A

Internship Report on

“AC INDUSTRIES PVT.LIMITED.”

Submitted by
Mr. GUNJAL NARAYAN RAMNATH

Under the Guidance of

Prof. Y.R.GUNJAL

Submitted in Partial Fulfilment of the Requirement for

Bachelor’s Degree of Mechanical Engineering
Of Savitribai Phule Pune University

Department of Mechanical Engineering

Amrutvahini College of Engineering,
Sangamner- 422608

(2023-24)
 CERTIFICATE
Amrutvahini Sheti & Shikshan Vikas Sanstha’s
Amrutvahini College of Engineering,

This is to certify that

Mr. GUNJAL NARAYAN RAMNATH
Has satisfactorily completed his internship
training report in the field of
“AC INDUSTRIES PVT.LIMITED.”

Under the Guidance of

Prof. Y.R.GUNJAL
Towards the Partial Fulfilment of
Internship training work in third year of Mechanical Engineering in
Savitribai Phule Pune University, Pune
During the academic year 2023-24

Date:
Place: Sangamner

Prof. Y.R.GUNJAL Dr. V. D. Wakchaure

Guide HOD (Mechanical)
 AMRUTVAHINI COLLEGE OF ENGINEERING, SANGAMNER
DEPARTMENT OF MECHANICAL ENGINEERING

Check List for Summer- 2024 Internship

As per AICTE Guidelines all the students have to complete the internship.
Following points must be completed after successfully completion of an Internship
Sr. No. Activity- Report Tick Mark
1. Student Internship Program Application
2. Internship Request Letter/e-mail from TPO/HOD to Company
3. Students Daily Diary or Daily Log
4. Supervisor Evaluation of Intern
5. Pro-Forma for Evaluation of Internship by Institute
6. Internship Evaluation Report
7. Internship Photos

Prof. Y.R.GUNJAL Prof. V. M. Mhaske

(College Guide) (In-Charge of that Div.)

Prof. S. T. Gadakh/Prof. K. K. Dighe Dr. M A Venkatesh Dr. V. D. Wakchaure

(Training & Placement Cell) (principal) (HOD)
 2. Student internship program application

1. Student Name: Narayan Ramnath Gunjal

2. Campus Address: Plot No C-78 Stice, Musalgaon MIDC Sinnar Phone:9960537473

Nashik 422112

3. Home Address: At post Gunjalwadi Tal -Sangamner Phone:9834483137

Dist.- Ahmednagar Maharashtra India
422601
3a. Student email address:[email protected]

4. Academic Concentration : Mechanical 5. Internship Semester: 3rd Year, after fifth semester
Engineering

6. Overall GPA:

7. Internship preference

Location Core Area Company/ institution

Preferance-1 Musalgaon MIDC, Injection Moulding A.C.Industries

Sinnar 422112

Faculty mentor Signature: Date .

Signature confirms that the student has attended the internship orientation and has met all paperwork and
process requirements to participate in the internship program, and has approval from his/her Advisor.

Student Signature: Date .

Signature confirms that the student agrees to the terms, conditions and requirements of the Internship
Program
 INDEX

Sr No. Name Page No.

1. Acknowledgement 1

2. Abstract 2

3. Introduction 3

4. Company Photograph 4

5. Company Products 5

6. Raw materials 10

7. Production process and machines 13

8. Quality control 19

9. Maintainance 20

10. Various departments 21

11. Conclusion 23
 ACKNOWLEDGEMENT

I take this opportunity to thank all those who have contributed in successful
completion of this Internship. I would like to express my sincere thanks to my guide
Prof. Y.R.GUNJAL and who have encouraged me to work and provided valuable
guidance wherever required. I also extend my gratitude to Dr. V.D. Wakchaure
(H.O.D Mechanical Department) who has provided facilities to explore the
subjectwith more enthusiasm.
I express my immense pleasure and thankfulness to all the teachers and staff of the
Department of Mechanical Engineering of Amrutvahini College of Engineering
for their co-operation and support.

Mr.Gunjal Narayan Ramnath

1
 ABSTRACT

AC Industries Private Limited is a sister company of L&TC, a trusted business

house that produces innovative and qualityproducts for the L&TC Company. AC
Industries has a satisfied customer base spread all over India.

AC Industries is a trusted business house since its inception. Guided by the

philosophy to produce innovative and quality products, AC Industries has come tobe
known for its successful customer centric approach.

