i

ii
iii
iv
 Acknowledgment

I express my sincere gratitude to Bhavani Industries Pvt. Ltd. for providing me with the
opportunity to undertake this internship and gain invaluable hands-on experience in the field
of gear manufacturing and quality assurance. This internship has been a crucial step in my
professional development, allowing me to bridge the gap between academic knowledge and
industrial practices.
I would like to extend my heartfelt thanks to Dr. (Ms.) M. P. Dale, Principal, Modern
Education Society’s Wadia College of Engineering, Pune, for her continuous support and
encouragement in fostering industrial exposure for students.
I am deeply grateful to Prof. V. N. Raibhole, Head of the Mechanical Engineering
Department, for his guidance and motivation throughout my academic journey. My sincere
appreciation also goes to Prof. A. R. Patil, Internship Coordinator, for his invaluable
assistance in coordinating this internship program.
A special thanks to my guide, Prof. V. S. Mane, for his constant support, mentorship, and
insightful feedback, which have greatly contributed to my learning experience.
I would also like to extend my appreciation to HR Gawli Sir, my Industry Mentor at
Bhavani Industries Pvt. Ltd., for his invaluable guidance and for providing me with
practical exposure to manufacturing processes, industrial workflows, and quality control
procedures. His expertise and mentorship have significantly enhanced my understanding of
real-world engineering applications.
Lastly, I extend my gratitude to my faculty members, colleagues, and fellow interns for
their encouragement and collaborative spirit during this internship. Their support has made
this learning journey enriching and insightful.
This experience has been immensely beneficial in shaping my technical skills, problem-
solving abilities, and industrial knowledge, and I am confident that it will serve as a strong
foundation for my future endeavors in the field of mechanical engineering and
manufacturing technology.

v
 Abstract

This report provides a comprehensive overview of my internship experience at Bhavani

Industries Pvt. Ltd., Chakan, Pune, a leading gear manufacturing company specializing
in high-precision components. The internship focused on understanding industrial
workflows, manufacturing processes, quality assurance standards, and engineering
analysis in a real-world production environment.
During the internship, I observed and documented critical manufacturing processes,
including CNC machining, gear hobbing, grinding, heat treatment, and final inspection.
I gained hands-on exposure to quality control procedures, such as dimensional checks,
hardness testing, and profile inspection using advanced metrology tools like CMM and
profile projectors. Additionally, I contributed to process optimization, workflow
improvements, and safety compliance, reinforcing my understanding of industrial
efficiency and regulatory adherence.
A significant aspect of my internship was the prototyping and design of external and
internal gears using SolidWorks, where I learned about the design validation process,
feasibility analysis, and production planning. This experience helped bridge the gap
between theoretical knowledge and practical application, deepening my understanding of
manufacturing feasibility, material selection, and process sequencing.
Furthermore, this internship enhanced my technical skills in precision manufacturing and
quality assurance, as well as soft skills such as teamwork, communication, and problem-
solving. The exposure to ISO standards, lean manufacturing principles, and Industry 4.0
trends has provided valuable insights into the evolving landscape of the mechanical and
manufacturing sector.
This report details my learnings, contributions, and reflections, highlighting how this
internship has shaped my career aspirations and technical competencies. The knowledge
gained will serve as a strong foundation for future roles in mechanical engineering and
advanced manufacturing technologies.

vi
 Table of Contents
Abstract.....................................................................................................................................vi
List of Figures...........................................................................................................................ix
List of Tables..............................................................................................................................x
CHAPTER 1: INTRODUCTION..............................................................................................1
1.1 OVERVIEW.....................................................................................................................1
1.2 ABOUT COMPANY........................................................................................................2
1.2.1 Global Presence and Advanced Facilities..............................................................................2
1.2.2 Certifications and Compliance..............................................................................................3
1.2.3 Manufacturing Excellence.....................................................................................................3
1.2.4 Key products.........................................................................................................................4
1.2.5 Clients...................................................................................................................................5
1.3 COMPANY ADDRESS...................................................................................................6
1.4 QUALITY POLICY.........................................................................................................6
1.5 VISION & MISSION.......................................................................................................7
1.6 ORGANIZATION STRUCTURE...................................................................................7
1.7 PLANT/ COMPANY LAYOUT......................................................................................9
CHAPTER 2: INDUSTRIAL PROCESSES AND DEPARTMENTS.....................................10
2.1 Overview of Departments..............................................................................................10
1. Machining Cell :.......................................................................................................................10
2. Quality Assurance Department:...............................................................................................11
3. Heat Treatment Department:..................................................................................................11
4. Gear Profiling and Inspection Department:.............................................................................12
7. Final Assembly and Dispatch Department:..............................................................................12
8. Maintenance Department:......................................................................................................12
9. Administrative Department:....................................................................................................12
2.2 Production Process.........................................................................................................13
2.3 Quality Control Procedures............................................................................................19
2.4 Tools and Equipment Used............................................................................................21
2.5 Various Advanced Machines..........................................................................................27
1. AMS MCV-350 Vertical Machining Center..........................................................................27
2. Haas Vertical Machining Center (VMC)..............................................................................28
3. Liebherr LCS 300.................................................................................................................29
4. PITTLER SkiveLine...............................................................................................................30

vii
 5. LMW LX20T L5....................................................................................................................31
6. Liebherr LC 200...................................................................................................................32
7. Liebherr LC 250...................................................................................................................33
2.5 Safety and Compliance..................................................................................................34
CHAPTER 3: LEARNING OUTCOMES AND ROLES........................................................37
3.1 Role and Responsibilities...............................................................................................37
3.2 Skills Acquired...............................................................................................................38
3.3 Learning Outcomes........................................................................................................40
3.4 Prototyping and Design Process.....................................................................................41
CHAPTER 4: ANALYSIS AND INSIGHTS...........................................................................47
4.1 Strengths of the Company..............................................................................................47
4.2 Areas for Improvement..................................................................................................48
4.3 Industrial Trends.............................................................................................................50
CHAPTER 5: INTERNSHIP EXPERIENCE AND REFLECTIONS.....................................52
5.1 Internship Experience.....................................................................................................52
5.2 Contribution to the Company.........................................................................................52
5.3 Reflections......................................................................................................................53
CONCLUSION........................................................................................................................55
REFERENCES.........................................................................................................................56

viii
 List of Figures
Figure 1 Bhavani Industries PVT LTD......................................................................................1
Figure 2 Transmission Components...........................................................................................4
Figure 3 Engine Components.....................................................................................................4
Figure 4 Braking System Components......................................................................................4
Figure 5 Clients..........................................................................................................................5
Figure 6 Organization Structure.................................................................................................7
Figure 7 Company Layout.........................................................................................................9
Figure 8 Machining Cell..........................................................................................................10
Figure 9 Quality Assurance Department..................................................................................11
Figure 10 Heat Treatment Department.....................................................................................11
Figure 11 Gear Profiling and Inspection Department..............................................................12
Figure 12 Incoming Inspection Department............................................................................13
Figure 13 Gear Hobbing...........................................................................................................14
Figure 14 Heat Treatment.........................................................................................................15
Figure 15 Gear Grinding..........................................................................................................16
Figure 16 Inspection Machines................................................................................................17
Figure 17 Assembly and Final Touches...................................................................................17
Figure 18 Packaging and Dispatch...........................................................................................18
Figure 19 In-Process Inspection...............................................................................................19
Figure 20 Hardness tests..........................................................................................................20
Figure 21 Coordinate Measuring Machine (CMM).................................................................22
Figure 22 Profile Projector.......................................................................................................23
Figure 23 Hardness Testers......................................................................................................23
Figure 24 Surface Roughness Tester........................................................................................23
Figure 25 Bore Gauges.............................................................................................................24
Figure 26 Vernier Callipers and Micrometres..........................................................................24
Figure 27 Gear Tooth Vernier...................................................................................................24
Figure 28 Go/No-Go Gauges...................................................................................................25
Figure 29 Magnetic Particle Inspection (MPI).........................................................................25
Figure 30 Optical Comparator.................................................................................................25
Figure 31 Digital Height Gauge...............................................................................................26
Figure 32 Plunge Indicators.....................................................................................................26
Figure 33 Thread Gauges.........................................................................................................26
Figure 34 AMS MCV-350 Vertical Machining Center............................................................27
Figure 35 Haas Vertical Machining Center (VMC).................................................................28
Figure 36 Liebherr LCS 300....................................................................................................29
Figure 37 PITTLER SkiveLine................................................................................................30
Figure 38 LMW LX20T L5.....................................................................................................31
Figure 39 Liebherr LC 200......................................................................................................32
Figure 40 Liebherr LC 250......................................................................................................33
Figure 41 Personal Protective Equipment (PPE).....................................................................34

