CHAPTER 1

INTRODUCTION
The training report is about the Different aspects of material management of RICO Auto
Industries Ltd. RICO AUTO is a dynamic world class engineering company supplying a
broad range of high precision fully machined ferrous and aluminum components and
assemblies to automotive OEM’s globally. Material and its management is not a new thing,
it is there from the starting of the business, unfortunately earlier nobody realize its
importance but it has gained a lot of importance for the past few years because of the
benefits offered by it. It has emerged as the most critical component as corporations
globalize their operations.

Rico Auto Industries, is amongst the large auto components companies in India and leading
supplier to Indian and global automotive OEM. It commenced operations in 1983 at
Dharuhera (Haryana) with activities in aluminium high-pressure die-casting and machined
components and assemblies. In 1992 it added ferrous casting and machining capabilities at
its Gurgaon (Haryana) facilities by adding a high speed moulding line. In 1996 the
company entered into a 50:50 joint venture with FCC Co Ltd (Japan) to manufacture clutch
and fly wheel assemblies for two wheelers and passenger cars at its plants in Manesar
(Haryana).

The promoters hold the majority stake in the company at 44.67 per cent. Public holding in
the company is 22.09 per cent whereas foreign institutions hold 16.6 per cent.The rest of
the stake is held by domestic institutions, non-resident Indians, non-promoter corporate
bodies and others.

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1.1 VISION & GOAL

Vision:
To be the preferred supplier to Original Equipment Manufacturers across the globe.

Goal
“To be a US $ 10 billion Enterprise by 2021”

RICO AUTO is a dynamic world class engineering company supplying a broad range of
high precision fully machined ferrous and aluminium components and assemblies to
automotive OEM’s globally.
RICO Group is to be defined as a corporate in commercial, organizational, and technical
terms, which is a self-contained unit in the System with its own master data and processes.

1.2 THE EARLY YEARS

RICO Group was founded in the year 1977 with a ferrous foundry and a machining shop
at Ludhiana under the present company name RICO Castings Ltd. In 1984, RICO
diversifies into Aluminum high pressure Die Casting by setting up its plant at Dharuhera
under the company RICO AUTO INDUSTRIES LTD. In 1992,RICO AUTO started its
plant at Dharuhera. By installing Automatic High Pressure Moulding Ferrous Foundry and
Machining shop. Subsequently the Aluminum High Pressure Die casting and Machining
facility at Gurgaon, Rico soft tech LTD Gurgaon, RICO AUTO INDUSTRIES Inc USA;
RICO AUTO INDUSTRIES (UK) LTD, UK were added to its fold in the year 2001, 2001,
2001 & 2004 respectively.
RICO Group Companies Account Management, Logistics & Warehousing, Assembly
Operations
1. Michigan USA 2. London UK
Manufacturing Facilities in India 1. RICO (Dharuhera) –Aluminium Die Casting &
Machining 2. RICO (Gurgaon) –Aluminium + Ferrous + Dies & Moulds, R&D, Testing &
Validation, CAD CAM CAE 3. Joint Venture –FCC RICO (Manesar) –Clutches 4. Group

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Company –RCL (Ludhiana) –Ferrous Casting & Machining (Low Volume) 5. Group
Company –RCL (Manesar) –Aluminum Casting & Machining (Small to Medium Size
Parts) 6. Joint Venture –FCC Rico (Chakan Pune) + Planning New Plant RICO (Pune) 7.
New Plant RICO (West Bengal) 8. New Plant RICO (Chennai)

1.3 TURNOVER

RICO Group’s Turnover 10 Times over Last 10 Years (From 2006 to 2016) Manufacturing
& Engineering Capabilities.
In the Aluminium division, the RICO AUTO INDUSTRIES LTD. has continued to
establish its leadership in the high pressure die casting (HPDC). Today it is one of the
largest HPDC companies with 76 HPDC machines (from 135 tns to 1800 tns locking force).
Its efforts for developing complex and intricate components like high-pressure die cast
Cylinder Block, along with its technology provider Teksid Aluminium are on track. During
the year 2006-07 it started implementation of low pressure and gravity casting processes
and commenced working on Cylinder Heads and Alloy Wheels.
In the Ferrous division it has 4 moulding lines. During the year 2006-07 it successfully
launched Ferrous Cylinder Blocks for Maruti Suzuki. It also started supplies of complex
turbine center housing for Honeywell and launched new metallurgies used for higher
temperature applications. It has set up casting capacity in advance and is working towards
bringing value creating business for the same

1.4 PRODUCTS
Rico manufactures auto components predominantly in the engine, transmission and
braking and suspension categories.

Engine: Products include oil pump assembly, fuel system parts, lube oil filter heads,
exhaust system parts, turbo charger parts, crank cases and covers, cylinder head cover, cam
cover, intake manifold cover, front & rear cover, valve cover, balance shaft assembly,
thermostat housing, main bearing caps, water & air connections, flywheel assembly, EGR

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plate, rocker arm and engine brackets. There are two important parts under development
which are cylinder block and cylinder head.

Transmission: Products include clutch assembly, transmission supports, differential case

and housings

Braking and suspension:

Products include wheel hub assembly, brake panel assembly, brake disc, drums & rotors,
knuckles and FEAD brackets. The company has positioned itself as a full service supplier
to its customers by providing integrated solutions involving design, development, tooling,
casting, machining and assembly across its ferrous and aluminium products.

Financial analysis

Rico has witnessed an impressive growth in its revenues and profits in the last few years.
Gross sales increased from only USD 34.6 million in 1999 to USD 157.4 million in 2015,
thus exhibiting a It undertakes full-service product design and development projects
including concept design, simulation, tool design, and prototyping, including development
of robust manufacturing solution.

CAGR of 28.8 per cent.The growth in net profit was even higher at 33.9 per cent, with net
profit having grown from USD 1.4 million in 1999 to USD 8.1 million in 2015.This growth
has been driven largely by the substantial growth in the domestic two-wheeler and
passenger car segment as well as the outsourcing potential realised by the global OEM
from the most cost competitive countries, one of these being India. Rico’s exports have
been focused towards leading global OEM in Europe and North America, who have
selected the company as a single source supplier for critical high value added engine and
transmission components and assemblies. The company’s return on net worth and return
on capital employed remain healthy at 36.3 per cent and 18.9 per cent respectively.