Customer satisfaction is a marketing term that measures how products or

services supplied by a company meet or surpass a customer's expectation. Customer
satisfaction is important because it provides marketers and business owners with
ametric that they can use to manage and improve their businesses.

"Within organizations, customer satisfaction ratings can have powerful effects.

They focus employees on the importance of fulfilling customers' expectations.
Furthermore,when these ratings dip, they warn of problems that can affect sales and
profitability....
These metrics quantify an important dynamic. When a brand has loyal
customers, it gains positive word-of- mouth marketing, which is both free and highly
effective."

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 Introduction

AC Industries is a pioneering leader in the manufacturing industry, specializing in the

production of high-quality products through precision injection molding processes. With a legacy
of innovation and excellence spanning several decades, AC Industries has established itself as a
trusted name synonymous with reliability, efficiency, and superior craftsmanship.

At AC Industries, we leverage cutting-edge injection molding technology and state-of-the-

art manufacturing facilities to create a diverse range of products tailored to meet the evolving needs
of our customers across various industries. From automotive components and consumer
electronics to medical devices and industrial applications, our injection molding expertise enables
us to deliver custom solutions that exceed expectations.

Our commitment to excellence extends beyond product quality to encompass every aspect
of our operations. We prioritize innovation, sustainability, and continuous improvement in all that
we do, striving to push the boundaries of possibility and set new standards of excellence in the
industry.

At the heart of our success lies a dedicated team of skilled professionals who bring
passion, expertise, and creativity to every project. From design and engineering to production and
quality control, our team works collaboratively to deliver solutions that inspire confidence and
drive success for our customers.

As a customer-centric organization, we place a strong emphasis on building lasting

relationships based on trust, integrity, and mutual respect. We partner closely with our clients to
understand their unique requirements, anticipate their needs, and deliver solutions that add value
and drive innovation.

With a relentless focus on customer satisfaction and a commitment to excellence, AC

Industries continues to be at the forefront of the injection molding industry, empowering
businesses around the world to thrive and succeed in an ever-changing marketplace. Join us on our
journey as we shape the future of manufacturing and create a world of possibilities through
injection molding excellence.

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 COMPANY PHOTOGRAPH

AC industries
Plot No C-78 Stice, Musalgaon MIDC Sinnar Nashik 422112

4
 COMPANY PRODUCTS

1. Enclosures:
- Enclosures are protective cases or housings that shield electrical components from environmental factors
and provide safety to users.
- Example: Plastic enclosure for a circuit breaker panel.

Fig1.1 Enclosures

2. Connectors:
- Connectors are devices used to join electrical circuits or components together securely.
- Example: RJ45 Ethernet connector used in networking equipment.

1.2 Connectors

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3. Switches:
- Switches are devices used to control the flow of electricity in a circuit by opening or closing contacts.
- Example: Plastic rocker switch used in household appliances.

Fig1.3 Switches

4. Terminal Blocks:
- Terminal blocks are modular blocks used to connect electrical wires or components together.
- Example: DIN rail-mounted terminal block used in industrial control panels.

Fig1.4 Terminal Blocks

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5. Insulators:
- Insulators are materials that prevent the flow of electrical current and provide electrical insulation.
- Example: Plastic insulator used in a high-voltage transformer.

Fig1.5 Insulators

6. Busbars:
- Busbars are conductive bars or strips used to distribute electrical power within a system.
- Example: Copper busbar used in electrical distribution panels.

Fig1.6 Busbars

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7. Fuses:
- Fuses are safety devices designed to protect electrical circuits from overcurrent conditions by interrupting
the flow of electricity.
- Example: Ceramic cartridge fuse used in a power distribution board.

Fig 1.7 Fuses

8. Circuit Breakers:
- Circuit breakers are automatic electrical switches designed to protect electrical circuits from damage
caused by overload or short circuits.
- Example: Plastic-molded circuit breaker used in residential electrical panels.

Fig1.8 Circuit Breakers

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9. LED Holders:
- LED holders are fixtures used to mount and secure Light Emitting Diodes (LEDs) in electronic circuits or
lighting applications.
- Example: Plastic LED holder used in LED light fixtures.

Fig1.9 LED Holders

10. Relays:
- Relays are electromagnetic switches used to control the flow of electricity between circuits.
- Example: Plastic relay housing used in automotive electronics.

