage-180 Front Assembly Cell

Manual Clip Welding

Forward Inspection

12
 REAR ASSEMBLY CELL

Stage-190 Rear Assembly Cell

Stage-200 Rear Assembly Cell

Stage-210 Rear Assembly Cell

Stage-220 Rear Assembly Cell

Stage-230 Frame Complete

Manual Clip
Welding

Rework

Spatter
Removal

Retapping

13
Add on Gauge

Frame Visual Inspection

Boring Machine

Final Gauging

14
 3.Parts Clamped on Functional Line
AAGE
Stage-10&20
 Head Pipe
 Down Tube
 Pipe Central Joint
Stage-30
 Body Comp. R&L
 Stay Plate Lower
Stage-40
 Pipe Centre Joinery
 Stay Relay L
 Centre Tube Joinery
Stage-50
 Stay Side Lower L
 Collar Fuel Tank
Stage-60
 Main Stand R&L
 Engine Mounting
 Stay Plate
 Stay ING Coil
 Stay Canister
Stage-70
 Patch Rear Upper

15
Stage-80
 Patch Plate
 Stay Relay L
 Stay Centre Pipe
 Collar Tube Down
Stage-90
 Tube R&L
 Plate Tail Cross
 Plate Tank RR Cross
 Upper Tube R&L
Stage-100
 Cushion R&L
 Patch R&L
Stage-110
 Stay CDI
Stage-120
 FR & RR Frame Welding
 Hook Spring
 Plate Cushion Cross
 Stay RR Fender L&R
Stage-130
 Stay Air Cleaner
 Bkt RP Step

16
 AAGG
Stage-100&110
 Steering Head
 Body R&L
Stage-140
 Button Plate
 Centre Pipe R&L
Stage-120
 Down Tube R&L
 Pipe Down Tube Bridge
 Pipe Lower Cross FR&RR
 Bkt Comp. L Step
 Collar Down Tube
Stage-130
 Plate Engine Lower Cross
 Hook Spring Cross
 Plate Lower Pipe
 Horn Comp.
Stage-150
 Bkt Engine Guard
 Patch Front
Stage-160
 Collar Fuel Tank

17
Stage-170
 Stay Utility Box
 Bkt M Stand L&R with Collar
 Plate Centre Pipe Cross
 Stopper
 Stay ING Coil
 Stay Canister
 Bkt U Box
Stage-180
 Stay L Side Lower
Stage-190
 Upper Pipe R&L
 Down Tube R&L
 Plate Tank RR Cross
 Plate Tail Cross
Stage-200
 Cushion R&L
 Patch RR Upper R&L
Stage-210
 Stay Air Cup
 Stay L CDI
 Plate Air/C Duet

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Stage-220
 Hook Spring
 Plate Cushion Cross
 Side Stand Mounting
 Stay Guard
Stage-230
 Bkt Pillion Step R&L
 Stay Side Cover R
 Stay Air Cleaner

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 AANP
Stage-100&110
 Steering Head
 Body R&L
Stage-140
 Centre Pipe L&R
 Button Plate
 Cross Plate
Stage-120
 Down Tube Pipe L&R
 Pipe Lower Cross FR
 Collar Down Tube
 Bkt Comp. L Step
Stage-130
 Plate Engine Lower
 Plate Lower Pipe
 Hook Spring
 Horn Comp.
Stage-150
 Centre Tube
 Down Tube
 Patch Plate
 Bkt Engine Guard

20
Stage-160
 Stay Front Fuel Tank
 Collar Fuel Tank
Stage-170
 Stay Utility Box
 Bkt M Stand L&R Collar
 Plate Centre Pipe Cross
 Stopper RR
 Stay IGN Coil
 Bkt U Box
Stage-180
 Side Cover L&R
Stage-190
 Upper Pipe L&R
 Sub Tube L&R
 Fuel Tank Plate
 Plate Tank Cross
Stage-200
 Cushion L&R
 Patch L&R
Stage-210
 Plate Tail Cross Bkt
 Helmet Holder
 Dash Cover
Stage-220

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 Side Stand Mounting
 Plate Cushion Cross

Stage-230
 Bkt R Pillion Step
 Stay Air/C UP
 Bkt L Pillion Step
 Stay Air Cleaner

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 4.Sub Assembly
Stage-10 A&B
 Collar
 Pipe Body Steering Head
 Plate
 Stopper
Stage-20 A&B
 Plate
 Hook Spring
 Plate Side Stand Bkt
 Patch Side Stand Bkt
Stage-40 A&B
 Bkt Cushion
 Cushion Bolt
 Nut
Stage-50 A&B
 Plate
 Guide Drain Tube
Stage-60 A&B
 Bkt M Step
 Pipe
 Plate Bottom R&L
 Pivot
 Gusset Pivot

