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INTERNSHIP REPORT
(10/12/2010 – 03/01/2011)
Submitted By:
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DEDICATION
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ACKNOWLEDGEMENT
All praise unto Almighty ALLAH, the Lord of all worlds, who endowed us
with the ability to complete successfully this period as internee, Though we
did not conceal our self capable to do so
We are thankful to Mr. Javed Iraqi (GM - HR) for providing us this great
opportunity of doing internship at Atlas Engineering Ltd. We are highly
obliged for the kindness and great cooperation provided by Staff of the Atlas
Engineering Ltd.
We are extremely thankful for the cooperation and help provided by:
Mr. Junaid Ahmed Siddiqui (Manager Al dept.),
Engr. Muhammad Umair (Engineer machining dept.),
Engr. Waseem (Foundry Engineer),
Mr. Khwaja (Assistant manager Al dept.) and
Mr. Qamar (Supervisor Al-foundry)
for spending their valuable time and responding to our queries and giving us
an insight of how an organization runs, what are the important principles of a
working environment.
Group members
Muhammad Ali Khalid
Muhammad Hammad Khan
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Muhammad Shoaib Idrees
INTRODUCTION OF THE COMPANY
ATLAS GROUP:
The foundation of the Atlas Group was laid in 1962 with the
establishment of Shirazi Investments (Pvt) Limited with a capital of half a
million rupees and three men doing business in trading shares and real estate.
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Atlas group operates in three sectors:
1- Engineering Sector
2- Trading Sector
3- Financial Sector
1- ENGINEERING SECTOR:
3- Atlas Engineering
4- Atlas Battery Limited
5- Atlas Power
2- TRADING SECTOR:
3- FINANCIAL SECTOR:
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ATLAS ENGINEERING:
Atlas Engineering Limited (formerly Allwin Engineering Industries
Limited) was established in 1951 as a partnership firm. It became a private
limited company in 1964, and a public limited company in 1967. The control
of the company was acquired by the Atlas Group in 1981. At present, Atlas
Engineering is one of the largest and oldest manufacturers of automotive
parts and components in the private sector in Pakistan.
Atlas Engineering has state-of-the-art facilities to produce Cast Iron
process pig iron and aluminum alloys through various stages into high
precision automotive components and has full access to technical know-how
and back-up of world renowned manufacturers like the Shindengen Japan,
F.C.C. Co. and Honda Foundry Japan.
The Company manufactures diesel pistons, piston pins, cylinder
liners/sleeves, motorcycle pistons, cylinders, CDI & Regulator, Pressure Die
Casting, Aluminum Components, radiator assemblies and radiator cores and
a host of fully-machined cast iron parts (both grey and ductile). These
include brake drums, brake discs, flywheels and other high quality precision
engineered components for all manufacturers of cars, light commercial
vehicles, trucks, buses and tractors including Millat's Massey Ferguson and
Al-Ghazi's Fiat Tractors, besides Honda, Suzuki, Toyota, Daihatsu and
Hyundai cars, Nissan , Hino, Mazda, Dong Feng trucks & buses and Honda
and Yamaha motorcycles. Atlas Engineering products are comparable with
those of any international manufacturer and as such are also exported
wherever demanded. Various assemblers have given excellence awards to
Atlas Engineering for achievements in quality and delivery.
The facilities at Atlas Engineering have been extended and
modernized steadily over the last decade, and are amongst the best in the
engineering sector of the country. As old machines are phased out, new
machines including CNCs, and semiautomatic machining lines are being
added. Further expansion of facilities for manufacture of piston and allied
products pressure die casting and cast iron parts is being undertaken. The
production facilities are backed by well-equipped quality assurance system,
design and applied research facilities.
Atlas Engineering policy and operations are guided by the
management approach of Atlas Group, Organization development through
self development.
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Location Atlas Engineering is situated at 15th mile, National Highway,
Landhi, Karachi –75120Pakistan.
Land 83,651sq.m.
Built-up (covered) area 31,217sq.m.