Fig1.10 Relays

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 RAW MATERIAL

1. Polyethylene (PE):
- Types: High-Density Polyethylene (HDPE), Low-Density Polyethylene (LDPE), Linear Low-Density
Polyethylene (LLDPE)
- Density: Typically ranges from 0.910 to 0.940 g/cm³
- Melt Flow Rate (MFR): Varies depending on the grade and application

Fig 2.1 Polyethylene (PE)

2. Polypropylene (PP):
- Types: Homopolymer, Copolymer
- Density: Typically ranges from 0.895 to 0.905 g/cm³
- Melt Flow Rate (MFR): Varies depending on the grade and application

Fig 2.2 Polypropylene (PP)

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3. Acrylonitrile Butadiene Styrene (ABS):
- Types: Standard ABS, Flame-Retardant ABS
- Density: Typically ranges from 1.03 to 1.06 g/cm³
- Melt Flow Rate (MFR): Varies depending on the grade and application

Fig 2.3 Acrylonitrile Butadiene Styrene (ABS)

4. Polyethylene Terephthalate (PET):

- Types: PET, PETG (Glycol-Modified PET)
- Density: Typically ranges from 1.33 to 1.35 g/cm³
- Intrinsic Viscosity (IV): Important for assessing polymer chain length and processing characteristics

Fig 2.4 Polyethylene Terephthalate (PET)

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5. Polycarbonate (PC):
- Types: Standard PC, Flame-Retardant PC
- Density: Typically ranges from 1.20 to 1.22 g/cm³
- Melt Flow Rate (MFR): Varies depending on the grade and application

Fig 2.5 Polycarbonate (PC)

6. Nylon (Polyamide):
- Types: Nylon 6, Nylon 66, Nylon 12
- Density: Varies depending on the specific type and grade of nylon
- Melt Flow Rate (MFR): Varies depending on the grade and application

Fig 2.6 Nylon (Polyamide)

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 Production process and machines

In injection molding, the product, process, and machine are interconnected elements that work together
to produce plastic parts efficiently and effectively. Here's an overview of each component:

1. Product: -
The product refers to the plastic parts or components that are manufactured using the injection molding
process. These parts can vary widely in size, shape, complexity, and material properties. Injection
molding is used to produce a vast array of products across numerous industries, including automotive,
consumer electronics, medical devices, packaging, and more.

Fig. products

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2. Process: -
The injection molding process involves several key steps:
a. Clamping: -
The mold halves are securely closed and clamped together under high
pressure to prevent any leakage of molten plastic during the injection phase.

Fig 2.a Clamping

b. Injection: -
Molten plastic material is injected into the closed mold cavity under high
pressure using an injection molding machine. The plastic material, typically
in the form of pellets or granules, is heated and melted in the injection unit
before being injected into the mold.

Fig 2.b injection

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 c. Cooling: -
After the mold cavity is filled with molten plastic, the material is allowed to
cool and solidify inside the mold. Cooling time is crucial for achieving
proper part quality and dimensional stability.

Fig2.c Cooling

d. Ejection: -
Once the plastic part has sufficiently cooled and solidified, the mold opens,
and the finished part is ejected from the mold cavity using ejector pins or
plates.

Fig 2.d. Ejection

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e. Mold Close and Clamp: -
After ejection, the mold closes again to start the next injection cycle.

Fig2.e. Mold Close and Clamp

3. Machine: -
Injection molding machines are specialized equipment designed to
perform the injection molding process. Key components of an injection
molding machine include:

Fig 3.1.Machine

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 a. Injection Unit: -
The injection unit consists of a hopper, barrel, screw or plunger, and nozzle.
It is responsible for heating, melting, and injecting the plastic material into
the mold cavity.

Fig 3.a Injection Unit

b. Clamping Unit: -
The clamping unit is responsible for opening and closing the mold,
as well as applying and maintaining the necessary clamping force during the
injection process.

Fig 3.b Clamping Unit

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c.Mold: -
The mold, also known as the tool or die, is a precision-engineered
component that forms the shape and features of the plastic part. It consists of
two halves: the cavity side and the core side.

Fig 3.c-1 Cross section of mold Fig 3.c-2

mold d.Control System: -

Modern injection molding machines are equipped with sophisticated
control systems that monitor and control various parameters such as
temperature, pressure, injection speed, and cycle time to ensure optimal
process performance and part quality.

Fig3.d Control System

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 QUALITY CONTROL
Quality control in injection molding industries is crucial to ensure that the manufactured products
meet the required standards of quality, consistency, and reliability. Here are some key aspects of
quality control in injection molding:

1. Material Inspection: Quality control starts with the inspection of raw materials. The raw
materials used in injection molding, such as plastic resins, additives, and colorants, must meet
specified criteria for purity, consistency, and physical properties.

