Summer Training Report

DURATION -7DAYS SUBMITTED BY: 1.NAGMANI BHARDWAJ 2.MITHILESH KUMAR 3.PAWAN KUMAR 4. RANA RANJEET

HR SIGNATURE

HOD SIGNATURE

Co te t 1.IN ODUC ION

2. AW MA E IAL 3.DEPA 4.P OCE 5.P OCE 6.P OCE MEN FLOW CHA FLOW CHA FLOW CHA FO P E U E DIE CA ING

FO MACHINING FO A EMBLY

7.MAIN P ODUC 8. YPE 9.CU OF CA BU E O

OME

10.CONCLU ION

INTRODUCTION
UFSL is a part of UCAL group of companies founded by Shri K. Gopalakrishna, a visionary leader who built the multi-dimensional enterprise. UCAL as a group today manufactures a wide spectrum of products for automotive sector. It is a perfect amalgam of people, technology and resources reinforced by the advantage of thorough understanding of automotive industry. UCAL FUEL SYSTEMS LTD. (UFSL) was established in 1985 by Carburettors Limited, pioneers In India in the manufacturing of Carburettors and mechanical fuel pumps. In 1987 UCAL entered into a joint venture with Mikuni Corporation of Japan,an internationally renowned company for Fuel Management System and products. UCAL became public limited in 1989. With the factories in Maraimalai Nagar ,Puducherry and Gurgaon commissioned and the product range enlarged, UCAL witnessed a quantum leap in the last decade of the century . UCAL started to manufacture world class Carburetors and mechanical fuel pumps using advanced technology in the state of the art facilities and began supplying as OEM to MarutiSuzuki, Premier 118 NE, HM . The Pondicherry plant started to manufacture Carburettors and Secondary Air Valves for two wheelers and Multi point fuel injection hardware products for passenger cars 1996 A Vignette given below explains UFSLs growth towards becoming truly an internationally respected Brand and becoming a proud supplier to some of the globally acclaimed companies such as Maruti-Suzuki, Hero Honda, TVS, Bajaj, Yamaha, Piaggio, Fiat, Tata Motors, Cummins and many more.
y y y y y y

2003 - Collaboration with Orbital Inc ,Australia for development of Direct Injection systems. 2004 - Krishnamurthy centre for Technology a R&D centre, 2005 - Acquired Amtec Precision Products Inc in US. 2006 - Started development of products for Diesel applications. 2008 - Close of JV agreement with Mikuni Corporation.Supply of full volume of pumps for Suzuki power train 2009 - Supply of Fuel Pump to Visteon started

The journey continues, but moving rapidly towards becoming a globally key player in Automotive industry worldwide.

RAW MATERIALS
1.ALUMINIUM ALLOY (for cold chamber) 2.ZINC ALLOY or mazack (for hot chamber)

VARIOUS ROCESS IN RESSURE IE CASTING

2. et l egassing (wit egasser ing owder) etal ing 00)

3. etal fl

(wit coverall

4. leaning of olten . ross remove after fl

. olten metal transfer from melting f rnance to olding f rnance . . . to spray of dycoat on die face tolanding of molten metal from olding f rnance of die toextraction of casting from die

0. isual inspection of casting & reaking of overflow pad . atrol inspection of casting ( y gauscs) 2. utting of runner in t e machine 3.Final inspection of casting

DEP

T ENTS

1.Pressure ie cating
2. ac inig secti n

IN P ODUCT
1. Four W eelers y y y ulti oint uel In ection ( arburettors mission ontrol roducts

2. Two / T ree W eelers

Carburettors Emission Control roducts EMS System roducts ensets

.
y y

Carburettors Pumps

.Pumps
y y y y

Oil Pump ssembly Vacuum Pump ssembly Fuel Pumps Water Pump ssembly

5. Machined Component
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High Pressure ie Casting Products Precision Machined Products

Types of caburettor 1.v type(ventury odel )

2. Bs type( utterfly slide)

3. sse

ly secti n

I) arts

ther

PR CESS FL W CHART F R PRESSURE DIE CASTI G C LD CHAMBER MACHI ES

MODEL: bs 5-

F,bs 6-176 , bs

- 1 vm 18-

7 ,mx carchpw

ADC 1 ALLOY PU CHASED (ALLOY P OCU EMENT USING KANBAN SYSTEM_ SELF CE TIFIED VENDO (COUNTE IN TH EE MONTH) ADC 1 ALLOY IN THE STO T EQUI ED ADC 1 MACHINES ALLOY IS T ANSFE ED T O P ESSU E DIE CASTING CHECK ON CHEMICAL COMPOSITION ONCE

MELTING THE ALLOY METAL (A)FU NANCE STA TING (B)INGOT SC AP CHA GING METAL DEGASSING (D)METAL FLUXING (E)MOLTEN METAL CLEANING (F) EMOVAL OF D OSS (G)MOLTEM METAL T ANSFE FU NANCE F OM MELTING FU NANCE TOI HOLDING

DIE CASTING (A) DIE CLOSING (B) LADDING OF MOLTEN METAL (C) METAL INJECTION (D) SOLIDIFICATION (E) DIE OPENING INSPECTION

y y

Custo ers

Four Wheelers

Two Three Wheeler

Gensets

Machined Co ponents

PROCESS FLOW CHART FOR MIXIN PDF NO :- PFD/MC/UCD26/08 MODEL : JE C (Z MODEL)

BODY MACHIN REV:0

UCD26 JE MODELS

CONTROL PLAN REF: BS-MB-MC-UCD 26

CASTING IN THE STO ES EQUI ED CASTING A E T ANSFE -STATION LINEA T ANSFE ED TO MIXING BOIDY MACHINE LINE.

