internship report

Muhammad HAMMAD (Im-138)

SECOND year (industrial &manufacturing engineering)

Ned University of engineering and technology

Internee at:

INTERNATIONAL AUTOMOTIVE
ENGINEERS (pvt) limited
Assembly line
After passing through the dyeing and chain process. The lot of chain in continuous
form is delivered to assembly department. The lot of continuous chain is
delivered along with its ticket which contain all necessary information for
operators, packaging and dispatching staff, and after completing all operations of
assembly line and finished order is packed with product ship and delivered to
dispatch.

Assembly line is divided into the following four sections

1. Metal fastening close end

2. Metal fastening open end
3. Vislon fastening open and close end
4. Coil fastening open and close end

Metal fastening close end

This section of assembly line is for the close end zippers. In metal fastening close
end different pneumatic machines are used for attachments of bottom stop,
slider, top stop and cutting and finally zippers are checked and packed and for
dispatching. Followings are the detail machine of metal fastening close end.

1) F-32 ( BOTTOM ATTACH)

The function of this machine is the attachment of bottom stop on the
continuous chain at a pre determined distances as indicated in ticket.
2) F-40 (SLIDER INSERTION AND TOP STOP ATTACMENT)
After the attachment of bottom stop the next operations are performed by
this machine. The function of this machine is the insertion of slider as indicated
in ticket. In ticket the quality color and shape of slider. After slider insertion
attachment of top stop and cutting of continuous chain of zipper is being
performed by this machine.
 3) CHECKING AND PACKING
After the operations of F-40 machine the bundle of close end zippers are
checked, by opening and closing chain, top stop and bottom stop position. The
bundles are packed. After completion of lot the whole lot is then transferred
to dispatch.

4) F-47 ( BOTTOM STOP, SLIDER AND TOP STOP ATTACHMENT)

This machine is the multiple station machines which simultaneously perform
the function of bottom stop attachment. Slider insertion and top stop
attachment. This machine in fact perform the functions of both f-32 and f-40
machines.

(F-47) (F-32)
Order receive
Bottom stop, Slider, Bottom stop
Top stop attachment attachment

(F-40)

Checking and packing Slider, Top stops

attachment
Principle of operations
All the machines in metal fastening close end section are pneumatic i.e. all the
mechanical work is due to air pressure while part feeders either of bottom stop.
Top stop and slider are piezoelectric i.e. vibration is source of current and feed
the parts. No of sensors are there to sense flow of operation and all undesirable
material and chain or in machine.

Quality control machine

Metal fastening close end sections production is qualitatively checked by check
sheet on which top stop thickness, bottom stop thickness, top and bottom stop
positions and shape and slider opening and close are checked either they are with
in pre determined tolerance level or not. Also engineering check points includes
sensors checking that they are working properly or not.

Maintenance system
Basically maintenance system includes reactive and preventive maintenance.
Reactive maintenance is performed when ever any fault occur in machine is
performed every month which includes cleaning, lubrication, wear/abrasion
check. Abnormal cause check, air leakage check etc.

Metal fastening open end

This section of assembly is for open end metal fastening zippers for 5M, 7M and
10M sizes. In this section of open end metal fastening different pneumatic
machines are used for the attachment of top stop, insertion of slider and the
attachment of separable pin and retainer pin box. Finally zippers are checked,
packed and delivered to dispatch department, also metal fastening open end
section are further divided into Right open (OR) and Left open (LO) section.
Following are the details of machines and operations of open end mental
fastening.
Ticket
Ticket is of the order contain all necessary information about the requirement of
the order information excludes size, total quantity, pre section quantity, length,
type of retainer pin box etc. Orders are distinguish as left open or right open by
the code mention in ticket.

1) F-52 (Cord Pressing Machine):

This machine is pneumatic and the operation of this machine is the pressing of
cord. Although cord pressing is not merely necessary but it will provide a better
surface for thee next operation of film pressing.

2) F-60 (Film Pressing & Hole Punching)

This is pneumatic machine and there are two stations in this machine .At first
station plastic film is pressed in order to harden the surface and cord of spaced
portion of tape. At second station a hole is punched .this hole will help in the
insertion of separable pin and retainer pin box.

