Training Project

TRAINING REPORT
TO REDUCE THE REJECTION RATE IN PISTONS

Submitted by:
Karan gupta
Roll No. : CO12124
Under the Guidance of

Faculty coordinator
Industry coordinator
MR.Amoljit singh gill
Er. Charanjeet Singh
Training coordinator,CCET
Asst.Manager,PMS
FMGIL
CHANDIGARH COLLEGE OF
ENGINEERING
&
TECHONOLOGY
DECLARATION
I hereby declare that the project work entitled To Reduce the Rejection Rate in Pistons is
an authentic record of my own work carried out at Federal Mogul Goetze India Ltd as
requirements of training for the award of degree of B.Tech (Mechanical Engineering),
Chandigarh College of Engineering and technology
Charanjeet Singh (industry coordinator),
under the guidance of Er.
MR.AMOLJIT SINGH GILL (faculty
coordinator) from 09.06. 2014 to 05.07.2014.
(Signature of student)
Place: __________________
Date: __________________
Name of Student: Karan gupta

Roll No.: 10903053 (4ME2)
Certified that the above statement made by the student is correct to the best of our knowledge
and belief
Faculty coordinator
MR.Amoljit singh gill
Professor,CCET
Industry coordinator
Er. Charanjeet Singh
Asst. Manager,PMS
FMGIL
ACKNOWLEDEMENT
I Karn gupta would like to give my sincere thanks to all people (Piston Machine Shop)
who have contributed in completing it. These are people who simply by being there
influenced and insspired me to do different things. I acknowledge my gratitude and indebted
to Er.Charanjeet Singh(Training coordinator) who is a source of continuous guidance and
inspiration to me. Without their guidance and motivation this report could not completed.
I acknowledge my indebted and gratitude to both of these as
they had taken keen interest in work and gave their valuable advice from time to time. I really
thanks to them for guide me to complete my project.
Place: ______________
Date: ______________
KARAN GUPTA
CONTENTS
Summary/abstract
General introduction (organization)
General introduction (shop)
Projects
1. Rejection reduction in pistons on defect operation missing.
CONTAINS:
Introduction ( projects)
Objective of project
Methodology adopted
Analysis procedure
Testing
Implementation
Result/Salient outcomes of project
Summary/Abstract
This report contains lot of content about study of the pistons, project on rejection reduction in
the pistons.
PROJECT STUDY ABOUT PISTONS: This topic contains the all the processes done
on the pistons, different parameters of piston, constructional details.
PROJECT-I (Rejection reduction in pistons on defect operation missing)

this project contains a technique tom reduce the scrap in piston on defect of the operation
missing. First of all, problem is analyzed by daily inspection then reasons are founded
behind the problem. After this flow process diagrams and 5s techniques used for
reducing the operation missing scrap. Prato chart analysis is used for obtaining the
final result.
PROJECT-II (Rejection reduction in pistons on defect skirt size diameter)

this project contains a technique tom reduce the scrap in piston on defect of the skirt size
dia. First of all, problem is analyzed by daily inspection & fishbone diagram then
reasons are founded behind the problem. After this why why technique used for
reducing the scrap skirt size dia. X and R chart is used for obtaining the final result.
PROJECT-III (Rejection reduction in pistons on defect of PH & KH) this

project contains a technique tom reduce the scrap in piston on defect of the KH & PH.
First of all, problem is analyzed by daily inspection & fishbone diagram then reasons
are founded behind the problem. After this why why technique used for reducing the
scrap KH & PH. X and R chart is used for obtaining the final result.
PROJECT-IV (Rejection reduction in pistons on defect of transport scrap)

this project contains a technique tom reduce the scrap in piston on defect of the transport
scrap. First of all, problem is analyzed by daily inspection & fishbone diagram then
reasons are founded behind the problem. After this why why technique used for
reducing the transport scrap. Direct analyzing technique is used for obtaining the final
result.
Introduction About
Organization:
Federal Mogul
(Goetze) India ltd.
FEDERAL MOGUL GOETZE (INDIA) LIMITED BAHADURGARH

LOCATION: GOETZE LIMITED BAHADURGARH is situated at Patiala Rajpura road at
about 10 kilometers from Patiala.
INTRODUCTION: GOETZE (I) LIMITED, BAHADURGARH was set up in 1954 with the
collaboration of M/S GOETZE WERKE, GERMANY, which started its production of piston
rings for automobile industry in 1957.
Considering the need of complete piston assembly ESCORTS LIMITED
ventured into the manufacturing of pistons in 1958 with the collaboration of M/S MAHLE,
GmbH GERMANY, which delivered the pistons in 1960.
ESCORTS entered in collaboration with M/S SUKO GmbH, GERMANY for
pistons pin in 1967 and manufacturing started in 1968.
To meet the increasing demand of market in 1977 a parallel unit for
manufacturing pistons ring was set up in BENGALURU.
1. Established in 1954.
2. 22000 employees.
3. 20 plants in all.
4. The headquarters are in Delhi.
5. Pride of establishing the first dealer networking in the country.
6. Collaboration with GOETZE of Germany.
7. Productions of 1st class pistons ring.
8. Collaboration with MAHLE of Germany.
ORGANIZATION OVERVIEW
Federal-Mogul Corporation is a global supplier of automotive components, systems and
modules serving the world's original equipment manufacturers and the global aftermarket.
The company utilizes its engineering and materials expertise, proprietary technology,
manufacturing skill, distribution flexibility and marketing power to deliver products, brands
and services of value to its customers. Federal-Mogul is focused on global profitable growth
to create value for and bring greater satisfaction to its customers, employees and
stakeholders.
Federal-Mogul World Headquarters is located at 26555 Northwestern Highway, Southfield,
MI 48033, U.S.A. It also have 111 manufacturing sites worldwide.
Federal-Mogul has 45,000 employees in 35 countries. Worldwide annual sales for year-end
2007 were $6.9 billion. In 2005, OE accounted for 58% of our annual sales, while
aftermarket sales are 42%.
Federal-Mogul design, engineer and manufacture a variety of automotive products for its
aftermarket and OE customers. Its products include, but are not limited to, bearings, pistons,
piston pins, rings and liners, valve seats and guides, dynamic seals, hot and cold static gaskets
and seals, liquid elastomeric molded (LEM) seals, systems protection, friction products and
aftermarket products (engine components, gaskets, antifriction bearings and seals, brakes,
chassis, wipers, fuel pumps, ignition and lighting).
Federal-Mogul aftermarket products are sold under a variety of power brands, including, but
not limited to, AE engine products, ANCO wipers, Champion spark plugs and wipers,
Fel-Pro gaskets, Ferodo brake pads, Glyco bearings, Goetze piston rings, Moog
chassis products, National Wheel End Components, Nral pistons, Payen gaskets,
Sealed Power engine products and Wagner lighting and brake products.
GOETZE (I) LIMITED, BAHADURGARH was set up in 1954 with the collaboration of M/S
GOETZE WERKE, GERMANY, which started its production of Piston Rings for automobile
industry in 1957. Considering the need of complete PISTON assembly ESCORTS LIMITED
ventured into manufacturing of Pistons. In 1958 with the collaboration of M/S MAHLE,
GERMANY, this delivered the Indian automobile industry its Piston in 1960. ESCORTS
entered in collaboration with M/S SUKO, GERMANY, for Piston Pins in 1967 and
manufacturing started in 1968.To meet the increasing demand of market, in 1977 a parallel
unit for manufacturing Pistons and Pistons Pins was set up in BANGLORE.
Technological leadership matched with innovated thinking has made ESCORTS and
GOETZE products to enjoy a high degree of customer confidence and are the first choices of
discerning for application ranging from BI-WHEELER to BATTLE TANKS. The plant
manufacture over 3.4 million & 2.9 million Piston-Pins & Crank Pins annually .Around 50%
of its production is being fitted by original equipment manufacturers of Automobile, Biwheelers, Tractors, Stationary Engines, Generator etc. Among its biggest customers are the
MUL for which it manufactures pistons for Maruti-800, Esteem, Zen etc. Other customers
include Peugeot, Escorts Division-Faridabad, Bajaj, Hindustan Motors, TVS, Rajdoot and
many others. The company also directly supplies its products to all the authorized dealers of
the spare part for the above companies throughout INDIA.
From 1st October, 1996, ESCORTS LIMITED entered into joint venture with M/S
MAHLE GmbH, GERMANY with the formation of new company, ESCORTS MAHLE
LIMITED. In 1998, GOETZE also became the part of FEDERAL MOUGAL, a well
known group of U.S.A.
9. In June 2000, both ESCORTS MAHLE LIMITED and GOETZE have become QS 9000
certified companies. Wide range of pistons and pins are also exported to U.K., Iran,
Bangladesh, Sri-Lanka, Egypt, Singapore and Malaysia.
10. In October 2006 name changed Goetze (India) Limited to FEDERAL-MOGUL
GOETZE (INDIA) LIMITED because majority stake holding acquisition by FederalMogul Corporation. Federal-Mogul Goetze (India) Limited is the largest manufacturer of
pistons and piston rings in India Pistons are varying from 30mm to 300mm diameter. The
most modern production facilities at Federal-Mogul Goetze (India) Limited Patiala is
certified TS 16949, ISO14001 and OHSAS 18001.
GOETZE AND ITS PRODUCTS
GOETZE LIMITED is one of the biggest private concerns in India, which
manufactures a variety of products like pistons, gudgeon pins, rings, sleeves and cylinder
head. Its present chairman is Mr. ANIL NANDA
PRODUCTS OF PATIALA PLANT
PISTONS
PISTON RINGS
PISTON PINS
EXPORT DESTINATION
ANGOLA
BANGLADESH
BHUTAN
EGYPT
MOZAMBIQUE
NEPAL
SRI LANKA
CUSTOMERS
MARUTI UDYOG LTD.
HINDUSTAN MOTORS
BAJAJ AUTOS
TVS SUZUKI LTD.
MAJESTIC AUTO LTD.
KINETIC ENGINEERING LTD.
HERO MOTORS
EICHER MOTORS
ESCORTS LTD. (FARMTRAC DIVISION)