ix
Figure 42 Machine Safety........................................................................................................35
Figure 43 Shop Floor Safety....................................................................................................35
Figure 44 Fire Safety................................................................................................................36
Figure 45 Sheet 1 External Helical Gear..................................................................................44
Figure 46 Sheet 2 Ring Gear Internal Gear..............................................................................45

List of Tables
Table 1 Specifications of AMS MCV-350 Vertical Machining Centre....................................27
Table 2 Specifications of Haas Vertical Machining Centre (VMC).........................................28
Table 3 Specifications of Liebherr LCS 300............................................................................29
Table 4 Specifications of PITTLER Skive Line.......................................................................30
Table 5 Specifications of LMW LX20T L5.............................................................................31
Table 6 Specifications of Liebherr LC 200..............................................................................32
Table 7 Specifications of Liebherr LC 250..............................................................................33

x
CHAPTER 1: INTRODUCTION
1.1 OVERVIEW

The internship at Bhavani Industries Pvt. Ltd., Chakan, Pune, provided valuable hands-on
experience in precision manufacturing. The company specializes in engineered components
and assemblies for automotive, aerospace, and heavy machinery, with a strong expertise in
gear manufacturing, including spur, helical, bevel, worm gears, and spline shafts. This
internship bridged theoretical knowledge with practical applications, offering insights into
advanced machining, quality control, and production challenges. Under expert guidance, we
learned about gear production techniques, inspection procedures, and high-precision
manufacturing. The experience enhanced our technical skills, problem-solving abilities, and
understanding of industrial workflows. This report highlights key tasks, skills developed, and
the overall impact of this internship on our professional growth.

Figure 1 Bhavani Industries PVT LTD

1
1.2 ABOUT COMPANY

Established in 1975 by the Nandawana Brothers, Bhavani Industries India LLP is a family-
owned enterprise headquartered in Rajkot, Gujarat, India. Initially founded to meet the
demand for diesel engine components, the company has since grown exponentially,
expanding into the automobile sector by delivering high-precision components.
 Bhavani Industries is driven by a commitment to technological excellence and
exceptional customer service.
 The company has established itself as a market leader in supplying critical
synchronizer components.
 It serves various segments, including passenger vehicles (PV), commercial vehicles
(CV), and off-highway vehicles.
 Bhavani Industries is renowned for meeting the exacting demands of customers.
 The company specializes in producing highly precise components for power drive and
transmission systems.
 These components are used in both on-road and off-road vehicles.

1.2.1 Global Presence and Advanced Facilities

1. Global Presence:
o The Bhavani Group operates state-of-the-art production facilities across India,
strategically located in Rajkot, Sanand, Pune, and Rudrapur.
o These strategically placed plants enable the company to efficiently serve a
wide range of Original Equipment Manufacturers (OEMs), Tier 1 suppliers,
and global customers.
o Bhavani Industries caters to markets across Europe (EU) and North America
(NA), ensuring global reach and service.
2. Skilled Workforce:
o The Bhavani Group employs a workforce of over 1,300 skilled professionals,
contributing to its high standards of production and service delivery.
3. Advanced Technologies:
o The company integrates advanced technologies in its manufacturing
processes to ensure the highest precision and quality in all its products.

2
1.2.2 Certifications and Compliance
Bhavani Industries adheres to the highest international standards, ensuring consistent quality
and reliability in its operations. The Group holds the following certifications:
 IATF 16949:2016 for quality management in the automotive industry, demonstrating
the company's commitment to continuous improvement and customer satisfaction.
 ISO 14001 for environmental management, reflecting Bhavani Industries' dedication
to sustainable practices and minimizing its environmental impact.
 ISO 45001 for occupational health and safety, ensuring a safe and healthy work
environment for its employees.
In These certifications, the company's DUNS number 65-021-3655 signifies its credibility
and global business recognition, reinforcing its position as a trusted partner in the global
market. Bhavani Industries is also involved in ongoing research and development to stay at
the forefront of technological advancements in the industry. This focus on innovation and
quality has helped the company maintain long-term relationships with key customers and
suppliers across the world.

1.2.3 Manufacturing Excellence

Bhavani Group specializes in the forging of raw materials into net or near-net shapes through
advanced cold, warm, and hot forging techniques. The forging plant is equipped with state-of-
the-art mechanical presses, hammers, and an in-house die shop featuring CNC machines for
die manufacturing with utmost precision.
 Precision Turning: The first machining process involves precision turning to shape
components with high accuracy.
 Milling: Components are then processed using milling techniques to further refine
their form and dimensions.
 Gear Cutting: Advanced gear cutting techniques are employed to shape gears to the
required specifications.
 Heat Treatment: The parts are heat-treated in sophisticated furnaces to meet stringent
metallurgical requirements and enhance material properties.
 Grinding: Finally, components undergo grinding to achieve the necessary precision
for assembly and dispatch, ensuring smooth operation and high quality.

3
1.2.4 Key products

1. Transmission Components

Figure 2 Transmission Components

2. Engine Components

Figure 3 Engine Components

3. Braking System Components

4
 Figure 4 Braking System Components

1.2.5 Clients

5
 Figure 5 Clients

1.3 COMPANY ADDRESS

Bhavani Industries Private Limited

Address: PRQW+F5X, Alandi Fata, Kurali, Chakan, Maharashtra 410501, India
 Location: Situated in Chakan, a prominent industrial hub in the Pune district of
Maharashtra, Bhavani Industries operates within a strategically advantageous area
known for its well-developed infrastructure and connectivity to major transportation
networks.
 Proximity to Key Locations: The facility is located near Alandi Fata and Kurali,
ensuring easy access to important industrial zones and transportation routes that
facilitate efficient distribution and logistics.
 Industrial Area: Chakan is renowned for being home to a large number of
automotive and manufacturing companies, which allows Bhavani Industries to
collaborate with industry leaders and suppliers across various sectors such as
automotive, aerospace, and heavy machinery.
 Accessibility: The location is well-connected to Pune and other major cities in
Maharashtra, with proximity to national highways and railway stations, offering
efficient access for both inbound and outbound shipments.
This strategic location at PRQW+F5X enables Bhavani Industries to maintain a strong
presence in the competitive manufacturing sector, serving global customers with high-quality
precision-engineered components.

1.4 QUALITY POLICY

Bhavani Group of Industries is committed to exceed its customer expectations by

emphasizing on risk-based thinking and continually improve on
 Health and Safety
 Environment Protection
 Legal Requirement Compliance
 Product Quality
 We endeavour to provide best in Quality products and achieve it by
 Trained People
 Motivated Team
 Eco-Friendly Process

6
  Safe Work Practice
We achieve it by implementing effective Quality Management System throughout the
organization and supply chain
1.5 VISION & MISSION

Bhavani Group are visualizing a future with technological excellence, keeping in pace with
changing concepts, global innovations and technological excellence. We wish to sharpen our
focus in areas to be leading player embracing technological innovation and developments to
leave footprints as pioneers of upcoming technologies.
Aspire to have most modern production facilities keeping in pace with rapidly changing
Industrial environment to ensure satisfaction of the customer base with global presence in
high technology areas. Our man force should be highly competent with unfettered vision,
driven to excellence, dedicated, loyal and motivated to absolute performance to build our
core team.
Energy conservation, clean environment and pollution free world shall be our contributory
endeavor for a healthy global environment.