3) F-54 (Separable Pin & Retainer Pin Box Attachment

Machine)
This is pneumatic machine and there are two stations in this machine .At first
station separable pin is inserted and at second station retainer pin box is attached
.The die for left and right open zipper is different.

5) F-40 (Slider & Top Stop Attachment and Cutting)

This is pneumatic machine and there are two stations in this machine .At first
station insertion and at second station attachment of top stop and cutting takes
place simultaneously. For 10M size only two machines are used i.e. F-60 for film
pressing and hole punching and F-54 for separable pin and retainer box
attachment .All other operations are performed manually.
PRINCIPLE OF OPERATION:
Principles of operation of all the machines in open end metal fastening section are
same as that of machines of close end metal fastening. However cord pressing
and film pressing horns are heated electrically.

QUALITY CONTROL MEASURES:

For metal fastening open end section there is a check sheet for dimensional and
quality check with every machine .For Example Dimensional check of top stop
thickness with in tolerances, position of top stop, top stop and slider. Also quality
check sheet includes the check of cord pressing, element damage, tape damage,
punch position, punch shape, roller mark etc. Also checking includes pin bottom
and top thickness and retainer pin box thickness.

Final Quality Check includes checking of:

-Item Code -finish of parts -OR/OL

-slider picture -length of zipper

MAINTENANCE SYSTEM:
Maintenance system of metal fastening open end is same as that of close end
.Reactive and preventive maintenance is performed accordingly.
 FLOW CHART

F-52
F-52

Cord Pressing
OL ORDER OR Cord pressing

F-60 10M
F-60 Manual Slider &
Film pressing & Hole
Film Pressing & Hole
Top Stop
Attachment

F-54
F-54
Pin & Box
Pin & Box
F-40

Slider, Top Stop& Cutting

Checking and Packing

Dispatch
VISLON FASTENING OPEN AND CLOSE END
In this section open and close end vislon chain zippers are assembled .There are
different pneumatic machines for the different sizes (i.e. 3VS, 5VS&8VS) of vislon
fastening open and close end zippers. The process of assembling includes Spacing
of continuous chain, Film pressing, Hole punching, Attachment of top stop,
Insertion of slider and attachment of separable pin and retainer pin box for open
end and attachment of top and bottom stop. Details of vislon fastening open and
close end assembly are as follows

TICKET
Ticket contains all necessary information about the product. Information includes
distinction of open and close end, color, length, quantity, space, distinction code
of left and right open etc.

VISLON FASTENING CLOSE END

1) F-30 (Spacer Machine)
From vislon chain department continuous chain is delivered to vislon
fastening assembly .this continuous chain is then spaced as per
requirement of ticket in this machine.
2) F-48(Attachment of Top & Bottom Stop and Insertion of
Slider)
This machine is multistation machine which consist of three stations .At first
station insertion of slider, at second station attachment of top and bottom
Stop through injection molding and at third station cutting of zipper takes
place.
For injection molding chips of poly ethylene are used as a raw material and
this station operates hydraulically.
 VISLON FASTENING OPEN END
Following are the details of machines of vislon fastening open end assembly .
F-30 (Spacer Machine)
Continuous chain of is spacer in this machine and no. of elements remixed for
spacing are their disposed off.
F-60 (Film press & Hole punch)
After spacing a polyester film is pressed at first station of this machine and at
the second station of this machine hole is punched.
F-63(Attachment of top stop & separable pin)
In this machine top stop and separable pin are attached through an injection
molding in a single stroke of hydraulic punch. Polymer chips of desired color
are used as a raw material for injection molding.
F-61(slider retainer pin for attachment)
Operation of this machine is the insertion of slider and attachment of retainer
pin box. After that cutting are performed and bundles are released.
At the end of vislon fastening open end assembly bundle is
checked, counted and packed.