PMS (NEW) CUSTOMERS:
Maruti & Suzuki Ltd.
Renault Ltd.
Skoda India
Mahindra & Mahindra ltd.
Tata motors
MAJOR CUSTOMERS
I.
COMMERCIAL VEHICLES:
Telco
Ashok Leyland
Swaraj Mazda Ltd.
Bajaj Tempo Ltd.
Eicher Motors Ltd.
State Transport Undertakings
II.
BI-WHEELERS:
Yamaha Motor India Private Ltd.

Bajaj Auto Ltd.
Kinetic Engineering Ltd.
TVS Motor Company
Majestic Auto Ltd.
Ideal Jawa (I) Ltd.
Monto Motors Ltd.
Enfield
Hero Motors Ltd.
III.
TRACTORS:
Eicher Tractors Ltd.

Mahindra & Mahindra Ltd.
Escorts Ltd. (Td)
Escorts Ltd. (Farmtrac Division)
Mahindra Gujrat Tractor Ltd.
HMT Ltd. (Td)
Swaraj Engines Ltd.
New Holland Tractors Ltd.
International Tractors Ltd.
L & T John Deer
IV.
PASSENGER CARS & JEEPS:
Maruti Suzuki
Hindustan Motors Ltd.
Mahindra & Mahindra Ltd.

Telco.
V.
DEFENCE & RAILWAYS:
Vehicles Factory, Jabalpur.

Alco
VI.
COMPRESSORS /AIR CONDITIONERS:
Telco.
Elgi Equipments Ltd.
Voltas Ltd.
Sundram Clayton Ltd.
L & T - Komatsu Ltd.
State Transport Undertakings
VII.
STATIONARY ENGINES:
Kirloskar Oil Engines Ltd.

Ruston & Hornsby Ltd.
Birla Yamaha Ltd.
Greaves Lombardini Ltd.
VIII.
INTERNATIONAL CUSTOMER
Chevrolet
BMW
Mitsubishi
Ferrari
MANUFACTURING PLANT IN INDIA

Currently company has the following manufacturing facilities:
S No.
Plant
Products manufactured
Remarks
1.
PATIALA
Piston Rings, Pistons,

Pins
Original FMGIL facility

balance acquired through
Escorts Pistons Ltd.
2.
Bhiwadi
Valve Train Components &

Structural Components
Acquired through merger of

Federal-Mogul Sintered
Products Limited with our
Company.
Bangalore
Piston Rings, Pistons, Pins
Partly original FMGIL

facility and the balance
acquired through merger
of Escorts Pistons Ltd.
4.
Bangalore
Steel Piston Rings
Facility of our subsidiary
FMG PATIALA PLANT

Product:
Pins, Piston & Piston Rings
Processes:
Melting.
Casting.
Cutting & machining.
Inspection
Packaging
Current Employees: over 2500

Site Square Meters: 243333.56 Sq.m
Pistons
Pins
Rings
FEDERAL MOGUL BRANDS

Federal-Mogul's Abex brand provides commercial-grade brake
products, including High-endurance brake pads, brake linings and
brake shoes.
AE is recognized throughout the world as a leading brand of quality

engine replacement parts. The AE product line includes pistons, piston
rings, bearings, valves, timing belts and kits, cam train and other
ancillary engine products.
ANCO is the leader in replacement wiper blades, refills, washer

pumps and wiper arms. ANCO products ensure the cleanest windshield
for every driving condition, making ANCO the Clearest Choice in
Wiper Blades.
The Atlas brand is Federal-Mogul's market-leading brand of gaskets

in Mexico for diesel engines and heavy-duty equipment. Atlas is part
of Federal-Mogul's Sealing Solutions group.
Federal-Mogul's Beral brand provides brake linings and disc brake

pads to millions of commercial vehicles, including trucks, trailers,
semi-trailers and buses all over the world.
The Carter fuel pump brand provides proven replacement parts with
OE fit and form. This approach makes Carter the first choice in
aftermarket fuel pumps.
For more than 100 years, Champion has been one of the world's most
respected brands, providing a wide array of service replacement parts.
These trusted products include spark plugs, wiper blades and filters.
DURON is a specialist in heavy-duty friction and brings exceptional

braking power and durability to commercial vehicles and original
equipment customers in Europe.
Fel-Pro is the industry's leading brand of aftermarket sealing

products for passenger cars, light trucks, medium-duty truck and
heavy-duty applications.
For more than a century, Ferodo has led the development of friction
materials in their modern form. Ferodo offers brake pads and shoes,
brake discs, brake fluids, racing products and motorcycle products.
FP Diesel heavy-duty engine parts and gaskets include a

comprehensive range of precision-engineered components for the
construction, marine, agricultural, mining, gas compression, trucking
and industrial sectors.
Each year, Glyco OE bearings are installed on more than 10 million

automotive, maritime and stationary engines, as well as on agricultural
and construction equipment.
Federal-Mogul's Goetze brand is a leading name in the automotive