1.6 ORGANIZATION STRUCTURE

7
 Figure 6 Organization Structure

The organizational structure outlines the hierarchical relationships within the company,
ensuring clear lines of authority and operational efficiency.

 Managing Director (MD): Provides overall leadership, strategic planning, and high-

level decision-making for the organization.

 General Manager (GM): Oversees all departments and ensures smooth coordination,

efficiency, and alignment with business objectives.

 Deputy General Manager (DGM): Heads each department, ensuring compliance

with company policies and strategic goals.

 Assistant General Manager (AGM): Supports the DGM in executing departmental

plans, overseeing managers, and maintaining workflow efficiency.

 Managers: Responsible for daily operations within their departments, optimizing

resources, and managing teams.

 Supervisors: Directly oversee floor activities, ensuring productivity, quality control,

and problem resolution.

 Operational Staff:

o Operators (Machining Cell, Heat Treatment) – Handle machine operations.

o Inspectors (Quality) – Conduct quality checks and ensure compliance.

o Production Staff (Assembly & Packaging) – Manage packaging and

assembly tasks.

o HR Executives (HR) – Handle recruitment, employee management, and

workplace policies.

o Technicians (Engineering) – Provide technical support and maintenance.

8
1.7 PLANT/ COMPANY LAYOUT

Figure 7 Company Layout

9
CHAPTER 2: INDUSTRIAL PROCESSES AND DEPARTMENTS
2.1 Overview of Departments

Bhavani Industries Pvt. Ltd. has several departments working collaboratively to ensure high-
quality production and efficient operations. Each department plays a specific role in the
manufacturing process. Below is a detailed description of the major departments:
1. Machining Cell :
 Responsible for managing the end-to-end manufacturing process.
 Includes CNC machining, gear cutting, grinding, and heat treatment cells.
 Ensures timely production of components while maintaining quality standards.

10
 Figure 8 Machining Cell

2. Quality Assurance Department:

 Conducts inspections and quality checks at every stage of production.
 Ensures compliance with industry standards and customer requirements.
 Works closely with the production team to resolve quality issues.

Figure 9 Quality Assurance Department

3. Heat Treatment Department:

 Handles processes such as hardening, tempering, and annealing of gears and
components.
 Ensures optimal material properties for durability and performance.

11
 Figure 10 Heat Treatment Department

4. Gear Profiling and Inspection Department:

 Ensures gears meet precise dimensional and functional specifications.
 Utilizes advanced tools for profile grinding and measurement.

Figure 11 Gear Profiling and Inspection Department

7. Final Assembly and Dispatch Department:

 Handles the final inspection, assembly, and packaging of finished products.
 Coordinates with logistics to ensure timely delivery to customers.

12
8. Maintenance Department:
 Responsible for the upkeep of machinery and equipment.
 Ensures minimal downtime through preventive and corrective maintenance.
9. Administrative Department:
 Manages HR, finance, and other support functions.
 Facilitates smooth operations across all departments.
Integration of Departments
Each department works in synergy to maintain production efficiency and meet customer
demands. The integration of quality checks, precision machining, and effective maintenance
ensures that Bhavani Industries consistently delivers high-quality products.

2.2 Production Process

The production process for manufacturing gears at Bhavani Industries Private Limited
involves the following detailed steps:
1. Blank Inspection:
o Blanks such as steel billets or rods are sourced from trusted suppliers.

o A comprehensive quality check is performed to ensure the blanks meet the

required specifications for composition and physical properties.
o Non-conforming blanks are either rejected or sent for rework.

13
 Figure 12 Incoming Inspection Department

2. Cutting and Shaping:

o The blanks are cut to the required size using high-precision saws or CNC
cutting tools.
o Gear blanks are shaped using CNC lathes or turning centers to ensure
dimensional accuracy and surface finish.
o Machinists verify the initial dimensions of the gear blanks before proceeding
to the next step.
3. Gear Hobbing/Generation:
o Gear teeth are cut into the blanks using hobbing machines or shaping
machines. The hobbing process uses a rotating hob cutter to create the required
tooth profile.
o Gears requiring internal teeth undergo shaping on specialized machines.

o Operators check for uniform tooth profiles and dimensions during this stage.

14
 Figure 13 Gear Hobbing

4. Heat Treatment:
o Gears are heat-treated to improve hardness, strength, and wear resistance.

o Processes like carburizing are used to harden the surface while maintaining a
tough core.
o Tempering is done to relieve internal stresses after hardening.

o Quality tests, such as hardness checks, are performed post-treatment.

15
 Figure 14 Heat Treatment

5. Grinding:
o Precision grinding is performed to achieve the desired tooth profile and
surface finish.
o Grinding ensures high dimensional accuracy, which is critical for gears used in
high-performance applications.
o The process also eliminates heat treatment distortions.

16
 Figure 15 Gear Grinding

6. Inspection:
o Finished gears undergo rigorous inspections using advanced tools such as
Coordinate Measuring Machines (CMM), profile projectors, and micrometres.
o Tests include dimensional accuracy, tooth profile verification, and surface
finish checks.
o Non-conforming gears are identified and either reworked or rejected.

17
 Figure 16 Inspection Machines

7. Assembly and Final Touches:

o For specific applications, gears are assembled with hubs, shafts, or other
components.
o Cleaning is performed to remove any residues or debris.

o Surface treatments like phosphating or coating are applied for corrosion

resistance, if required.

Figure 17 Assembly and Final Touches

8. Packaging and Dispatch:

o Gears are packed in protective materials like foam or cardboard to prevent
damage during transit.
o Products are labeled with batch numbers, customer details, and specifications.

18
 o Logistics planning ensures timely delivery to customers, maintaining client
satisfaction.

Figure 18 Packaging and Dispatch

Each step in the production process is carefully monitored and documented to maintain
consistency, quality, and traceability. The integration of modern machinery and skilled labour
ensures Bhavani Industries delivers reliable and high-quality gears to its clients.

2.3 Quality Control Procedures

The Quality Control (QC) procedures at Bhavani Industries Pvt. Ltd. are designed to ensure
that all gears meet stringent industry standards and customer-specific requirements. Below is
a detailed explanation of the quality checks and standards followed by the company:

19
1. Raw Material Inspection
 Objective: To verify that the raw materials meet the required specifications before
production begins.
 Tests Performed:
o Chemical composition analysis to ensure the material grade matches design
requirements.
o Mechanical property checks, including hardness and tensile strength testing.
o Dimensional accuracy verification using tools like micrometers and calipers.
 Outcome: Materials that do not conform to specifications are rejected or returned to
suppliers with non-conformance reports.
2. In-Process Inspection
 Objective: To monitor and control the quality of components during the production
process.
 Steps:
o Regular dimensional checks are performed after every critical operation (e.g.,
turning, hobbing, grinding).
o Use of go/no-go gauges to ensure tooth profile and pitch accuracy during gear
cutting.
o Visual inspections for surface defects like scratches or dents.
o Real-time machine calibration to maintain accuracy in CNC and grinding
processes.
 Outcome: Immediate correction of process deviations to avoid production defects.

Figure 19 In-Process Inspection

3. Heat Treatment Inspection

 Objective: To ensure that the heat-treated gears meet the desired hardness and
microstructural properties.
 Tests Performed:

20
 o Hardness tests using Rockwell or Vickers hardness testers.

o Microstructure analysis to verify proper carburization or tempering.

o Dimensional checks post-heat treatment to account for distortions.

 Outcome: Gears with improper hardness or structural inconsistencies are re-treated or

rejected.

