Repor

ton
St
art
erAssembl
yandTPM

DONEAT

I
ndustr
ialgr
owthcent
re,
Hassan-573201,Kar
nat
akaStat
e,

Undert
hev
aluabl
egui
danceof
Mr
.RameshB
Seni
orengi
neer

SEGAUTOMOTI
VES

Submi
tt
edby
NAME USN
Har
ishHR 4MC14I
P033
SandeshK 4MC16I
P406
Sat
yaj
it
h 4MC15I
P018

DEPARTMENTOFI
NDUSTRI
AL&PRODUCTI
ONENGG
MALNADCOLLEGEOFENGI
NEERI
NG
HASSAN,
573201
 COMPANYPROFI
LE
MACUREXSENSORPVTLTD

Macurexisal eading manufact
urerandexpor terofElect
rical
/Electroni
c/Electro-
Mechanicalpart
sf ortheAutomotive&Appl iancesectors 
.Wear eaTS16949&I SO
9001:2000cer t
ifi
edcompany .Wehav eat eam ofy ounganddy nami cprofessionals,
whoconst antl
ystrivet
opr ov
idethebestwor kcul
tureaswel lasemphasi ze
cont
inuouslyoni mprovingthequali
tyofthepr oducts,
sot hatitdeli
ver sonlythebest
toit
sev er-
demandi ngexpectati
onsofcust omer swhoar eourpar tnersingrowt h. 

Ourcorestrengthhasbeendev elopmentandmanuf actur

eof El
ectrical
/Electr
o-
Mechanical Automot i
veProducts f
ortwowheel er
s,fourwheelers,refri
gerator
s,
washingmachi nesandf arm equi
pment.As AppliancesWashingMachi ne
Manufacturers and 
Ref r
iger
atorPartsManufacturerandexporter 
,ourkeyf ocusi s-
Qual
it
y,Deli
veryCommi t
mentandCost .Ourf
ocusedappr oachenablesust oachieve
ourcustomerexpect ati
on;ourdeterminat
iontoofferexcell
entproduct stoour
esteemedcl ientshelpsustomai nt
ainpreferredsuppli
erstatus. 

Pr
oductRange:

 Aut
omot i
vePr oductsforfourwheeler
s
Twowheel ersAut omoti
veProducts
 Appl
iancepart
sforRef ri
gerator
sandwashi ngmachi
nes
 Pressuret
ransducers f
ort heI
ndianSpaceprogr
ams
 Farm Equipmentmanuf act
urer
s

Compet
it
iveEdge:
 

Ourcorestr
engthl
iesi
nourunwav er
ingcommitmenttoqual
i
ty.Weareatr
ustedand
soughtaf
ternameintheindustr
y,havingl
ongassoci
ati
onwithel
ect
ro-
mechanical
,
elect
roni
candelect
ri
calproductsbecauseofourexcel
l
enceinpr
oduci
ngsuperior
quali
typr
oduct
s. 

Speci
ali
sat
ion:
 

Wespeci
ali
zei
ndev
elopment&manuf
act
uri
ngofel
ect
ri
cal
/el
ect
ro-
mechani
cal
par
ts
 f
orAut
omot
ive,
Appl
i
anceet
c. 

Technol
ogyDet
ail
s: 

West
ri
vet
oupdat
eourf
aci
l
iti
eswi
tht
helat
estt
echnol
ogi
est
obeawor
ldcl
ass
suppl
i
er.
 

Capabi
l
ity
: 

Ourcor
est
rengt
hisDesi
gn,
Dev
elopmentandHI
GHv
olumemanuf
act
uri
ng.
 

PRODUCTS
Ar
mat
ure

Sol
enoi
d
St
art
er
CUSTOMERS
 ACKNOWLEDGEMENT

We woul d li
ke to conv
ey our sincere gr
atit
ude and
appreci
ati
ontoal li
ndi
vidual
swhoseguidanceandcont r
ibuti
onhas
prov
edt othev
aluabl
einthecompl
eti
onofourint
ernshi
p.

