1

PROJECT REPORT



SKH METALS PVT. LTD.



Name- Saurabh Khurana
Roll no-13342
Guide name- Mr. Ajay
Kumar Singh
Designation- HOD (Weld Shop)


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ACKNOWLEDGEMENT




I am grateful to Mr. Vijay Yadav (HR dept.), Mr Ajay Kumar Singh (HOD WELD SHOP)
and Er. Sunil Gulia. Without the wise counsel and guidance it would have been impossible to
complete the report in this manner.
The help rendered by (Mr. Ajay Kumar Singh) for experimentation is greatly acknowledged.











Name of student and signature
SAURABH KHURANA

3

ABSTRACT



I did my internship at SKH METALS PVT. LTD. which is situted at Manesar Haryana.
SKH METALS Ltd. Is one of the successful division of KRISHNA group that deals with the
sheet metal requirements of the automotive industry.SKH METALS supply its products
mainly to MSIL.
In SKH METALS, I worked in the PRODUCTION Dept. on YP8 line under the
guidance of Mr. Ajay Kumar Singh. Actually YP8 line is known for producing
FRONT FRAME SUSPENSION for SWIFT, SWIFT DZIRE , A STAR models of MARUTI
SUZUKI.
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Table of contents






S.no Content Page no
1
Ch-01 Company profile
i. About company
ii. Products range
iii. Plant layout

6


7
8
2
Ch-02 Department
YP8/YL8 front frame suspension
9
3
Operation Parameters
15

4
Robotic welding
17
5
Defects
18
6
YC5 front frame suspension
19
7
Red bin analysis
5S
21
5

List of figures

S.No Figure number Description
1 Fig-1 Company profile
2 Fig-2 Products range
3 Fig-3 Layout of SKH3
4 Fig-4
Fig-4.1
Fig-4.2
Fig-4.3
Fig-4.4
Fig-4.5
Fig-4.6
YP8 FRONT FRAME SUSPENSION
OP10
OP20
OP30
OP40
OP50
OP60
5 Fig-5 Flow diag. of YP8 model
6 Fig-6 Defect-M14 nut out
Welding NG












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COMPANY PROFILE


fig-1 Company profile






7

PRODUCTS

Products that are manufactured in SKH 3


Fig-2 Products range of SKH3
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LAYOUT
Layout of SKH3


Fig-3 plant layout of SKH 3

This is plant layout of SKH 3
rd
plant located at Manesar
In the fig. the RED path resembles the Gangway
On the left the purple area resembles the Raw material store area.
In the fig. the pink region resembles the Press Shop Area.
In the middle of the fig. the Green area resembles the area for the production of FRONT
FRAME SUSPENSION (YP8 and YC5).



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Department of work

YP8/YL8 FRONT FRAME SUSPENSION


Fig-4 YP8/YL8 FRONT FRAME SUSPENSION


A YP8 FRONT FRAME SUSPENSION is a structural component of a vehicle, such as an
automobile that uses a discrete , separate structure within a larger body on frame or unit body
to carry certain components ,such as the engine, drivetrain, or suspension. the frame is
welded/bolted to the vehicle. manufactured in various steps
It is manufactured in various steps
Its first step is OP10.









10


OP 10


It is the first operation of series in the manufacture of YP8 model.
No. of child parts used in OP 10 = 19 nos.
1. Stabilizer reinf. -2 nos.
2. Stud frame LH back side
3. Collar rear -2 nos.
4. Collar steering
5. M-14 flange nut (back side) 2 nos.
6. Stud frame RH
7. Reinf. rear 2 nos.
8. Pipe exhaust RH
9. Upper shell
10. M8 nut-4 nos.


Fig 4.1-OP10


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OP 20

This is the second operation of series for the manufacture of YP8 model.



No. of child parts used in OP 20 =2 nos.
1. Subassembly 1- 1 nos.
2. Lower shell -1 nos.