Figure 20 Hardness tests

4. Final Inspection
 Objective: To validate that the finished gears meet all design and functional
requirements.
 Tests and Checks:
o Dimensional accuracy is checked using Coordinate Measuring Machines
(CMM).
o Gear profiles and tolerances are verified using profile projectors and gear
testers.
o Surface finish is inspected using roughness testers to ensure proper meshing
and performance.
o Functional testing, including load tests for critical gears, to assess performance
under operating conditions.
 Outcome: Only components that pass all final inspections are approved for packaging
and dispatch.
5. Documentation and Traceability
 Each inspected gear is tagged with a unique identification number for traceability.
 Inspection reports are generated and stored for future reference or customer audits.

21
  Non-conformance reports are issued for defective parts, and corrective actions are
documented.
6. Standards and Certifications
 The company adheres to ISO 9001:2015 quality management standards.
 Products are manufactured to comply with international standards such as AGMA
(American Gear Manufacturers Association) and DIN (Deutsches Institut für
Normung).
Conclusion
The robust quality control procedures ensure that Bhavani Industries delivers high-
performance, reliable gears to its customers, maintaining their reputation for excellence in
gear manufacturing.
2.4 Tools and Equipment Used

Bhavani Industries Pvt. Ltd. employs a variety of advanced tools and machinery to ensure
precision and efficiency in its operations. Below is an overview of the key tools and
equipment used across different departments:
1. Production Department
 CNC Machines (Lathe and Milling): For precision machining of gear blanks and
components.
 Gear Hobbing Machines: Used to cut gear teeth with high accuracy.
 Gear Grinding Machines: Ensures smooth surface finishes and tight tolerances for
gear teeth.
 Broaching Machines: For creating internal gear profiles and keyways.
 Drilling Machines: Used for creating holes in gear components.
2. Quality Control Department
 Coordinate Measuring Machines (CMM): For highly accurate dimensional
inspection.
 Profile Projectors: Used to inspect gear profiles and verify tolerances.
 Hardness Testers: For measuring the hardness of heat-treated components.
 Surface Roughness Testers: Ensures the desired finish is achieved on critical
surfaces.
 Vernier Calipers and Micrometers: For quick and accurate dimensional
measurements.

22
3. Heat Treatment Department
 Carburizing Furnace: Used for surface hardening of gears.
 Quenching System: For rapid cooling to enhance material properties.
 Tempering Furnace: Reduces internal stresses in the components post-quenching.
4. Design and Development Department
 CAD Software: Tools like SolidWorks or AutoCAD for designing gear systems.
 Simulation Tools: For analyzing gear performance under different load conditions.
5. Maintenance Department
 Toolkits and Diagnostic Tools: For repairing and maintaining production machinery.
 Oil Filtration Systems: Ensures the hydraulic systems of CNC machines function
smoothly.
6. Dispatch and Logistics Department
 Packaging Tools: For securely packing gears to prevent damage during transit.
 Weighing Machines: Ensures proper weight and documentation of outgoing
products.
By using state-of-the-art equipment and tools, Bhavani Industries achieves precision,
consistency, and high productivity in its gear manufacturing processes.
 Tools and Equipment
1. Coordinate Measuring Machine (CMM):Used for precise dimensional inspection
of gears.Verifies complex geometries, including gear profiles and tolerances.

Figure 21 Coordinate Measuring Machine (CMM)

2. Profile Projector: Measures gear tooth profiles and ensures proper alignment and
accuracy.

23
 Figure 22 Profile Projector

3. Hardness Testers: Rockwell and Vickers Hardness Testers: Measure surface and
core hardness of heat-treated gears.

Figure 23 Hardness Testers

4. Surface Roughness Tester: Ensures the desired surface finish for smooth gear
meshing.

Figure 24 Surface Roughness Tester

5. Bore Gauges: Measures internal diameters of gear hubs with high precision.

24
 Figure 25 Bore Gauges

6. Vernier Callipers and Micrometres: Used for quick dimensional measurements of

length, diameter, and thickness. Available in digital and analogue variants.

Figure 26 Vernier Callipers and Micrometres

7. Gear Tooth Vernier: Specifically designed for measuring gear tooth thickness and
pitch.

Figure 27 Gear Tooth Vernier

8. Go/No-Go Gauges: Verifies whether gears meet specified dimensional tolerances.

25
 Figure 28 Go/No-Go Gauges

9. Magnetic Particle Inspection (MPI): Detects surface and sub-surface defects like
cracks in metal components.

Figure 29 Magnetic Particle Inspection (MPI)

10. Optical Comparator: Magnifies and compares gear profiles against design
templates.

Figure 30 Optical Comparator

11. Digital Height Gauge: Measures heights, depths, and other vertical dimensions.

26
 Figure 31 Digital Height Gauge

12. Plunge Indicators: Used to measure small deviations in gear flatness or alignment.

Figure 32 Plunge Indicators

13. Thread Gauges: Verifies the threads on screws or bolts associated with gear
assemblies.

Figure 33 Thread Gauges

27
2.5 Various Advanced Machines

1. AMS MCV-350 Vertical Machining Center

Introduction
The AMS MCV-350 is a high-performance vertical machining center designed for precision
machining operations. It is commonly used in manufacturing industries for milling, drilling,
tapping, and other operations on a variety of materials, including metals and composites. Its
compact footprint and advanced CNC control make it an ideal choice for small to medium-
sized component production.

Table 1 Specifications of AMS MCV-350 Vertical Machining Centre

Feature Details

Travel (X-axis) Typically, ~350 mm

Travel (Y-axis) Typically, ~300 mm

Travel (Z-axis) Typically, ~300 mm

Table Size Approximately 600 x 300

mm

Maximum Table ~250-300 kg

Load

Spindle Speed Up to 10,000 RPM

(varies)

Rapid Traverse ~24 m/min (X/Y/Z)

Rate

Feed Rate ~10 m/min

Spindle Power ~5-7.5 kW

Control System Fanuc, Siemens, or AMS

Control

Operations Milling, Drilling,

Tapping

Figure 34 AMS MCV-350 Vertical Machining Center

28
 2. Haas Vertical Machining Center (VMC)

Introduction
The Haas VMC is a versatile CNC machine designed for a variety of machining operations
such as milling, drilling, and tapping. Known for its user-friendly interface and high
precision, it is a popular choice in industries requiring both productivity and flexibility.

Table 2 Specifications of Haas Vertical Machining Centre (VMC)

Feature Details
Travel (X-axis) Typically, ~500-1000 mm (varies by model)
Travel (Y-axis) ~400-800 mm (varies by model)
Travel (Z-axis) ~400-600 mm (varies by model)
Table Size 700 x 400 mm to 1200 x 500 mm (varies)
Maximum Table Load ~300-500 kg
Spindle Speed Up to 12,000 RPM (model dependent)
Rapid Traverse Rate ~25 m/min (X/Y/Z)
Feed Rate ~10 m/min
Spindle Power ~7.5-20 kW (based on model)
Control System Haas CNC Control System
Operations Milling, Drilling, Tapping, Contouring

29
 Figure 35 Haas Vertical
Machining Center (VMC)

3. Liebherr LCS 300

Introduction:
The Liebherr LCS 300 is a high-performance gear grinding machine used in precision
engineering industries. It is designed for continuous generating grinding and profile grinding,
ensuring high accuracy and surface quality for gears used in automotive, aerospace, and
industrial applications.

Table 3 Specifications of Liebherr LCS 300

Parameter Specification

Machine Type CNC Gear Grinding Machine

Model Liebherr LCS 300

Travel (X-axis) Varies based on configuration

Travel (Y-axis) Varies based on configuration

Travel (Z-axis) Varies based on configuration

Max Workpiece Diameter 300 mm

Table Size Suitable for gear workpiece

Max Load Capacity Approx. 500 kg

Grinding Wheel Speed Up to 80 m/s

Feed Rate CNC controlled

Spindle Speed High-speed grinding spindle

Machining Operations Continuous generating grinding, Profile grinding

30
 Figure 36 Liebherr LCS 300

4. PITTLER SkiveLine
Introduction:
The PITTLER SkiveLine is an advanced gear skiving machine designed for high-speed,
high-precision machining of internal and external gears. It is widely used in the
automotive, aerospace, and industrial sectors for manufacturing complex gear profiles
with high efficiency and accuracy.