Wewoul dli
ketothankMr .Ar
unKumar ,HOD&professorof
departmentofI ndust
ri
al&Product
ionEngineering,Mal
nadColl
egeof
Engineer
ingforsupporti
ncompleti
ngthi
sinternship.

We expr ess ourdeep gratit

ude t
o ourguide atMacur ex
sensors privat
e Li mited,Mr . Ramesh B. Seni or engi
neer ,SEG
AUTOMOTI VESf orgui di
ngandspar ingti
mei nfrequentdiscussi
ons
andguidingust hroughoutt hecompleti
onofthereport.Hi
ssuppor tin
everyaspectofthei nternshi
phasbeent hekeyfactori
ncompl eti
onof
theint
ernshipintime.

WORKCULTURESATMACUREX
Macurexbeli
eves t
hatits human capi
tali
sthe mostval
uabl
e asset,
nurt
uri
ng and i
nvest
ing i
n hi
gh perfor
ming t
eam hel
ps t
o meetcust
omer ’
s
changi
ngneedsandremaincompet i
ti
ve.
AtMacur
ex,ev
ery
onecont
ri
but
est
ooursuccessandcant
akeadv
ant
ageof
growthopport
unit
iestoenhancethei
rcar
eer.Ourtal
entmanagementprocess
helpusident
if
ydev el
opandpromotethehi
ghcali
breindi
vi
dual
stosupportthe
organi
zati
onsfut
ureleader
shi
pneeds.

Wor
kingpr
inci
pleofst
art
erassembl
y

A st
art
er (
also 
selfstart
er,
 
self
, 
cranki
ngmot or,
or st
artermot
or)
isadeviceusedt orotate(
crank)an i
nter
nalcombustionengi
ne
soast oini
ti
atetheengine'
soper at
ionunderit
sownpower .
Tomakean engine 
star
titmustbet
urnedatsomespeed,
sot
hati
tsucks 
fuel
 
andai
r
i
ntot
he 
cyl
inders,andcompressesi
t.

Thepower f
ul 
elect
ricst
arter
 motor
doest
hetur
ning.It
sshaftcar
ri
esasmal
lpi
nion
(gear
 wheel
)whi chengageswithalar
gegearr
ingaroundtheri
m of
the 
engi
nefly
wheel .

I
naf
ront
-engi
nel
ayout
,the 
star
ter
 i
smount
edl
owdownneart
hebackoft
heengi
ne.

Thestart
erneedsaheavyel
ectr
ic 
current,
whichitdr
awsthr
oughthickwi
resfr
om
the 
batt
ery.Noordi
nar
yhand-
operated swit
chcoul
dswit
chiton:
itneedsalar
ge
swit
chtohandlethehi
ghcurr
ent.

Theswitchhastobeturnedonandoffveryqui
ckl
ytoavoi
ddanger
ous,
damaging
spar
king.Soa 
solenoi
d i
sused-anarrangementwher
easmallswi
tcht
urnson
an 
elect
romagnet 
tocomplet
ethe 
cir
cuit.

Tomakean engine 
star
titmustbet
urnedatsomespeed,
sot
hati
tsucks 
fuel
 
andai
r
i
ntot
he 
cyl
inders,andcompressesi
t.

Thepower f
ul 
elect
ricst
arter
 motor
doest
hetur
ning.It
sshaftcar
ri
esasmal
lpi
nion
(gear
 wheel
)whi chengageswithalar
gegearr
ingaroundtheri
m of
the 
engi
nefly
wheel .

I
naf
ront
-engi
nel
ayout
,the 
star
ter
 i
smount
edl
owdownneart
hebackoft
heengi
ne.

Thestart
erneedsaheavyel
ectr
ic 
current,
whichitdr
awsthr
oughthickwi
resfr
om
the 
batt
ery.Noordi
nar
yhand-
operated swit
chcoul
dswit
chiton:
itneedsalar
ge
swit
chtohandlethehi
ghcurr
ent.