world, offering quality piston rings and cylinder liners as well as a
range of sealing solutions.
The Federal-Mogul Moog line is the preferred brand of replacement

chassis parts by professional technicians. Our Moog products solve
steering and suspension problems and make installation easier.
Federal-Mogul's National brand has built a reputation as one of the

most respected names in wheel end products. Our design team keeps
pace with the industry and provides advanced solutions to meet the
needs of today's vehicles.
Necto, the main friction brand in Spain, is characterized in offering

an exceptional power of braking and durability. The wide Necto
product range includes the most advanced friction materials on the
market.
Nral is at the forefront of piston technology. Nral has years

of experience in rapid product development, ultra-modern production
technology and flexible service.
The Federal-Mogul Payen brand of gaskets, oil seals and cylinder

head bolts represents innovative design technology and strict
manufacturing standards - qualities that support our reputation as a
trusted manufacturer to the automotive aftermarket.
PowerMAX spark plug wire delivers maximum protection and

maximum power.
The quality of Federal-Mogul Precision Universal Joints can be

seen in all aspects of our parts, from our forged and case-hardened
alloy steel crosses to our high-quality, heat-treated needle bearings.
Raimsa is a trusted brand in Mexico that provides an extensive line of

kingpins, clutch-release bearings and hanger bearings.
Federal-Mogul's Sealed Power product line represents a complete

system of application-engineered internal components, including
pistons, piston rings, engine bearings, camshafts, oil pumps, timing
components and valve train products.
Speed-Pro has built a reputation for performance engine

components. Meeting specific needs - from increased durability to
reduced weight, higher temperature demands or excellence in oil
control - is the Speed-Pro advantage.
Wagner - the world's leader in brake pads - offers product lines

that feature quick, convenient, precise installation for passenger
vehicles and medium-duty commercial applications.
Wagner Lighting Products, the Automotive Lighting Experts,

has been a visionary in automotive lighting since the development of
the sealed-beam headlamp.
MILESTONES
1954: Incorporated as a JV with Goethe Werke
1957: Ring & Liner Production, Patiala
1958: Piston Production as Escorts (Automotive Division) (Collaboration: Mahle), Patiala
1960: Cast Iron / Forged Piston Production, Patiala
1968: Pins / Ring Carrier Production. Patiala
1977: Piston / Ring Production, Bangalore
1982: Steel Rings / Large Bore Locomotive Piston, Bangalore
1985: Light Alloy Products, Patiala
1989: Auto Thermic Pistons Production, Bangalore
1990: Molly coated / IKA / Chrome Oil Rings, Patiala
1992: Large Bore Rings / Pistons for Battle Tanks Bangalore
1994: Composite Pistons / New Ring Foundry, Bangalore
1996: Escorts (Automotive Division) hived off into joint venture with M/s Mahle, Germany
1997: Goetze TP (India) Ltd. setup for manufacture of Steel Rings
2000: Merger of Federal-Mogul Sintered Products Ltd. with Goetze (India) Ltd.
2003: Merger of Pistons activities with Goetze (India) Ltd.
2004: Introduction of CHROME-CERAMIC RINGS
2004: Technical Collaboration for Pistons with Federal-Mogul Corporation
2006: Majority stake holding acquisition by Federal-Mogul Corporation
2006: Name changed Goetze (India) Limited to FEDERAL-MOGUL GOETZE (INDIA)
LIMITED
RECEIVED BY COMPANY SINCE 1998

1998-1999
1999
Received the best performing supplier award from Tata Cummins Ltd.
Our plant at Bhiwadi received the OHSAS 18001:1999 certificate from TUV
Certification Body for Environmental Management Systems of RWTUV
2000-2001
Systems GmbH.
Escorts Mahle Ltd. received an award of excellence for performance in quality
2001-2002
from Maruti Udyog Ltd.

Escorts Mahle Ltd. received a certificate of appreciation from Kinetic
2002
Engineering Limited for supply of quality materials and meeting schedules.

Received the best performance vendor award for casting from Yamaha Motors
2004
India Pvt. Ltd.

Our plant at Bhiwadi received ISO 14001:2004 certificate from TUV
Certification Body for Environmental Management Systems of RWTUV
2004-2005
Systems GmbH
Received the award for QCDDM in Machining Category from Honda
2005 2006
Motorcycle & Scooter India (Pvt.) Limited.

Received a certificate of appreciation from Standard Group of Companies for
2005 2006
Supply of components, maintaining quality and adhering to schedules.

Received the best supplier performance award from Mahindra & Mahindra
Ltd in the category Proprietary and Electrical.
Introduction:
Piston
machine shop
(New)
LVD
PISTON MACHINE SHOP

The pistons from piston foundry shop are sent to blank stores. From there they are then
transported to Piston Machine Shop for machining purpose. Most of the machines are
imported from Germany and Japan having very high accuracies up to few microns. In this
shop, the cast or the forged pistons are machined to the required size and finish; this is done
in a series of operations performed on a piston on different machines. After the pistons have
been properly machined, finished and finally inspected; they are send for packing in finished
Article.
The pistons are produced in machine shop in groups or batches. Each batch contains a
particular type of piston and is machined for particular time according to demanded customer
order. After one batch has been produced, another batch can be brought for production on the
machine line. The machines are readjusted according to the specifications of the new type.
Identical machine lines have been set up in GASOLINE. Each machine line is used for
particular range of sizes of pistons. Different operations on pistons are performed on the
different machines, which are placed in sequences so that the pistons can be taken from one
place to the other without wastage of time.
This shop equipped with the most modern and sophisticated machines have very high
accuracies. Each machine does different operations and the piston goes from one machine to
another in a sequential way.
SHOP ALLOTED: PISTON MACHINE SHOP

Major Customers
LVD1
LVD2
LVD3
LVD4
MARURI SUZUKI, FIAT, TATA

RENAULT, TOYOTA
TATA, MAHINDRA & MAHINDRA
MAHINDRA & MAHINDRA
MACHINING SECTION
MACHINE SHOP IS DIVIDED INTO FOLLOWING SECTIONS: 1.
Machine section.
2.
Surface treatment section.
3.
Lock pin assembly.
4.
Groove cutter section.
5.
Tool store.
6.
Maintenance (Electrical & Mechanical) section.
7.
Intermediate & Final Inspection
PROJECT STUDY ABOUT PISTONS

FUNCTION OF A PISTON:
The functions which a piston is called upon to perform in an I.C. engine are:
1. To transmit the force of explosion to the crankshaft.
2. To form a seal so that the high pressure gases in the combustion chamber do not
escape into the crank case.
3. To serve as guide & bearing for small end of the connecting rod.
DESIRABLE CHARACTERSTICS OF PISTON
1. It should be silent in operation both during warming up & on normal running.
2. The design should be such that the seizure does not occur.
3. It should offer sufficient resistance to corrosion due to some product of combustion.
(Exp. Sulphur dioxide)
4. It should have the shortest possible length so as to decrease over all engine size.
5. It should be lighter in weight so as inertia forces created by its reciprocating motion
are minimum.
6. It must have long life.
OPERATING CONDITIONS
The pressure in Combustion Chamber
GASOLINE: Up to 75 bar in NA (Naturally Aspirated)
DIESEL
80 to 110 bars in Naturally Aspirated Engines
130 to 180 bars in Supercharged Engines
Piston Speed
Gasoline17m/Sec
Diesel22m /Sec
During each working cycle, the pressure and inertial forces generates complicated load
system, depending upon power and speed. The mechanical loads are superimposed by
Thermal stresses, which are generated by temperature gradient.
PISTON DESIGN & MATERIAL RECUIREMENT