2. Machine Calibration and Maintenance: Injection molding machines need to be properly

calibrated and maintained to ensure consistent performance and dimensional accuracy. Regular
maintenance schedules and calibration checks help prevent defects and ensure optimal machine
operation.

3. Process Monitoring: Monitoring the injection molding process in real-time is essential for
detecting and correcting any deviations from the desired parameters. This includes monitoring
parameters such as temperature, pressure, injection speed, and cooling time to maintain process
stability and product consistency.

4. Mold Inspection and Maintenance: The injection mold plays a critical role in determining the
quality of the molded parts. Regular inspection and maintenance of the mold are necessary to
identify and address any issues such as wear, damage, or improper alignment that could lead to
defects in the molded products.

5. Quality Assurance Testing: Conducting quality assurance tests on molded parts is essential to
ensure that they meet the specified dimensional tolerances, surface finish requirements, and
mechanical properties. This may involve visual inspection, dimensional measurements, mechanical
testing, and other non-destructive testing methods.

6. Root Cause Analysis and Corrective Action: Inevitably, defects may occur during the
injection molding process. Implementing a systematic approach to root cause analysis helps
identify the underlying causes of defects and implement corrective actions to prevent recurrence.

7. Documentation and Traceability: Maintaining comprehensive documentation of the injection

molding process parameters, quality inspection results, and material traceability information is
essential for quality control and compliance with regulatory requirements.

8. Continuous Improvement: Continuous improvement initiatives, such as Six Sigma, Lean

Manufacturing, and Total Quality Management, help drive ongoing improvements in injection
molding processes, product quality, and operational efficiency.

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 MAINTAINANCE
Maintenance in injection molding is crucial for ensuring the reliability, efficiency, and
longevity of the equipment and molds, as well as the quality of the produced parts. Here are
some key aspects of maintenance in injection molding:
1. Scheduled Preventive Maintenance: Implementing a regular preventive maintenance
schedule is essential for minimizing downtime and preventing unexpected equipment failures.
This includes routine inspections, cleaning, lubrication, and replacement of worn or damaged
components.

2. Machine Maintenance: Injection molding machines require regular maintenance to

ensure optimal performance. This includes checking and adjusting machine settings, such
as injection pressure, temperature, and cycle time, to maintain consistent part quality.
Components such as screws, barrels, heaters, hydraulic systems, and electrical controls
should be inspected and serviced according to manufacturer recommendations.

3. Mold Maintenance: Proper maintenance of injection molds is essential for achieving high-
quality parts and maximizing mold life. Mold maintenance tasks include cleaning, polishing,
lubricating, and inspecting mold components for wear, damage, or corrosion. Regular
maintenance helps prevent defects, such as flash, sink marks, and warping, and ensures
dimensional accuracy and surface finish of molded parts.

4. Temperature Control System Maintenance: Maintaining precise temperature control

is critical for achieving consistent part quality and minimizing processing variations.
Regular maintenance of temperature control systems, including heaters, thermocouples,
and cooling channels, helps ensure uniform heat distribution and optimal cooling rates
during the molding process.

5. Material Handling System Maintenance: Proper maintenance of material handling

systems, including hoppers, loaders, dryers, and conveying systems, is essential for
preventing contamination, moisture absorption, and material degradation. Regular cleaning,
inspection, and calibration of material handling equipment help ensure the quality and
consistency of raw materials used in the injection molding process.

6. Safety Inspections: Conducting regular safety inspections of injection molding equipment

and work areas helps identify potential hazards and ensure compliance with safety regulations
and guidelines. Safety features such as guards, interlocks, emergency stop buttons, and safety
protocols should be inspected and tested regularly to prevent accidents and ensure operator
safety.
7. Documentation and Record-Keeping: Maintaining detailed records of maintenance
activities, including inspection reports, maintenance logs, and equipment manuals, helps track
maintenance

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 VARIOUS DEPARTMENTS

In an injection molding industry, various departments work collaboratively to ensure the

smooth functioning of the manufacturing process, quality control, and overall business
operations. Here are some key departments commonly found in injection molding industries:

1. Production Department:
- The production department oversees the actual manufacturing process of injection
molded parts.
- Responsibilities include setting up and operating injection molding machines,
monitoring production schedules, and ensuring the timely completion of orders.

