G

Plant Layout
1

G2

OFFICE
R&D
CUTTING LINE QA LAB
S FABRICATION
C
INVENTORY
R
ASSEMBLY LINE
A
P
PAINT LINE
STORE
 PROCESS LAYOUT BAY 1

[Cutting Line]
Oxy fuel cutting,
&
Plate Storage
Plasma cutting.
Area

Grinding Area

Levelling Area

Drilling Area
Sub Assembly
Area
Bending Area

Office
CUTTING LINE
There are two type of cutting machine is used in the Industry.
 Oxyfuel Cutting
 Plasma Cutting
Oxyfuel Cutting is use for cutting plates between 22mm to 60mm & Plasma
Cutting is use for 6mm to 20mm.
Oxyfuel Cutting
The oxyfuel process is the most widely applied industrial thermal cutting process
because it can cut thickness from 0.5mm to 250mm .
The cutting process is basically, a mixture of oxygen
and the fuel gas is used to preheat the metal to its
'ignition' temperature which, for steel, is 700°C -
900°C (bright red heat) but well below its melting
point. A jet of pure oxygen is then directed into the
preheated area instigating a vigorous exothermic
chemical reaction between the oxygen and the metal
to form iron oxide or slag. The oxygen jet blows away
the slag enabling the jet to pierce through the material
and continue to cut through the material.
There are four basic requirements for oxy-fuel
cutting:
 the ignition temperature of the material must be
lower than its melting point otherwise the material
would melt and flow away before cutting could take
place
 the oxide melting point must be lower than that
of the surrounding material so that it can be
mechanically blown away by the oxygen jet
 the oxidation reaction between the oxygen jet
and the metal must be sufficient to maintain the
ignition temperature
 a minimum of gaseous reaction products should be produced so as not to
dilute the cutting oxygen
As stainless steel, cast iron and non-ferrous metals form refractory oxides ie the
oxide melting point is higher than the material, powder must be injected into the
flame to form a low melting point, fluid slag.
Process Parameters
Cutting Pressure 3-5 Bar (Oxygen Gas)
LPG Pressure 0.5-2 Bar
Heating Pressure 3-5 Bar (Oxygen+LPG)
Plasma Cutting
This is a cutting system utilizing heat generated by arc discharge between the
cutting object material and the electrode inside the torch. Arc discharge heat
forms working gas into the plasma state of high temperature; the plasma jet of
high temperature and high-speed is blown out from the nozzle; and the cutting
object material is fused to be cut.
Heating a gas to a high temperature makes kinetic energy of its molecule or atom
large, such particles vigorously collide each other; electron inside the atom is
taken away resulting in positively charged ions and negatively charged electrons
being mixed up; as a whole, each charge offsets one another, producing a state of
electrically neutral, which state is called plasma. This plasma appears when a gas
is heated to 5 to 7 thousand degrees or higher at the atmospheric pressure.

Grinding
Grinding is an abrasive machining process that uses a grinding wheel as the
cutting tool. A wide variety of machines are used for grinding: Hand-cranked
knife-sharpening stones (grindstones) Handheld power tools such as angle
grinders and die grinders.

Beveling / PUG Cutting

Beveling refers to an edge of a structure that
is not perpendicular to the faces of the piece.
The words bevel and chamfer overlap in
usage; in general usage they are often
interchanged, while in technical usage they
may sometimes be differentiated as shown
in the image at right. A bevel is typically
used to soften the edge of a piece for the sake
of safety, wear resistance, or aesthetics; or to
facilitate mating with another piece.
LEVELLING OPEREATION
Nine roller bending machine is used to flatten the parts after cutting operation.
On this machine up to 34mm thickness plates can be levelled. If the deflection of
the plate (having thickness greater than 34mm) is up to 3mm they can be flattened
by using a punching machine, if the deflection is greater than 5mm then the part
is rejected
RADIAL DRILLING MACHINE
A radial drilling machine or radial arm press is a geared drill head that is mounted
on an arm assembly that can be moved around to the extent of its arm reach. The
most important components are the arm, column, and the drill head. The drill
head of the radial drilling machine can be moved, adjusted in height, and rotated.
Aside from its compact design, the radial drill press is capable of positioning its
drill head to the work piece through this radial arm mechanism.

BENDING MACHINE
Press Break
Press break is used for point bending of the plates. The maximum force that can
be applied by using the hydraulic press is tons. The maximum thickness of
the plate that can be bend is 25mm.The dye used for bending must have the
diameter greater than the 8 times of the thickness of the plate
 .

Four Roller Bending Machine

Four roller bending machine is used for curved bending of different parts. There
are two rollers one on each other which are known as drive rolls. These can be
moved up and down for different thickness of the plates. Other two rolls are left
side roll and right side roll which can be moved up and down that makes the plate
to bend.
PROCESS LAYOUT BAY 2, BAY 3, BAY 4.
PAINT LINE

DRILLING
OFFICE
SCBM

SCBM
BUCKET New Double
Column Boring
STORAGE Machine
(NDCBM) &

W DCBM

E
L W W Local &
D E E SKD S
BORING
I I
OPERATI I L L
ON
N N
I N D D V V
N E
G I I E
V N N
E N N T T
N G G O O
T R R
O Y Y
R
Y BENGI
NG
LATHE M/C

M/C
M/C
LATHE MACHINE
Lathe machine is used for facing and plain turning of the circular parts which can
be attached to the bucket seat, articulation of the front and rear frames, lever,
boom.
BORING MACHINE:
Boring is usually referred to as enlarging the diameter of the drilled hole. This
can be brought out in three stages.
ROUGH BORING:
In rough boring operation maximum amount of material is removed at
low cutting speed with corresponding maximum feed rate. 5-10mm
MEDIUM BORING:
In medium boring operation minimum amount of material is removed
with corresponding cutting speed and feed rate.2-3mm
FINISH BORING:
In finish boring operation the amount of material removed is in microns
and the feed rate is very low to maintain the good surface finish.0.5mm
Hss carbide
MILLING OPERATION:
Milling is a cutting process that uses a milling cutter to remove material
from the surface of a part to achieve the good surface finish.Cutter &
White Tool

HARD FACING: This is welding operation performed on the bucket which

comes in contact in the working field. To increase the hardness and strength of
the bottom cutting edge, Number of runs (As given in process card) passed
along the length of the bucket. Zed alloy 550 is used as the electrode and
Shielded metal arc welding is used.