-Low Density to lower inertial forces
-High Thermal Conductivity so the temperature remains low
-Good strength properties at elevated temperatures, so that thereis high resistance to
deformation and fatigue fracture.
-Good wear characteristics even at high temperatures.
-Low co-efficient of thermal expansion; as close as possible to that of Cast Iron in order to
limit running clearance in the cylinders.
The above properties are satisfied by AlSiCu alloy
PISTON MATERIALS
Introduced in 1926 as standard piston alloy with 12% Silicon varying between 11% ~13% Si
and approx. 1% Cu. CSA 12
Increasing the Si contents with approximately 18% varying between 17~19% gives hypereutectic alloy. -CSA 18
Increasing the Si contents with approximately 24%, high Silicon alloy CSA 24
The later 2 alloy allowed reduction in heat expansion and wear. However strength is scarified.
Aluminum Copper Alloy with 3~4% Cu is used for increased Hot strength, limited used in
high Load applications-CSCU / S2N
Constructional Features
OPERATIONS
PISTON CASTING
OD turning/crown facing
Spigot turning
Oil hole Drilling
Rough pin hole Boring/ Circlip grooving/Counter boring/Outer Chamfer
Ultrasonic Testing
Combustion Bowl Formation
Eddy current testing
Valve pocket milling
Aluminum & Cast iron grooving
Finish Surface Turning
Finish pin hole Boring
Washing
Surface heat Treatment
PROFILE OF THE PARAMETERS

In the manufacture of pistons there are various problems that are being faced by the firms.
Some of these are:1. STEP ON GROOVE GROUND
With the step on groove ground, the ring does not fit properly and the piston assembly
could not be installed.
2. GROOVE WIDTH
Groove Width is one of the very important parameters of a piston because if the width
of the groove is more than the ring then the ring will be loose in the assembly and the
gases may escape from the ring surface to the bottom of the piston.
Whereas, if the groove width is less than the ring will not fit and the assembly could
not be installed.
3. GROOVE DIAMETER
If the groove diameter is less than the ring will start fluttering and the gases may
escape from the piston top to the bottom of the cylinder.
Whereas, if the diameter is more, than the ring will not fit and problem will be faced
during the assembly installation.
4. WEIGHT
In case of multi-cylinder engines the pistons are assembled according to weight as it
has a lot of impact inside a running engine.
The weight of the pistons are kept in the range of 2 grams because if there is too
much variation in the weights of the pistons inside a running engine than the pistons
may exert an unbalancing force on the crankshaft which may bend the crankshaft.
5. SKIRT SIZE
Skirt size is also one of the main parameters of the pistons.
If the skirt size is more than the given tolerance than it will seize the engine and if it is
less than the lubricating oil will start leaking and the lubrication will not be done
properly.
6. STEP ON SKIRT
A step on the skirt will increase the diameter of the skirt more than the tolerance
which may either damage the cylinder lining or seize the engine or both.
7. PIN HOLE DIAMETER

The PH. Diameter is also an important parameter which is being checked.
If the diameter of the pin hole is more than the pin will be loose, which will allow
fluttering of the pin causing damage to the boss.
Whereas, if the pin hole is tight than the pin will not pass through the hole
8. PIN HOLE SQUARENESS
The pin hole squareness means that whether the crown is perpendicular to the axis of
the pin or not.
If the squareness is not ok than the piston will move in a tilted state and will damage
the cylinder lining.
9. PIN HOLE OFFSET(acc. to drawing)
In pin hole offset the pin is tilted horizontally. Offset is decided according to the
design of the connecting rod. If the offset is more than the required value, the
connecting rod may touch the skirt of the piston and damage it.
10.
UNCLEAR PIN HOLE

If the pin hole is unclear than it will not result in smooth functioning of the pin, as the
pin will not rotate smoothly.
11.
DAMAGE IN PIN HOLE

Due to damage in pin hole the pin will not operate properly.
12.
STEP IN PIN HOLE

If there is step in pin hole, it will reduce the pin hole diameter and the pin will not be
inserted in the pin hole.
13.
COMPRESSION HEIGHT
14.
COMPRESSION HEIGHT
Compression height is another parameter which has an important role in the working
of the piston.
If the comp. height is more than the tolerances than it will surpass the T.D.C and will
touch the cylinder head and damage it.
Whereas, if the comp. height is less than the tolerances than more fuel will start
entering the assembly which will result in lesser mileage and efficiency.
15. CAVITY
Cavity is another parameter of piston as according to drawing. The main function of
the cavity is to properly burn the mixture of air and fuel because if the fuel drops at
the centre of the cavity then the force is exerted mainly on the piston.
Whereas, if the fuel is distributed equally inside the chamber than the force is exerted
equally in all the directions and only a part of the force is exerted on the piston which
produces lesser power.
16.
CIRCLIP GROOVE(Snap ring)

Circlip groove is a groove in the pin hole which is provided for the locking of the pin.
If the groove is not correctly made than the pin will not stay at its place and
connecting rod may move out of the assembly and seize the engine.
17.
CRACKS
These refer to the cracks which are present on the piston surface.
18.
TOTAL HEIGHT
Total height refers to the length of the piston from top to bottom.
Whereas, if the height is increased from the top, it will touch the top of the cylinder .
19.
ROUGHNESS AVERAGE(Ra)
The roughness which is provided on the piston surface helps in retaining the oil film
20.
GROOVE ANGLE
Groove angle should always be positive so that when the pressure is exerted from the
top the ring is sealed.
Whereas, if the groove angle is already negative, the pressure exerted will further
increase the angle and result in more space and leakage of gases will be there
accompanying further consequences.
21.
GROOVE WAVINESS
Waviness of the groove flank is checked. If there is waviness the ring will rest on
lesser surface area and will press the flank resulting in more space, which will result
in leaking of gases.
22.
CONCENTRICITY
If the chamfer of the skirt is not concentric, the piston will move in a tilted position in
the engine which may result in eroding of the cylinder lining.
23.
OPEN BORE
To regulate the weight of the piston, open boring is done on some of the casting pistons. A cut
as per the requirement is made on the boss.
Based upon Performance and Fitment

-Alloy / Material
-Hardness
-Profile / Outside Diameter
-Compression Height
-Groove Axial / Groove Geometry

-Pin Hole Geometry
-Surface Roughness
-Circlip Groove Geometry
-Eye Distance
-Weight
Casting Simulation:
Compression
-Compression Height
-Roundness / Flatness
-Roughness
In the Engine Piston compression Height is designed to produce optimum Compression

Ratio. Any variation in the same may cause drop in Engine power or hitting of piston with
Cylinder Head or Valves in case of Diesel Engine or Gasoline Engines have Valve Recesses.
Flatness in any case should be with 0.025 and in any case should not be CONVEX other wise
hitting chances will improve.
GROOVE GEOMETRY
BLOW-BY: Blow-by is the amount of combusted and non combusted fuel air mixture
flowing per unit time between piston and cylinder wall into the crankcase.
OIL CONSUMPTION: An engine has a lot of moving and sliding parts. Certain amount of
lubrication oil is continuously consumed to reduce friction. The owner comes to know when
the engine starts consuming higher quantity of oil . Reduction of oil consumption is one of
the main problem in construction of an engine.
SURFECE ROUGHNESS
Where the Cup shape and V-Shape helps in containing the lubricating oil, Saw tooth type
profile helps in quick drainage. Piston roughness helps in achieving good bedding in pattern
during engine operation and should be controlled with a pitch 0.15+/-0.05, if not defined in
drawing.
Circlip Groove Geometry