Rico is headquartered in Gurgaon. All its manufacturing facilities are ISO-14001 and
OHSAS- 18001 certified. As part of its capacity expansion plans, the company is in the
process of setting up manufacturing facilities in Bangalore (Karnataka) and Manesar
(Haryana), for which land has already been acquired. While the Manesar facility would
manufacture aluminium die-casting and machining, the Bangalore facility would be used

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for machining and assembly, aluminium casting and ferrous casting. Given its strong
products and services range, the company is in a position to supply to prestigious
automotive OEM like Hero Honda, Honda Motorcycle and Scooters India, Maruti and Tata

Cummins in the domestic market.To establish a global footprint the company has chosen
the route of exports. Globally it is a supplier-of-choice to companies like Ford, General
Motors, Jaguar, Land Rover,Volvo, Cummins, Caterpillar, Detroit Diesel and Honeywell.

In 2001 the company also entered in the field of Itenabled services with the formation of
its wholly owned subsidiary, Rico Softech, which was subsequently amalgamated with the
parent company in 2004. Consequent to the merger, Rico now offers engineering services
to customers by focusing on CAD (computer aided designing), CAM (computer aided
manufacturing), CAE (computer aided engineering) and tool and product design. Material
management is an interactive Materials requirement, planning and control system. The
objective of the system is to make it easier to deal with complexities of operating a
manufacturing company by taking into account various aspects of information flow of
management. The material management helps:

1. To control investment in materials at the optimum level by efficiently organizing

the purchase and sales operations.
2. To maintain a sufficient and large size inventory to meet the demand of finished
goods and to meet the demand of raw materials by production department.
3. To make the best utilization of the available space, by managing the material in such
a way so that it can be easily available.
4. To decide the right lead time.
5. To make Right control by properly checking each and every aspect of material this
led to uninterrupted supply of materials from external and internal sources, which
led to increase in profit.
6. In right Handling by taking measures to reduce wastage. The waste materials are
continuously disposed of, which increase the working capital and increase the space
for the incoming materials.

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1.5 Rico’s contribution

In making “Made in India” global Rico’s global presence has been established mostly
through exports, which began in the year 1994. It is today, a tier-1 supplier to auto OEM
in the international market. Its global customers include reputed brands across developed
markets. In the US, it supplies to Ford, General Motors, Cummins, Caterpillar and Detroit
Diesel. In Europe, its clients include Ford, Land Rover, Jaguar, General Motors,
Cummins, Caterpillar, Volvo, Perkins and Honeywell. In Japan supplies are made to
Cummins, Nissan, Honeywell and Matsusaka Engineering Company. The company is in
the advanced stages of launching new products for other automobile OEM both in Europe
and North America. Alliances and joint ventures have been leveraged to grow in the global
markets. Rico entered into a technical collaboration with FCC, Japan in 1985 and later in
1996, it converted this technical collaboration into a 50:50 joint venture for supplying
clutch assemblies for two-wheelers and automobiles and flywheels for automobiles. FCC
is the OEM supplier to Honda, Yamaha and Suzuki in Japan and is the world leader in this
category of auto components. In 2006, the company entered into an agreement with
Pierburg for technology assistance to produce water pumps and oil pumps particularly for
Maruti for their new diesel engine project with GM-FIAT. Pierburg is a world leader in
water, oil and vacuum pumps and emission control systems. Further, in the same year, the
company has entered into a licensing and technological assistance agreement with Teksid
Aluminium of Italy, in order to add higher `value-add' components to its product portfolio
such as aluminium engine blocks and heads. With most producers relying on imports, this
opens up a huge market for these components in India.
In 2003, Rico became a part of Ford’s Global Supplier Development Programme, wherein
Ford began to develop Rico as a key supplier of aluminium and ferrous components and
assemblies. Rico has acquired wide ranging experience and better understanding of Ford's
processes and successfully launched a number of new products for Ford and their associate
brands. Though the agreement was discontinued in 2005, Rico continues to work with Ford
world-wide on its current and new programmes. To oversee its overseas interests and
promote exports in the international markets, Rico has two subsidiaries in the US and UK.
The subsidiary in the US has assembly operations that focus on providing logistics, local
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customer and engineering support services to its customers. The company is planning to
expand its product offering for the customers by entering into new processes like gravity
and low pressure and horizontal sand moulding. It is also focused towards enhancing its
engineering capabilities and acquiring technologies to target additional high-end
components with customers across the board.

Factors fuelling Rico’s global initiatives

Globally, sourcing of automotive components from low cost countries is accelerating,
especially in areas of machined components and assemblies. The opportunities for global
growth in Rico’s core area of business are immense. Cost competitiveness as well as its
engineering and investment capabilities are increasingly meeting the global sourcing needs
of automotive OEM and tier-1 suppliers. Rico’s competitive strengths as an integrated full
service supplier and capabilities to understand customer requirement and meeting tight
deliveries schedule have resulted in creating confidence among global players.
Leading European and North American OEM have selected Rico as a single source supplier
for critical engine and transmission components and assemblies. Moreover Rico is working
with its customer’s right from the concept stage, with its involvement in co-design and
development work increasing significantly.
Rico has also focused on setting up systems to comply with international quality standards,
thus remaining at the forefront in attaining international quality certifications like ISO TS
16949, ISO 14001 and OHSAS 18001.To become a world class manufacturing company
and upgrade the skills and abilities of its people, it is implementing Total Productive
Maintenance (TPM), Six Sigma and SAP across the Company. Future plans Rico plans to
be a USD 1 billion enterprise by 2011, mainly by expanding its global presence, which
would be done by introducing new products. The licensing and technological assistance
agreement with Teksid Aluminium for aluminium engine blocks and heads is a step in this
direction.The company also plans capacity expansion at its plants.

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 CHAPTER – 2

AUTOMOBILE INDUSTRY PROFILE

2.1 History of the Automobile Industry

In the year 1769, a French engineer by the name of Nicolas J. Cugnot invented the first
automobile to run on roads. This automobile, in fact, was a self-powered, three-wheeled,
military tractor that made the use of a steam engine. The range of the automobile, however,
was very brief and at the most, it could only run at a stretch for fifteen minutes. In addition,
these automobiles were not fit for the roads as the steam engines made them very heavy
and large, and required ample starting time. Oliver Evans was the first to design a steam
engine driven automobile in the U.S.

A Scotsman, Robert Anderson, was the first to invent an electric carriage between 1832
and 1839. However, Thomas Davenport of the U.S.A. and Scotsman Robert Davidson were
amongst the first to invent more applicable automobiles, making use of non-rechargeable
electric batteries in 1842. Development of roads made traveling comfortable and as a result,
the short ranged, electric battery driven automobiles were no more the best option for
traveling over longer distances.

