BY-

AKHIL MAZARI
14001004003 1
 TABLE OF CONTENTS
MASTER GEAR SHIFTER ASSEMBLY
DRUM STOPPER ASSEMBLY
CNC SECTION
PRT SECTION
MACHINING SECTION
HEAT TREATMENT
QUALITY

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ER AUTO PVT. LTD. is an automotive industry located in
manesar.
The firm is an industry under Hero group.
The company provides its services to Hero motocorp and
Mahindra (bike industry).
The company mainly deals with components of gearbox that
largely include master gear shifters and drum stoppers and push
rod tensioners. The company also hosts a variety of machining
operations that mainly includes rotor oil filter. The company also
hosts a facility of heat treatment that includes facilities like
tempering furnace.

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MASTER GEAR SHIFTER ASSEMBLY

This component of
gearbox in bikes helps in
shifting between different
gears.
The individual
components are imported
from other firms and only
assembly takes place
within the firm.

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RETURN SPRING COLLAR 12MM

MASTER ARM SPRING

5
FIXTURE CUM GO-NO-GO GAUGE INSPECTION

The master gear shifter assembly finally

after completion is set up in the fixture and
tested for its geometric dimensioning and
tolerances.
A small cubical type block is used as a go
no-go gauge.
On one surface there is a projection (half
surface is higher as compared to other)
which serves the purpose.

Production defects include defective

materials like
UNDERSIZED SPINDLE, WELD
DEFECTS (MIG welding).
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DRUM STOPPER ASSEMBLY

This is yet another component of

gearbox.
The individual components are
imported from other firms and
only assembly takes place.

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 ARM

SEQUENCE WISE ASSEMBLING

ROLLERS AND COLLARS

FOR RIVETING AND
PIVOTING OPERATIONS

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PRODUCTION DEFECTS

BENDS
NON CIRCULAR HOLES
IMPROPER RIVETING
IMPROPER PIVOTING
MANUFACTURING
DEFECTS (import)

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 CNC SECTION

The cnc section includes

machines mainly of Siemens
make.
These machines are mostly
devoted to machining of rotor
oil filters and collars.

CNC MACHINE 10
UNMACHINED ROTOR OIL FILTER CNC MACHINE

MACHINED SEMI-FINISHED COMPONENT TOOL FOR CNC M/C

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 DRILLS ON FACE SIDE
MULTI-DRILL

FINE HOLE DRILL DRILLS ON RADIAL SIDE

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PRT SECTION

The push rod tensioner is an

essential element of engine-
gearbox.
The element plays a vital role
when the oil has to flow within
the prt but at the same time the
component has to be leak-
proof.
This component is completely
manufactured within the firm.

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 BLANK MACHINED PRT

SEAT VALVE, CAP

ASSEMBLED PRT VALVE AND BALL

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BALL TAPPING M/C

GRINDER

CAP PRESSING M/C

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DEFECTS

BURRS
BUTFFING
IMPROPER MACHINING

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 MACHINING SECTION

The machining section hosts a

variety of machining operations
that include traubs, clgs, press etc.
Operations ranging from drilling
to boring, cutting to grinding, etc.
are all carried out in this section.

TRAUB MACHINE 17
 Dressing of the
grinding wheel
CENTRE LESS GRINDER is required after
particular
GRINDED COMPONENTS OIL JET intervals that
ensure smooth
grinding
process.

CENTRE LESS GRINDING

OPERATION
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THREAD CUTING M/C PRESSING M/C 5 TON

THREADED COMPONENT COLLARS AND SLEEVE

TO BE PRESSED

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HEAT TREATMENT
The heat treatment section in the
industry allows for heat treatment
of components within the firm.
A variety of components are heat
treated in different formats by
stacking them in different ways in
different quantities and for
different durations of time.

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 GASES INVOLVED

AMMONIA
LPG
NITROGEN
METHANOL

FIRE AT
END
METERING APPARATUS INDICATES
THAT THE
FURNACE
IS
ACTIVE

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 QUALITY
Quality inspection and control deals with sampling,
checking and inspecting the quality of products.

This deals with inspecting components and assemblies for

their geometric dimensioning and tolerances.

This also deals with maintaining the quality of processes

by maintaining tools and machines involved in the process.

It also deals with product manufacturing technique

correctness and approving or rejection of components.

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Vernier callipers and Micrometers are essential
components of quality check in almost all industries
and are mostly used and most common in all quality
checks.
Height gauges and surface gauges also form
essential instruments in quality inspection along with
I/D and O/D gauges.
Air plug gauges have evolved in the recent times and
have found a vast implications in quality inspection
and control.

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The air plug
gauge allows to
check for the
diameters of
various
components
based on air
pressure.
These are of
different ranges
and different
least counts.

MASTER GAUGE FOR

AIR PLUG GAUGE
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HEIGHT GAUGE
OD GAUGES
This gauge is used to
check height of This gauge is used to
components. check outer dia of
components 25
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