The function of Circlips is to lock the piston pin and restrict the end play. Any deviation in
Circlip Groove parameters like distance, diameter and width may hinder the fitment or may
increase the end play due to which circlip may come out and fail the engine.
Unique Design and Quality Features

Thin Grooves
70% of friction is caused due to rings only. Thin low tension grooves reduce friction and
improve fuel economy.
Matching of Boss Oil Hole with Groove Oil Hole
Matching of Boss oil hole with groove oil holes ensure better lubrication of gudgeon pin.
Accumulator Groove Pressure spikes that get trapped between the first and second
compression ring tend to unseat the top ring. This action encourages Ring Flutter and loss of
ring seal thereby increasing the reverse blow, which carries oil into the combustion chamber
therefore increasing oil consumption. Accumulator groove creates an extra volume of space
that tends to average the normal pressure present, keeping the pressure low enough to prevent
lifting of top ring.
J -Groove
This groove is machined on the second ring land of the piston to create a reservoir of oil that
is scrapped off the second ring and also to control inter ring pressure. This groove helps in
more effective oil drainage.
Wedge shape groove and Keystone Groove
Keystone / Wedge type geometry of ring and groove leads to greater ring mobility relative to
groove This results in continual local change in the gap width between ring and ring groove
side by which any residue that are formed are worked off and ring sticking is prevented.
Wedge shape groove are usually in Bi-Wheeler two stroke application and Keystone are in
Diesel engine application
First Groove -Lower Flank Sharp Edge
The edge of first groove lower flank i.e the line where the surface of the piston skirt intersects
with the groove side should be located as far to the outside as possible with limiting the
clearance between piston and cylinder at this point. This results in a phenomenal decrease in
the gases escaping downward i.e. blow by.
SURFACE TREATMENT
Phosphate Coating: Dark grayish color with thickness around 1 micron. It is used to produce
a crystalline corrosion resisting layer. This coating helps to have a good anti frictional
properties. Phosphating is done all over the piston.
Graphite Coating: Grayish black in color with thickness around 15 -25 microns. It is done on
the piston skirt and serves the purpose of emergency lubrication in newly assembled engine
till such time normal lubrication is attained. Graphite acts as a dry lubricant and thereby
prevents scoring / seizure of the piston till normal oil film is established.
Tin Coating: Ceramic white coating with layer thickness 1-3 microns. It is used to ensure
smoother running in of the engine, better lubricated cylinder walls and freedom from cold
start scuffing. Tin coating may be done all over the piston or with the exception of gudgeon
pin hole.
Anodizing: Grayish layer of Aluminum oxide done on piston crown with thickness around
five microns. Anodizing is done due to the fact that during combustion process, piston crown
is exposed to very high temperatures. In order to avoid development of cracks in the piston
crown due to thermal stresses, the upper layer is hardened by specialized anodizing process.
This also prevents corrosion of piston crown.
MolyCoating: Black in cooler with layer thickness 5 -15 microns. Coating acts as anti friction
layer which prevents pistons from scuffing during cold start. In some applications, this
coating is also provided to reduce clearance, thereby reducing noise phenomenon. Unlike
graphite coating this coating should be intact throughout the life of the piston.
PROJECT-I
Rejection reduction
in pistons on defect
of operation missing
INTRODUCTION (PROJECT)
In LVD machine line; there are lots of surface removal processes done for converting the raw
material to the finished work part (piston). During the lot of processes a no of times the piston
is input & output to the different machines. But the no of work parts to be produced are more
due to this reason, sometimes work parts remained operation free & declared scrap at the
Final Inspection. Work part is called the OPERATION MISSING SCRAP. The process
in which the piston remains operation free and without operation it reaches to the next
machine called the Operation missing.
Common operation missing processes
Eddy current
Oil hole Drilling
Stamping
Washing/Surface treatment
CODING TO THESE OPERATION MISSING SCRAPS
Surface treatment A1
Oil holes A2
Stamping A17
Eddy current-A29
OBJECTIVE OF PROJECT
To reduce the scrap rejection rate at the end of final inspection: At the end of Final
inspection lot of pistons founded operation free & these are declared as scrap. Main
operations misses are stamping, eddy current testing, oil hole drilling, surface
treatment/washing. These scraps are rejected at the end. To reduce this rejection rate
controlling on operation missing to be done under this project.
To improve the economy of the plant: If the rejection rate will be more means more
scrap founded at the end. More the scrap means, wastage of the material, wastage of time,
wastage of labor cost. Hence these wastages directly affect the economy of the plant. To
impure the economy, there is necessary to minimize the operation missing.
To reduce the wastages during the manufacturing: Sometimes the operator misses the
operation and piston goes to next machine without machining and after that it founded unmachined during the manufacturing. It declared as scrap or waste. To reduce this wastage
during the manufacturing controlling the operation is necessary.
REASONS BEHIND THE OPERATION MISSING

1) Due to the lake of concentration of the machine operator.
2) Occupied space all around.
3) Wrong method of placing the piston.
4) Using same bin for Input & output wok parts.
.
5) Both input & output bins at same side.
6) During the checking sometimes operator misses the part.
7) During the time when the operator remains 2 or less pistons behind in box before any
interruption (e.g. Washroom, tea break, tool install).
8) When the operator does not follow the standard operating procedure and flow process
chart.
9) Input and output bins are not arranged systematically.
PROBLEM ANALYSIS
For the whole 1st month after the joining, the team was gathering information that despite
so many measures taken, why the rejection rate is still so high. The reports are as follows.
So many pistons are founded scrap due to operation missing.
Eddy current operation missing scrap rate was so high.
DISCUSSION ABOUT SOLUTION TO THE PROBLEM

After finding out the various reasons to the problem of scrap rate, discussions were carried
out to find out the possible solutions. The solutions that were considered are as follows:
Training to be given to the operators.

Process follow diagram.
Standard operating procedure.
Control plain.
Visually check around 10 pistons in every cell.
THE SHIFT INCHARGE WAS TO BE GIVEN THE REPORT OF EVERY

CELL AFTER EVERY ROUND IN THE SHOP.
METHODOLOGY ADOPTED
FOLLOW THE PROCESS FLOW DIAGRAM:

Process flow diagram can be defined as movements of the operator & flow of the wok
piece from one machine to other in a machining line, while it converted from raw
material to the end product.
A) FLOW PROCESS DIAGRAM FOR CONTROLLING THE OIL

HOLE DRILLING MISSING
o MOVEMENT OF OPERATOR: left hand for un-loading

Right hand for loading.
B) FLOW PROCESS DIAGRAM FOR CONTROLLING THE EDDY

CURRENT & STAMPING MISSING:

C) FLOW PROCESS DIAGRAM FOR CONTROLLING THE

ULTRASONIC & STAMPING MISSING:

5S TECHNIQUE
5S is the Japanese technique uses for systematic, good and clean working environment in
an organization.
o Meaning of 5s
Seiri- sorting
Seiton- straightening or setting in order / stability
Seiso- systematic cleaning / sweeping and shining
Seiketsu- standardizing
Shitsuke- sustaining the decipline
HOW 5S USED FOR THE OPERATION MISSING:

1) If machines and bins are sorted in systematically order, the input and output parts will not
mix up.
2) If the workers will maintain discipline in the line, lesser chance of operation missing.
STANDARD OPERATING PROCEDURES FOR TRAINING

PURPOSE:
Standard operating procedures are those in which training is given to the operators
About
The setup the machines before starting them
Which parts should be machined
How to place the wokparts to the Machine
How to run the machine
Which bins used for which purpose so that they cannot mix up.
Controlling the movements of the hand.
Both the input and output bins should not places at same side.
To ensure the checked part.