The Automobile Industry finally came of age with Henry Ford in 1914 for the bulk
production of cars. This leads to the development of the industry and it first begun in the
assembly lines of the car factory. The several methods adopted by Ford, made the new
invention (that is, the car) popular amongst the rich as well as the masses.

According the History of Automobile Industry US, dominated the automobile markets
around the globe with no notable competitors. However, after the end of the Second World
War in 1945, the Automobile Industry of other technologically advanced nations such as
Japan and certain European nations gained momentum and within a very short period,
beginning in the early 1980s, the U.S Automobile Industry was flooded with foreign
automobile companies, especially those of Japan and Germany.

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2.2 Global Trends

The current trends of the Global Automobile Industry reveal that in the developed countries
the Automobile Industries are stagnating as a result of the drooping car markets, whereas
the Automobile Industry in the developing nations, such as, India and Brazil, have been
consistently registering higher growth rates every passing year for their flourishing
domestic automobile markets.

In keeping with the Automobile Industry Trends, the leading automobile manufacturers are
turning to the Asian markets that appear set to grow immensely over the next decade. The
automobile markets in the U.S., Europe and the Japan have almost matured as a result of
saturation and appear set to decline through the next decade. In contrast, the automobile
markets spread over the entire Asian continent (with the exception of Japan), are constantly
increasing in size and will be the destination for most of the globally leading automobile
manufacturers.

The rapid growth of the national economy of the BRIC countries (including Brazil, Russia,
India, and China) have enabled a growing section of the population of these countries to
purchase automobiles. Global surveys conducted recently reveal that within the next ten
years, these emerging automobile markets will account for nearly a whopping 90 percent
of the global automobile sales growth. As a result of this, leading Automobile
manufacturers of the world are setting up factories in the emerging markets, in order to
serve the potential consumers better as well as reduce manufacturing and shipping costs.
In addition, these arrangements are enabling the leading global automobile manufacturers
to compete with the local automobile manufacturers, which were flourishing in the absence
of quality competition.
The prosperity of the national economy is reflected in the rising per capita income of the
developing nations. Therefore, increasing Gross Domestic Product and per capita income
have raised the purchasing ability of the population that constitutes these emerging
markets.
7.

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In 2007, a total of 71.9 million new automobiles were sold worldwide: 22.9 million in
Europe, 21.4 million in Asia-Pacific, 19.4 million in North America, 4.4 million in Latin
America, 2.4 million in the Middle East and 1.4 million in Africa. [2] The markets in North
America and Japan were stagnant, while those in South America and Asia grew strongly.
Of the major markets, Russia, Brazil and China saw the most rapid growth.

History of Indian Automobile Industry

Automobiles were introduced to India in the late 1890's, the manufacturing industry only
took off after independence in 1947. The protectionist economic policies of the government
gave rise in the 1950's to the Hindustan Motors Ambassador, based on a 1950's Morris
Oxford, and, is still ubiquitous in the roads and highways of India. Hindustan Motors and
a few smaller manufacturers such as Premier Automobiles, Tata Motors, Bajaj Auto, Ashok
and Standard Motors held an oligopoly until India's initial economic opening in the 1980's.
Tata Motors launches its first truck in collaboration with Mercedes-Benz. The great Indian
politician Sanjay Gandhi championed the need for a "people's car"; the project was realized
after his death with the launch of a state-owned firm Maruti Udyog which quickly gained
over 50% market share. The Maruti 800 became popular because of its low price, high fuel
efficiency, reliability and modern features relative to its competition at the time. Tata
Motors exported buses and trucks to niche markets in the developing world.

The liberalization of 1991 opened the flood gates of competition and growth which have
continued up to today. The high growth in the Indian economy has resulted in all major
international car manufacturers entering the Indian market. General Motors, Ford, Toyota,
Honda, Hyundai and others set up manufacturing plants. Rolls Royce, Bentley and
Maybach are examples of the few high end automobile manufacturers which entered India
in the recent years. The Tata Nano is at the lower end of the price range costing approx
US$ 2,500 and Bugatti Veyron at the other with a price tag of over US$ 2 million.

India's love affair with the automobile is famously embodied in the 1920's Rolls Royce
collections of the erstwhile maharajas. The growing middle class aspires for the automobile
for its convenience and as a status symbol. Upper middle class and wealthy car owners

10
employ full-time chauffeurs to navigate the aggressive and seemingly lawless traffic
patterns of most cities. The construction of expressways such as the Mumbai-Pune
expressway have opened up new touring opportunities. The expected launch of a Formula
One circuit in New Delhi is expected to spark public enthusiasm for a motor sporting
industry.

2.3 Current Scenario

Over a period of more than two decades the Indian Automobile industry has been driving
its own growth through phases.
India is one of the largest automobile industries in Asia . The automobile industry in India
is the tenth largest in the world with an annual production of approximately 2 million units.
According to the UNIDO report , India has made it to the top 15 automakers of the world
and occupies the fourth position in the leading developing countries category of motor
vechile manufacturers . It has become a huge attraction for car manufacturers around the
world.

Fig. 2.1 Growth of Automobile Industry

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Though several major foreign automakers, like Ford, Suzuki, GM,and Honda have their
manufacturing bases in India, Indian automobile market is dominated by domestic
companies. Maruti Suzuki is the largest passenger vehicle company, Tata Motors is the
largest commercial vehicle company while Hero Honda is the largest motorcycle company
in India. Other major Indian automobile manufacturers include Mahindra & Mahindra,
Ashok Leyland and Bajaj Auto.
The entry of Suzuki Corporation in Indian passenger car manufacturing is often pointed as
the first sign of India turning to a market economy. Since then the automobile sector
witnessed rapid growth year after year. By late-90's the industry reached self reliance in
engine and component manufacturing from the status of large scale importer.
With comparatively higher rate of economic growth rate index against that of great global
powers, India has become a hub of domestic and exports business. The automobile sector
has been contributing its share to the shining economic performance of India in the recent
years.
With the Indian middle class earning higher per capita income, more people are ready to
own private vehicles including cars and two-wheelers. Product movements and manned
services have boosted in the sales of medium and sized commercial vehicles for passenger
and goods transport. Side by side with fresh vehicle sales growth, the automotive
components sector has witnessed big growth. The domestic auto components consumption
has crossed rupees 9000 crores and an export of one half size of the figure.

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 CHAPTER-3
DETAILS OF PLANT

3.1 RICO DIES PRODUCTION SHOP:

1. RICO dies unit moulds the dies required in the HPDC Shop. It involves from
manufacturing of new dies to the maintenance of old once.
2. There are 18 high pressure die casting machines in the HPDC Shop.