Theswitchhastobeturnedonandoffveryqui
ckl
ytoavoi
ddanger
ous,
damaging
spar
king.Soa 
solenoi
d i
sused-anarrangementwher
easmallswi
tcht
urnson
an 
elect
romagnet 
tocomplet
ethe 
cir
cuit.

Tomakean engine 
star
titmustbet
urnedatsomespeed,
sot
hati
tsucks 
fuel
 
andai
r
i
ntot
he 
cyl
inders,andcompressesi
t.

Thepower f
ul 
elect
ricst
arter
 motor
doest
hetur
ning.It
sshaftcar
ri
esasmal
lpi
nion
(gear
 wheel
)whi chengageswithalar
gegearr
ingaroundtheri
m of
the 
engi
nefly
wheel .

I
naf
ront
-engi
nel
ayout
,the 
star
ter
 i
smount
edl
owdownneart
hebackoft
heengi
ne.

Thestart
erneedsaheavyel
ectr
ic 
current,
whichitdr
awsthr
oughthickwi
resfr
om
the 
batt
ery.Noordi
nar
yhand-
operated swit
chcoul
dswit
chiton:
itneedsalar
ge
swit
chtohandlethehi
ghcurr
ent.

Theswitchhastobeturnedonandoffveryqui
ckl
ytoavoi
ddanger
ous,
damaging
spar
king.Soa 
solenoi
d i
sused-anarrangementwher
easmallswi
tcht
urnson
an 
elect
romagnet 
tocomplet
ethe 
cir
cuit.
Tomakean engine 
star
titmustbet
urnedatsomespeed,
sot
hati
tsucks 
fuel
 
andai
r
i
ntot
he 
cyl
inders,andcompressesi
t.

Thepower f
ul 
elect
ricst
arter
 motor
doest
hetur
ning.It
sshaftcar
ri
esasmal
lpi
nion
(gear
 wheel
)whi chengageswithalar
gegearr
ingaroundtheri
m of
the 
engi
nefly
wheel .

I
naf
ront
-engi
nel
ayout
,the 
star
ter
 i
smount
edl
owdownneart
hebackoft
heengi
ne.

Thestart
erneedsaheavyel
ectr
ic 
current,
whichitdr
awsthr
oughthickwi
resfr
om
the 
batt
ery.Noordi
nar
yhand-
operated swit
chcoul
dswit
chiton:
itneedsalar
ge
swit
chtohandlethehi
ghcurr
ent.

Theswitchhastobeturnedonandoffveryqui
ckl
ytoavoi
ddanger
ous,
damaging
spar
king.Soa 
solenoi
d i
sused-anarrangementwher
easmallswi
tcht
urnson
an 
elect
romagnet 
tocomplet
ethe 
cir
cuit.

Thepr
ocesspl
anthasequal
l
ydi
vi
dedi
nto

Ar
mat
urel
i
ne

Sol
enoi
dli
ne

St
art
erl
i
ne
STAGE1:Ar
mat
urel
ine
Pr
ocessf
low
1.Pr
essi
ngshaf
tint
olamel
la
2.Papershi
fti
ntol
amel
la
3.Paperi
nser
ti
on
4.Paperwel
ding
5.Fabr
icat
ionofwi
ndi
ngel
ement
s
6.Manuali
nser
ti
onwi
ndi
ngel
ementi
ntomagazi
ne
7.For
mingandi
nser
ti
on
8.Pr
e-t
wist
ing
9.Fl
uxi
ngandt
ini
ng
10. Fi
nalt
wist
ing
11. Reduci
ngofel
ement
s
12. Cut
ti
ngofwi
reends
13. Pr
essi
ngcommut
atoronshaf
t
14. Wel
ding
15. Tur
ningofr
ingseat
16. Ri
ngpr
essi
ng
17. Pr
e-el
ect
ri
cal
test
ing
18. I
mpr
egnat
ion
19. Tur
ningofcommut
atorandl
amel
la
20. br
ushi
ng
21. bal
anci
ng
22. sungeart
est
ingandf
inalel
ect
ri
calt
est
ing
23. l
asermar
king