OK parts should be stamped.
OBSERVATION: By this procedure the operators are tested to their technique &
founded comfortable to reduce scrap.
ANALYSIS PROCEDURE
PARETO ANALYSIS CHART:
What is a Pareto Chart?
The Pareto Chart is named after Vilfredo Pareto, a 19 th century economist who postulated that
a large share of wealth is owned by a small percentage of the population. This basic principle
translates well into quality problems. A Pareto Chart is a series of bars whose heights reflect
the frequency or impact of problems. The bars are arranged in descending order of height
from left to right. This means the categories represented by the tall bars on the left are
relatively more significant then those on the right. This bar chart is used to separate the vital
few from the trivial many. These charts are based on the Pareto Principle which states that
80 percent of the problems come from 20 percent of the causes. Pareto charts are extremely
useful because they can be used to identify those factors that have the greatest cumulative
effect on the system, and thus screen out the less significant factors in an analysis. Ideally,
this allows the user to focus attention on a few important factors in a process.
Why should a Pareto Chart be used?

You can think of the benefits of using a Pareto Charts in economic terms. A Pareto Chart
breaks a big problem down into smaller pieces, identifies the most significant factors, shows
where to focus efforts, and allows better use of limited resources. You can separate the few
major problems from the many possible problems so you can focus your improvement
efforts, arrange data according to priority or importance, and determine which problems are
most important using data, not perception.
A Pareto Chart can answer the following questions:
o What are the largest issues facing our team or business?
o What 20% of sources are causing 80% of the problems?
o Where should we focus our efforts to achieve the greatest improvements?
When should a Pareto Chart be used?

A Pareto Chart is a good tool to use when the process you are investigating produces data
that are broken down into categories and you can count the number of times each category
occurs. A Pareto diagram puts data in a hierarchical order, which allows the most significant
problems to be corrected first. The Pareto analysis technique is used primarily to identify and
evaluate nonconformities, although it can summarize all types of data. It is the perhaps the
diagram most often used in management presentations. Making problem solving decisions
isnt the only use of the Pareto Principle. Since Pareto Charts convey information in a way
that enables you to see clearly the choices that should be made, they can be used to set
priorities for many practical applications. Some examples are:
o Process improvement efforts for increased unit readiness
o Skills you want your division to have
o Customer needs
o Suppliers
o Investment opportunities
PARETO ANALYSIS CHART FOR SCRAP
Frequency
46.45
88.5
97.56
FEB MAR 2012
TESTING
Team members worked on the project regularly and the following results were obtained.
Are the workers working according to the flow process diagram & following the
standard operating procedure.
How much worker working to his concentration.
Are the work parts visually analyzed continuously?
Are the workers maintaining 5s properly?
All the piston of any bin are finished before any break.
IMPLEMENTATION
The results that were obtained were as desired by the team. So the same routine was firmly
accepted and put to practice for the rest of the time period also.
RESULTS/ SALIENT OUTCOMES
SCRAP REJECTION RATE: By using this project, scrap rejection rate

decreased.
In 2011 (before this project)
operation
code
Scraps
Eddy current/ Oil hole
A29/A6
1.52%
operation
code
Scraps
Eddy current/Oil hole
A29/A6
0.50%
In 2012 (till 31/07/2012)
Reduce in the scrap rejection rate will definite increase the economy of plant.
Lesser scrap at the end of final inspection.
Good working culture and flexibility in working.
Fluency in the work.
COMPERISON OF SCRAP DATA 2011-2012
In 2011 (operation missing scrap): 1.52%

In 2012 (operation missing scrap): 0.50% (till 31/07/2012)
Annual savings after accomplishing the project: 3.65lacs
PROJECT-II
Rejection reduction
in pistons on defect
of skirt size
Skirt Size (d1 or d2): Skirt size is also one of the main parameters of the pistons. If the
skirt size is more than the given tolerance than it will seize the engine and if it is less than the
lubricating oil will start leaking and the lubrication will not be done properly.
Diameter below the oil sweeping ring and combustion head (3rd ring) at 90 degree from
pinhole symmetry axis.
Skirt Size dia. Scraps:

The scrap which does not fulfilling the dimensional accuracy on size of skirt dia. known as
skirt size dia. scraps.
Coding to skirt size dia. scrap: A7
Problem:
skirt diameter is not in proper dimensions.
Over the tolerance limit

Given tolerance: -5u to +5u
Not accomplishing the end specifications.
To reduce the scrap rejection rate: Skirt size dia. is the maximum dia. of the piston. so
it should be within the tolerance limit. If it is not within limits means these pistons will be
founded scrap at the end of final inspection. To reduce this rejection rate is this projects
main objective.
To improve the economy of the plant: If the rejection rate will be more means more
scrap founded at the end. More the scrap means, wastage of the material, wastage of time,
wastage of labor cost. Hence these wastages directly affects the economy of the plant. To
impure the economy, there is necessary to control the skirt size dia.
PROBLEM ANALYSIS
Machine name: Weisser OVAL TURNING machine
Details of problem
TO REDUCE SKIRT SIZE DEFECT FROM 0.064% TO 0.2 %
SKIRT SIZE REJECTION TREND MONTHWISE
PROBLEM ANALYSIS TECHNIQUE

Technique used: FISHBONE Analysis
KEYWORDS:
Cause-and-Effect Diagram, Ishikawa diagram, Fishbone diagram, Root Cause Analysis.
What Is a Cause-and-Effect Diagram?

A graphic tool that helps identify, sort, and display possible causes of a problem or quality
characteristic.
OBJECTIVES:
The main goal of the Fishbone diagram is to illustrate in a graphical way the relationship
between a given outcome and all the factors that influence this outcome. The main objectives
of this tool are:
Determining the root causes (G) of a problem.
Focusing on a specific issue without resorting to complaints and irrelevant

discussion.
Identifying areas where there is a lack of data.
Benefits of Using a Cause-and-Effect Diagram
Helps determine root causes
Encourages group participation
Uses an orderly, easy-to-read format
Indicates possible causes of variation
Increases process knowledge
Identifies areas for collecting data
FIELD OF APPLICATION:
The Fishbone diagram could be applied when it is wanted to:
Focus attention on one specific issue or problem.
Focus the team on the causes (G), not the symptoms.
Organize and display graphically the various theories about what the root causes
(G) of a problem may be.
Show the relationship of various factors influencing a problem.
Reveal important relationships among various variables and possible causes (G).
Provide additional insight into process behaviors.
RELATED TOOLS
Pareto chart, Scatter diagram, Flowcharts Check sheets
DESCRIPTION
Dr. Kaoru Ishikawa, a Japanese quality control statistician, invented the fishbone
diagram. It is often also referred to as the Ishikawa diagram. The fishbone diagram is
an analysis tool that provides a systematic way of looking at effects and the causes
that create or contribute to those effects. Because of the function of the fishbone
diagram, it may be referred to as a cause-and-effect diagram. The design of the
diagram looks much like the skeleton of a fish. Therefore, it is often referred to as the
fishbone diagram. A cause-and-effect diagram can help identify the reasons why a
process goes out of control. Often the fishbone diagram can be used to summarize the
results of a brainstorming session, identifying the causes of a specified undesirable