3.2 CAD/CAM DIVISION:

1. This unit works on the activities like product design, tool design etc. AUTOCAD
is the software used by the department. To make dies, processes are decided on
CAM.
2. These codes are then transferred to CNC machines through LAN system.

3.3 COMPUTER NUMERICAL CONTROL MACHINE (CNC):

1. There are 15 CNC machines in the machine shop .These machines are used to
perform different machining operations.
2. The CNC works according to the program written by the operator .CNC have two
or more programmable directions of motion called axis . An axis can be linear or
rotary.
3. Common linear axis are X,Y and Z.
4. Common linear axis are A,B and C.

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FLOW CHART OF PROCESS OF MANUFACTURING:

MELTING

CASTING

FETTLING

MACHINING

PAINT SHOP

ASSEMBLY

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 CHAPTER-4
MANUFACTURING PROCESS
4.1 FURNACE (MELTING)

An Electric Arc Furnace (EAF) is a furnace that heats charged material by means of an
electric arc.
Industrial arc furnaces range in size from small units of approximately one ton capacity
(used in foundries for producing cast ironproducts) up to about 400 ton units used for
secondary steelmaking. Arc furnaces used in research laboratories and by dentistsmay have
a capacity of only a few dozen grams. Industrial electric arc furnace temperatures can be
up to 1,800 °C (3,272 °F), while laboratory units can exceed 3,000 °C (5,432 °F).
Arc furnaces differ from induction furnaces in that the charge material is directly exposed
to an electric arc and the current in the furnace terminals passes through the charged
material.

Fig 4.1 Electric Arc Furnace

Alloys are melted in a furnace at 1000°C. When the Aluminum enters the red hot furnace
maintained at 1000°C aluminum melts and the molten metal passed to moulding machines
through channels (pipes) which pour the molten metal into a reservoir.

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4.2 FOUNDRY SHOP
The foundry department handles the following operations:-

MELTING: The ADC-12 & ADC-14 alloys are melted in a furnace at 650-800 degree
Celsius. The returns including rejections like runners, risers and casting and machining
rejections are also send for melting. They are loaded in the trolley’s using an electromagnet
of 5 ton capacity. A charging vibrator is used to transfer this material into the induction
furnace.

SAND PREPARATION: (sand + water + bentonite clay + carbonaceous material) . this

mixture is heated and then passed on a conveyor where a mixer thoroughly mixes it.

Fig 4.2 Sand Preparation

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SAND MOULD:

1. The mixer sand is transferred to sand moulding machine which applies a

pressure of 15 kg/cm^2 to make the sand moulds.
2. It operates at a fixed cycle time.
3. These sand moulds are passed onto a moving belt and the melted material is
poured in them by a pressure funnel (which has heater arrangement to keep the
molten material at fixed temp.).
4. The molten metal is kept in pouring furnaces connected funnel.
5. The temp. of pouring – 1380 to 1450 degree Celsius depending upon the
component to be made.

Fig 4.3 Sand Mould

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4.3 CASTING

Casting is basically melting a solid material, heating to a special temperature, and pouring
the molten material into a cavity or MOULD, which is in proper shape. Casting has been
known by human being since the 4th century B.C.
Today it is nearly impossible to design anything that cannot be cast by means of one or
more of the available casting processes. However, as with other manufacturing processes,
best results and economy can be achieved if the designer understands the various casting
processes and adapts his designs so as to use the process most efficient.

Solidification of Melts
When a melt is poured into a colder MOULD, metal in contact with the MOULD solidifies
in the form of roughly equated fine grains, because cooling rates are high, and the wall
induces heterogeneous nucleation.
Solidification proceeds by the growth of a few favorably oriented nuclei, in the direction
of heat extraction. This leads to be observed columnar structure. Because of the preferred
growth direction of the large grains, the casting will have very anisotropic properties.
Since most metals shrink on solidification, the liquid meniscus gradually drops and a
shrinkage cavity (pipe) remains.

Figure 4.4 Solidification proceeds with (a) the growth of columnar grains in pure metals
but, (b) with the growth of dendrites in solid solutions. (c) Dendrites grow in
crystallograhically favorable directions.

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Figure 4.5 Development of the macrostructure of a casting during solidification: (a)
Nucleation begins, (b) the chill zone forms, (c) preferred growth produces the columnar
zone, and (d) additional nucleation creates the equiaxed zone.

Casting Materials
Although some non-metals are cast, the process is primary importance in the production of
metal products. The metals most frequently cast are iron, steel, aluminium, brass, bronze,
magnesium, and certain zinc alloys.

Casting Procedure
In all casting processes six basic factors are involved. These are as follows:

1. A MOULD cavity, having the desired shape and size and with due allowance for
shrinkage of the solidifying metal, must be produced. Any complexity of shape
desired in the finished casting must exist in the cavity. Consequently, the MOULD
material must such as to reproduce the desired detail and also have a refractory
character so that it will not be significantly affected by the molten metal that it
19
 contains. Either a new MOULD must be prepared for each casting, or it must be
made from a material that can withstand being used for repeated castings, the latter
being called permanent MOULDs.
2. A suitable means must be available for melting the metal that is to be cast, providing
not only adequate temperature, but also satisfactory quality and quantity at low cost.
3. The molten metal must be introduced into the MOULD in such a manner that all
air or gases in the MOULD, prior to pouring or generated by the action of the hot
metal upon the MOULD, will escape, and the MOULD will be completely filled.
A quality casting must be dense and free from defects such as air holes.
4. Provision must be made so that the MOULD will not cause too much restraint to
the shrinkage that accompanies cooling after the metal has solidified. Otherwise,
the casting will crack while its strength is low. In addition, the design of the casting
must be such that solidification and solidification shrinkage can occur without
producing cracks and internal porosity or voids.
5. It must be possible to remove the casting from the MOULD so a permanent
MOULD must be made in two or more sections.
6. After removal from the MOULD, finishing operations may need to be performed
to remove extraneous material that is attached to the casting as the result of the
method of introducing the metal into the cavity, or is picked up from the MOULD
through contact with the metal.

