FOUR MONTHS INDUSTRIAL TRAINING

TRAINING REPORT
UNDERTAKEN AT

“ MOBILITY SOLUTIONS LIMITED,LALRU”

IN

“MECHANICAL ENGINEERING”

SUBMITTED IN PARTIAL FULLFILLMENT OF THE DEGREE

OF

BACHELOR OF TECHNOLOGY

PUNJAB COLLEGE OF ENGINEERING AND TECHNOLOGY,LALRU

SUBMITTED TO:- SUBMITTED BY:-

DR.BEANT SINGH BHUSHAN KUMAR
(HOD, ME) ROLL NO:-1317806
 ACKNOWLEDGEMENT

It is a matter great for me to undertake training from Mobility solution

limited lalru. I take this opportunity with much pleasure to thank all the people
who have helped me through the course and producing this project report. I
sincerely thanks my project guide , Mr.Sandeep Singh for his guidance, help and
motivation. A part from the subject of my course, I learnt a lot from him ,which I
am sure, will be useful in the difference stages of my life.

I am grateful to HOD of mechanical engineering in pursuing this training in a

smooth and organized manner.

I thanks my training managers Manish kumar who constantly motivates may

to achieve my Goal.

My sincere gratitude also goes to training and placement department that allow
me for undertaking training into the company.

I would also like to express my gratitude to all other members of my report

advisory committee. I would like to thank MSL and company staff for their help.

Last but not the least, I would like to thanks my family and the all Mighty
God.

Name:- Bhushan Kumar

Roll No :- 1317806
 INDEX

Sr. No. Topic Page No.

1. INTRODUCTION 1-1

2. MSL PRODUCT 2-9

3. WORKING CERITERIA OF PLANT 10-10

LAYOUT
4. MANUFACTURING PROCESS FOR 11-12
SEATS
5. MACHINES TO BE USE IN MSL PLANT 13-25
 1-INTRODUCTION
MOBILITY SOLUTIONS LIMITED (MSL):A JCBL Group Company is a
leading

Indian multi-technology player.MSL design, develops and promotes specializated components

for buses and coaches. The company has established in the year 1997 for manufacturing bus 7

coach seats, FRP components, windows frames and bus interior and accessories etc.

Over the past one and a half decade, MSL registred significant growth and today enjoys

strong brand equity in both Indian and the overseas markets. MSL is manufacturing FRP

product in joint venture with stratiforme industries France who is leader in railway FRP product

in Europe to develop state of the art FRO based high speed railway end cabs and toilet modules.

MSL is manufacturing seats in collaboration with M/s. APM Malaysia. APM’s

world

class standards of high safety reliability and quality make them world leaders in seat

manufacturing. MSL’s prestigious customers are Indian railway, all major OEM’s STU’s and

other Indian players. MSL is also a vendor to global brands like Alstom, general electronics

(GE) USA, and bombardier for Railway component.MSL is TS-16949 certified company since

November 2013 and most of its products are approved by ARAI comply with recently

introduced bus code by Govt. of india. MSL is also one of the few companies in india to get

IRIS certification for its railway products.

Today the company produces around 10000 sets of seats and 12000 sets of windows

frame and also develops customized products to meet specific requirements of its customers.

Over a period, MSL has strengthened its position as a one stop shop for bus and coach

components.With a strong resource base that includes skilled worker’s highly qualified

engineers and supports staff, the company is all poised to make deeper inroads on the Indian

and global map.

 2. MSL PRODUCTS
2.1- SEATS

BLOW MOULDING SEAT (FIGURE 2.1.1 )

JUMBO SEAT (FIGURE 2.1.2)

 RUBY 3-SEATER SEAT (FIGURE 2.1.3)

2.2- WINDOW FRAME FOR BUS

EXPORT BUS WINDOW FRAME (AL) (FIGURE 2.2.1)

 (FIGURE 2.2.2)

SUNSHINE WINDOW FRAME (AL) (FIGURE 2.2.3)

2.3- AC DUCTS AND HATRACKS
(FIGURE 2.3.1)

(FIGURE 2.3.2)
 (FIGURE 2.3.3)

2.4 LOCK ASSEMBLY FOR BUS

(FIGURE 2.4.1)
 ( FIGURE 2.4.2)