outcome. It helps to identify root causes (G) and ensures a common understanding of
the causes. The steps for constructing and analyzing a Cause-and-Effect Diagram are
outlined below:
Step 1 - Identify and clearly define the outcome or effect to be analyzed2.
Formulate the problem and write it in a box on the right side of the diagram. Everyone must
clearly understand the nature of the problem and the process/product being discussed. If
everyone is not clear on the purpose of the session, the session will not resolve the problem.
In this step the following rules have to be applied:
Decide on the effect to be examined. Effects are stated as particular quality

characteristics, problems resulting from work, planning objectives, and the like.
Use Operational Definitions. Develop an Operational Definition of the effect to

ensure that it is clearly understood.
Remember, an effect may be positive (an objective) or negative (a problem),

depending upon the issue thats being discussed.
Using a positive effect which focuses on a desired outcome tends to foster pride and
ownership over productive areas. This may lead to an upbeat atmosphere that
encourages the participation of the group. When possible, it is preferable to phrase the
effect in positive terms.
Focusing on a negative effect can sidetrack the team into justifying why the problem
occurred and placing blame. However, it is sometimes easier for a team to focus on
what causes a problem than what causes an excellent outcome. While you should be
cautious about the fallout that can result from focusing on a negative effect, getting a
team to concentrate on things that can go wrong may foster a more relaxed
atmosphere and sometimes enhances group participation.
You must decide which approach will work best with your group.
Step 2 - Use a chart pack positioned so that everyone can see it, draw the spine and create
the effect box.
Draw a horizontal arrow pointing to the right. This is the spine.
To the right of the arrow, write a brief description of the effect or outcome which
results from the process.
Draw a box around the description of the effect.
Step 3 - Identify the main causes (G) contributing to the effect being studied. These are the
labels for the major branches of your diagram and become categories under which to list the
many causes related to those categories.
Establish the major causes, or categories, under which other possible causes will be
listed. You should use category labels that make sense for the diagram you are
creating.
Write the main categories your team has selected to the left of the effect box, some
above the spine and some below it.
Draw a box around each category label and use a diagonal line to form a branch
connecting the box to the spine.
Step 4 - For each major branch, identify other specific factors which may be the causes of the
effect
Identify as many causes or factors as possible and attach them as sub branches of the
major branches.
Fill in detail for each cause. If a minor cause applies to more than one major cause,
list it under both.
Step 5 - Identify increasingly more detailed levels of causes and continue organizing them
under related causes or categories. You can do this by asking a series of why questions. You
may need to break your diagram into smaller diagrams if one branch has too many sub
branches. Any main cause (3Ms and P, 4Ps, or a category you have named) can be reworded
into an effect.
Step 6 - Analyze the diagram. Analysis helps you identify causes that warrant further
investigation. Since Cause-and-Effect Diagrams identify only Possible Causes, you may want
to use a Pareto Chart to help your team determine the cause to focus on first.
Look at the balance of your diagram, checking for comparable levels of detail for
most of the categories.
A thick cluster of items in one area may indicate a need for further study.
A main category having only a few specific causes may indicate a need for further
identification of causes.
If several major branches have only a few sub branches, you may need to combine
them under a single category.
Look for causes that appear repeatedly. These may represent root causes.
Look for what you can measure in each cause so you can quantify the effects of any
changes you make.
BENEFITS
Helps determine root causes
Encourages group participation
Uses an orderly, easy-to-read format to diagram cause and effect relationships

Indicates possible causes of variation
Increases knowledge of the process by helping everyone to learn more about the
factors at work and how they relate
Identifies areas for collecting data
PREREQUISITES
A problem is composed of a limited number of causes, which are in turn composed of

sub causes.
Distinguish these causes and a sub cause is a useful step to deal with the problem.
How CAUSE-&-EFFECT Diagram used in this problem analyzing
Facts behind the problem

Method:
Wrong input method
improper loading.
Material:
Material consumption
Machine:
Incorrect cutting parameters
Chilling unit temperature
Uneven clamping pressure
Hot axis alignment
Measurement:
Instrument not calibrated
Instrument damage
Man:
Low skill level
Lack of training

Loading method should be proper.
Control plain.
Operator should check the instrument by comparing with masters.
Operator should check the machine parameters.

Methodology Adopted
Methodology adapted to reducing the skirt size dia. scraps (A7): WHY WHY
ANALYSIS.
WHY WHY ANALYSIS
There are so many reasons behind every problem. So the every action for problem is taken
first all the reasons investigated behind the problem and then a flow diagram is made which
tells all the reasons behind the problem. Then from flow diagram first of all last (bottom)
problem is solved then one by one problems solved from lower problem to upper problem.
This process is called the why why analysis.
How this applied to controlling skirt size diameter
Why?
Why did we take above action?
Why?
Due to high scrap percentage of Skirt Size Defect
Why?
Due to temp variation

Why?
Due to the difference in temperature of Final inspection and line
PROCESS
Coolant flow inside match to control the temperature variation
Control the temp. Variation b/w line & final inspection
Scrap of skirt size diameter will reduce
One point lesson

Master pistons put in the continue coolant flow inside match to control the temperature
variation.
RESULT/ SALIENT OUTCOMES

DATA ANALYSIS
How: Directly by observations
Instrument used: Skirt dia. checking instrument.
Range of instrument: +30u to +30u
Least count of instrument: 0.01mm

Given Tolerance: -10u to +10u
DATA BEFORE 7/01/2012:

Present level of the scrap: 0.64%
DATA TILL 31/07/2012:

Target level of the scrap: 0.20%
CHART OF SCRAP DATA COMPERRISON B/W 2011 & 2012
Saved amount: 4.27 lacs/year
PROJECT-III
Rejection reduction
in piston on defect of
PH & KH
Faculty members:
Gurpreet Singh (senior engineer)
& co-workers
PH (Pinhole): The bore of the piston in which the pin is inserted to connect the connecting
rod and piston known as the PIN HOLE.
PH offset tolerance: -10u to +10u

PH squreness: -25u to +25u
COMPRESSION HEIGHT (KH):

Compression height is another parameter which has an important role in the working of the
piston.
If the comp. height is more than the tolerances than it will surpass the T.D.C and will touch
the cylinder head and damage it.
Whereas, if the comp. height is less than the tolerances than more fuel will start entering the
assembly which will result in lesser mileage and efficiency
Compression height tolerance: -25u to +25u

Coding: A (14)
To reduce the scrap rejection rate: master piston is not compared to the instrument &
pistons are not visually analyzed, these pistons will be founded scrap at the end of final
inspection. To reduce this rejection rate is this projects main objective.
To improve the economy of the plant: If the rejection rate will be more means more scrap
founded at the end. More the scrap means, wastage of the material, wastage of time, wastage
of labor cost. Hence these wastages directly affect the economy of the plant. To impure the
economy, there is necessary to reduce the scrap of the pinhole & comp. height.
PROBLEM ANALYSIS
Machine name: Weisser Finish PH machine
Details problem (PH)

1. PIN HOLE DIAMETER
The PH. Diameter is also an important parameter which is being checked.
If the diameter of the pin hole is more than the pin will be loose, which will allow
fluttering of the pin causing damage to the boss.
Whereas, if the pin hole is tight than the pin will not pass through the hole
Pinhole dia. scraps: A10
2. PIN HOLE SQUARENESS
The pin hole squareness means that whether the crown is perpendicular to the axis of
the pin or not.
If the squareness is not ok than the piston will move in a tilted state and will damage
the cylinder lining.
Pinhole squreness scraps: A11
3. PIN HOLE OFFSET(acc. to drawing)
In pin hole offset the pin is tilted horizontally. Offset is decided according to the
design of the connecting rod. If the offset is more than the required value, the
connecting rod may touch the skirt of the piston and damage it.
Pinhole offset scraps: A12
4.
UNCLEAR PIN HOLE