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 5.Welding
Welding is a fabrication or sculptural process that joins materials,
usually metals or thermoplastics, by causing fusion, which is distinct
from lower temperature metal-joining techniques such as brazing and
soldering, which do not melt the base metal. In addition to melting the
base metal, a filler material is typically added to the joint to form a pool
of molten material (the weld pool) that cools to form a joint that, based
on weld configuration (butt, full penetration, fillet, etc.), can be
stronger than the base material (parent metal). Pressure may also be
used in conjunction with heat, or by itself, to produce a weld. Welding
also requires a form of shield to protect the filler metals or melted
metals from being contaminated or oxidized.

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 6.Types of Welding
Resistance
Resistance welding involves the generation of heat by passing current
through the resistance caused by the contact between two or more
metal surfaces. Small pools of molten metal are formed at the weld
area as high current (1000–100,000 A) is passed through the metal. In
general, resistance welding methods are efficient and cause little
pollution, but their applications are somewhat limited and the
equipment cost can be high.
 Spot Welding
Spot welding is a popular resistance welding method used to join
overlapping metal sheets of up to 3 mm thick. Two electrodes are
simultaneously used to clamp the metal sheets together and to
pass current through the sheets. The advantages of the method
include efficient energy use, limited work piece deformation, high
production rates, easy automation, and no required filler
materials. Weld strength is significantly lower than with other
welding methods, making the process suitable for only certain
applications. It is used extensively in the automotive industry—
ordinary cars can have several thousand spot welds made by
industrial robots. A specialized process, called shot welding, can
be used to spot weld stainless steel.
 Projection
It is a modification of spot welding. In this process, the weld is
localized by means of raised sections, or projections, on one or
both of the work pieces to be joined. Heat is concentrated at the
projections, which permits the welding of heavier sections or the
closer spacing of welds. The projections can also serve as a means

25
 of positioning the work pieces. Projection welding is often used to
weld studs, nuts, and other threaded machine parts to metal
plate. It is also frequently used to join crossed wires and bars. This
is another high-production process, and multiple projection welds
can be arranged by suitable designing and jigging.
 Seam
seam welding relies on two electrodes to apply pressure and
current to join metal sheets. However, instead of pointed
electrodes, wheel-shaped electrodes roll along and often feed the
work piece, making it possible to make long continuous welds. In
the past, this process was used in the manufacture of beverage
cans, but now its uses are more limited.

Arc Welding
These processes use a welding power supply to create and maintain an
electric arc between an electrode and the base material to melt metals
at the welding point. They can use either direct current (DC) or
alternating current (AC), and consumable or non-consumable
electrodes. The welding region is sometimes protected by some type of
inert or semi-inert gas, known as a shielding gas, and filler material is
sometimes used as well.
 TIG
Gas tungsten arc welding (GTAW), also known as tungsten inert
gas (TIG) welding, is an arc welding process that uses a non-
consumable tungsten electrode to produce the weld. The weld
area and electrode is protected from oxidation or other
atmospheric contamination by an inert shielding gas (argon or
helium), and a filler metal is normally used, though some welds,

26
 known as autogenous welds, do not require it. A constant-current
welding power supply produces electrical energy, which is
conducted across the arc through a column of highly ionized gas
and metal vapors known as a plasma.

GTAW is most commonly used to weld thin sections of stainless

steel and non-ferrous metals such as aluminum, magnesium, and
copper alloys. The process grants the operator greater control
over the weld than competing processes such as shielded metal
arc welding and gas metal arc welding, allowing for stronger,
higher quality welds. However, GTAW is comparatively more
complex and difficult to master, and furthermore, it is significantly
slower than most other welding techniques. A related process,
plasma arc welding, uses a slightly different welding torch to
create a more focused welding arc and as a result is often
automated.
 MIG or MAG
Gas metal arc welding (GMAW), sometimes referred to by its
subtypes metal inert gas (MIG) welding or metal active gas (MAG)
welding, is a welding process in which an electric arc forms
between a consumable wire electrode and the workpiece
metal(s), which heats the workpiece metal(s), causing them to
melt and join. Along with the wire electrode, a shielding gas feeds
through the welding gun, which shields the process from
contaminants in the air. The process can be semi-automatic or
automatic. A constant voltage, direct current power source is
most commonly used with GMAW, but constant current systems,
as well as alternating current, can be used.

