INTERNSHIP REPORT ON FUKOKU INDIA PVT LTD.

Accredited by NAAC with B++ and An ISO 9001:2015 Certified Institute

SANT GAJANAN MAHARAJ COLLEGE OF ENGINEERING, MAHAGAON
Vision and Mission of the Institute

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ABSTRACT
Internship or Industrial training is an important phase of a student life. A well
planned, properly executed and evaluated Internship helps a lot in developing an awareness of
industrial approach to problem solving, based on a board understanding of process and mode of
operation of organization. The aim and motivation of this internship is to receive discipline, skills,
teamwork and technical knowledge through a proper training environment, which help me, as a
student in the field of industrial section during internship, to develop a responsiveness of the self
disciplinary nature of problems in industries. I am completed my 20 days Internship at YASH
ENGINEERING WORKS, SHINOLI. During internship I had learned about how actually the work
process in industry sectors. Like behevior,attitude,communication skills, team work with other
workers etc.

YASH ENGINEERING WORKS, SHINOLI

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[Link] & MISSION OF ORGANIZATION

❖ Continually improve our quality, delivery, and cost of products, processes and

systems by focusing on the applicable national &international standards.

❖ Set our IMS objectives and targets with respect to current performance and

future requirements.

❖ Reduce all types of wastage to ensure optimum utilization of resources.

❖ Upgrade technology to suit to changing business needs.

❖ Protect the environment and prevent pollution, work related injury and ill

health by effectively identifying aspects & hazards

❖ Provide a healthy and safety-driven work environment for all employees to

prevent any incidents, illness and injury.

❖ Eliminate hazards & reduce OH&S risks.

❖ Consultation and participation of workers on matters related to IMS.

❖ Comply with applicable legal and other obligation requirements.

❖ Improve awareness of people to understand their role, customer needs and

contribution in achieving IMS objectives.

❖ Reduction in all types of IMS risks.

❖ Ensure satisfaction of stake holder and interested party.

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2. INTRODUCTION
❖ YASH ENGINEERING WORKS was established on 24 DECEMBER 2014 in
Shinoli
❖ The President & CEO of this company is Mr. Tushant Malke.
❖ YASH ENGINEERING WORKS Main Business areas : Manufacture & sales of
Rubber, Metal, Ceramics & Synthetic resin Products.
❖ In company we Manufacture DEMPER PULLEY (The combination of HUB &
PULLEY ).
❖ YASH ENGINEERING have 3 Sections 1) FOUNDRY
2) MACHINE SHOP
3) ASSEMBLY
❖ YASH ENGINEERING have 15 CNC Machines, 2 VMC Machines, 5 Lapping
& Broaching Machines in Machine Shop.
❖ YASH ENGINEERING have 75 Employees in Machine Shop.

COMPANY PROFILE :
Address Shinoli, Maharashtra
MD [Link]
Year of Established 2014
Working Hours 1st Shift – 6:30am to 3:30pm
2nd Shift – 3:30pm to 11:30pm
3rd Shift – 11:30pm to 6:30am
Monday Holiday

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3. ROLES & RESPONSIBILITIES OF PERSONAL IN THE

ORGANIZATION

PERSON ROLE RESPONSIBILITIES

[Link] Observing all the work

[Link]

Design, Development
[Link] M.D &
Marketing
Finance, Purchase
[Link] HR &
sales

[Link] QA/QC Head Quality Inspector

[Link] HOD CNC Programmer & CAD

Machine Shop Designer

[Link] Vice HOD CNC Program inbuilding &

Machine shop Changing

[Link] Supervisor CNC Program Setting &

Machine shop CNC Parts Setting

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6. MACHINE AVAILABLE
❖ Types of Machine in the Organization
1)CNC Machine.
2)VMC Machine.
3)Lapping & Broaching Machine.

In the organization they have 15 CNC Machines, 2 VMC Machines, and 6 Lapping
& Broaching Machines. For the daily production. They produce Damper Pulley.

1) CNC Machine :

MODEL : Tsugami M08SY -II CNC Lathe Machine

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MODEL : LMW LL20T L5 CNC Lathe Machine

What is CNC Machining?