St
age2:sol
enoi
dli
ne
1Assemblyofswi
tchi
ngpi
n,E-
armatur
eandgreasi
ngofwindi
ng
assembly
2Magnetassembl
y
3Magetgr
ouphousi
ng
4Swi
tchcov
erhousi
ng
5Swi
tchcov
err
ivet
ingst
ati
on
6Adj
usti
ngcont
actbur
nreser
ve
st
ati
on
7Earmatureandswi
tchi
ngpi
n
caul
kingstat
ion
8Bur
rcl
eani
ngst
ati
on
9Pr
otect
ionassembl
yst
ati
on
10mechani
cal,
elect
ri
calandl
aser
mar
kingst
ati
on
St
age3:assembl
yli
ne
1AssemblyofORCIBf
ri
cti
onwasher
andret
ainerr
ing
2Assembl
yofNRBi
ntopl
anet
ary
gear
3Assembl
yofNRBi
ntopl
anet
ary
gear
4Ringgeargr
easi
ngal
ongwi
th
cameracheck
5Greasi
ngofspl
ineandassembl
yof
PGTassembly
6AssemblyofPGTst
opr
ingand
ret
ainerr
ing
7Capsulepr
essingandf
orkl
ever
gr
easingstat
ion
8Assembl
yoff
orkl
everandcoi
led
spr
ing
9Sol
enoi
dscr
ewt
ight
eni
ngf
orkl
ever
 assembl
yandDEF
10magnet
izi
ng andf
inali
nspect
ion.

Mai
ntenance
Acombinationofact
ioncar
ri
edoutt
oretai
namachi neina
r
eli
abl
e, accept
ableandsaf
econdi
ti
onforproduct
ionis
maint
enance
Maint
enancei
sver
yimport
antact
ivi
tyt
oext
endt
heusef
ul
l
if
eofanassetormachi
ne.
 Br
eakdownMai
ntenance
I
nbr eakdownmaint
enancetheequi
pmenti
sgeneral
l
y
attendedonl
ywhenthem/ cisbr
okendownandnotabl
eto
functi
on.

Pr
event
iveMai
ntenance
I
tisdef i
nedasmaintenanceundert
akenbeforetheneedis
developedtomi
nimizethepossibil
i
tiesofanunanti
cipat
ed
breakdownandproductionint
err
upti
on

Pr
edi
cti
veMai
ntenance.
Thi
snewtechni
queofmaint
enanceistopr
edictthefai
l
ureof
an equi
pmentormachinetoolbyusi
ngdiagnosti
cs.

Thiscanbecomparedtotheact
ivi
tycar
ri
edouti
nmedi
cal
diagnost
ics f
orchecki
ngourheal
th.

I
ntheappli
cati
onofthi
st echni
quet
her
ear
eequi pmentor
i
nstr
umentsusedf orchecki
ng Noi
se,vi
brat
ion,oi
l
anal
ysi
s,etc.

Bythi
st heli
kel
yfai
lur
eofcomponentsorpar
tsi
sest
imated
,
correcti
oniscar
ri
edoutt
hust
helif
eofthemachi
netool
is
enhanced

Rout
ineMai
ntenance

Thi
sty
peofmai
ntenancei
ncl
udeper
iodi
cal
lubr
icat
ionof
machi
nescl
eani
ngofexposedpar
tsandpl
aceswher
edust

col
l
ect
ioni
smor
eandper
iodi
cal
l
yinspect
ionandadj
ust
ment

ofcl
utches,
brakeset
c.Themai
nobj
ect
iveofr
out
ine

mai
ntenancei
ssmoot
hrunni
ngofmachi
nes

Mai
ntenanceConcept

Moder
nindustri
esar
echaract
eri
zedbyahighlevel
of
aut
omati
on, depl
oyi
ngcomplexandsophi
sti
cated
machi
nes.

Theobjectbehi
ndaut
omationistoachi
evehi
gher
product
ivi
tyandprof
iti
nbusiness.