( FIGURE 2.4.3)
2.5 FRP AND ABS COMPONENTS
FRP SIDE COVER( FIGURE 2.5.1)

ABS SHEET COVER( FIGURE 2.5.2)

`
( FIGURE 2.5.3)

2.6-PU COMPONENTS

ARMREST PU PAD ( FIGURE 2.6.1)

 HANDLE ( FIGURE 2.6.2)

( FIGURE 2.6.3)

2.7-COACH COMPONENT
LOUVER ( FIGURE 2.7.1)

( FIGURE 2.7.2)
LIGH( FIGURE 2.7.3)

( FIGURE 2.7.4)
 ( FIGURE 2.7.5)

( FIGURE 2.7.6)

3. WORKING CRITERIA OR PLANT LAYOUT

RAW MATERIAL

(FROM STORE)

FABRICATION LINE

( MAKING FOR SEAT STRUCTURE)

PAINT SHOP

(FOR POWDER COATING)

 STORE DEPARTMENT SEAT

(NEED FOR NUT,BOLT & HANDLE ETC.) ASSEMBLY LINE

STITCHING DEPARTMENT

(STITCH THE SEAT COVER OF REXINE)

CARPENTERY SECTION PU SECTION

(FOR CUTTING OF WOODEN PLY) (FOR CUSHION & BACK PU)

 4. MANUFACTURING PROCESS FOR SEAT
Three main units for manufacturing the seats :-
4.1-FABRICATION SHOP:-
In this shop, firstly spot welding
operation of bracket has

done. After that MIG welding operation of bracket from back hinge was performed.

Then crimping operation of frame component has done. After that spot & MIG welding

operations for frame component and lifter has done. Then tightening operation is performed.

Finally, spring crimping has done.

MIG welding was used for the manufacturing of the seats base. Mild steel wire of

diameter 0.8, 1.0 and 1.2 mm were used as filling material during welding and Argon gas was

used as inert gas in MIG welding process. The material of consumable wire was formed by

copper coating on mild steel. The robotic arm could weld of 6 units at one time and each unit

was placed at gapping of 60.

4.2-PU SECTION:-

The full form of PU is POLYURETTEN. PU is the mixture of

ISOCYNATE and POLYOL. Firstly the POLYOL is sent to blend-tank automatically and

ISO-CYANATE is send to machine-tank manually. The capacity of the

machine-tank is 400kg. The agitation of POLYOL took place in the blend-tank. After that the

POLYOL is sent from blending tank to machine tank where it mixed with ISO-CYANATE in

the ratio of 3:7. The

temperature of the mixture is maintained between 180C to 280C.

Now a machine is used having hydraulic device,mechanical arm and control

unit. The mixture of POLYOL and ISOCYANATE is sent to the hydraulic device through pipes

which are also known as ‘Transferring unit’. After that the mixture of POLYOL and ISO-

CYANATE is sent to the mechanical arm. The function of mechanical arm is to pouring the
mixture of POLYOL and ISO-CYANATE into the mould. The mechanical arm is operated

fully automatically, where the quantity of the mixture which should be pour and the duration of

pouring time could be fix by programming in the machine.

Before pouring, the mould is heated upto 560C-660C. The chemical mixture is poured

in the mould after placing a wire frame in the mould. After pouring the chemical mixture, the

rising of it takes place gradually.

The pouring of the material took place according to the hardness and density

required of the seats. Total time taken to manufacture of one set of seat was 5 minutes and time

required for the removal and cleaning of the unit was 3 minutes. RI spray was used to clean the

unit. Therefore for completion of one cycle for one set of seat, the total time required was 8

minutes and 432 Bus seats were manufactured per batch. After checking the Code and quality

of the seats they were sent to assembly line.

4.3-ASSEMBLY SHOP:-

The final stage of operation was done in the Assembly shop. seats are

assembled as per batch. M-8 and M-10 bolts are used in the assembly process. The machine

which could fix the bolts was sensor based. The conveyor belt does not move further if the

assembly operation is improper or not completed. The driver and co-driver seats were

assembled on same conveyor belt and the back seats were assembled on different conveyor

belt. Hot water was used for cleaning purpose after assembly.

Assembled seats are also exported to Europe countries.