CNC stand for “ Computer Numerical Control” and CNC Machining is defined as
a subtractive manufacturing process, usually using computer control and machine tools, to produce
custom-designed part. CNC machining works on a variety of materials, including metal, plastic,
wood, glass, foam, and composites, and is used in a wide variety of industries.

CNC Machining Process :

CNC machining is a manufacturing process that utilizes computer controls to
operate and manipulate machines and cutting tools to shape raw materials, such as metal, plastic,
wood, etc to produce custom part.

How does CNC machining work?

When the CNC system is started and the required cutting programming is
entered into the software, the CNC will perform the specified cutting, milling, and other tasks.

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Application of CNC Machining:

• CNC machining is a manufacturing process used in a variety of industries, including
automotive, aerospace, construction, and agriculture.

• CNC machining processes are suitable for a variety of engineering materials,including

metals such as aluminium, brass, stainless steel, alloy steel,etc and also plastics such as
PEEK, PTFE,nylon, etc also such as wood, foam, composite materials, etc.

Industries that Use CNC Machining

• Aerospace Industry
• Automative Industry
• Consumer Electronics Industry
• Defence Industry
• Healthcare Sector
• Oil & Gas Industry

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2) VMC Machine :

MODEL : AMS mcv-300 VMC Milling Machine Definition

:
VMC machining refers to machining operation that utilize vertical machining centres (VMCs),
which, as the name suggests, have vertically oriented machine tools. These machines are primarily
utilized to turn raw blocks of metal, such as aluminium or steel, into machined component.

Use of VMC Machine :

VMC machine are cutting machines that are primarily used to remove aluminium, steel, or other
hard metals. Using a VMC, you can shape a hard block of metal into any shape that you need. This
process will give you a machined surface on your basic material.

How many axis are in VMC machine?

Mainly VMC Machines have only three axis that move on x, y and z axises. On
standard VMCs the cutter stays in vertical directions. To increase the benefits of VMC additional
axis can be added.

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Types of VMC Machines :

• Hard Rail & Linear Rail.
• Low Speed & High Speed.
• C-Type & Gantry type.
• Fixed Column & Moving Column.

Application of the VMC Machine :

• Vertical machining centers may produce part and produce parts and products for various
industries and uses.
• These are typically used for high-precision, high-accuracy, and mass-production
applications, such as those that contain the following machined components.
• The most common industrial applicatios of these are cutting, drilling, shaping and molding
of any kind

Lapping and Broaching Machine :

Broaching :
Broaching is a machining operation in which a tool used is called as Broach Having series of
cutting teeth. In this operation broach is either PULLED or PUSHED with the help of broaching
machine on the workpiece surface. parts that is produced by the broaching have good surface finish
and dimensional accuracy.

Lapping :
This process also called as a polishing process. This polishing process creates perfectly flat,
polished part. It functions by rubbing an abrasive between two surface, and can be used on a variety
of materials, such as metal, ceramics, and glass. While it is often used to create a flat surface, lapping
can also create domed surface with a great deal of precision.
Broaching used for producing the variety of shapes, internal and external, regular and
irregular profiles.

Applications of the Lapping & Broaching :

• Bearing caps
• Bearing bodies
• Cylinder blocks
• Connecting rods
• Gears and Turbines
• Keyway cutting
• Splines

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Advantages of Lapping & Broaching :

• Broach has a longer life than other tools.
• Broach can perform roughing and finishing operation.
• High skilled operator is not required.
• Interchangeable components can be produced at faster rate.
Disadvantages of Lapping & Broaching :
• In this process, all jobs need a fixture.
• Sharpening of broach is difficult and expensive..
• With the help of broaching, it is difficult to produce blind holes.  Initial cost of broach
and broaching machine is very high.
Types of Lapping & Broaching :
• Horizontal Broaching Machine.
• Vertical Broaching Machine.
• Surface Broaching Machine.
• Keyway Broaching Machine.

Horizontal Broaching Machine Vertical Broaching Machine

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Surface Broaching Machine Keyway Broaching Machine

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[Link] & MANUFACTURING

PRODUCTS

Types of Products :
• Brake Boosters
• Wiper Rubbers
• Rack & Pinion Boot
• CVJ Boots
• Precision Parts for Engine
• Disc Brake Seal
• Radiator Packing
• Master Cylinder Seals
• Drum Brake W/C Boot
In this industry we produce Damper Pulley the combination of hub and pulley

What is Damper Pulley?