CASTING PROCESSES
Much of the development that has taken place in the foundry industry has been directed
toward meeting these six objectives with greater economy. Six major casting processes
currently are used. These are:

1. Sand casting
2. Plaster-MOULD casting
3. Investment casting
4. Centrifugal casting
5. Permanent-MOULD casting
6. Die casting
7. Squeeze casting
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  SAND CASTING
Sand casting is a flexible, inexpensive process. Sand is used as the MOULD material. The
sand grains, mixed with small amounts of other materials to improve the MOULD ability
and cohesive strength, are packed around a pattern that has the shape of the desired casting.
Products covering a wide range of sizes and detail can be made by this method. A new
MOULD must be made for each casting, and gravity usually is employed to cause the metal
to flow into the MOULD. The process is not so accurate as die casting or investment
casting.

 PLASTER-MOULD CASTING
Plaster-MOULD casting is somewhat similar to sand casting in that only one casting is
made and then the MOULD is destroyed, in this case the MOULD is made out of a specially
formulated plaster. 70 to 80% gypsum and 20 to 30% fibrous strengtheners. Water is added
to make a creamy s1urry. This process is limited to non-ferrous metals, because ferrous
metals react with sulphur in gypsum. The core boxes are usually made form brass, plastics,
or aluminium.

 INVESTMENT CASTING
Casting processes in which the pattern is used only once are variously referred to as "lost-
wax" or "precision-casting" processes. In any case they involve making a pattern of the
desired form out of wax or plastics (usually polystyrene). A metal flask is placed around
the assembled patterns and refractory MOULD slurry is poured to support the patterns and
form the cavities. A vibrating table equipped with a vacuum pump is used to eliminate all
the air from the MOULD. After the MOULD material has set and dried, the pattern material
is melted and allowed to run out of the MOULD.
When the metal is cooled, the investment material is removed by means of vibrating
hammers or by tumbling. As with other castings, the gates and risers are cut off and ground
down.
 CENTRIFUGAL CASTING
Centrifugal casting consists of having sand, metal, or ceramic MOULD that is rotated at
high speeds. When the molten metal is poured into the MOULD it is thrown against the

21
MOULD wall, where it remains until it cools and solidifies. The process is being
increasingly used for such products as cast-iron pipes, cylinder liners, gun barrels, pressure
vessels, brake drums gears, and flywheels. The metals used include almost all castable
alloys.
Because of the relatively fast cooling time, centrifugal castings have a fine gram size. There
is a tendency for the lighter non-metallic inclusions slag particles, and dross to segregate
toward the inner radius of the casting where it can be easily removed by machining. Due
to the high purity of the outer skin, centrifugally cast pipes have a high resistance to
atmospheric corrosion.

 PERMANENT-MOULD CASTING PROCESSES

The process utilizes a metal casting die in conjunction with metal or sand cores. Molten
metal is introduced at the top of the MOULD that has two or more parts, using only the
force of gravity. After solidification, the MOULD is opened and the casting ejected. The
MOULD is reassembled and the cyc1e is repeated. The MOULDs are either metal or
graphite and, consequently, most permanent-MOULD castings are restricted to lower
melting point nonferrous metals and alloys.

 DIE CASTING
Die casting differs from ordinary permanent-MOULD casting in that the molten metal is
forced into the MOULDs by pressure and held under pressure during solidification. Most
die castings are made from nonferrous metals and alloys, but substantial quantities of
ferrous die castings now are being produced. Because of the combination of metal
MOULDs or dies, and pressure, fine sections and excellent detail can be achieved, together
with tong MOULD life. Special zinc-, copper-, and aluminium-base alloys suitable for die
casting have been developed which have excellent properties, thereby contributing to the
very extensive use of the process.
Because die-casting dies usually are made from hardened tool steel, they are expensive to
make. In addition, the die sections must contain knockout pins, which eject the casting.

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  SQUEEZE CASTING
Squeeze casting, also known as liquid-metal forging, is a process by which molten metal
solidifies under pressure within c1osed dies positioned between the plates of a hydraulic
press. Squeeze casting consists of metering liquid metal into a preheated, lubricated die
and forging the metal while it so1idifies. The load is applied shortly after the metal begins
to freeze and is maintained until the entire casting has solidified. Casting ejection and
handling are done in much the same way as in closed die forging.
The applied pressure and the instant contact of the molten metal with the die surface
produce a rapid heat transfer condition that yields a pore-free fine-grain casting with
mechanical properties approaching those of a wrought product.
The squeeze casting process is easily automated to produce near-net to net shape high-
quality components.
The process was introduced in the United States in 1960 and has since gained widespread
acceptance.

ADVANTAGES
With the current emphasis on reducing materials consumption through virtually net shape
processing and the demand for higher-strength parts for weight savings, the emergence of
squeeze casting as a production process has given materials and process engineers a new
alternative to the traditional approaches of casting and forging. By pressurizing liquid
metals while they solidify, near-net shape can be achieved in sound fully dense castings.
Improved mechanical properties are additional advantages of squeeze cast parts. The micro
structural refinement and integrity of squeeze cast products are desirable for many critical
applications.
Squeeze casting has been successfully applied to a variety of ferrous and nonferrous alloys
in traditionally cast and wrought compositions. Applications include aluminum alloy
pistons for engines and disk brakes; automotive wheels, truck hubs, barrel heads; brass and
bronze bushings and gears; steel missile components and differential pinion gears; and a
number of parts in cast iron, including ductile iron mortar shells.

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CORE DESIGN
Cores are MOULD parts used to shape internal holes and cavities. They are also
fortification parts of MOULDs where wearing occurs. These parts are made of sand and
organic-inorganic bonders such as cereal meals, dextrin, sodium silicate, cement etc. Some
properties of cores must have are the followings:

a. High-Temperature Resistivity
b. Metal Erosion Resistivity
c. Easiness of Deformation After Casting
d. Gas Insertion Ability
e. Smooth Surfaces
f. Saving Physical Properties During Storage

Internal Cavity Projecting Parts MOULD Fortification

Fig 4.6 Designs of Core

The most difficult and important part of melting & alloying process is the removal of
impurities from the liquid. These operations differ according to the type of furnace.

INTERACTION OF THE MOULD WITH MOLTEN METAL

Castings are often subjected to gas porosity, both closed and open. Gas cavities are voids
in the cast material, and the surface of which is clean, smooth, and nonoxidised, or shows
small colored oxide spots. Gases in metal castings can be present as compounds and
solutions. The gases dissolved in metal impairs its plasticity, tend to form blow holes and
pinholes. Metals and alloys both in liquid and solid states dissolve in considerable amount

24
of gases. A melt can absorb gases from the moist, rusty or oil coated scrap charged into the
melting furnace, from the air supplied to the furnace for fuel burning, from the moisture
contained in the fuel, ore, and fluxes, and also the result of the prolonged contact of the
melt with the furnace atmosphere whose gases can dissolve in the molten metal/alloy.