FACILITIES:
THE INTERNSHIP
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Aluminum products department was our department of interest. An
introductory visit started our internship. Diesel piston was made our product
of study. Objective was to completely study the process followed by Atlas
Engineering Limited in manufacturing diesel pistons and to give sound
recommendations to improve the process with respect to cost effectiveness,
production rate increment and control over rejection.
THE PLANT
Aluminum Products Plant at Atlas Engineering Limited is the purpose
build plant which fulfils the needs of the company. Workers working in plant
are very skilled persons; they show their devotion to work. Numerous quality
products are manufactured here, including precision engine and body parts
and pistons for diesel as well as petrol engine, pressure die components and
other Aluminum components.
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Millat Tractors
Piston, MF240
Al Ghazi Tractors
Piston FIAT
Other Parts
Bracket upper (L) Yamaha
Crown handle Yamaha motorcycle
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Fig 2: Piston – brief overview
THE PROCESS
FLOW CHART:
RAW MATERIAL
CASTING
REJECTION
MACHINING
REJECTION
FINAL INSPECTION
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the plant and complete pistons are delivered form the other side, only the
scrap has the opposite flow.
RAW MATERIAL:
Mainly Aluminum is used for manufacturing pistons, where as, little
quantities of other elements such as Silicon, Magnesium, and Iron also take
part in piston manufacturing.
VIRGIN INGOTS:
Company purchases virgin ingots from different dealers. Since our
project is related to diesel pistons so we will discus the composition of ingots
purchased for diesel pistons. Mainly two types of ingots are purchased for
diesel piston, namely, LM-13 & LM-28.
LM-13 are purchased from SUN METAL (local dealer) and LM-28
imported from LUCKY ALLOY (Dubai). A single bundle contains up to 108
virgin ingots, weighs approx. 700 kg.
Our piston of interest is of FIAT tractor, LM-28 type of ingots is
used for manufacturing these pistons. Composition is shown below:
Elements Si Fe Cu Mn Mg Cr Ni Zn Ti Ca
% % % % % % % % % %
Compositio 17.0 0.0 1.3 0.0 1.0 0.0 0.8 0.0 0.0 0.0010
n 0 0 0 0 0 0 0 0 0
Range 19.0 0.6 1.8 0.3 1.3 0.6 1.3 0.2 0.2
0 0 0 0 0 0 0 0 0
Elements Cd Co Na P Pb Sn Al
% % ppm ppm % % %
SWARF INGOTS:
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Swarf ingots are those ingots which are made by atlas itself from
the chips which are removed from the piston in the machining operation and
the slag and residue left in the furnaces. In these, usually the composition of
magnesium decrease from the permissible limit, to over come this problem,
few ingots of magnesium are also added along with swarf ingots.
CASTING:
In foundry, the casting starts from melting the ingots.
Five electric furnaces are there in foundry for diesel pistons, out of
which four were currently working for diesel pistons, where as, one
was busy for child parts (due to there high demand).
Furnaces have the capacity of max. 500 kg.
Virgin ingots along with swarf ingots, runner, risers and magnesium
ingots as per requirement are melted in the furnace.
It takes around 1.5–2 hours in melting and degassing both.
Degassing means to remove the impurities such as slag etc.
When the metal melts a sample is taken out from this melt, poured in a
testing die and the specimen is sent to lab for testing its chemical
composition and hardness.
The lab quickly calculates its hardness and checks its chemical
composition by using SpectroMAX.
If the melt have its composition and hardness within the permissible
range, the melt is ready for pouring purpose, else, the element less or
more then its permissible limit is balanced by adding other ingots.
Gravity die casting is carried out in the foundry.
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Why gravity die casting ?
Die casting is an efficient, economical process offering a
broader range of shapes and components than any other manufacturing
technique.
Die casting provides complex shapes within closer tolerances
than many other mass production processes.
Die casting produces parts that are durable and dimensionally
stable, while maintaining close tolerances. They are also heat resistant.
MACHINING:
The casted parts are then moved to machining area, several machining
operations are performed here which gives pistons its required shape and
finish. Four machining lines are there in machining department out of which
three were currently working. One was making pistons for OEM, where as,
other two were making pistons for open market.
