ACKNOWLEDGEMENT

God gives us life to decorate it with knowledge. Life without knowledge is

like river without water.

It is my pleasant privilege to acknowledge my profound

gratitude & indebtedness towards my respected & learned teachers for their
inspiration, constructive criticism & valuable suggestions. Their precious
guidance & unrelenting support kept me on track throughout my till now
training.

I want to thank particularly Mr. CHARANJIT SINGH

(ASSISTANT MANAGER – QMS) our training coordinator, for me an
opportunity to work with such an experienced and dedicated person.

At last but not the least, I express my wholehearted thanks to

Mr. K.Z. Molla (Training Head) and Mrs.SHAKUNPREET

( Coordinator) for their sagacious efforts in accomplishment of this task.

In the end, I hope all of these esteemed people will help us in
the similar manner as till now.

Name:Diwank Vohra
INTRODUCTION TO GOETZE INDIA LIMITED PATIALA

Bahadurgarh! The ancient fort with a history of 500 years now over looks one of the most
modern industries in the country manufacturing highly sophisticated automobile components viz
piston rings, cylinders, liners ,pistons, gudgeons pins situated app. 9 K.M. from the city of
Patiala.

“Escort” was incorporated as a private limited company in Oct.'1944 at Lahore under the name of
Escorts (Agents) Pvt. Ltd. And the later converted into a public limited company in
Dec.'1959.The name was changed to Escorts in Jan'1960.H.P.Nanda founded the company; the
current C.M.D is Anil Nanda. An escort has spent the last few years cleaning up its corporate
structure, a process, which is now more or less complete. HP Nanda of the Escort group in
technical and financial collaboration with GOETZE WORKE FRIEDRICH GOETZE AG,
GERMANY promoted GIL in 1954, for making piston rings and cylinder liners. In the 90's the
company diversified into supermarkets, oilseeds processing and leather garments for exports.
GIL commands over half of the market for piston rings and cylinder liners and has strong
presence in the replacement segment ,which constitutes two thirds of the total market for piston
rings .With technical inputs from its German partner ,GIL has started making high value rings,
which fetch higher margins. GIL also supplies rings to stationary Diesel engines and air/gas
compressor manufacturers. At one point, it had two separate company making tractors, apart
from myriad joint venture, which were making everything from auto components to motorcycles
to construction equipments. The motorcycle business has also been rationalized and recast into
separate profit centers. The pay-off should come through in the coming years. The company will
benefit from the extensive restructuring it has carried out liberalized. Escorts, the company is
presently into farm equipment automobile components, railway ancillaries, etc. As a part of
restructuring business 1994-1995, the company hived off certain divisions into separate entities-
Escorts communications and Escorts construction equipment, whereby; Escorts communications
and the manufacture of construction equipment by Escorts construction Equipment are carrying
on manufacture of EPABX systems. They are wholly owned subsidiaries of the company. Other
subsidiaries are Escorts JCB, escorts class, Escorts Automotive and Escotel Mobile
Communication. Most if its subsidiaries have foreign collaborations. Escorts Tractors, a group of
company, was merged with the company in 1995-1996. A 50:50 joint venture-Escorts Yamaha
Motor, with Yamaha Motor Company (Japan), has been formed, for carrying on the two-wheeler
business, which was being carried on by Escorts prior to restructuring. During the year 1996-
1997, Escorts hived off its piston business to Escorts Mahle Ltd, A joint venture with its
erstwhile technical collaborator Mahle Group. The supermarket business was transferred to a
new JV, Escorts Mahle Ltd. The Delhi based tractor and motorcycle manufacturer, seems to have
suffered a decline in its sales and net profit in its last fiscal largely because of 70 day strike at its
factory. Given that this way was a one time incident, the company can be expected to show a
sign of revival after a year of stagnation in fiscal 1998-99.The company’s overseas investment
plan is in view to explore the possibility of establishing manufacturing, trading, joint ventures
and other operation overseas. It has signed a MoU in February this year with long manufacturing
(NC) Inc., North Carolina, and USA for a joint venture company, Long Agribusiness LLC, for
manufacture assembly and sale of tractors. An Escort is a creation of Nanda brothers with
construction vision committed and determined. The Escorts group under the dynamic leadership
of Mr.Anil Nanda ( Chairman and MD) is a professionally managed multi product organization.