CASTING LINE:

1. The casting are then moved on a vibrator on which sand moulds breaks.
2. The casting are passed through rotating drum having holes to remove sand from
the casting.
3. The casting then undergoes SHOT BLASTING operation. (Ball of specific
material are projected at high velocities on casting) to move the sand particles
from casting.
4. The components for casting rejections (shrinkage, blow holes, flow marks, flash
etc) are check after shot blasting.
5. The O.K component are passed for breaking of runner and riser.

SHOT BLASTING

Shot Blasting is a surface treatment process using high velocity steel abrasive. Shot blasting
is method through which it is possible to obtain excellent cleaning and surface preparation
for secondary finishing operations.

In general shot blasting concentrates abrasive particles at high speed (65-110 m/second) in
a controlled manner at the material thereby removing surface contaminates due to the
abrasive impact. Initially in the 1930’s the shot blasting process used compressed air for
propelling the steel shot. This method remains in use today for cleaning metal frames and
welded elements. Shot blast production lines, both manual and automated systems, became
possible with the introduction of centrifugal wheel blast machines.

25
 Fig 4.7 Shot Blasting
When it comes to finishing and cleaning operations, the shot blasting surface treatment
technique is a highly effective option. The high speed controlled shot blast creates an
abrasive impact which removes surface contaminates, thereby making it an effective
method for cleaning iron, steel, forgings, machine parts, fixtures etc..

CORE & PATTERN SHOP:

1. The foundry shop has in house facility of core making. The resin coated sand is
replicated to make core for cavities of CWI, exhaust manifold etc.
2. It is heated so that all the moisture in the sand is lost making the core to reach
the desired strength.
3. The final gating and pouring basin for the pattern are made here attaching
wooden pieces to the finished pattern obtained from the department.

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4.4 FETTLING

Fettling is a word that is used in several different senses. Most of the uses of the word relate
to cleaning, polishing, and maintaining systems so that they will be functional or will
remain functional. The word itself is derived from a root word referring to “condition,” as
seen in the phrase “in fine fettle,” which is meant to convey that the person or object being
described is in good condition, shape, or health.
In the railroad industry, this term is used to describe routine maintenance performed on
tracks. It includes confirming that the rails are aligned properly, checking drainage systems,
replacing ties if necessary, and conducting other tasks which will keep the tracks in good
condition. It is important for this maintenance to be performed on a regular basis since a
wide variety of situations can cause damage to the tracks, and this can result in damage to
trains passing over the tracks, most spectacularly in the case of a derailment.

Fig 4.8 Fettling

Track fettling is usually accomplished with the assistance of a small handcar or truck
specially fitted to roll on the tracks, which allows track workers to carry tools and
replacement parts as they traverse the track to inspect it. This is done in constant rotation
to make sure that all of the track is seen at some point or another.

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In metalworking, the term refers both to lining a chamber into which metal is poured for
molding, and to cleaning metal after molding to remove the materials used for lining. This
can include cutting, sandblasting, and polishing, all of which are performed to bring the
metal to high luster and an even texture so that it will be functional and visually appealing.
For cast parts, this action is very important to ensure that the parts will work properly.
People can also see this word used in ceramics, to refer to trimming, finishing, and
polishing pieces. A fettling knife can be used to cut in patterns and details, and also to trim
away excess clay, to remove marks left by molds and stands, and so forth. This action is
performed so that the finished piece will be even and attractive, whether it is a ceramic
bowl or a molded insulator for electronics.
In some regions of the word, this is a slang term used in general to talk about maintenance,
tidying up, and making something presentable or functional. People may suggest that
objects in disrepair just need “a bit of fettling” to be set to rights.

4.5 MACHINING
Machining is any of various processes in which a piece of raw material is cut into a desired
final shape and size by a controlled material-removal process. The processes that have this
common theme, controlled material removal, are today collectively known as subtractive
manufacturing, in distinction from processes of controlled material addition, which are
known as additive manufacturing. Exactly what the "controlled" part of the definition
implies can vary, but it almost always implies the use of machine tools (in addition to just
power tools and hand tools).

Machining is a part of the manufacture of many metal products, but it can also be used on
materials such as wood, plastic, ceramic, and composites. A person who specializes in
machining is called a machinist. A room, building, or company where machining is done
is called a machine shop. Much of modern-day machining is carried out by computer
numerical control (CNC), in which computers are used to control the movement and
operation of the mills, lathes, and other cutting machines.

The precise meaning of the term machining has evolved over the past one and a half
centuries as technology has advanced. In the 18th century, the word machinist simply

28
meant a person who built or repaired machines. This person's work was done mostly by
hand, using processes such as the carving of wood and the hand-forging and hand-filing of
metal. At the time, millwrights and builders of new kinds of engines (meaning, more or
less, machines of any kind), such as James Watt or John Wilkinson, would fit the definition.
The noun machine tool and the verb to machine (machined, machining) did not yet exist.

Around the middle of the 19th century, the latter words were coined as the concepts that
they described evolved into widespread existence. Therefore, during the Machine Age,
machining referred to (what we today might call) the "traditional" machining processes,
such as turning, boring, drilling, milling, broaching, sawing, shaping, planing, reaming,
and tapping.[3] In these "traditional" or "conventional" machining processes, machine
tools, such as lathes, milling machines, drill presses, or others, are used with a sharp cutting
tool to remove material to achieve a desired geometry.

Since the advent of new technologies in the post–World War II era, such as electrical
discharge machining, electrochemical machining, electron beam machining,
photochemical machining, and ultrasonic machining, the retronym "conventional
machining" can be used to differentiate those classic technologies from the newer ones. In
current usage, the term "machining" without qualification usually implies the traditional
machining processes.

In the decades of the 2000s and 2010s, as additive manufacturing (AM) evolved beyond
its earlier laboratory and rapid prototyping contexts and began to become common
throughout all phases of manufacturing, the term subtractive manufacturing became
common retronymously in logical contrast with AM, covering essentially any removal
processes also previously covered by the term machining. The two terms are effectively
synonymous, although the long-established usage of the term machining continues. This is
comparable to the idea that the verb sense of contact evolved because of the proliferation
of ways to contact someone (telephone, email, IM, SMS, and so on) but did not entirely
replace the earlier terms such as call, talk to, or write to.

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MACHINING OPERATIONS

There are many kinds of machining operations, each of which is capable of generating a
certain part geometry and surface texture.

