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Daily Progress Overview

20/05/19:

Introduction to Kiloskar company and project overview.

21/05/19:
Guide allotment and project introduction.

22/05/19:
PP01-Cope PC01-cope of core box
PP02-Drag PC02-Drag of core box
BHM-Bore whole mode (Mixed flow)
BHR-Bore hole radially
BHA-Bore hole axially
Types of pattern:

loose piece
Pattern

pattern
Cope and drag
pattern

Sweep pattern

Pattern Making depends upon:


1. Number of casting.
2. Possibility of repeat order.
3. Surface finish required.

AKASH SWAMI 1
Daily Progress Overview

23/05/19:
Pattern modification process
1. Carp age is used to fill the crack in the pattern.
2.Champion sheet is used to increase the thickness of the pattern .It is available in the size of
1mm,3mm,5mm.
3. Thermocol is used to make pattern which will be used for making 2/3 casting.
4. Wooden patterns are used to make more than 8 casting.
Allowances:
CI-1% allowance
Nonferrous -1.5% allowance
AL, Steel -2% allowances

24/05/19:
Visiting to the
1. Pattern shop SNPD
 Used to store patterns of small and medium sized pump.
 Contains 8*21 rack system which is totally automatic.
 Al patterns are used for high machinability purpose.
 Suction having large diameter as compared to delivery.
2. CPM
Central pattern making shop.
3. Composite
It the section in which assembly of pump was done and also pumps are coloured and finished.
4. LPD (Large pump division)
It used for making parts required for making large pump.
5. NDT (Non Destructive testing):
1. Radiography testing (X-ray testing)

AKASH SWAMI 2
Daily Progress Overview

2. Dye penetrant testing

Surface with Cleaning the Filling Dye


crack with grease surface with Penetrant in the
,dirt cleaner cracked surface

After penetrating Apllying


remove excess Developer on the
penetrant surface

25/05/19:
1. Time Study of BHR3 Impeller (7 Vane).
D.NO.15346AZ103-232 HT.19F64
In this process they use a pneumatically operated hand grinder having pointed cutter tool
attached to it.
2. Inventory feeding of Shop no.1 in excel format.

27/05/19:
1. Time study of ladle lining of 4 ton ladle.
(Ladle lining –for removal of excess material inside the ladle and to maintain capacity of ladle.)
In this process they apply mixture of WHYTHEAT and Water on the inner surface of ladle.
2. feeding of inventory of Shop no.1 in excel format.

AKASH SWAMI 3
Daily Progress Overview

28/05/19:
1. feeding of inventory data of shop no .1 in excel format.
2. Pattern modification process & foundry process.

Pattern Testing &


Making Inspetion

Moulding &
Fettling
Core Making

furnane Melting &


Charging Casting

3. Buffing operation.

29/05/19:
1. Time study of Balancing of two BHR28 impeller of 7 vane.
D.NO.15301AZ0103-242 HT-18E215
Total normal time-0:29:39
Idle time -0:02:01
Total effective time -0:27:38
2. ERP (Enterprise resource planning) & SAP system
Advantages of ERP system –
 Increase revenue
 Customer Delight
 No data duplication

AKASH SWAMI 4
Daily Progress Overview

ERP ERP
Decentralised Centralised
system system

Data maintain Data maintain


locally centrally

AKASH SWAMI 5
Daily Progress Overview

30/05/19:
1. Taking time study of Balancing of BHR28 Impeller (7 Vane).
D.NO.15301AZ103-242 HT-18E215
2. Railway line pattern shop Rack no.6 loading & yellow painting.

01/06/19:
1. Taking time study of Bowl Cleaning BHR3
DR .NO.1541011202P.563
2. Study of Pattern modification process.
3. Numbering and taking physical inventory of Rack No.6 in Railway line pattern shop.
4. feeding of inventory of Rack no.6 in excel format.

03/06/19:
1. Taking Physical inventory of pattern kept in the free space of Shop No.1 and also Rack
no
2. Feeding of inventory of Rack no .3 in excel format.
3. Taking information about –
 MCP
 Laser Calibration
 Split case pump for parallel discharge
 Multi stage pump ( for high discharge two pumps are connected
parallel ,For high head impeller are connected in series )
 CNC Machine

05/06/19:
1. Taking time study of Bowl Cleaning of BHR42 (8 Vanes )
D.No.153A8FH009-012
Total Normal time -1:32:56
Total Idle time -0:26:54
Total effective time -1:06:52

AKASH SWAMI 6
Daily Progress Overview

Bowl Cleaning Process:

with With with


wheel Pointed Pointed
Grinder Cutter tool grinder

06/06/2019:
1. Study of Pattern modification process.
2. Vertical tarrate lathe operation (VTL) 52inch

Facing

Operation
Boring
performed Turning
on the
BHM40 Bowl

Chamfering

AKASH SWAMI 7
Daily Progress Overview

08/06/19:
1. Tapping Operation, Boring, Drilling operation
Tapping operation –This operation is used to create internal thread in the drilled hole.
Boring operation –This operation is used to enlarge the drilled hole up to required
dimensions.
Drilling operation –In this operation drill bits of sizes ranges from 17.5,18,21,25,27 are
used to drill hole in the Vertical pump stool.
2. Go and No Go gauge for checking proper tapping.
3. Taking information about material testing lab.

Rockwell test
For checking
hardness
Test carried out Izod & Chapy test
in material
testing lab
Chemical testing
for checking Spectrosscopy
properties

09/06/19:
1. Time study of VT250 Impeller Balancing.
2. Allotment of workers for numbering of Railway line pattern shop& also checking their
progress.
3. Remaining part of inventory near NDT shop feeding in excel format.
4. Feeding inventory of shop no.1 in excel format.

AKASH SWAMI 8
Daily Progress Overview

11/06/19:
1. Taking Physical inventory of remaining part of rack no.3 in shop no.1 and also Impeller
rings in the shop no.1
2. Allotment of workers for numbering of Railway line pattern shop& also checking their
progress.
3. Nearby 60 % numbering with paint completed in the Railway line pattern shop.
4. Feeding of inventory data of Impeller ring in excel format.
12/06/19:
1. Time study of BHR28 Impeller (5Vane).
D.NO.15301AZ101-242 HN-19E46
In this process they apply pointed cutter tool, Buffing tool & use a balancing machine.
2. feeding of inventory of Shop No.1 in excel format.
3. feeding of inventory data of Impeller ring in excel format.
4. Workers allotment for painting and numbering of Pattern in Railway line pattern shop
and checking their progress.

14/06/19:
1. Time study of Tip sizing of BHR24A (5 vane) impeller.
Total normal time: 0:24:35
Idle time: 0:03:16
Total effective time: 0:21:19
2. Workers allotment for painting and numbering of Pattern in Railway line pattern shop
and
Checking their progress.
15/06/19:
1. Time study of BHM25 Impeller
DR.no.15007EV002-232 HT.19F399
2. Rack shifting in shop no.2

AKASH SWAMI 9
Daily Progress Overview

17/06/19:
1. Shop No.2 pattern arrangement.
2. Fettling –
The casting as obtain from mould are not fit for immediate use as they carry unwanted
metal attached in the form of gates & risers. Sand particles also tend to adhere to the
surface of the casting.
In fettling section the unnecessary projections are cut off, the adhering sand was
removed.

Operation involved in fettling:

cleaning &
fettling

Cleaning &
knocking out of
smothing of
dry sand core
casting

Removal of fins
Removal of gate
& unwanted
& risers
projections

AKASH SWAMI 10