The Escorts was founded at Lahore in Pakistan on October 1944 as an Agency house
Escorts. The Escorts Agents Lodi came into being with a vision that was nurtured by Mr.Hari
Nanda, Mr.Yudi Nanda, Mr.C.K.Hazari and Mr.Ranjit Singh. In its infancy it suffered severe
blow because of partition of India in 1947.However,the founder members with firm
determination shifted their operations to New Delhi, the capital of our country and in the short
span steered the concern to a place of recognition, which is crystal clear performance
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After partition in 1947, Nanda bros. continued the agency for electric products for wasting house
and in the mean time undertaking another agency for heavy machinery. In 1949, following the
devaluation of a rupee the company found that their agency is not working up to the mark. They
found that their major irrigation and industrial projects after independence.

Grabbing the opportunity-Escorts took an agency for heavy machinery from various countries
like USA, UK, Germany, Yugoslavia, Japan, and Poland. During this time Escorts (agents) Ltd
and Escorts (agriculture and machines Ltd) were formed.

Yudi Nanda looked after the second company, which imported and sold "Massey Ferguson"
tractors in India. With a fraternity of 22,000 employees, 20 manufacturing plants and a turn over
exceeding Rs.3, 000 crores , the Escorts group today runs among the top industrial giants. In the
country there was a persistent annual growth rate of 27% of the past decade. It is the fifth largest
engineering company among both public and private sectors.

According to economic times Escorts is ranked among seventh in sales and fifth in profit while
amongst engineering companies. It is ranked fourth in sales and second in profits. For four
decades Mahle pistons and Goetze Rings are remained undisputed leaders in OEM and after
merit segments. The demand for tractors was fast increasing and the company decided to set up
tractors manufacturing plant at Faridabad. Next to follow were motorcycles leading birth to
Rajdoot. Both were runaway successes for two reasons:

 The company has adapted the technology to suit Indian conditions.

 It has an efficient and well spread distribution system included service support and
availability of spares.

From then on all though the 1960's and 1970's, Escorts continue to diversify into core sectors
collaborating with global leaders and bringing into India the most sophisticated and relevant
technology.
GOETZE (I) LTD Patiala was incorporated in 1955 through collaboration with GOETZE
WORKS AG Germany. Manufacturing plant for piston ring was set up at Bahadurgarh, Patiala,
which delivered the Indian automobile industry its piston in 1957.It was started in 1955 when
Chief Minister of erstwhile Pepsu State Hon'ble Shri Brish Bhan laid its foundation stone.
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Licensed to manufacture three million piston rings with collaborations of M\s Goetze Weite
West Germany, one of the leading manufacturers of piston rings in the world, the unit took rapid
strides under capable leadership and achieved the capacity in short span of three years after the
machines were installed and commissioned.

The Escorts Mahle Ltd. Bahadurgarh is a joint venture of Escorts Ltd and Mahle, KNORR
BRERNSE Germany since 1-10-96.As a corollary, the management brought in the manufacture
of pistons progressively to enable the engine builders in the country to get the latest advancement
made in Europe as far as pistons were concerned. Over the years Escorts has collaborated with
many leading enterprises and engineering groups like Goetze, Mahle, Suko etc. Piston assemblies
engineered in this progressive unit in Punjab became the first choice boomed. The demand for
outstripped the production expansion inevitable. By the year, the expansion scheme doubling the
capacity of pistons and rings were a complete shape, the employment potential too increased.