Table 4 Specifications of PITTLER Skive Line

Parameter Specification

Machine Type CNC Gear Skiving Machine

Model PITTLER SkiveLine

Travel (X-axis) Varies based on configuration

Travel (Y-axis) Varies based on configuration

Travel (Z-axis) Varies based on configuration

Max Workpiece Diameter Up to 500 mm (varies by model)

Table Size Suitable for gear components

Max Load Capacity Approx. 500-1000 kg (varies)

Spindle Speed High-speed cutting spindle

Feed Rate CNC controlled, optimized for skiving

Machining Operations Gear skiving (internal & external), finishing,

deburring

31
 Figure 37 PITTLER SkiveLine

5. LMW LX20T L5
Introduction:
The LMW LX20T L5 is a high-precision CNC turning center designed for turning, facing,
drilling, boring, and threading operations. It is widely used in automotive, aerospace,
and general engineering industries for manufacturing precision cylindrical components.

Table 5 Specifications of LMW LX20T L5

Parameter Specification

Machine Type CNC Turning Center

Model LMW LX20T L5

Travel (X-axis) Approx. 160-200 mm

Travel (Z-axis) Approx. 400-500 mm

Max Turning Diameter Approx. 250 mm

Max Turning Length Approx. 500 mm

Table/Chuck Size 200-250 mm (varies by model)

Max Load Capacity Varies based on chuck size

Spindle Speed Up to 4000 RPM

Feed Rate CNC controlled, varies

Spindle Motor Power Approx. 10-15 kW

Machining Operations Turning, facing, drilling, boring, threading

32
 Figure 38 LMW LX20T L5

6. Liebherr LC 200
Introduction:
The Liebherr LC 200 is a high-performance CNC gear hobbing machine designed for
precision machining of gears, including spur and helical gears. It is widely used in industries
such as automotive, aerospace, and heavy machinery. The machine is known for its high-
speed machining, rigid construction, and automated tool handling, making it ideal for
mass production and precision manufacturing.

Table 6 Specifications of Liebherr LC 200

Parameter Specification

Travel Along X-Axis Approx. ±100 mm (adjustable)

Travel Along Y-Axis Not applicable (fixed setup)

Travel Along Z-Axis Approx. 500 mm

Table Size Suitable for workpieces up to Ø200 mm

Max Load Capacity Approx. 300 kg

Spindle Speed Up to 3000 RPM

Feed Rate Variable CNC-controlled

Spindle Feed Adaptive (based on gear size)

Machining Operations Gear Hobbing, Chamfering, Deburring

33
 Figure 39 Liebherr LC 200

7. Liebherr LC 250
Introduction:
The machine in the image is a Liebherr LC 250, a CNC gear hobbing machine used for
precision gear cutting applications. It is an advanced machine designed for high-accuracy
gear manufacturing in industries like automotive, aerospace, and heavy engineering.

Table 7 Specifications of Liebherr LC 250

Parameter Specification

Travel Along X-Axis Approx. ±100 mm (adjustable)

Travel Along Y-Axis Not applicable (fixed setup)

Travel Along Z-Axis Approx. 600 mm

Table Size Suitable for workpieces up to Ø250 mm

Max Load Capacity Approx. 500 kg

Spindle Speed Up to 4000 RPM

Feed Rate CNC-controlled, adaptive

Spindle Feed Variable based on gear size

Machining Operations Gear Hobbing, Chamfering, Deburring

34
 Figure 40 Liebherr LC 250

2.5 Safety and Compliance

Bhavani Industries Pvt. Ltd. prioritizes the safety of its employees and compliance with
industry regulations to ensure a secure and efficient work environment. Below are the key
safety measures and adherence practices followed:
1. Workplace Safety Measures
 Personal Protective Equipment (PPE):
o Mandatory use of helmets, safety glasses, gloves, and steel-toed boots in
production areas.

35
 Figure 41 Personal Protective Equipment (PPE)

 Machine Safety:
o Installation of emergency stop buttons and machine guards on all heavy
machinery.
o Regular calibration and maintenance to avoid operational hazards.

36
 Figure 42 Machine Safety

 Shop Floor Safety:

o Clear demarcation of walkways and restricted areas.

o Proper ventilation and lighting to maintain a safe work environment.

o Use of anti-slip flooring in high-risk zones.

Figure 43 Shop Floor Safety

2. Fire Safety

 Fire extinguishers and hydrants are strategically placed throughout the plant.
 Regular fire safety drills are conducted to train employees for emergency scenarios.

37
  Flammable materials are stored in designated areas with appropriate labeling.

Figure 44 Fire Safety

3. Training and Awareness

 Regular safety training sessions for all employees, covering topics such as:
o Safe handling of tools and materials.
o Hazard identification and reporting.
o Use of safety equipment and protocols for emergencies.
 Posters and signage are displayed across the plant to promote safety awareness.
4. Compliance with Regulations
 The company adheres to local and international occupational safety standards such as:
o OSHA (Occupational Safety and Health Administration) guidelines.

o ISO 45001 for Occupational Health and Safety Management Systems.

 Environmental compliance includes proper disposal of waste materials and adherence

to pollution control norms.
5. Monitoring and Incident Reporting
 A dedicated safety team monitors adherence to safety standards and conducts audits.
 A formal system is in place for reporting and investigating workplace incidents to
prevent recurrence.
6. Emergency Preparedness
 Emergency evacuation plans are clearly outlined and communicated to all employees.
 First aid kits are available at multiple locations on the shop floor.
 Trained first responders are designated for handling medical emergencies.

By implementing these comprehensive safety measures and complying with industry

regulations, Bhavani Industries ensures the well-being of its workforce and the efficient
functioning of its operations.

CHAPTER 3: LEARNING OUTCOMES AND ROLES

3.1 Role and Responsibilities

During the internship at Bhavani Industries Pvt. Ltd., my primary role was to observe,
analyze, and understand the various processes involved in gear manufacturing and the
operations of different departments. My responsibilities included:

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1. Observation and Documentation
 Observed the entire gear manufacturing process, from raw material inspection to
packaging and dispatch.
 Documented each production stage, including CNC machining, gear hobbing,
grinding, and heat treatment.
 Maintained detailed notes on quality control procedures and inspection techniques.
2. Learning Departmental Workflows
 Explored the workflows of departments like production, quality assurance, heat
treatment, and maintenance.
 Understood how departments coordinate for seamless operations and efficiency.
3. Understanding Machinery and Tools
 Studied the specifications, operations, and applications of key machines, including:
o CNC machines (Turning, milling).

o Gear hobbing and grinding machines.

o Hardness testers and profile projectors.

 Gained insights into the tools used for quality inspections, like CMMs, vernier
calipers, and micrometers.
4. Assistance in Production and Inspection
 Assisted operators and technicians in monitoring machine performance during gear
hobbing and grinding.
 Shadowed quality inspectors to understand how dimensional accuracy, surface finish,
and hardness are verified.
5. Safety and Compliance
 Followed all safety protocols, including the use of PPE and adherence to shop floor
regulations.
 Participated in safety drills and hazard identification sessions.
6. Reporting and Feedback
 Prepared daily reports on the processes observed and key learnings.
 Shared observations and suggestions for improvement with the mentor and team
members.

39
These responsibilities allowed me to gain hands-on exposure to gear manufacturing
processes, develop a better understanding of industrial workflows, and appreciate the
importance of quality and safety in production environments.