A Damper pulley, commonly known as a crankshaft pulley, is a pulley mounted at the front
end of the crankshaft. It drives the accessory belt, which in turn drive the alternator, air conditioning
compressor, power steering pump, water pump etc.

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What is the material of Damper pulley?

The damper is composed of two elements; an inertia mass and an energy dissipating element.
Most often made of a synthetic elastomer, a clutch, a spring or fluid.

The function of the damper on an engine?

The most purpose of the harmonic damper, of course, is to protect the engine from these
damaging vibration. Most quality harmonic damper designs reduce the vibrations traveling up and
down the crankshaft by absorbing the vibrations and converting them to heat energy.

Advantages of the Damper pulley :

• It is one of the simplest tools for heavy lifting.
• It provides great support for the object.
• Force can be applied in any [Link] helps to change the direction force or movement.
• The pulley system does not store energy while performing the work.

Disadvantages of the Damper pulley :

• It is not a suitable solution for very high-power transfer at high rpm.
• While taking mechanical advantages lifting distance increases.
• In long time fatigue and creep happens to rope.  Not as reliable when compared with ger.

Application of the Damper pulley :

• I-pulley can be used as can idler: the same case which is used for fetching water from the
well.
• For motion transfer between shaft and rope or belt.

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[Link] CHART
CASTING PART

MACHINING

LAPPING/BROACHING

VISUALLY INSPECTION

ASSEMBELING

QUALITY CHECKING

PACKING

DISPATCH

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[Link] SECTION

Some important topics that quality sections having in industries :

• Statistically process control
• Six sigma rules and lean manufacturing.
• Root cause analysis.
• Inspection and testing.
• Metrology.
• Quality management systems.

Most commonly they used to check the job or objects with the various gauges like vernier
caliper,micrometer,height gauge etc for dimension ckecking as per requirement of the
dimensions should be there.

Vernier caliper :
A vernier caliper is usually used to measure the diameter of
circular objects. The circular jaws of the Vernier caliper fit perfectly on the circumference
of round objects. Vernier caliper consist of two scales, the main scales which is fixed and a

moving vernier [Link] main scale has reading in milimeter. The least count of Vernier
caliper is 0.002mm.

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Micro Meter :

Micrometer also called as micron ,metric unit of measure for length equal to
0.001mm,or about 0.000039 inch. Its symbol is um. The micrometer is commonly employed
to measure the thickness or diameter of microscopic objects, such as microorganisms and
colloidal particles.

Height Gauge ;

A Vernier height Gauges is used for measuring the height of the objects. Vernier
height gauges are used in metrology and metalworking to detect or measure the vertical
distances. The height gauge are often used to measure a granite surface or scribe part features
from a datum plane. The least count of Vernier height gauges is 0.02mm.

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[Link] precautions

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Blowing dust or particels, metal shavings, acids or

caustics liquid, welding light etc.

Loud machinery and tools sound, poorly maintain

equipment.

Falling or flying objects, overhead objects.

Falling or rolling objects, falling heavy objects, hot surfaces,

electrical hazards.

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[Link] JOB TRAINING - 1

❖ Operating CNC Machine

❖ Checking the job on AIR GAUGE (BAKER GAUGE)
❖ Checking the job with various GAUGES
❖ Checking the job with Vernier calliper
❖ Giving offsetting in CNC machine
z
CNC MACHINE

MODEL : Tsugami M08SY-II CNC Lathe Machine

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❖ SPECIFICATION

❖ Key Features
• Key feature of the MWR120 series include Y-axis stroke of +/- 60mm, direct
drive with no gearboxes for less power loss, and 8,000 rpm live tooling in all
station.
• The built-in gantry automation is also available with a choice of single or dual
gantries, depending on processing needs.
• Small job shops and big OEM operators share the same ongoing challenge the
need for reliability and productivity at scale , in short order.
• The MWR120 represents an expansion and evolution of the production
possibilities for the twin spindle CNC turning power.