The Escorts limited has been generous unit to its employees by providing then with financial
incentives along with good pay scales. It has adopted various labour welfare and social security
measures for the betterment of working and living conditions of its workers.

The Personal Department of this unit has left no stone unturned to take such steps with a view to
establish harmony between workers and management. The policies followed by this unit are truly
in line with the general policy of the Government of India followed in public sector enterprises.
The Escorts limited Bahadurgarh unit is paying full attention to providing good working
conditions to its employees for getting the best out for them in the matter of production. The
employees are allowed Dust allowance, washing
allowance, house rent allowance, conveyance allowance, local traveling expenses, transport
subsidy as per rules. A very interesting feature of this unit is that there are various gift schemes
for meeting and breaking the target/records of production.

Considering the needs of complete PISTON assembly ESCORTS LIMITED ventured into
manufacturing of pistons. In 1958 with the collaboration of M/S MAHLE Group, GERMANY,
which delivered the Indian automobile industry its PISTON in 1960. ESCORTS entered in
collaboration with M/S SUKO Group, GERMANY for piston pins in1967 and manufacturing
started in 1968.
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To meet the increasing demand of market, in 1977 a parallel unit for manufacturing pistons and
piston pins was set up in BANGLORE.

Technological leadership unmatched with innovative thinking has made Escorts and Goetze
products to enjoy a high degree of customer confidence and is the first choice for applications
ranging from Bi – wheeler to Battle Tanks.

From 1st October 1996, ESCORTS LIMITED entered into joint venture with M/S MAHLE
Group, GERMANY with the formation of a new company, ESCORTS MAHLE LIMITED.

In 1998, GOETZE also became the part of Federal Mogul, a well known group of USA. In June
2000, both ESCORTS MAHLE LIMITED and GOETZE have become QS 9000 certified
companies.

In the year 1978,a parallel unit for manufacturing the piston rings was established in
BANGLORE.
In 1994, M/S GAG became a member of M/S T and N group of U.K, which has now been
acquired by M/S Federal Mogul global manufacturer of broad range of automobile parts.

In 1996, M/S GIL has upgraded IS certificate from IS 9002 to 9001.In 2000, M/S GIL achieved a
prestigious QS 9000 Certification.

By virtue of streamlining quality system, developed of quality culture, adaptation of latest

technology and equipment and with continuous endeavor towards improvement, Goetze products
enjoy a high degree of customer confidence and are the first choice of discerning for application
ranging from BI-WHEELER to BATTLE TANKS.

Production boomed the demand for outstripped the production expansion became inevitable. By
the year 1966, the expansion scheme doubting the capacity of pistons and rings was given a
complete shape. The year 1968 saw the commencement of Gudgeon pins.

Employing about 3500 people this progressive unit has an annual turn about Rs.80 Crores and is
biggest of its kind in Punjab adding lusture of the emerging industrial horizon of the country.

From then on all through the 1960’s and 1970’s Escorts continue to diversify into the core
sectors collaborating with global leaders and bringing into India first the most sophisticated and
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relevant technology. Among the company’s international collaboration are Goetze, Mahle,
Knoor, Bemse, Faun and class of Germany, Ford and Hughes network system of USA, JCB of
the UK,Yamaha of Japan and Dynapac of Sweden.

The variety of products being produced by Escorts includes tractors, motorcycles, cranes,
loaders, excavators, auto ancillaries (pistons, piston rings, piston pins, automotive shock
absorbers, telescopic front forks,Mc Pherson struts and carburetors, railway ancillaries (double
action hydraulic shock absorbers, center buffer coupler and brakes),harvest combines, EPABX,
key telephone system and road computers.