3.2 Skills Acquired

During my internship at Bhavani Industries Pvt. Ltd., I developed a range of technical and
soft skills that enhanced my understanding of industrial operations and improved my
professional competence.

 Technical Skills
1. Understanding CNC Operations:
o Learned the basics of CNC programming and the setup of machines for
turning and milling.
o Understood tool selection and the importance of maintaining tolerances.

2. Gear Manufacturing Processes:

o Gained knowledge about gear cutting (hobbing), grinding, and surface
finishing techniques.
o Studied the end-to-end process flow of gear production, from raw material to
finished product.
3. Quality Testing and Inspection:
o Acquired skills in using precision measurement tools, such as:

 Coordinate Measuring Machine (CMM).

 Vernier calipers, micrometers, and bore gauges.
o Learned quality control procedures like hardness testing and profile
inspection.

4. Heat Treatment Understanding:

o Observed carburizing, quenching, and tempering processes and their effects on
material properties.
5. Safety and Compliance Protocols:

40
 o Learned to follow safety standards and handle tools and machinery safely.

o Understood workplace compliance requirements, including ISO standards.

 Soft Skills
1. Teamwork:
o Collaborated effectively with operators, technicians, and quality inspectors to
observe and understand their workflows.
o Learned the importance of interdepartmental coordination for efficient
production.
2. Communication:
o Enhanced my ability to interact professionally with mentors, supervisors, and
colleagues.
o Presented observations and suggestions clearly during feedback sessions.

3. Problem-Solving:
o Analyzed production bottlenecks and participated in brainstorming solutions
with the team.
o Suggested improvements in inspection frequency for specific processes.

4. Time Management:
o Balanced multiple tasks, such as observing different departments, assisting in
inspections, and preparing reports.
5. Adaptability:
o Adapted quickly to the fast-paced industrial environment and learned to
manage challenges efficiently.

These skills have significantly contributed to my technical knowledge and professional

development, preparing me for future opportunities in the field of mechanical engineering.

3.3 Learning Outcomes

41
The internship at Bhavani Industries Pvt. Ltd. provided me with invaluable knowledge and
practical experience in gear manufacturing processes and industrial workflows. The key
learning outcomes are as follows:

1. Knowledge of Gear Manufacturing Processes

 Gained in-depth understanding of each stage in gear production, including:
o Cutting and shaping of raw materials.

o Gear hobbing for tooth generation.

o Grinding for achieving precision and surface finish.

o Heat treatment processes to enhance strength and durability.

 Learned how tolerances and surface finishes impact gear performance and longevity.
2. Industrial Workflow Understanding
 Observed how different departments (e.g., production, quality assurance, and heat
treatment) coordinate to ensure smooth operations.
 Understood the importance of time management and process efficiency in achieving
production targets.
 Learned about supply chain integration, from raw material procurement to final
dispatch.
3. Quality Assurance Techniques
 Developed an understanding of how quality standards are maintained at each stage of
production.
 Learned to use advanced tools like Coordinate Measuring Machines (CMM), profile
projectors, and hardness testers for inspection.
 Observed how non-conforming products are handled and reworked to meet customer
specifications.
4. Safety and Compliance
 Understood the importance of adhering to safety protocols and using protective
equipment.
 Gained insights into regulatory compliance and certifications, such as ISO standards,
followed by the company.

42
5. Application of Theoretical Knowledge
 Applied classroom knowledge in a practical setting, such as:
o Material science principles during heat treatment processes.

o Design concepts when observing CAD models for gears.

o Metrology techniques during quality checks.

6. Professional Growth
 Improved my ability to work in a team and communicate effectively with industry
professionals.
 Gained exposure to real-world problem-solving and decision-making on the shop
floor.
This internship has significantly enhanced my understanding of mechanical engineering
applications and industrial workflows, preparing me for future challenges in the
manufacturing industry.

3.4 Prototyping and Design Process

During the internship, we worked on the design and prototyping of two critical gear
components:
1. GFD Gear (Final Drive Gear) – External Teeth Helical Gear
2. Ring Gear – Internal Gear
These prototypes were designed on SolidWorks to match the original shape but with
different dimensions as per company policies. This process allowed us to understand the
detailed design-to-production workflow, including:
1. Design and Engineering Analysis
Before the manufacturing process begins, the design and engineering analysis phase
plays a crucial role in ensuring that the gear meets both customer specifications and
manufacturability constraints. This stage involves the following key steps:
Understanding the Customer’s Design Requirements
When a customer places an order for a gear, they provide detailed specifications that must
be carefully analyzed. These requirements include:
 Gear Type & Geometry: Whether it is a helical gear, spur gear, bevel gear, or
internal gear (e.g., ring gear).
 Module & Pitch Diameter: Defines the size and spacing of gear teeth.

43
 Material Selection: The type of material required (e.g., alloy steel, cast iron, case-
hardened steel) based on application needs.
 Load & Torque Specifications: Determines the gear’s ability to withstand
operational forces.
 Surface Finish & Tolerances: Specifies precision levels required for noise reduction,
efficiency, and longevity.
 Heat Treatment Requirements: Whether the gear needs to be hardened,
carburized, or tempered to enhance strength.
The engineering team evaluates these inputs and verifies if they align with standard
manufacturing capabilities. If any specifications are unclear or impractical, they
communicate with the customer for modifications.

 Feasibility Analysis by the Engineering Department

Once the initial design specifications are reviewed, the engineering department
conducts a feasibility study to determine if the gear can be manufactured efficiently while
maintaining quality and cost-effectiveness. This includes:

1. Material Feasibility
 Checking if the specified material is available, cost-effective, and machinable with
existing tools.
 Evaluating the heat treatment impact on strength, wear resistance, and dimensional
stability.
2. Manufacturing Process Selection
 Determining the most suitable gear cutting method (hobbing, shaping, or
broaching) based on gear type.
 Assessing the need for grinding, chamfering, or additional finishing operations to
achieve precision.
 Verifying if current CNC machines and tooling can handle the design without
excessive wear or rework.

3. Tolerance and Dimensional Accuracy Check

44
 Evaluating whether required tolerances (±0.01 mm, ±0.005 mm, etc.) are achievable
with existing machining and grinding processes.
 Ensuring that measuring instruments like CMM, profile projectors, and
micrometers can verify the final dimensions accurately.

4. Production Time and Cost Analysis

 Estimating cycle time per gear, considering machine availability and workforce.
 Calculating cost implications based on material selection, tooling, energy
consumption, and finishing processes.
5. Design Optimization (If Required)
 If the design has complex features that increase production difficulty or cost,
engineers suggest alternative designs with minor modifications.
 This step involves using CAD software (SolidWorks, AutoCAD, CATIA) to
simulate the gear performance before physical manufacturing.
 Engineers conduct Finite Element Analysis (FEA) to evaluate stress distribution and
potential failure points.

Final Decision and Approval

Once the feasibility analysis is complete, the engineering team:
✅ Confirms manufacturability if the design meets all process constraints, ensuring that
the selected material, machining processes, tolerances, and heat treatments can be
executed efficiently with existing resources. The team verifies that production can
proceed without excessive material wastage, tool wear, or prolonged cycle times.
❌ Suggests modifications if certain features cannot be produced efficiently or if the
design would lead to excessive machining complexity, high production costs, or reduced
durability. In such cases, engineers recommend alternative geometries, material
substitutions, or adjustments to tolerances while maintaining the gear’s functional
integrity.
🔄 Communicates with the customer for design validation before moving to
procurement and production. Any necessary design revisions are shared through detailed
CAD models, technical reports, and feasibility test results, ensuring the client’s
approval before proceeding. This stage helps prevent costly redesigns or manufacturing
bottlenecks later in production.