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❖ Operating CNC Machine

Operating the CNC Machine. to
produce the job (hub). Operating 2
machines at a time. 1st machine
for inner diameter ,face. and 2nd
machine for outer diameter,
width, height etc. the cycle time
for 1 job is 1min 4sec. there are 5-
5 working tool in 1 machine each.
Minimum coolant level is 3% for
running machine. After the completing of operation take out the job clean the job with the help
of air gun because of there is burr and coolant stick on the job.

❖ Checking the job on AIR GAUGE and VERNIER

After completing cnc operation check the job dimensionally with the help of AIR
GAGUE, SNAP GAUGE,VENIER CALPER . The work of air

Gauge is displaying the ID,OD of the Job

digitally on the screen of the air
Gauge. after that check the height, Width,
centreheight ect, with the,Snap gauge and
Vernier calliper. If all ok then pass the job to next
operation. If any variation in dimension then
give the offset in machine.

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❖ Giving offsetting in CNC Machine

After checking the job dimensions
If all ok then pass the job to next
Operation to lapper for lapping and
Broaching process. If there is same
Variation in dimension then give
The offset in machine. There is 2
Section for offsetting one is WEAR And
on other one is GEOMETRY.
The variations of dimensions is

Comes in microns. EX : The boss

ID of the job is 28.017 to 28.022 as per requirement of dimensions. If the job ID is over size ex:
28.028 then minus the ID go to offset click on GEOMETRY select the no. of tool working on ID
then enter the numbers like -0.008 then click the +input button then execute.

After completing all the work then clean the machine. There is 400 job target daily
in 12 hours shift. Write the documentry like fill the Check Sheet, fill the tool monitoring sheet daily
before the work or after the work. In middle when completing of 50,100,150 jobs gives 1 job for
QA/QC (Quality) for checking. Then fill the lot card for OK and NG jobs

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14. ON JOB TRAINING - 2

❖ Visual Inspection (VI)
❖ Checking the job visually
❖ Checking the job dimensionally
❖ Identifying the job

➢ Visual Inspection (VI)

After the machining and lapping broaching process the next operation is visual
inspection (vi). VI is to checking the job visually and dimensionally.

➢ Checking the job visually

VI is to checking the job visually like Casting defects like Sand, BH, Gas, Hot
tears, Drop, Shift, Mismatch, Cold shut, Swell, Pin holes, Porosity etc.

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➢ Checking the job Dimensionally

VI is to checking the Dimensionally like Machining defects like Dent,
Scratch mark, line mark, Dimensions NG etc. Check the job with the Gauges. If there is
all ok then keep the job in blue bin and pass the job to next operation for packing. If there
is any doubt in checking the job visually or dimensionally then keep the job in yellow
bin for hold. If there is NG job Casting NG or Machining NG then keep the job in red bin
for rejection .

➢ Identifying the job

After the visual inspection there is some job will be rejected for casting
NG or Machining NG. and some job will be in hold position. and all the ok job will be
passed to the next operation there will be packing or assemble. But before going to pass this
job identify the job with marking on them like write the line no. where your working then
write your name in short form and then write the date and month when your working like
9NS30/5 after the identifying the job then pass the job to next operation.

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➢ Gauges for checking the job

WIDTH-GAUGE PLUG-GAUGE V-GROOVE

DISTANCE GAUGE KEYWAY WIDTH GAUGE

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15. Skills and Techniques learned during Internship

This Internship helps in career development by exploring various career
alternatives which is necessary for us prior to our graduation. Further this Internship by
providing real work experience that helps us with opportunities to explore our interests and
also to develop professional skills and competencies. During the internship, we are provided
with options to apply what we learnt in classes to actual practice. We are examined as to
how our attitudes, beliefs and values influence the production process.

It was fruitful time here in YASH ENGINEERING WORKS, SHINOLI and we

learnt enormously on various aspects of production and manufacturing. I have summarized
what I learnt in the form of few points which are given below.

➢ We learnt about the leadership & Team work and how it helps in performing effective
work.

➢ We learnt about tactics to maintain discipline & how to deal with workers.

➢ We learnt how to control defects in materials.

➢ We have learnt how to make a powerful team to achieve target and to solve the
problems.

➢ We have learnt about all machining process.

➢ We have learnt about CNC machining process in CNC cell Learn how to face
problems in industrial sector.