In turning, a cutting tool with a single cutting edge is used to remove material from a
rotating workpiece to generate a cylindrical shape. The primary motion is provided by
rotating the workpiece, and the feed motion is achieved by moving the cutting tool slowly
in a direction parallel to the axis of rotation of the workpiece.

Drilling is used to create a round hole. It is accomplished by a rotating tool that typically
has two or four helical cutting edges. The tool is fed in a direction parallel to its axis of
rotation into the workpiece to form the round hole.

In boring, a tool with a single bent pointed tip is advanced into a roughly made hole in a
spinning work piece to slightly enlarge the hole and improve its accuracy. It is a fine
finishing operation used in the final stages of product manufacture.

Reaming is one of the sizing operations that removes a small amount of metal from a hole
already drilled.

Fig 4.9 Machining Processes

In milling, a rotating tool with multiple cutting edges is moved slowly relative to the
material to generate a plane or straight surface. The direction of the feed motion is

30
perpendicular to the tool's axis of rotation. The speed motion is provided by the rotating
milling cutter. The two basic forms of milling are:

1. Peripheral milling
2. Face milling.

Other conventional machining operations include shaping, planning, broaching and

sawing. Also, grinding and similar abrasive operations are often included within the
category of machining.

4.6 PAINT SHOP

The objective of painting is to form a coating film on the surface of an object in order to
protect the object and give a fine appearance. Painting may also have other special
functions. There are various types of painting methods, and spray painting is currently used
in many types of industrial painting. A flow diagram of the spray painting process is shown
as an example in Fig. 1.

“Spray painting” consists of the painting operation itself followed by coated film drying.
The paint used in the painting process is diluted with thinner, and solid portions in the paint
form the coating film after the spraying operation. Annual amount of handled Class I
Chemical Substances in paints and thinners is calculated based on the content of each
chemical in paints and thinners, which should be obtained by MSDS and etc.

In the painting operation, various types of painting methods are used according to the
shape, size, quality, and quantity of the object(s) to be painted. The “transfer efficiency”
differs, in other words, the ratio of the quantity of the coated film formed on the object to
the quantity of the paint sludge generated from overspray differs according to the
differences in these operational conditions.. In “spray painting” inside a coating booth,
most of the auxiliary solvent portions in the paints vaporizes to air. The solid portions over-
sprayed are collected in the coating booth circulating solution (water or oil), and separated
as paint sludge. So, vaporization of solvents in spraying operation and coated film drying
process makes air emissions from total painting processes. In some cases, a vent gas from

31
coated film drying process is treated by deodorizing device. Paint sludge caused by
overspray is either off-site transferred in waste, or incinerated. Releases to water bodies, or
off-site transfers of waste oil occur at the time of renewal of circulating solution. Residual
paints and cleaning thinners are on-site or off-site recycled in some cases.

Sometimes the (same) solvent is used to dilute paint and also to wash painting lines, so in
this manual, the former is designated as thinner and the latter as cleaning thinner. Many
different types of painting processes are used in different industries, and so different figures
are selected as transfer efficiency. For PRTR reporting, estimate the reasonable value
referring to the calculation examples in this manual.

Automotive paint is paint used on automobiles for both protection and decoration purposes.
Enamel paint is currently the most widely used paint for reasons including reducing paint's
environmental impact.

Modern automobile paint is applied in several layers, with a total thickness of around 100
µm(0.1mm). Paint application requires preparation and primer steps to ensure proper
application. A basecoat is applied after the primer paint is applied. Following this, a clear
coat of paint may be applied that forms a glossy and transparent coating. The clear coat
layer must be able to withstand UV light.

High-pressure water spray jets are directed to the body. Without proper pretreatment,
premature failure of the finish system can almost be guaranteed. A phosphate coat is
necessary to protect the body against corrosion effects and prepares the surface for the E-
Coat.

The body is dipped into the Electro-Coat Paint Operation (ELPO/E-Coat), then a high
voltage is applied. The body works as a cathode and the paint as an anode sticking on the
body surface. It is an eco-friendly painting process. In E-Coat, also called CED paint,
utilization is approximately 99.9% and has great salt spray test life compared to other
painting processes.

32
Primer

The primer is the first coat to be applied. The main functions of the primer are to act as a
leveler and protector, and to make the base coat easier to apply to the component to which
it is applied. The primer serves several purposes. It serves as a leveler, which is important
since the cab often has marks and other forms of surface defect after being manufactured
in the body shop. A smoother surface is created by leveling out these defects and therefore
a better final product. It serves as a protector, the primer will protect from corrosion, heat
differences, bumps, stone-chips, UV-light, etc. It also improves ease of application by
making it easier for paints to stick to the surface, a more varied range of paints can be used.

Basecoat

The base coat is applied after the primer coat. This coat contains the visual properties of
color and effects, and is usually the one referred to as the paint. Base coat used in
automotive applications is commonly divided into three categories: solid, metallic, and
pearlescent pigments.

Solid paints have no sparkle effects except the color. This is the easiest type of paint to
apply, and the most common type of paint for heavy transportation vehicles, construction
equipment and aircraft. It is also widely used on cars, trucks, and motorcycles. Clear coat
was not used on solid colors until the early 1990's. The base coat is applied after the primer
coat. This coat contains the visual properties of color and effects, and is usually the one
referred to as the paint. Base coat used in automotive applications is commonly divided
into three categories: solid, metallic, and pearlescent pigments. Solid paints have no sparkle
effects except the color. This is the easiest type of paint to apply, and the most common
type of paint for heavy transportation vehicles, construction equipment and aircraft. It is
also widely used on cars, trucks, and motorcycles. Clear coat was not used on solid colors
until the early 1990s. Metallic paints contain aluminium flakes to create a sparkling and
grainy effect, generally referred to as a metallic look. This paint is harder to manage than
solid paints because of the extra dimensions to consider. Metallic and pearlescent paints
must be applied evenly to ensure a consistent looking finish without light and dark spots
which are often called "mottling".