45
 Figure 45 Sheet 1 External Helical Gear

PITCH = 10 IN PRESSURE ANGLE PA = 14.5O

TEETH = 40
THEORITICAL DIAMETER PD = 4 IN

NORMP 14.1422 IN
Distance
OUTER DIAMETER OD =from
4.14a point
IN on the face of one
tooth to the same point on the face of an
adjacent tooth on the same gear measured
on the pitch circle. FACE 0.88 IN

FACE 0.88 IN
STYLE A

HAND R

HA 45O

46
 Figure 46 Sheet 2 Ring Gear Internal Gear

PITCH = 10 IN PRESSURE ANGLE PA = 20O

TEETH = 40
THEORITICAL DIAMETER PD = 4 IN

NORMP 14.1422 IN
OUTER DIAMETER OD = Distance
6 IN from a point on the face of one
tooth to the same point on the face of an
adjacent tooth on the same gear measured
on the pitch circle.

FACE = 2.50 IN
OAL = 1.125 IN

2. Manufacturing Process Sequence

47
 1. Purchase Order for Parts and Tooling: Once the design was approved, procurement
for raw materials and tooling was initiated.
2. Gear Blank Preparation: Ready blanks arrived from the company’s Rajkot plant.
3. Teeth Cutting (Hobbing Generation): Gear teeth were cut to precise specifications.
4. Teeth Chamfering: Edges of gear teeth were chamfered to improve performance.
5. Heat Treatment: Strengthened the gear to increase its lifespan and reduce
machining-induced stresses.
6. Internal Diameter and Face Grinding: Ensured dimensional accuracy.
7. Teeth and Profile Grinding: Achieved the final precision required for performance.
8. Surface Finish Treatments: Applied coatings or treatments if required.

3. Customer Validation and Production Scaling

 The first 5 to 10 samples were sent to customers for validation.
 If any issues were found, modifications were made before full-scale production.
 Once approved, the mass production (PIPAP batch) was initiated.
 Final packaging and dispatch were completed as per company logistics.
This hands-on experience in design and prototyping deepened our understanding of gear
manufacturing beyond theoretical learning.

48
CHAPTER 4: ANALYSIS AND INSIGHTS
4.1 Strengths of the Company

Bhavani Industries Pvt. Ltd. has established itself as a reliable and efficient gear
manufacturing company, with several key strengths contributing to its success:
1. Advanced Machinery and Technology
 The company uses state-of-the-art equipment, including:
o CNC machines for precision machining of gear blanks.

o Gear hobbing and grinding machines for high-quality gear production.

o Heat treatment furnaces for enhancing material properties.

 Regular maintenance and upgrades ensure the machinery operates at peak efficiency,
delivering consistent results.
2. Skilled Workforce
 Bhavani Industries employs experienced operators, technicians, and engineers who
excel in their respective domains.
 The workforce demonstrates excellent teamwork and collaboration, ensuring smooth
operations across departments.
 Continuous training programs keep employees updated on the latest manufacturing
trends and technologies.
3. Robust Quality Assurance System
 A dedicated Quality Assurance (QA) department ensures that every gear meets
stringent quality standards.
 Advanced inspection tools like Coordinate Measuring Machines (CMM) and profile
projectors enable precise quality checks.
 Adherence to ISO certifications and international standards reflects the company’s
commitment to excellence.
4. Efficient Workflow and Coordination
 Seamless integration between departments, such as production, quality control, and
logistics, ensures timely delivery of products.
 A well-defined workflow minimizes bottlenecks and maximizes productivity.
5. Customization and Flexibility
 The company offers tailored solutions to meet specific customer requirements, such as
unique gear profiles or material compositions.
49
  Flexibility in production processes allows Bhavani Industries to cater to diverse
industries, including automotive and heavy machinery.
6. Commitment to Safety and Compliance
 Bhavani Industries prioritizes employee safety through strict adherence to safety
protocols and regular training.
 Compliance with environmental and occupational safety standards demonstrates the
company’s responsibility toward sustainability.
7. Strong Market Reputation
 Known for delivering high-quality products within stipulated timeframes, the
company has earned trust and loyalty among its clients.
 Long-term relationships with leading industries reflect Bhavani Industries’ credibility
and reliability.
These strengths collectively enable Bhavani Industries to maintain its position as a leader in
the gear manufacturing industry, driving innovation and customer satisfaction.

4.2 Areas for Improvement

While Bhavani Industries Pvt. Ltd. is a well-established and efficient gear manufacturing
company, there are opportunities for further improvement to enhance productivity and stay
ahead in a competitive market. Below are some suggestions:

1. Implementation of Advanced Automation

 Observation: Some processes, such as material handling and inspection, are partially
manual, leading to increased cycle times.
 Suggestion: Introduce advanced robotics and automated systems for material
movement and assembly. This will improve efficiency and reduce human effort.

2. Integration of Industry 4.0 Technologies

 Observation: Data logging and analysis are primarily manual, limiting real-time
decision-making.
 Suggestion: Implement IoT-enabled sensors and devices to monitor machine
performance and production data in real-time. This will enable predictive maintenance
and optimize workflows.

50
3. Investment in Modern Inspection Tools
 Observation: While the current quality assurance tools are effective, adopting the
latest inspection technologies could improve accuracy and speed.
 Suggestion: Invest in advanced 3D scanning systems for rapid and detailed gear
inspections to further minimize dimensional inaccuracies.

4. Upgradation of Heat Treatment Systems

 Observation: The heat treatment process is well-managed but relies on conventional
furnace systems that can be energy-intensive.
 Suggestion: Introduce more energy-efficient and eco-friendly furnaces, such as
vacuum heat treatment systems, to reduce operational costs and emissions.

5. Employee Training and Skill Development

 Observation: While the workforce is skilled, continuous training in emerging
technologies could improve adaptability.
 Suggestion: Organize workshops and certifications on topics like CNC programming,
Industry 4.0, and quality management to enhance employee expertise.

6. Digital Workflow Management

 Observation: Inter-departmental communication and task tracking rely on traditional
methods.
 Suggestion: Implement ERP (Enterprise Resource Planning) software to streamline
workflow, enhance communication, and provide real-time updates on production
status.

7. Sustainability Initiatives
 Observation: There is room to further integrate sustainability practices in production
processes.
 Suggestion: Adopt renewable energy sources like solar panels and focus on waste
reduction by implementing a recycling system for metal scraps and coolant fluids.

By addressing these areas, Bhavani Industries can further improve its operational efficiency,
reduce costs, and stay competitive in the evolving manufacturing landscape.

51
4.3 Industrial Trends

The gear manufacturing industry is constantly evolving, driven by advancements in

technology, material science, and automation. Below are some key trends shaping the
industry:

1. Adoption of Advanced Materials

 High-Performance Alloys: The use of lightweight, high-strength materials such as
titanium and aluminum alloys is becoming common, especially in industries like
aerospace and automotive.
 Composites and Polymers: These materials are being increasingly used for
applications requiring lightweight gears with good wear resistance.

2. Precision Manufacturing
 Micro Gears: The demand for highly precise and miniature gears is growing,
particularly in medical devices and robotics.
 Advanced Gear Grinding: Technologies like profile grinding and honing are being
enhanced to achieve superior surface finishes and tighter tolerances.

3. Automation and Robotics

 Robotic Gear Manufacturing: Automation is being integrated across production
lines, from gear cutting to assembly, improving efficiency and consistency.
 Collaborative Robots (Cobots): These robots work alongside humans to handle
repetitive tasks, enhancing productivity while reducing physical strain on workers.

4. Industry 4.0 and Smart Manufacturing

 IoT Integration: Sensors and IoT devices are being used to monitor machine
performance and gather production data in real-time, enabling predictive
maintenance.
 Digital Twins: Virtual models of production systems are used to simulate and
optimize gear manufacturing processes before physical implementation.

52
5. Sustainability Initiatives
 Eco-Friendly Processes: Manufacturers are adopting energy-efficient equipment and
methods, such as vacuum heat treatment and additive manufacturing, to reduce their
carbon footprint.
 Recycling and Reuse: Metal scraps and cutting fluids are being recycled to minimize
waste and lower costs.