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PROCESS FLOW FOR DIESEL PISTONS (FIAT):
Grooving
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In machining area the manual lathes, automatic lathes, plc and drilling
machines take part. The process flow is a “U” which utilizes the workers in
there best way. Each worker at the same time works at two machines. The
preferred process flow is not followed here, the actual process starts with
making seats first, discussed below:
SEAT MACHINING:
Machining process starts from making the seat of the piston. Seat
basically sets the reference for the preceding machining operations.
Automatic lathe is used for this purpose and two tools take part in this
operation. The machining time is approx. 18 sec here.
HEAD SHAPE:
Here also automatic lathe is used. Worker clamp the part w.r.t the
seat made. Two tools take part in the operation. One tool removes the
material from head giving it primary rough finish and specifying its length,
where as, the second tool makes the rough cavity in the head. Cutting fluid is
used here to reduce the friction and heat and to carry the chips away. The
machining time is approx. 25sec here.
PROOF TURNING:
This step gives the piston its finished head (not the head cavity)
and the rough surface to piston skirt. Three tools take part for the operation.
Firstly two tools give rough finish to the piston skirt (two tools are used for
this purpose because different diameters are required). Then, the third tool
descends to give piston head (not the head cavity) its final finish. Cutting
fluid is also used here. The machining time is approx. 39 sec here.
After every 5-10 parts the worker checks for the accuracy. Dial
indicator is used for this purpose. Firstly the dial indicator is set with the help
of gauge for the desired length of the piston and then, after wards the dial
indicator shows whether the piston is within the tolerance limit or not. OK
parts are moved to get there head cavity finished.
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TAPER OIL HOLE:
Automatic drilling machine is used here to drill the taper holes.
Worker clamp the piston with respect to the seat made and machine
automatically drills 4 holes. These holes allow oil to get inside the piston.
COPY TURNING:
Automatic lathe machine with two diamond tip cutting tools
gives piston skirt its super finish here. Worker just clamps the piston and the
machine operating automatically super finishes piston skirt.
ACCURIZING:
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It is the final step of whole machining operation. Here the bore
is made accurate. First a rough finish then fine finish is achieved. After this
process the bore finish is inspected using an air pressure gauge machine.
FINAL INSPECTION:
All the manufactured parts are then sent to piston inspection area
for final and thorough inspection. Following parameters are checked and
cleared in inspection area.
• PIN SQUARENESS.
• BORE OFFSET.
• TOP COMPRESSION.
• CASTING DEFECTS.
If any defect is seen then the piston is send back to the machining
area or foundry, as per requirement.
Around 300 – 400 diesel pistons are checked on daily basis. In case
of over production to achieve the target max 700 diesel pistons can be
inspected in one day.
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RECOMMENDATIONS
COST EFFECTIVENESS:
Forged pistons should be manufactured instead of cast pistons. They
are found very effective with respect to cost. Most of the companies
globally are manufacturing forged pistons and saving cost now a days.
Gas furnaces should be used instead of electric furnaces. They also can
reduce the cost up to some extent.
Traditional lathe machines should be replaced with CNCs as they are
the one time cost. A single CNC can do the job of several lathes, with
more efficiency and less cost. Fewer workers will b needed for them.
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maintenance can solve the problem, after every 10–15 castings the part
should be checked for its dimensions, this will reveal the condition of
die side by side and maintained before getting in to adverse conditions.
In machining, the tools used were cheaper and not of such a good
quality, good quality tools can give excellent results.
The cutting fluid being used in the machining area is replaced when it
comes to adverse conditions, it should be replaced periodically,.
MISCELLANEOUS:
Safety precautions were lacking in the plant. It should be made
compulsory for the workers to at least wear the glasses, gloves and
helmet, cap where applicable, as:
“Quality makes no sense without U & I ”
2 shutdowns per year should be managed for complete maintenance of
the machines and every thing in the plant.
Machines should be periodically oiled, it was not practically followed
in the plant.
In a nut shell, 5S should be followed.
CONCLUSION:
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