The Escorts rural development program under which has adopted over 60 villages Escorts center
at Faridabad and Escorts Heart Institute and Research center are crowning examples of the
company's belief that the welfare of business is intermixed with the welfare of society.
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PRODUCT RANGE
Piston rings
Cylinder line
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 MAJOR CUSTOMERS OF GOETZE

PASSENGER CARS AND JEEPS:

Hindustan Motors
Mahindra and Mahindra
Fiat India Limited
Monto Motors

BI WHEELERS:
Escorts Yahama Motor Ltd
Escorts Automobiles Ltd
Bajaj Auto Ltd
Kinetic Engg. Ltd
TVS Suzuki Ltd
Majestic Auto Ltd
Scooters India Ltd
Idea Java (I) Ltd
Royal Enfield
• LML Ltd

TRACTORS:
Mahindra and Mahindra Ltd
Eicher Tractor Ltd
Escorts Ltd
Escorts Ltd (Farmtrack division)
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HMT Ltd
Swaraj Engines Ltd
International Tractors Ltd
Standard Tractors Ltd
New Holand Ltd
VST Tillers Ltd
Harayana tractors

COMMERCIAL VEHICLES:

Telco
Swaraj Majda Ltd
San Engg. and Locomotives Tata Cummins

PISTON RING PRODUCTION

Ring in foundry shop The ring first produce in the foundry shop from the Meltoncast iron in the form
of rough ring.which dia and finish is very far from the actualring.

1.SEMI FINISH SIDE FACE GRINDING

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When the ring comes in the “ring plant” the first process which does on the ring is‘semi finish side
face grinding’ in this process in grinding machine the face of the
ring is ground upto axial height 0.83(+.015,-.015)

2.WASH IN SOLVENT After grinding of ring ,ring is washed in solvent ,for the remove rust and dirt.

3. Heat treatment processThis is the process ,which follow after second step. This is very important
processbecause in this process we change the molecular structure of the rings and improvethe needed
quality of the ring such as reduce the brittleness and increase strength,also in heat treatment process the
ring become totally flate due to heat.This process held on 530 centigate temperature half hour and than
leave for cool inair.

4.Diskas machine:-
After heat treatment the ring sends to disckas machine ,in this machine the sideface of the rings is get
final finish upto axial height .8(-.01,.-.02)

5. Again the rings are washed in the solvent as the after first process

6. DEMAGNETISETION :-
When the rings passed through the grinding machine due to friction it get magneticproperties due to
which rust and dirt of the iron are stuck of its surface. Whichcreates problem ,like destroy the finish of
surface. Therefore its is necessary toremove this properties .so for remove this process the Rings are held
ondemagnetize machine for few minutes under which counter magnetic force applyon its and
remove magnetize properties

7. CAM TURNING :-
The shape of ring is not totally circular instead of it ,it is oval shape which isproduce in cam turning
machine where we produce the value of Cam% :10E-value :151.95Tso-dia :53.63D-150-dia :53.28its is the
most important process of the ring making because the next step dependon it , if the ovality on the ring
not produce then it will not suitable for piston.

8. GAP CUTTING :-
In this process the ring cut from the one side ,which is known as gap. The gap is cutin the ring for make it
flexible ,because when the ring is fit in the piston and pistonmove the due to flexibility it make contact
with linear. And the close gap cut isequal to D+.05 (+.1,-.1)

9. OD GAP EDGE CHAMFER :-

It is also used for save the work energy of piston during work. The edge of outer diais chamfer. As given
amount. It done if given in process card. Otherwise we can skipthat process .

10.FINISH GAP GRINDING :-

For the proper function of ring it is very important to provide finish in the gapbecause I f gap is not
finish and rough than the accuracy and efficiency of theengine can be reduce .it might be possible the
ring not properly in the piston.Therefore for eliminate all this error we provide finish gap grinding.
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12. ID GAP EDGE CHAMFERING:-

It is also like the OD chamfering and used for same function. It maximam amount is.2mm.and than send
fir next process.

13. WASH IN SOLVENT:-

Once again the ring is wash in solvent for remove it dirt and dust then it dried by thehigh pressure air .

14. BELDERING (SIDE FACE)

When we create gap In the ring then there is an unwanted small edge appear whichis know as burr. It
increase friction and ring jam in the piston there for remove thatwe use beldering process. The burr occurs
inside the ring therefore increase axialheight .and we have to maintain axial height.