 FIGURE- 4.3.1
5-MACHINES TO BE USE IN MSL PLANT

5.1- MIG WELDING:-

MIG (Metal Inert Gas) welding ,also known as MAG (Metal Active Gas) and

in the USA as GMAW (Gas Metal Arc Welding), is a welding process that is now widely used

for welding a variety of materials, ferrous and non ferrous. The essential

feature of the process is the small diameter electrode wire, which is fed continuously into the

arc from a coil. As a result this process can produce quick and neat welds over a wide range of

joints.
 FIGURE- 5.1.1

EQUIPMENT
 DC output power source
 Wire feed unit
 Torch
 Work return welding lead
 Shielding gas supply, (normally from cylinder)

5.2- DRILLING MACHINE

A drilling machine, called a drill press, is used to cut holes into or through metal,

wood, or other materials Drilling machines use a drilling tool that has cutting edges at its

point. This cutting tool is held in the drill press by a chuck or Morse taper and is rotated and

fed into the work at variable speeds. Drilling machines may be used to perform other

operations. They can perform countersinking, boring, counterboring, spot facing, reaming,
and tapping .Drill press operators must know how to set up the work, set speed and feed,

and provide for coolant to get an acceptable finished product. The size or capacity of the

drilling machine is usually determined by the largest piece of stock that can be center-

drilled. For instance, a 15-inch drilling machine can center-drill a 30-inch-diameter piece

of stock. Other ways to determine the size of the drill press are by the largest hole that can

be drilled, the distance between the spindle and column, and the vertical distance between

the worktable and spindle.

OPERATION OF DRILLING MACHINE (FIGURE- 5.2.1)

 (FIGURE- 5.2.2)
DRILLING MACHINE SAFETY PRECAUTIONS:-

Drilling machines are one of the most dangerous hand operated pieces of

equipment in the shop area. Following safety procedures during drilling operations:-

 Never clean away chips with your hand. Use a brush.

 Keep all loose clothing away from turning tools.

 Make sure that the cutting tools are running straight before starting the operation.

 Never make any adjustments while the machine is operating.

 Never place tools or equipment on the drilling tables.

 Keep all guards in place while operating.

 Remove all chuck keys and wrenches before operating.

 Always wear eye protection while operating any drilling machines.

5.3-MECHANICAL PRESS MACHINE

A mechanical power press is a machine used to supply force to a die that is used to blank,

form, or shape metal or nonmetallic material. Thus, a press is a component of a manufacturing

system that combines the press, a die, material and feeding method to produce a part. The

designer of the manufacturing system must also provide proper point of operation guards to

safeguard pressroom personnel. Each of the components of this manufacturing system is

important and will be discussed in turn later in this work. A foundation for understanding the

system is acquiring a working knowledge of the press.

TYPES OF PRESSES:-

Mechanical presses fall into two predominant press types Gap frame and Straight

side types. The frame types used in mechanical presses are similar to those used in many

hydraulic presses. Here, we will limit our discussion to mechanical presses.

The drive systems, clutches, brakes, counterbalance systems, die cushions,

electrical, hydraulic and pneumatic features are similar in both the gap frame and straight side

types. The type and size of press selected is mainly determined by the work to be done.
 (FIGURE- 5.3.1)
5.3.1- GAP FRAME PRESS MACHINE:-
One type of gap frame press. The principle feature of gap frame
machines is

the C-shaped opening. For this reason, gap frame presses are also referred to as C-frame

presses. In press force capacities up to approximately 250 tons (2,224 kn.) and larger, gap

frame presses are less costly than a straightside press having the same force capacity and

control features. In the 35 to 60-ton (311 to 534 kN) force range, they may cost approximately

half as much as straightside press.

5.3.2- BASIC STRAIGHT SIDE MECHANICAL PRESS:-

Straightside presses derive their name from the vertical columns or
uprights on

either side of the machine. The columns together with the bed and crown form a
strong housing

for the crankshaft, slide and other mechanical components. The housing or frame of most

straightside presses is held together in compression by pre-stressed tie rods. Some straightside

presses have solid frames. Generally a solid frame straightside press is less expensive than one

having tie rods. However, tie rod presses are easier to ship disassembled and have better ability
to withstand overloads.