6. Advancements in Gear Design

 Optimization Through Simulation: CAD and FEA (Finite Element Analysis) tools
are widely used to optimize gear designs for durability and performance under
varying loads.
 Non-Circular Gears: Innovations in gear geometry, such as elliptical or oval gears,
are enabling new functionalities in specialized machinery.

7. Additive Manufacturing (3D Printing)

 Prototyping and Production: 3D printing is being used for rapid prototyping and, in
some cases, for producing low-volume, highly customized gears.
 Complex Designs: Additive manufacturing enables the creation of complex
geometries that are difficult to achieve with traditional machining.

8. Increased Demand for Noise Reduction

 Silent Gears: Industries such as electric vehicles are driving demand for gears with
reduced noise and vibration levels, achieved through precision manufacturing and
advanced materials.

These trends highlight the ongoing innovations and improvements in the gear manufacturing
industry, driven by technological advancements and the need for higher efficiency, precision,
and sustainability. By staying updated on these trends, companies can maintain
competitiveness and meet evolving market demands.

53
CHAPTER 5: INTERNSHIP EXPERIENCE AND REFLECTIONS
5.1 Internship Experience

Overall Experience:
My internship at Bhavani Industries Pvt. Ltd. was an enriching experience that offered hands-
on exposure to the industrial environment and a deeper understanding of gear manufacturing
processes. The structured workflow, advanced machinery, and supportive mentors helped me
bridge the gap between theoretical knowledge and practical applications. I gained insights
into production processes, quality assurance practices, and the coordination required for
smooth operations in a manufacturing plant.
Challenges Faced and Solutions:
1. Understanding Complex Machinery:
Initially, it was challenging to comprehend the working of advanced CNC machines
and the gear hobbing process.
o Solution: I overcame this by spending additional time observing the operators,
taking detailed notes, and asking relevant questions to my mentor.
2. Adapting to Industrial Workflow:
Adjusting to the fast-paced environment and meeting reporting deadlines were
initially demanding.
o Solution: I developed better time management skills by prioritizing tasks and
following a daily schedule.
3. Familiarity with Quality Standards:
Learning about international standards like ISO and the inspection tools required
effort.
o Solution: I took the initiative to assist the quality team during inspections,
which helped me understand the standards and tools more effectively.

5.2 Contribution to the Company

During my internship at Bhavani Industries Pvt. Ltd., I actively contributed to various aspects
of the manufacturing process through observation, documentation, and process improvement
suggestions. My contributions included:
1. Documentation and Reporting

54
  Assisted in recording and organizing production workflows, ensuring clarity and
efficiency in process documentation.
 Created detailed layouts of the plant, highlighting key areas of operation and material
flow.
 Summarized critical observations and findings, providing valuable insights to my
mentor and supervisors.
2. Process Observations and Improvement Suggestions
 Identified minor inefficiencies in material handling and recommended adjustments to
optimize workflow and reduce cycle time.
 Analyzed machine performance trends and suggested a more frequent maintenance
schedule for critical equipment to prevent downtime.
3. Quality Control and Inspection Support
 Assisted the Quality Assurance (QA) team in conducting dimensional checks, gear
profile inspections, and hardness testing.
 Helped in verifying tolerances using precision measurement tools like CMM,
micrometers, and profile projectors, contributing to smoother QA operations.
4. Safety Awareness and Compliance
 Actively participated in company safety drills and hazard identification exercises.
 Provided feedback on improving emergency evacuation plans to enhance workplace
safety.
These contributions were acknowledged by my mentor and reinforced the importance of
active participation, attention to detail, and continuous improvement in a professional
manufacturing environment.

5.3 Reflections

Academic and Career Growth:

My internship at Bhavani Industries Pvt. Ltd. has been a transformative experience,
bridging the gap between academic learning and real-world industrial applications. It has
significantly contributed to my technical expertise, problem-solving abilities, and
professional growth.
1. Practical Application of Knowledge
 Enabled me to apply theoretical concepts from material science, metrology, and
manufacturing processes in real-world production scenarios.

55
  Provided hands-on exposure to gear cutting, grinding, CNC machining, and
quality control techniques, strengthening my understanding of industry practices.


2. Skill Development
 Technical Skills:
o Gained expertise in CNC machining operations, quality inspection
procedures, and gear manufacturing processes.
o Developed proficiency in using industry-grade tools and equipment, such as
CMM, hardness testers, and profile projectors.
 Soft Skills:
o Improved teamwork, communication, and adaptability, essential for
working in a professional industrial environment.
o Enhanced problem-solving and decision-making skills by analyzing
production challenges and suggesting process improvements.
3. Career Aspirations and Future Growth
 This internship has solidified my interest in manufacturing and mechanical
engineering, motivating me to pursue a career in this field.
 Gained insights into industrial automation, precision machining, and quality
assurance, which are crucial for future advancements in manufacturing technology.
4. Broader Perspective on Industrial Standards
 Learning about ISO quality standards, process optimization, and industry best
practices has expanded my understanding of global manufacturing trends.
 Observing how quality compliance and efficiency improvements drive business
success has given me a new appreciation for lean manufacturing and continuous
improvement.
This internship has not only enhanced my technical and professional capabilities but has
also inspired me to continuously learn, adapt, and contribute to innovation in the
manufacturing sector.

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CONCLUSION

The internship at Bhavani Industries Pvt. Ltd. provided valuable insights into gear
manufacturing, quality assurance, and industrial workflows. Through hands-on experience, I
gained practical knowledge of key manufacturing processes, including CNC machining, gear
hobbing, grinding, heat treatment, and final inspection. Observing industry professionals and
engaging in real-time production activities helped bridge the gap between theoretical learning
and practical applications.
Exposure to advanced machinery and precision engineering techniques reinforced the
importance of maintaining high-quality standards in manufacturing. The structured workflow,
rigorous quality control measures, and adherence to ISO standards enhanced my
understanding of industrial best practices. Additionally, working with departments such as
Production, Quality Assurance, Heat Treatment, and Maintenance provided a comprehensive
understanding of the interdependency of various processes in achieving efficiency and
reliability.
Beyond technical learning, the internship strengthened essential soft skills, including
teamwork, communication, problem-solving, and time management. Adapting to a fast-paced
industrial environment and working under strict deadlines improved my ability to analyze
challenges and contribute effectively to process improvements.
Overall, this internship has been a pivotal experience in my academic and professional
journey. The knowledge and skills acquired during this period have deepened my interest in
mechanical engineering and manufacturing technology. The insights gained at Bhavani
Industries will serve as a strong foundation for my future career in the manufacturing and
automotive industries.
Key Learnings:
 Manufacturing Processes: Gained practical exposure to CNC machining, gear
hobbing, grinding, heat treatment, and final inspection.
 Precision Engineering: Observed advanced machinery and techniques ensuring high
manufacturing accuracy.
 Quality Assurance: Understood the importance of rigorous quality control measures
and adherence to ISO standards.
 Interdepartmental Collaboration: Worked closely with Production, Quality
Assurance, Heat Treatment, and Maintenance departments, understanding their
interdependency in achieving efficiency.
 Problem-Solving Skills: Developed the ability to analyze production challenges and
contribute to process improvements.
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  Soft Skills Enhancement: Strengthened teamwork, communication, time
management, and adaptability in an industrial environment.

REFERENCES

[1] https://bhavani.co.in/
[2] https://www.engineering.com
[3] https://www.sciencedirect.com
[4] https://www.iso.org
[5] https://www.hexagonmi.com
[6] https://www.nde-ed.org
[7] https://knowledge.autodesk.com
[8] https://www.plm.automation.siemens.com
[9] https://www.asminternational.org
[10] https://www.heattreattoday.com

[11] https://www.ieee.org

[12] https://ocw.mit.edu

[13] https://www.agma.org

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