33
 Fig 4.10 Paint Shop

Metallic paints contain aluminium flakes to create a sparkling and grainy effect, generally
referred to as a metallic look. This paint is harder to manage than solid paints because of
the extra dimensions to consider. Metallic and pearlescent paints must be applied evenly
to ensure a consistent looking finish without light and dark spots which are often called
"mottling". Metallic basecoats are formulated so that the aluminium flake is parallel to the
substrate. This maximises the "flop". This is the difference in the brightness between
looking perpendicularly at the paint and that at an acute angle. The "flop" is maximised if
the basecoat increases in viscosity shortly after application so that the aluminium flake
which is in a random orientation after spraying is locked into this position while there is
still much solvent (or water) in the coating. Subsequent evaporation of the solvent (or
water), leads to a reduction in the film thickness of the drying coating, causing the
aluminium flake to be dragged into an orientation parallel to the substrate. This orientation
then needs to be unaffected by the application of the clear coat solvents. The formulation
of the clear coat needs to be carefully chosen so that it will not "re-dissolve" the basecoat
and thus affect the orientation of the metallic flake but will still exhibit enough adhesion

34
between the coatings so as to avoid delamination of the clear coat. A similar mode of action
occurs with pearlescent pigmented basecoats.

Pearlescent Paints contain special iridescent pigments commonly referred to as "pearls".

Pearl pigments impart a colored sparkle to the finish which works to create depth of color.
Pearlescent paints can be two stage in nature (pearl base color + clear) or 3 stage in nature
(basecoat + pearl mid-coat + clear-coat).

Clear coat

Usually sprayed on top of a colored basecoat, clearcoat is a glossy and transparent coating
that forms the final interface with the environment. For this reason, clearcoat must be
durable enough to resist abrasion and chemically stable enough to withstand UV light.
Clearcoat can be either solvent or water-borne.

One part and two part formulations are often referred to as 1k and 2k respectively.[6] OEM
(original equipment manufacture) clear coats applied to the metal bodies of cars are
normally 1K systems since they can be heated to around 140 deg C to effect cure. The clear
coats applied to the plastic components like the bumpers and wing mirrors however are 2K
systems since they can normally only accept temperatures up to about 90 deg C. These 2
K systems are normally applied "off line" with the coated plastic parts fixed to the painted
metallic body. Owing to the difference in formulation of the 1K and 2K systems and the
fact they are coated in different locations they have a different effect on the "redissolving"
of the metallic base coat. This is most easily seen in the light metallic paints like the silver
and light blue or green shades where the "flop" difference is most marked.

4.7 QUALITY CONTROL AND INSPECTION:

Quality control in the production field is defined as the systematic control of various
factor that affect the quality of the product. It depends upon the raw material, tools, type
of labor, working condition, measuring instruments etc.

35
INSPECTION:

1. INCOMING NSPECTION :
a) Dimensional inspection
b) Surface inspection
c) Material inspection

2. IN PROCESS INSPECTION:
a) RPM of the machine
b) Tool change frequency

c) Finished good inspection

d) Process flow diagram of product

3. FINAL INSPECTION:

The number of pieces of the products are checked on CMM (Coordinate

Measuring Machine) and then filled in the pre delivered inspection report.

DIFFERENCE BETWEEN QUALITY CONTROL & INSPECTION:

Inspection means checking the material, product or component at various stages with
reference to some pre-determined defects and thus sorting out the faulty once. Quality
control is a broad term, it means inspection at particular stages only.

36
 CHAPTER-5
SAFETY RULES & GUIDELINES

1) Be Aware Of Your Surroundings

This step requires knowing the particular hazards of your job or workplace. Once you’ve
learned these risks, you are able to keep clear of potential hazardous areas, and potential
hazardous situations. Also, always be alert of machinery.

2) Keep Correct Posture To Protect Your Back

If you work at a desk, keep your shoulders in line with your hips to avoid back problems.
If you’re picking things up, use correct form so your back doesn’t get hurt. Avoid stooping
and twisting. If possible, always use ergonomic designed furniture and safety equipment
so everything you need is within easy reach.

3) Take Regular Breaks

So many work-related injuries and illnesses occur because a worker is tired, burned out
and not alert to their surroundings. Taking regular breaks helps you stay fresh on the job.
One trick to staying alert is to schedule the most difficult tasks when your concentration is
best, like first thing in the morning.

4) Use Tools And Machines Properly

Take the proper precautions when using tools, and never take shortcuts. Taking shortcuts
is one of the leading cause of workplace injury. It’s a huge safety risk to use scaffolding as
a ladder or one tool in place of another for a specific job. Using tools the right way greatly
reduces the chance of workplace injury.

5) Keep Emergency Exits Easily Accessible

In case of an emergency, you’ll need quick, easy access to the exits. It’s also recommended
to keep clear access to equipment shutoffs in case you need to quickly stop them from
functioning.

37
 6) Report Unsafe Conditions To Your Supervisor

Your supervisor needs to be informed about any workplace safety hazards or risks. They
are legally obligated to ensure their employees have a safe working environment and will
take care of the unsafe conditions and make them safe for you and your coworkers.

7) Use Mechanical Aids Whenever Possible

Instead of attempting to carry or lift something that’s really heavy in an attempt to save a
sliver of time during your workday, take the extra minute to use a wheelbarrow, conveyor
belt, crank or forklift. Too many injury risks are involved with trying to lift something that
weighs too much.

8) Stay Sober

Around three percent of workplace fatalities occur due to alcohol and drugs. When a
worker’s ability to exercise judgment, coordination, motor control, concentration or
alertness is compromised, this leads to any number of risks for workplace injury and
fatalities.

9) Reduce Workplace Stress

Stress can lead to depression and concentration problems. Common causes of workplace
stress include long hours, heavy workload, job insecurity and conflicts with coworkers or
managers. Take your concerns about workplace stress to your supervisor to see how they
might help you address them.

10) Wear The Correct Safety Equipment

If you’re not wearing the correct safety equipment for a task, you may get injured.
Depending on the job, equipment like earplugs, earmuffs, hard hats, safety goggles, gloves
or a full-face mask greatly reduce the risk of workplace injury.

38
 CONCLUSION
Summer training undergone at RICO Auto Industries, Dharuhera (Haryana) helped me
develop new skills such as learning Pro E software and basics of AutoCAD which is very
essential from industrial point of view. Material management is an important management
tool which will be very useful in getting the right quality and right quantity of supplies at
right time, having good inventory control and adopting sound methods of condemnation
and disposal will improve the efficiency of the organization and also make the working
atmosphere healthy any type of organization, whether it is private, government, small
organization, big organization and household.

Even a common man must know the basis of material management so that he can get the
best of the available resources and make it a habit to adopt the principles of material
management in all our daily activities. At last the vocational training is helping me
throughout my studies as well as my engineering career.

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 REFERENCES

1. www.ricoauto.com
2. www.themetalcasting.com
3. www.slideshare.net/rico-auto-industries-ltd
4. https://en.wikipedia.org/wiki/Machining
5. https://en.wikipedia.org/wiki/Melting
6. http://www.ricoauto.com/engineering-rd.html

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