TACK WELDING
Tack welding can be used to set up the workpieces without using fixtures.
Typically, tack welds are short welds. In any construction, several tack welds are
made at some distance from each other to hold edges together
Tack welding is real welding, even if the welds are deposited in separate short
beads. It performs the following functions:

 Holds the assembled components in place and establishes their mutual

location
 Ensures their alignment
 Complements the function of a fixture, or permits its removal, if
necessary
 Controls and contrasts movement and distortion during welding
 Sets and maintains the joint gap
 Temporarily ensures the assembly's mechanical strength against its own
weight if hoisted, moved, manipulated, or overturned

FULL WELDING

In full welding process permanent joining of all the parts takes place to form
the final product. The type of welding preferred for full welding is GMAW
(metal inert gas welding).An electric arc is formed between the continuously
fed wire electrode and the workpiece which causes them to melt and join. In
GMAW welding DC (direct current) is used with electrode as positive and
workpiece as anode. This is known as reverse polarity.
Welding Parameters -
Current (240 ~ 270 ) A
Voltage (28 ~30) V
Rate of Gas flow (18 ~22) L /
min

GMAW

GMAW stands for gas metal arc welding. This is also commonly referred to as
metal inert gas welding, or MIG welding. In GMAW the electrode is a roll of
wire which the welder feeds out of a ‘gun’ to the work piece. You control the
speed of the wire, so you can make long welds without stopping to replace a rod.
This type of welding is generally considered to be the easiest to learn. The gun
also feeds out an inert gas such as Argon or CO2 to displace oxygen at the weld
site. This means you don’t have any slag to chip away, but you do need a tank
and regulator to go with a MIG welder.

Inventory
Inventory is the collection of unassembled products waiting to be assembled.
Inventory is listed as a current asset on a company.There are two type of
Inventory for assembly line .

1. Complete knock-down ( CKD)

2. Semi-knocked-down (SKD)

A knock-down kit is a kit containing the parts needed to assemble a product.

The parts are typically manufactured in one country or region, then exported
to another country or region for final assembly. Variant names include
knockdown kit, knocked-down kit, or simply knockdown, and the abbreviated
KD or CKD.
A common form of knock-down is a complete knock-down (CKD), which is a
kit of the completely non-assembled parts of a product. It is also a method of
supplying parts to a market, particularly in shipping to foreign nations, and
serves as a way of counting or pricing.[1] CKD is a common practice in the
automotive, bus, heavy truck and rail vehicle industries, as well as electronics,
furniture and other products. Businesses sell knocked-down kits to their
foreign affiliates or licensees for various reasons, including the avoidance of
import taxes, to receive tax preferences for providing local manufacturing jobs,
or even to be considered as a bidder at all (for example, in public transport
projects with "buy national" rules).
A semi-knocked-down kit (SKD) is a kit of the partially assembled parts of a
product. It is also called an incompletely disassembled kit, although it has
never been assembled. Both types of KDs, complete and incomplete, are
collectively referred to within the auto industry as KDX (for knocked-down
export), and cars assembled in the country of origin and exported whole to the
destination market are known as BUX (for built-up export).

Paint Line

Putty
Short Primer Paint
Primer & Paint
Blasting Oven Oven
Sanding
The Paint line consist of seven stations. Six stations are situated in bay2, bay 3,
bay 4. Maximum work is done in these six stations only. In seventh station final
coat, company name and logo are painted on the vehicle. The seventh station is
in rework area.

Short Blasting
Shot Blasting is a surface finishing technique that involves rapidly impacting the
surface of an object with a controlled abrasive shot material. It is faster and more
effective than filing for removing flash Shot Blasting also removes burrs, scale
and rust that may interfere with the part's integrity, Shot blasting can also prepare
the surface of a part for coating by removing surface contaminants and provide a
surface profile for increased coating adhesion.
Abrasive - Grit, Steel Balls / Cut Wire

Primer
Applying primer over new surfaces reduce the amount of paint being absorbed
by the surface. The primer will help y in hiding seams and joints, and probably
other small defects when it is applied on surfaces. The main function of priming
is to ensure that any successive layers of paint adhere to the surface properly.
Primer used in Industry is Epoxy.
Primer Oven
After applying the primer the part is kept in oven at 100 deg./C for 20 min.

Putty & Sanding

Fine layer of putty is applied for level the irregular surfaces after the primer.
Sander is done after putty to get smooth surface finish to the part.
Paint
After sanding now the part moves into station five where it is painted. The paint
used for the parts is Sherwin Williams (Valspar)
Oven
After painting the part is once again kept into oven at 100 deg/C for 20 min

Assembly Area
Assembly Area consist of two Assembly lines and each line consist of seven
stations . On some stations there are sub station also, i.e station one has two sub
station one for front frame and second for rear frame. On Line One there is
assembly of Wheel Loaders, (856H, 856, 835 818) Motor Grader (414)&
Compactor (611).In Line One there is batch production for Wheel Loaders &
Motor Grader vehicle .For compactor there is One off Production .On Line 2 there
is Assembly for Excavators ( 921, 922, 939).