Thi
shasr
esul
tedi
ntot
aldependencyofmachi
nes.

Theref
oremachi
nesmustr
emai
nsi
noper
ati
onwi
thout
anyt
rouble.

Foroper
atingwi
thoutanyt
roubl
eitr
equir
esmaintenance
ofmachinesThi
sisknowasmai nt
enanceconcept.

TPM
TheTPM boar dachiev
estransparencybyv i
sualizati
onandmakesi teasytomodi f
y
theline’
stool
sandequipmentmai nt
enancet asks’status.Itbecomeseasi l
ydispl
ayed
forthepersonwhoisresponsibleforthetaskthatcer taintaskshavetobedoneor
don’tneedtobedonei nt
hecur rentTPM timef rame/ calendarweek.Withtheboard’s
guidedocumentsitbecomescl eartoeveryoneifthel ine’splannedmaintenance
tasksarecompletedorbei
ngf ull
yexecuted.

TPM wasi
ntr
oducert
oachi
evet
hef
oll
owi
ngobj
ect
ives.
 1.Av
oidwast
agei
naqui
ckl
ychangi
ngeconomi
cenv
ironment.
2.Pr
oduci
nggoodswi
thoutr
educi
ngpr
oductqual
i
ty.
3.Reducecost
4.Pr
oduceal
owbat
chquant
it
yatt
heear
li
estpossi
blet
ime
5.Goodssentt
othecust
omer
smustbenondef
ect
ive
TPM Hi
stor
y

1.Tot
alpr
oduct
ivemai
ntenancewasi
ntr
oducedi
njapansi
nce1960
2.Nippondensowast
hef
ir
stcompanyt
oint
roducepl
antwi
depr
event
ivemai
ntenancei
n
1960
3.Basedonthedev
elopment
snippondensowasawar dedthedist
ingui
shedplantpr
izef
or
devel
opi
ngandimplement
ingTPM bytheJapaneseinst
itut
eofplantengi
neers
4.ThusNippondensooft
heToy
otagr
oupbecomet
hef
ir
stcompanyt
oobt
aint
heTPM
cer
ti
fi
cati
on.
TPM 8PI
LLARS
1.
AUTONOMOUSMAI
NTENANCE

2.
Kobet
sukai
zen

3.
Plannedmai
ntenance

4.
Qual
i
tymai
ntenance

5.
Dev
elopmentmanagement

6.
Educat
ionandTr
aini
ng

7.
Saf
ety
,heal
thandenv
ironment
 8.
Off
iceTPM

Ov
eral
lEqui
pmentEf
fect
iveness

Over
allEqui
pmentEffecti
venessisasy st
em of
measuresthatpr
ovidecontinuousvi
sibil
i
tyt
o
manufactur
ingpr
oductiv
ityandwaste.

OEEprov
idesacl
earf
ocusonut
il
izat
ionoff
aci
l
iti
esand
equi
pment.

OEEi
sacceptedworldwideast
hest
andar
dforquant
if
y
i
nmanufact
uringsuccess.
.

Overal
lEqui
pmentEff
ecti
veness,i
satop-
lev
elmetr
ic,
whichiscompri
sedof3underly
ingel
ements-Av
ail
abil
it
y,
Perfor
mance,andQual
it
y.

 Av
ail
abi
l
ityr
efl
ect
sequi
pmentandpr
ocessupt
ime.

 Perf
ormancerepor
tsspeedofpr
oduct
ioncompar
edt
o
desi
gnstandar
ds.

 Qual
i
tyi
ndi
cat
est
hepr
ocessy
iel
d.
OEEshouldbev iewedasa
'
Conti
nuousI mprovement
Engi
ne'thatprovi
desar obust
fr
amewor kfortheLean
Manufacturi
ngjourney
:
Tr
igger
sandmoni
tor
sKai
zenev
ent
s

Pr
ovi
desbasi
sforTot
alPr
oduct
iveMai
ntenance(
TPM)