If the pin hole is unclear than it will not result in smooth functioning of the pin, as the
pin will not rotate smoothly.
Pinhole unclear scraps: A13 (a)
5.
DAMAGE IN PIN HOLE

Due to damage in pin hole the pin will not operate properly.
Pinhole damage scraps: A13 (d)
6.
STEP IN PIN HOLE
If there is step in pin hole, it will reduce the pin hole diameter and the pin will not be
inserted in the pin hole.
Step in Pinhole scraps: A13 (d)
Details problem (KH)

Compression height was over the tolerance limit
-25u to +25u
TO REDUCE KH & PH SCRAP FROM 2.33%+0.60% TO 1.00%
COMP. HEIGHT REJECTION TREND MONTHWISE

KEYWORDS:

Method:
Wrong input method
Improper loading.
Material:
Material consumption
Machine:
Incorrect cutting parameters
Alignment of cooling pipes

Uneven clamping pressure
Measurement:
Instrument not calibrated
Instrument damage
Man:
Low skill level
Lack of training


Control plain.
Operator should check the instrument by comparing with masters.
Operator should check the machine parameters.

Methodology Adopted
Methodology adapted to reducing these scraps (A7): WHY WHY ANALYSIS.
WHY WHY ANALYSIS
How this applied to KH & PH scraps
Why?
Why did we take above action.
Why?
Due to high scrap percentage of Comp. height.
Why?
Due to Chip pressing on fixture seat.
Why?
Due to improper coolant flow on fixture.
Why?
Due to coolant pipe not proper position.
PROCESS
Pipe placed to proper position
Proper flow of mixture automated
Removal of chip
Compression height & pinhole within range
One point lesson (corrective actions)

Combustion bowl machine total height parameter +10u with finish PH compression height.
Maintain PH master gauge temperature & use SP (setting piston) at shift start to control
temperature variation.

BY DATA ANALYSIS
Instrument used:
a) compression height checking instrument (KH).
Range of instrument: -30u to +30u

Given Tolerance: -25u to +25u
b) Pneumatic instrument (PH)
Range of instrument: -30u to +30u

Given Tolerance: +1u to +5u

Present level of the scrap: 2.33% + 0.60% (KH & PH)
DATA TILL 31/07/2012:

Saved amount: 9.2 lacs/year
PROJECT-IV
Rejection reduction
in pistons on defect of
Transport
Scrap
The scrap of piston due to transportation from one place to other for the different processes
and shipping & it happens during the conveyor system problem mishandling.
Coding to transport scrap: A21

PROBLEMS:
Cracks.
Change in shape.
Edge breaking.
Total damage.
Etc.
To reduce the scrap rejection rate: master piston is not compared to the instrument &
pistons are not visually analyzed, these pistons will be founded scrap at the end of final
inspection. To reduce this rejection rate is this projects main objective.
To improve the economy of the plant: If the rejection rate will be more means more scrap
founded at the end. More the scrap means, wastage of the material, wastage of time, wastage
of labor cost. Hence these wastages directly affect the economy of the plant. To impure the
economy, there is necessary to reduce the scrap of transport.
PROBLEM ANALYSIS
Machine name: WASHING MACHINE
Details problem
TO REDUCE TRANSPORT DEFECT FROM 1.5% TO 0.5 %
TRANSPORT REJECTION TREND MONTHWISE

KEYWORDS:

Method:
Wrong input method
Improper transportation
Improper loading.
Machine:
Conveyor problem
Man:
Low skill level
Lack of training
Mishandling.


Handling the material.

Methodology Adopted
Methodology adapted to reducing these scraps (A7): WHY WHY ANALYSIS.
WHY WHY ANALYSIS
How this applied to transport scraps
Why?
Why did we take above action.
Why?
Due to high scrap percentage of Transport scrap.
Why?
Due to Improper material handling
Why?
Due to operation of washing was performed in another plant which was at some distance
from the final operation, because od which transportation was more.
PROCESS
A washing machine installed nearby
Proper material handling
Reduction in transport scrap
One point lesson (corrective actions)

Single piston flow implement inline & single point lesson for process flow display for all
awareness as per PFD.

DATA ANALYSIS

Present level of the scrap: 1.52%
DATA TILL 31/07/2012:

Saved amount: 8.11lacs/year

Training Project

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Training Project

Caricato da

Copyright:

Formati disponibili

TRAINING REPORT

TO REDUCE THE REJECTION RATE IN PISTONS

Under the Guidance of

MR.Amoljit singh gill

Er. Charanjeet Singh

under the guidance of Er.

MR.AMOLJIT SINGH GILL (faculty

coordinator) from 09.06. 2014 to 05.07.2014.

Name of Student: Karan gupta

PROJECT-I (Rejection reduction in pistons on defect operation missing)

PROJECT-II (Rejection reduction in pistons on defect skirt size diameter)

PROJECT-III (Rejection reduction in pistons on defect of PH & KH) this

PROJECT-IV (Rejection reduction in pistons on defect of transport scrap)

FEDERAL MOGUL GOETZE (INDIA) LIMITED BAHADURGARH

MARUTI UDYOG LTD.

TVS SUZUKI LTD.

MAJESTIC AUTO LTD.

KINETIC ENGINEERING LTD.

ESCORTS LTD. (FARMTRAC DIVISION)

Maruti & Suzuki Ltd.

Mahindra & Mahindra ltd.

Yamaha Motor India Private Ltd.

Eicher Tractors Ltd.

PASSENGER CARS & JEEPS:

Mahindra & Mahindra Ltd.

DEFENCE & RAILWAYS:

Vehicles Factory, Jabalpur.

COMPRESSORS /AIR CONDITIONERS:

Kirloskar Oil Engines Ltd.

MANUFACTURING PLANT IN INDIA

Piston Rings, Pistons,

Original FMGIL facility

Valve Train Components &

Acquired through merger of

Piston Rings, Pistons, Pins

Partly original FMGIL

Steel Piston Rings

Facility of our subsidiary

FMG PATIALA PLANT

Pins, Piston & Piston Rings

Cutting & machining.

Current Employees: over 2500

FEDERAL MOGUL BRANDS

AE is recognized throughout the world as a leading brand of quality

ANCO is the leader in replacement wiper blades, refills, washer

The Atlas brand is Federal-Mogul's market-leading brand of gaskets

Federal-Mogul's Beral brand provides brake linings and disc brake

DURON is a specialist in heavy-duty friction and brings exceptional

Fel-Pro is the industry's leading brand of aftermarket sealing

FP Diesel heavy-duty engine parts and gaskets include a

Each year, Glyco OE bearings are installed on more than 10 million

Federal-Mogul's Goetze brand is a leading name in the automotive

The Federal-Mogul Moog line is the preferred brand of replacement

Federal-Mogul's National brand has built a reputation as one of the

Necto, the main friction brand in Spain, is characterized in offering

Nral is at the forefront of piston technology. Nral has years

The Federal-Mogul Payen brand of gaskets, oil seals and cylinder

PowerMAX spark plug wire delivers maximum protection and

The quality of Federal-Mogul Precision Universal Joints can be

Raimsa is a trusted brand in Mexico that provides an extensive line of

Federal-Mogul's Sealed Power product line represents a complete

Speed-Pro has built a reputation for performance engine

Wagner - the world's leader in brake pads - offers product lines