2. Quality Control Department:

- The quality control department is responsible for ensuring that all molded parts meet
specified quality standards and customer requirements.
- Activities include inspecting parts for defects, conducting dimensional checks,
and implementing quality assurance procedures.

3. Engineering Department:
- The engineering department is involved in the design, development, and optimization
of injection molding processes and tooling.
- Engineers may work on mold design, process optimization, material selection,
and troubleshooting technical issues.

4. Tooling and Maintenance Department:

- The tooling and maintenance department is responsible for the maintenance, repair, and
upkeep of injection molds and machinery.
- Technicians conduct routine maintenance tasks, troubleshoot equipment failures, and
perform mold changes and repairs as needed.

5. Materials Management and Procurement Department:

- The materials management and procurement department is tasked with sourcing,
purchasing, and managing raw materials, components, and supplies needed for production.
- Responsibilities include inventory management, supplier relations, and ensuring
timely delivery of materials to support production schedules.

6. Sales and Marketing Department:

- The sales and marketing department is responsible for promoting injection molding
services, acquiring new customers, and managing client relationships.
- Activities include developing sales strategies, preparing quotes and proposals, and responding
to customer inquiries and feedback.

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7. Research and Development (R&D) Department:
- The R&D department focuses on innovation, product development, and process
improvement initiatives.
- Engineers and technicians in this department may work on new product designs,
material testing, process optimization, and exploring emerging technologies.

8. Human Resources Department:

- The human resources department handles personnel management, recruitment, training,
and employee relations.
- Responsibilities include staffing, performance management, compliance with labor
regulations, and fostering a positive work culture.

9. Finance and Administration Department:

- The finance and administration department manages financial operations,
budgeting, accounting, and administrative functions of the business.
- Activities include financial reporting, budget analysis, payroll processing, and
overseeing administrative policies and procedures.

10. Health, Safety, and Environmental (HSE) Department:

- The HSE department is responsible for ensuring compliance with health, safety, and
environmental regulations and promoting a safe working environment.
- Activities include conducting safety training, implementing safety protocols, and
managing environmental sustainability initiatives.

These departments work together to ensure the efficient operation of the injection molding
industry, from raw material procurement to production, quality control, sales, and customer
service. Collaboration among departments is essential for achieving business objectives,
maintaining high product quality, and meeting customer expectations

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 INTERNSHIP FRAMEWORK

1. Company Research:
- Investigate the company's history, mission, and values.
- Understand its products or services, target market, and competitive landscape.
- Familiarize yourself with the company's organizational structure and key personnel.

2. Machine Knowledge:
- Study the types of machines used in the company's processes.
- Gain a deep understanding of how each machine functions and its role in production.
- Identify any specialized software or tools associated with these machines.

3. Materials and Product Information:

- Learn about the materials used in production and their properties.
- Understand the manufacturing process from raw materials to finished products.
- Familiarize yourself with product specifications, variations, and quality standards.

4. Maintenance of Machine and Mold:

- Get hands-on experience in machine maintenance routines.
- Understand preventive and corrective maintenance procedures.
- Learn about mold maintenance and its impact on product quality and machine efficiency.

5. Quality Checks:
- Explore the company's quality control processes and standards.
- Gain practical experience in conducting quality checks on products.
- Understand how deviations from quality standards are addressed and corrected.

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 CONCLUSION
In conclusion, my internship at AC Industries Pvt Ltd has been a valuable and enriching
experience that has provided me with a deeper understanding of the industryand enhanced my
professional skills. Throughout my time at the company, I had the opportunity to actively participate in
various aspects of the business, gaining practical insights into the operations of a dynamic and
innovative organization.

One of the key takeaways from my internship is the significance of effective communication
and collaboration in a corporate setting. Working closely with cross-functional teams, I learned how a
harmonious exchange of ideas and information cancontribute to the overall success of projects and
initiatives. This experience has not only sharpened my interpersonal skills but has also highlighted the
importance of adaptability in a fast-paced work environment. Furthermore, my exposure to the day-to-
day operations of AC Industries Pvt Ltd has provided me with a comprehensive understanding of the
manufacturing processes, quality control measures, and market dynamics within the industry.
Witnessing the company's commitment to excellence and innovation has inspired me to approach
challenges with creativity anda solution-oriented mindset.

As I conclude my internship report, I would like to express my gratitude to the entireteam at AC

Industries Pvt Ltd for providing me with this invaluable opportunity.
The knowledge and experiences gained during my time here have not only enhancedmy
academic learning but have also equipped me with practical insights that will undoubtedly contribute to
my future success in the field.

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