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 7.Welding Station

1. Wire Feeder – Device typically mounted on a robot that moves filler

wire at rates as programmed into the controller.
2. Welding Robot - The robot and end of arm tools such as a torch or
other manipulator. A robot is typically mounted on a pedestal to
maximize reach and access to parts.
3. Wire Cleaner - Used to remove spatter build up on the torch in
between work cycles, prolonging life of equipment and minimizing
downtime.
4. Torch – A torch uses power flowing to an electrode to join metals
together, inert gas to shield the arc area, and may be air or water
cooled.
5. Work Area - Fixtures to hold parts in place as the robot works are
mounted on surfaces such as stationary and indexing tables, headstock
tailstock setups, or other positioner systems based on cell design.

28
6. Fixtures and Tooling - Mechanisms that hold a part as it's welded,
may be designed to be operated automatically through the controller
with programming or manually by the worker running the cell.

7. Controller – The “brain” of a welding cell. In addition to supplying

power to the robot, the controller uses stored programs to move the
robot and positioners while working.
8. Teach Pendant - A teach pendant is a handheld interface system
allowing an operator to set welding parameters, manually move the
robot, and input new programs. Teach pendants are designed to
simple to learn and use, with large screens and intuitively designed
menus.

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9. Welding Power Supply - Supplies power to the welding torch to
produce an arc. Supplies will vary in size, performance, and cost
depending on customer need and are matched to the processes and
metals being welded in the cell.

10. Stack Light - Used to offer an easy to visual guide to what the cell is
doing. Red indicates an E-Stop or emergency that has stopped cell
movement, orange means the robot is in teach mode, and green means
a cell is running in auto.
11. Operation Box - Controls to start and stop a cell, and reset it after
any issues preventing normal operations have been corrected.
12. Safety Features - This cell is equipped with fencing and arc shielding
to prevent workers from being directly exposed to arc flash. Full fence
enclosures, access doors, and light curtains are all commonly used to
limit workers' exposure to hazardous light, fumes, and motion while a
cell works.

30
Work Station issues
 Clamped part length problem in fixtures.
 Problem in part clamping.
 Welding gap in processes.
 Welding gun nozzle get weld itself.
 Burr problem sometime on parts stop the station or cause
improper welding.

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 8.Quality
Receiving Area
To properly oversee beverage product deliveries the beverage
manager, or those who are responsible for product receiving, must
know the specifics of each order. This becomes easier when written
purchase orders, not verbal phone orders, are in use. Written purchase
orders can then be checked to ensure that the products being received
meet the specifics of the purchase order.
A copy of the purchase order or purchase record that was agreed on at
the time of purchasing should be available in the receiving area.
Personnel with receiving responsibilities will then know what to expect,
including the following:
• What products are coming in?
• In what volume or quantity will they arrive?
• What is the size of the purchase unit?
• What quality is expected?
By checking the quantity and quality of products delivered against
purchase orders, receiving personnel can ensure that they do not
accept items that were not ordered or are in damaged condition.
Finally, they must accept only items of proper quantity and quality.

Inspection
Activity of measuring, examine, testing one or more parameters of the
product and compare the result with specified requirements in order
whether conformity is achieved for each characteristic.

32
Then the record is prepared by the inspector they received material.
Sample are randomly taken from it and then compare it with the
specify parameters with the help of gauges.

33
34
Gauge
A gauge or gage, in science and engineering, is a device used to make
measurements or in order to display certain dimensional information. A
wide variety of tools exist which serve such functions, ranging from
simple pieces of material against which sizes can be measured to
complex pieces of machinery.
 Micrometer
A micrometer sometimes known as a micrometer screw gauge, is a
device incorporating a calibrated screw widely used for precise
measurement of components[1] in mechanical engineering and
machining as well as most mechanical trades, along with other
metrological instruments such as dial, vernier, and digital calipers.
Micrometers are usually, but not always, in the form of calipers
(opposing ends joined by a frame). The spindle is a very accurately
machined screw and the object to be measured is placed between the
spindle and the anvil. The spindle is moved by turning the ratchet knob
or thimble until the object to be measured is lightly touched by both
the spindle and the anvil.

 Radius gauge
Radius gauges require a bright light behind the object to be
measured. The gauge is placed against the edge to be checked

35
 and any light leakage between the blade and edge indicates a
mismatch that requires correction.

A good set of gauges will offer both convex and concave sections,
and allow for their application in awkward locations.

Every leaf has a different radius. The material of the leaves is

stainless steel. It is of two types: 1. Internal 2. External. It is used
to check the radius of inner and outer surfaces.