Basic Straight Side Mechanical Press (FIGURE- 5.3.2)

 5.4-SHORT BLASTING MACHINE

Blasting is the process where small angular or spherical particles are propelled at a

part by compressed air, or mechanical high speed rotating wheels or water pumps .

The blast media type, shape, size, density, and hardness, along with media acceleration

and volume of media, combined with blasting distance from the workpiece, angle of impact and

time cycles are important factors in the blast process capabilities.

The blasting equipment is produced to deliver, reclaim and contain the media, contain

the part to be blasted and collect the dust from the blasting process. Parts can be processed

individually as a batch process or can be automated thru the system.

Schematic diagram of abrasive grain impacting on the surface to be cleaned:-

(FIGURE- 5.4.1)
 (FIGURE- 5.4.2)

Surface affects from the blasting process are:

 Blending of tool marks

 Removal of weld discoloration

 Surface cleaning

 Pre plate and anodize finishes

 Paint and coating removal

 Heat treat, mill scale removal

 Weld splatter removal

 Rust removal
 Mold cleaning`

5.5- BENDING MACHINE

(FIGURE- 5.5.1)
Modern features on tube-bending machines, especially pressure-die assist,
have

permitted many tube-bending machine operators to rely more upon manipulating machine

controls to obtain adequate results than upon a precise, systematic tool setup.
Many optional controls on CNC tube-bending machines, such as variable assist

pressure, circumferential boost, and in-cycle mandrel retraction, were created to make the most

difficult applications practical. However, they are instead frequently used to push material

about at the point of bend to overcome the defects of a poor set-up on routine application
 (FIGURE- 5.2.1)

5.6-GRINDING MACHINE

Grinding is a material removal and surface generation process used to shape and

finish components made of metals and other materials. The precision and surface finish

obtained through grinding can be up to ten times better than with either turning or milling.

Grinding employs an abrasive product, usually a rotating wheel brought into

controlled contact with a work surface. The grinding wheel is composed of abrasive grains held

to gether in a binder. These abrasive grains act as cutting tools, removing tiny chips of material

from the work. As these abrasive grains wear and become dull, the added resistance leads to

fracture of the grains or weakening of their bond. The dull pieces break away, revealing sharp

new grains that continue cutting.

 (FIGURE- 5.6.1)

5.7-LATHE MACHINE

The lathe is a machine tool used principally for shaping articles of metal,

wood, or other material. All lathes, except the vertical turret type, have one thing in common

for all usual machining operations; the workpiece is held and rotated around a horizontal axis

while being formed to size and shape by a cutting tool. The cutter bit is held either by hand or

by a mechanical holder, then applied to the workpiece. Principal capabilities of the lathe are
forming straight, tapered, or irregularly outlined cylinders, facing or radial turning cylindrical

sections, cutting screw threads, and boring or enlarging internal diameters. The typical lathe

provides a variety of rotating speeds and suitable manual andautomatic controls for moving the

cutting tool.

Types of Lathes:-

Lathes can be conveniently classified as engine lathes, turret lathes, and special

purpose lathes. All engine lathes and most turret and special purpose lathes have horizontal

spindles and, for that reason, are sometimes referred to as horizontal lathes. The smaller lathes

in all classes may be classified as bench lathes or floor or pedestal lathes, the reference in this

case being to the means of support.

BENCH-TYPE ENGINE LATHE. (FIGURE- 5.7.1)

FLOOR-MOUNTED ENGINE LATHE. (FIGURE- 5.7.2)
 GEAR-HEAD ENGINE LATHE. (FIGURE- 5.7.3)

5.8-PAINT OVEN FOR POWDER COATING

5.8.1-Powder Coating Process:-

The powder coating process is very similar to a painting process except that the

“paint” is a dry powder rather than a liquid. The powder sticks to the parts due to electrostatic

charging of the powder and grounding of the parts. Any substrate can be used that can tolerate

the heat of curing the powder and that can be electrically grounded to enhance charged particle

attachment. The powder flows and cures during the application of heat.
 (FIGURE- 5.8.1)

Advantages of powder coating are:

 Powder recovery for reuse.

 Can be more durable than paints.

Disadvantages of powder coating are:

 Can have less leveling than paint (more orange peel)

 Curing is typically more energy intensive than paint drying due to higher temperature
requirements.