SPM -1.

(A) BOWL FIXING HOLE (B) TOP COVE P C D ILL PLACES (C) FCB TAPPING AT PLACES (D) TOP COVE TAP (M5) PLACES INSPECTION DI ECTION BASE BO E BO ING MACHINE :(A) EAMING OF TH OTTLE SHAFT HOLE 1 (B) EAMING OF TH OTTLE SHAFT HOLE SW TPS SIDE (C) BO ING OF 6 TH OTTLE BO E INSPECTION DI ECTION BASE BO E BO ING MACHINE :(A) BO ING OF PISTION BO E . (B) D ILL NEEDLE JET HOLE (C) BO ING OF NBOTTOM VENTU Y BO E . INSPECTION TOP VENTU Y BO ING MACHINE BO ING TOP VENTU Y MACHINE . INSPECTION STATION
(A) STA TE

STAGE MACHINE 1 CONNECTION HOLE (5. / .5)

P OCE

FLOW CHA
/VM18/ 1

FO CA BU E

O A

EMBLY

PDF O :- PFD/

MODLE : VM18 1

ONT OL PLAN EF : VM

AY

OMPONENT IN STORES VD18 R AY REQUIRED OMPONENT ARE TRANSFERRED TO ARBURETTOR ASSEMBLY LINE . MARK USTOMER PART NO . ON MI ING BODY MARK BAT H ODE NO . ON MI ING BODY SPECIAL PNUMATI PRESS PRESS FIT MAIN AIR JET , FUEL INLET NIPPLE MB P11 6 BILL PLUG SPECIAL PNUMATI PRESS , P11 , P11 9 , P11 8 ( PRESS FIT STARTER PIPE P11 APPLY LOCITITE IN P11 , P11 6 BALL PRESSED AREA . SPECIAL PURPOSE LEAK EQUIPMENT (A ) LEAK CHECK THROUGH FULL PASSAGE (B) PENETRATION CHECK FOR STARTER CIRCUIT . TIGHTEN PILOT JET, ASSEMBLE NEEDLE JET , PACKING AND TIGHTEN MASS JET ASSEMBLE PILOT SCREW WITH SPRING WASHED AND U RING ASSEMBLE IDLE ADJUSTING SCREW WITH SPRING WASHER ASSEMBLY STARTER PLUNGER ASSEMBLY AND GUIDE HOLDER ASSEMBLY WITH O RING AND SPRING PLACE THE PISTON VALVE ASSEMBLY AND LOCATE THE SPRING ON THE PISTON VALVE AND ASSEMBLY TOP CAP ASSEMBLY . STARTER PLUNGER RUBBER SEATING LEAK CHECK . P TEST M TEST NOS. ) MD

CONCLUSION
UCAL Fuel System Limited offers comprehensive Fuel Management Systems for Automotive sector. The company also manufactures pumps, emission control parts and various components for both ferrous and non ferrous material. From high pressure die casting to precision machined parts of micron level accuracy, UCAL is committed to produce the best the industry needs. UCAL is driven by technology; fully alive to the challenges of the ever-changing industry. Advanced technology is forefront in our thought processes; our endeavor is to offer new and better solutions, every time we deliver. With its expertise in automotive components, UCAL Group has been providing customers with end - to - end solution from product designing to analysis, prototyping, testing and validation services. The company has one of the most advanced D centers in the industry. The D center, named, K ISHNAMU THY CENT E FO AUTOMOTIVE TECHNOLOGY (KCAT) located in Ambattur, Chennai is recognized by the Department of Scientific and Industrial esearch, Government of India. The Manufacturing facilities in 5 locations - in Tamil Nadu, 1 in Pondicherry and one in Haryana are stat of the art. UCAL has achieved several milestones right from its inception in 1985.UCAL has, since been a preferred supplier for some of the top OEMs such as Maruti Udyog, Hyundai, Cummins, Bosch, Mikuni, eneral Motors, TVS Motor Company, Bajaj Auto, Suzuki, Yamaha, Hero Honda Motors, etc. 1 standards. UCAL believes in System The company is certified to TS 169 9 and ISO 1 thinking; system approach is our work philosophy which is reflected in the quality of products and services delivered. Being an integral part of society UCAL believes that its responsibility is to make positive impact on the quality of people of the society. UCAL undertakes regular initiatives and outreach programmes, in support of various causes, such as women upliftment, visually challenged, poor childrens education and many more. UCALs corporate philosophy has always been that the interest of all the stake holders is paramount. UCAL is eco friendly in all its operations.

Company s Vision
To be a Key Global Player in Fuel Management Systems

Company s Mission
To strive for co ti o s gro th i Fuel Ma ageme t Systems to meet the ever-exacti g Market Dema ds through Research & Develo me t a d Excelle ce i O eratio s Ma ageme t.Also Its aim is to mi imize fuel co sum tio a d elimi ate the orocity.