ORDER

F-30

SPACER M/C

F48 M/C Close End Open End F-60 M/C (FILM

ATTACHMENT PRESS & HOLE)
OF T.S, SLIDER,
B.S

F-63 ATTACHMENT
OF T.S, SEPARABLE
PIN
 F-61 SLIDER,
RETAINER PIN BOX
ATTACHMENT

CHECKING, COUNTING & PACKING

DISPATCH

Principal of Operation:
Principal of operation of vislon fastening machine is same as that of other
pneumatic machine. However there is hydraulic mechanism of operation of
injection molding machine.
Quality Control Measures
For vislon fastening open and close assembly there is a dimensional and
quality sheets foe every machine which includes check points length, space
portion, remaining element, tape damage, Die set function. Dimensional
include cord thickness etc. Also parts position, elements damage, short of
chips, top stop thickness, retainer and separable pin thickness are checked.
Engineering check points includes injection sensor, timer sensor, box sensor,
worn alignment, slider sensor checking etc.
Maintenance system
Maintenance system is same as that of other machines. Reactive and
preventive maintenance is performed accordingly.
COIL FASTENING OPEN AND CLOSER END ASSEMBELY
In this section of assembly a continuous chain of coil assembled. There are several
pneumatic chains for the attachment of top stop, bottom step slider etc. However
injection moulding machine is hydraulic. Different operation of machine includes
cord pressing, spacing, attachment of the bottom and top stop, Insertion of slides
and cutting. Detail explanation of coil fastening open and close assembly is as
fallows

Ticket:-
Ticket include all necessary information which includes distinction of open and
close end, color, length, Order& Pre section quantity, Packing unit and
Component code etc.

COIL FASTENING CLOSE END

F-64 (SPACER & CORD PRESSING MACHINE)
Function of this machine includes spacing and cord pressing. There are two
stations in this machine. At first station continuous is spaced ass per requirement
of ticket and at second station cord pressing occur.

F-32 (METALLIC BOTTOM STOP)

Function of this machine is the attachment of bottom stop .Coil of metal is used in
the form of rolled strip of different color as per requirement of ticket. This
machine cut the metallic coil and attaches it in the form of bottom stop.

YBMS-22
This machine is for plastic bottom stop attachment.
F-40 (ATTACHMENT OF TOP STOP, SLIDER AND CUTTING)
Function of this machine is the attachment of top stop, insertion of slider and
cutting. There are two stations in this machine. At first station slider is inserted
and at the second station top stop attachment and cutting takes place
simultaneously.

COIL FASTENING OPEN END

In coil fastening open end section .first of all chain is distinguish as left or right
open determined by ticket.

F-64 (TAPING, SPACING AND CORD PRESSING)

There are three stations in this machine .At first station staple joint cutting and
tapping occur. At second station spacing is performed by removing coil elements
from continuous chain .At third station cord is pressed to make the cord easy for
film pressing in next machine .

F-60 (FILM PRESSING & HOLE PUNCHING)

There are two stations in this machine .At first station film pressing and at the
second station hole is punched.

F-54(SEPARABLE PIN & RETAINER PIN BOX ATTACHMENT)

Function of this machine is the attachment of separable pin and retainer pin box
.There are two stations in this machine. At first station separable pin and at
second station retainer pin is attached.

F-40 (SLIDER, TOP STOP AND CUTTING)

In this machine there is only one station in which insertion of slider, top stop and
cutting takes place simultaneously.
 PRINCIPLE OF OPERATION
All the machines in coil fastening are pneumatic although for coil fastening open
end retainer pin box and separable pin are attached through injection molding
which operates hydraulically.

QUALITY CONTROL MEASURES

In coil fastening open and close end production is checked dimensionally and
qualitatively. It includes Chain feeding, length, spaced portion and element press.
Dimensional checks of bottom stop thickness & position, top stop thickness &
position and slider function. Engineering check points includes sensor working
check.

MAINTENACE SYSTEM
Maintenance system is same as that of other machines of the assembly. Reactive
and preventive maintenance is performed accordingly.

ORDER

F-6 4 F-64 Taping, spacing & cord pressing

SPACING & Cord Pressing

F-60 Film pressing & Hole punching

F-32 Metallic YBMS-22

B.S Plastic B.s F-54 Separable Pin & Retainer pin
box

F-40 T.S, Slider &

F-40 Slider, Top stop & Cutting
Cutting

Bundling, Counting
& Packing

Dispatch