 Vernier caliper
A popular refinement replaces the analog dial with an electronic
digital display that displays the reading as a numeric value. Rather
than a rack and pinion, these calipers use a linear encoder. Some
digital calipers can be switched between centimeters or
millimeters, and inches. All provide for zeroing the display at any
point along the slide, allowing the same sort of differential
measurements as with the dial caliper. Digital calipers may
contain a "reading hold" feature, allowing the reading of
dimensions after use in awkward locations where the display

36
 cannot be seen. Ordinary 6-in/150-mm digital calipers are made
of stainless steel, have a rated accuracy of 0.001 in (0.02mm) and
a resolution of 0.0005 in (0.01 mm).

 Bevel protector
A bevel protractor is a graduated circular protractor with one
pivoted arm used for measuring or marking off angles. Sometimes
Vernier scales are attached to give more precise readings. It has
wide application in architectural and mechanical drawing,
although its use is decreasing with the availability of modern
drawing software or CAD.

Universal bevel protractors are also used by toolmakers; as they

measure angles by mechanical contact they are classed as
mechanical protractors.

The bevel protractor is used to establish and test angles to very

close tolerances. It reads to 5 minutes or 1/12° and can measure
any angle from 0° to 360°.

37
 Height gauge
A height gauge is a measuring device used either for determining
the height of objects, or for marking of items to be worked on.

These measuring tools are used in metalworking or metrology to

either set or measure vertical distances; the pointer is sharpened
to allow it to act as a scriber and assist in marking out work
pieces.

38
 Rejection area
This area consists the rejected parts which cannot be used in
process or having unspecified parameter according to the
planned. It is decided by the inspector whether the part is minor
faulted or major faulted. Minor faulted parts are sent for the
rework for the further use. Major faulted parts are returned to
the supplier. Rejected part may have following issues;
 Burr
 Rust
 Dent
 Crack
 Failed in gauging test
 Weak material

Maintain 5’S for smooth flow of work

Sort
1S – a red tag area containing items waiting for removal.
Sorting through all items in a location and removing all unnecessary
items from the location.
Goals:
 Reduce time loss looking for an item by reducing the amount of
items.
 Reduce the chance of distraction by unnecessary items.
 Simplify inspection.
Check all items in a location and evaluate whether or not their presence
at the location is useful or necessary. Remove unnecessary items as
soon as possible. Keep the working floor clear of materials except for
those that are in use.
39
Set in order
2S – simple floor marking.
Set in order is putting all necessary items in the optimal place for
fulfilling their function in the workplace.
Goal:
 Make the workflow smooth and easy.
Implementation:
Arrange all necessary items so that they can be easily selected for use.
Make it easy to find and pick up necessary items.

Shine/Sweep
3S – cleanliness point with cleaning tools and resources.
Shine is sweeping or cleaning and inspecting the workplace, tools and
machinery on a regular basis.
Goals:
 Prevent deterioration.
 Keep the workplace safe and easy to work in.
 Keep the workplace clean and pleasing to work in.
Implementation:
Clean the workplace and equipment on a daily basis, or at another
appropriate (high frequency) cleaning interval.

40
Standardize
It is to standardize the processes used to sort, order and clean the
workplace.
Goal:
 Establish procedures and schedules to ensure the repetition of
the first three ‘S’ practices.
Implementation:
Develop a work structure that will support the new practices and make
it part of the daily routine.
Ensure everyone knows their responsibilities of performing the sorting,
organizing and cleaning.
Use photos and visual controls to help keep everything as it should be.

Sustain/Self-discipline
Sustain the developed processes by self-discipline of the workers. Also
translates as "do without being told".
Goal:
 Ensure that the 5S approach is followed.
Implementation:
Organise training sessions.
Perform regular audits to ensure that all defined standards are being
implemented and followed.
Implement improvements whenever possible. Worker inputs can be
very valuable for identifying improvements.

41
 INDEX

Sr. N. CHAPTER Page

No.
1 Introduction 4

2 Functional line flow chart 6

3 Parts clamped on functional line 15

4 Sub-Assembly 23

5 Welding 24

6 Type of welding 25

7 Welding station 28

8 Quality 32

42
 Name of figure
2.Functional line flow chart
 AAGE
 AAGG
 AANP
3.Parts clamped on functional line
 AAGE
 AAGG
 AANP
6.Types of welding
 Resistance
Spot
Projection
Seam

 Arc
TIG
MIG or MAG

8.Quality
 Receiving area
 Inspection
 Gauge
Micrometer
Radius gauge
Vernier caliper
Bevel protector
Height gauge
 Rejection area
 Maintain 5’S for smooth flow of work

43
44