15. STRAIGHT HONING :-

The next step is the honing .during honing process the outer dia have to finish and itis equally to d+.00.
and light thickness is 100%. This process done in vertical honingmachine in which we fit the mandrel
then start the machine during honing processoil emery paste is used.

16. FINAL SIDE FACE GRINDING :-

In final face grinding once more the side face have grind and find the required axialheight. This process
is done at last so that over come of undercut axial heightproblem.

17. WASH IN SOLVENT

18. DEMAGNETISE At the last demagnetize process done on ring under 10gauss max. because after
anumber of process ring may be magnetize .so for remove that we usedemagnetizing process.

19 .CRI INSPECTION :-
At the end it send for CRI inspection where ring finalize for export.

Piston Formation

 A piston is an important component of reciprocating engine helps to convert energy

obtained by the combustion of fuel in cylinder into useful mechanical power.
 It is like a disc which reciprocates within a cylinder.
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MANUFACTURING PROCESS

 Casting
 Heat treatment
 Machining process
 Pin fitting and Inspection

PROCESS

 The process starts by heating the material to 700 degrees Celsius.

 The material is then scooped up with a ladle from the crucible (the pot that holds the molten
material).
 This is then poured into the die through the sprue.

 The material is then allowed to cool before it is removed from the die .
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HEAT TREATMENT

 Heat Treatment is the controlled heating and cooling of metals to alter their physical and
mechanical properties without changing the product shape.
 Heat Treatment is often associated with increasing the strength of material, but it can also
be used to alter certain manufacturability objectives such as improve machining, improve

formability, restore ductility after a cold working operation .

MACHINING PROCESS

 Open end bore machining

 Rough outer diameter turning
 Grooves forming
 Semi finish hole boring
 Circle grooving oil hole drilling in 3rd groove and skirt
 Ring grooving and chamfering
 Final outer diameter turning
 Deburring and cleaning
 Tin coating
 Finish pin hole boring

PIN HOLE BORING

 At this stage of the piston manufacturing process, the casting has the gudgeon pin hole
rough machined.
 This is carried out on a simple lathe.

 The pin borer is only a rough machining process which allows the reamer to enter the
gudgeon hole later

.
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CNC TURNING

 Turning of the casting is carried out on CNC machinery.

 This equipment is the most accurate and fastest available for this application with very tight
tolerances and extremely fast spindle speeds. The following operations are performed on
this machine:
 Open end bore machining
 Rough outer diameter turning
 Grooves forming

DRILLING AND GRINDING

 Drilling includes all oil holes in places such as the gudgeon pin bosses and oil ring grooves.
 Slotting is done where slots are placed in the skirt or in the oil ring groove.
 Grinding involves the final size being machined on the piston.
 Semi finish hole boring
 Circlip grooving oil hole drilling in 3rd groove and skirt
 Ring grooving and chamfering

REAMING

 The final machining process for the piston is that of reaming.

 This process involves the piston being placed in a bath of oil and reamed at different sizes
to reach the final size required.
 Since the pin boring process is only rough it is necessary to ream the pin bore a number of
times to achieve the surface finish and size required.

DEBURRING AND TIN COATING

 Before coating, the pistons should be thoroughly cleaned to remove any soap or phosphate
residue, water spots, machining oil, dirt, etc. picked up during the manufacturing process.
 For optimum results a mechanical type cleaner (e.g. spray) is recommended.
 Recommended methods for applying Tin
Coating to pistons are either screen print or spray techniques.

PIN FITTING AND FINAL INSPECTION

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 At this stage the piston is cleaned, inspected by the instruments, fitted with the
appropriate gudgeon pin, stamped with the pistons oversize and any other markings, and
then sent to dispatch.
 Finally, the piston is wrapped and placed in the shipping container with the ring set and
sent to the customer.