Fig4.2-OP20


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OP 30
This is the 3rd operation of series for the manufacture of FRONT FRAME SUSPENSION (YP8
model)
No. of child parts used in OP 30 = 11 nos.
1. Reinf. Frame front
2. Reinf. Frame rear
3. Collar engine mount. - 3 nos.
4. Bracket link RH - 2 nos.
5. M-14 nut hex RH - 2nos.
6. Bracket link LH - 2 nos.
7. M-14 nut hex LH -2 nos.
8. Pipe exhaust LH
9. Frame upper shell


Fig4.3-OP30


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OP 40

This is the 4
th
operation of series for the manufacture of YP8 model.

No. of child parts used in OP 40 = 1 nos.
1. Frame lower shell



Fig4.4-OP40




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OP 50


Operation 50 is the 5th operation of series while manufacturing of a FRONT FRAME
OPERATION (YP8 model)
No. of child parts used in OP 50 = 6 nos.
1. Splash guard - 2 nos.
2. Subassembly no. 2 2 nos.
3. Subassembly no. 4 2 nos.



Fig4.5-OP50



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OP 60
it is the last operation of the series for the production of YP8 model.

No. of child parts used in OP 60 = 2 nos.
1. Pipe tower assembly
2. Bracket line assembly
MARU-A welding is used for joining of pipe tower assembly.

Fig4.6-OP60
PARAMETERS
Some important parameters used during various operations at YP8/YL8 line :-







Gas flow 16-20 lit/min
Voltage 17-24 V
Current 180-240A
Wire dia. 1.00mm

16

FLOW DIAGRAM


A flow diagram representing various processes of FRONT FRAME SUSPENSION



Fig-5 Flow diag. of YP8 model

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ROBOTIC WELDING (MIG)


Robotic MIG welding is generally used for the production of frame front suspension are :-
1. In this kind of welding Robotic arms are used to do the welding process.
2. Its arms move in X,Y, and Z directions.
3. There are two robotic arms. 6 motors are used on each arm.
4. A mixture of Argon and CO
2
gas is used in this welding through nozzle.
5. Mild steel (MS) wire is used in this process.
6. Upto 10 mm length of wire must be used while welding.


DEFECTS
Commonly observed defects during the manufacture of front frame suspension on YP8/YL8
line are :-
Collar out
Collar gap
Pipe out
Fitment NG
Welding NG
Arm out
Bracket link assembly NG
M-12 out
Rocking
Gas fault
M-8 nut out
M-14 nut out






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FIGURES SHOWING DEFECTS

Here is a figure of M-14 nut out.

Fig6 M-14 nut out

This is the figure for WELDING NG


Fig6.1-Welding NG


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YC5 FRONT FRAME SUSPENSION

PROCESS OF PRODUCTION OF YC5 FRONT FRAME SUSPENSION ON YC5 LINE IS AS
BELOW
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fig-YC5 model production flow diagram


projection welding of
parts in first five
operations
spot welding in 6th
MIG welding in 7th
projection welding in 8th
spot welding in 9th
operation
and robotic MIG welding in
10th operation
. joining of upper and
lower panel by Robotic
spot welding
ONE MINUTE
quality check.
then Robotic MIG
welding of YC5
suspension on next
4 operations
DATE
PUNCHING
GAUGING and
finally to PAINT
SHOP.
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REDBIN ANALYSIS



It is an analysis which is used by a company to analyze / check for the rejected components in
RED trolleys.
This is done to check
Why they are placed in that red bin or we can say what is the reason of placing that
component there.
What action/operation to be done on it.



22

5S
A 5S system is used by the organization for the best productivity.
It is a JAPANESE concept.
It uses the concept of keeping the wanted things at their proper place
It also uses the concept of keeping away the unwanted things from the work area.




5-S
Sr. No. 5s Japanese words English Meaning
1 1S Seiri Sorting
2 2S Seition Arrangement
3 3S Seiso Cleaning
4 4S Seiketsu Proper lines arrangement
5 5S Shitsuke Self-Discipline
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CONCLUSION


On YP8 line I have learnt all the processes for the manufacture of FRONT FRAME
SUSPENSION.
I also got involved in separation of defective items process.
I have learnt the types of defects that can occur on YP8/YL8 line.
I also learnt the various factors that can increase productivity at YP8.
I also learnt a bit of teaching process of robots used in welding at YP8 line.