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16. Case Study-1 on minor problems & there Suitable Solution

1) Working with the Wrong Tools
Using the wrong cutting tools results in the poor quality of the machined part. The
poor result is visible by rough edges or burn spots.
Solution : To fix this problem you will need to select the right tool and setting for the build
quality and material. And consult proper instruction manuals that detail the parameter for
the various tools and the quality of the material used.

2) Programming Errors
Poor programming is another common problem that affects product creation. All
CNC equipment is controlled by CNC computers and incorrect programming leads to
downgrading the quality of the machined part.
Solution : New operators must be properly trained in all methods of programming CNC
machines. Machine shop must provide the controller with all the details about the machine
operations, equipment manuals.

3) Problems with Power Supply

Power supply issues are the most basic ones that a manufacturer often experiences.
CNC machines are complex and require an adequate power supply. Failure in power supply
result in inaccurate result and the CNC machines are not able to operate. Solution : Keep in
mind to use the correct power and voltage supply for the input side. You can also call a
specialist to perform the check. Therefore, stable power is necessary for CNC machining to
work.

4) CNC machine tool overheating

CNC machining is a non-stop process and due to high orders are working continuously
and over run time. It’s results should be overheating of the machine tools. The temperature
reaches over 150 degrees. It impacts the CNC machine life.
Solution : Care of the CNC machine is the right way to do it. Clean all the areas of the
machine and don’t let liquids and metal shavings get accumulated. Try to use a spindle with
air oil lubrication for the cnc machine helping with no issues operating for long hours.
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5) Problems with chuck and fixtures

Chuck and fixtures get loose with time resulting in these fixture not clutched firmly by
the spindle. Clamping/unclamping
Of the chucks and fixtures can lead to the poor design of the machined part and injury to the
operator in the worst-case scenario.

Solution : One needs to ensure that the part is correctly positioned

Ensuring proper clamping. Check if the chuck is working on the

MDI M-code command.

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17. Case Study-2 on minor problems & theire Suitable Solution

1) Checking the job improperly
Checking the job improperly and then the NG job, sand job,
Casting defect job, without keyway job will be passed to the next operation or assembly.
Solution : Check the job properly. If you have some time then check the job 2 times. If your
facing any difficulty to checking the job or any doubt then keep the job in yellow bin for
hold position and inform your superior.

2) Checking the job without gauges

Checking the job without gauges and then the NG job, dimensions NG, MR NG job
will be passed to the next operation or assembly.
Solution : Check the job properly with the gauges. The gauges will be matched to the job
as per requirement of dimensions.
If your facing any difficulty to checking job or any doubt then keep the job in yellow bin for
hold position and inform your superior.

3) Gauges are not good/not ok

If the gauges fallen down from the VI table then the gauges will be expand or loss the
actual size and dimensions. After checking with the gauges if any scratches then the job will
be rejected.
Solution : Check the gauges before using or by mistakenly gauge will be fallen down then
inform your superior and take new gauges. The gauges should be matched to the job as per
requirement of dimensions. check the job with Vernier scale for some time.
4) Mixing the job (Hub and Pulley)
When mixing the hub and pulley job for combination to pass the job to next
operation. Some time by mistakenly or improper work the combination of hub and pulley
mixing way is wrong. This process is crucial.
Solution : they have identification on the jobs like K15B hub-pulley, K15C hub-pulley,
K12C hub-pulley, TNGA hub-pulley
So work properly and mix the job properly as per the identification on the job and customers
requirement.

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18. CONCLUSION
It was a wonderful learning experience at "Yash Engineering Works" Shinoli, For 20 days.
I gained a lot of insight regarding almost every aspect of plant. I was given exposure in almost all
the departments at the plant. I very much appreciate the friendly behaviour from all the employees
and supervisors for sharing their experience and giving their advice which they have gained in their
long journey of work. This Internship helped us to clear the basic concepts, which will be surely
beneficial for us in the future. The working environment was friendly and the workers and
supervisors around helped us to clear our doubts and made our task easier. During the period of the
Internship, I was exposed to the necessary and significant qualities of a successful worker like
teamwork, work ethics, adaptability skills, responsibility and time management.

I am very much thankful for all the facilities provided to me by the "Yash Engineering
Works". I hope this experience will surely help me in my future and also in shaping my career.

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