PRICOL LIMITED

Plant III Perianaickenpalayam Coimbatore

INDUSRTIAL VISIT SEMINAR

Presented by,
ABHIN CHANDRAMOHAN , 8302

ARJUN CHANDRAN , 8309

DHEERA J MURALI , 8316 PEEYUSH U, 8341 SHIJIL P K , 8352

ABOUT PRICOL

PRICOL - Premier Instruments & Controls Limited Started in 1975 as Automobile Ancillary Unit Diversified to Electronic Control Instruments, Precision Machine Tools Panel and Sensor Instruments Only Indian automotive instrumentation firm to obtain the coveted ISO 9001 Certificate

LOCATIONS

QUALITY & TPM

TPM- Total Productive Manufacturing

TPM :- system with total involvement of all employees to achieve utilization of all resources. Good quality achieved through i. Systematic training and motivation of employees ii. Complying with customer requirements iii. Complying with statutory/regulatory requirements iv.Improving the efficiency and effectiveness of the Quality Management Systems

CERTIFICATES

OHSAS 18001
International occupational health and safety management system specification

ISO 14000
Environmental management standards

ISO TS 16949
Defect prevention and the reduction of variation and waste in the supply chain

PRODUCTS

Hydraulic Cab Tilting & Cylinder Assembly

Oil pump

Idle Speed Control Valve

Sintered components

CAB TILTING & CYLINDER ASSEMBLY

Pump Assembly Hand-operated reciprocating Piston type In-built Pressure Relief Valve Cylinder Assembly Double Acting Cylinder Bore Size- 25 mm, 35 mm & 50 mm

OIL PUMP
Geo

rotor type Chain Driven / Crankshaft Driven Inbuilt Pressure Relief Valve

IDLE SPEED CONTROL VALVES

Part of the Fuel Management System Controls the volume of air flowing through the throttle valve based on signals from ECU Improves fuel efficiency by reducing and stabilizing the idle speed

SINTERED COMPONENTS

Gears Gerotors Hubs Valve Plates

Oil-less Bearings Gear Shifter parts Pistons Slack Adjuster Parts

CUSTOMERS

DEPARTMENTS
PDE

Pumps i. Endurance testing ii. Protoshop Pump production and assembly Cabin lift Production and assembly Quality control Heat treatment Powder metallurgy

PDE PUMPS
Flow Of Activities

RFQ

Design & Drawings

Cost Estimation

Manufacturin g

Protoshop

Evaluation

RFQ
RFQ-

request for quote An order from customer Specifications of product like dimensions, performance characteristic , duration of usage etc specified Fed to PLM software PLM software used is WINDCHILL Connects sales, purchase, QE, Materials section, production etc

DESIGN & DRAWING

Developers

will sit together to decide on the mode of operation

modes of development :i. existing design ii. modify a design iii.develop an entirely new design

Modifications Cost

to existing design preferred over entirely new design of development is considerably reduced drawings are made in

Dimensioned

AUTOCAD

COST ESTIMATION
Costs

of individual parts added together to form the net cost Includes i. Transportation ii.Handling charges iii.Tooling cost iv.Assembly line expenses v.Modification cost vi.Development cost

EVALUATION

Evaluation of product is done with respect to RFQ Unsatisfactory Redisgn

Estimate of product passing the evaluation stage will be send to the customer.
If they are satisfied an order for sample product is placed.

PROTOTYPE
Done in protoshop 2 type samples are created 1.Proto sample 2. Tooled up sample Prototypes tested for endurance and performance Products send to the customer Customer use those products and send a report back

contd

Feedback include corrections and alterations

Corrections made and product is send back

Procedure followed till a refined product is obtained Frequent and orderly customer relations make up an essential part of PDE. Proto type production is done by human beings without help of CNC machine. contd

Pricol houses machines like lathe, surface grinder, filing machine, drilling machine, ultra finishing machines Prototypes produced are tested for accuracy and dimensional correctness Quality analysis of prototypes produced are done Instruments like profile projector, hardness testing machines, gauges, circularity checker etc. are present

ENDURANCE & PERFORMANCE TESTING

Testing

a product is generally done in three

stages. 1.Before Endurance 2. Endurance Test 3. After Endurance.

Before

Endurance testing Specifications are entered into test report. Visually inspected for severe damage. Run in test rig to detect any loosely fitted part

Endurance

testing:Major part of testing procedure. Product subjected to extreme condition Pumps are run at rated speed for 500 hours. Every day the machine runs as three shifts. Continuous supervision of testing is carried out. After the prescribed testing duration report send to supervisor. Endurance test: Data is verified by supervisor Checks whether value is in permissible range If values within limits then the product is certified fit for working

After

TEST RIGS AT PRICOL

Various test rigs present at Pricol are

Endurance Test Rig -Oil Pump Assy 4S 2. Endurance Test Rig -Table Top Type 3. Endurance Test Rig -AFC & Fuel Pump Assy 4. Endurance Test Rig -Oil Pump Assy - 2S 5. Endurance Test Rig- Actuator - 2S 6. Endurance Test Rig-Cabin cylinder & Pump 7. Climatic Chamber -Hot, Cold & Humidity Chamber
1.

POWDER METALLURGY

PRICOL has the most modern PM plant in South India Process of -Blending fine powdered materials, -Pressing them into a desired shape -Heating the compressed material 4 basic steps: (1) Powder manufacture (2) Powder mixing and blending (3) Compacting (4) Sintering

Powdered metal - obtained from suppliers stored in silos based on their grade number. Blending: Proper mixing of powders and additives to achieve metal composition of desired quality. Fe, Cu and C: major constituents

To the mixture lubricant named kenolube is added.

Blending is done by rotating the powdered mixture for about 40 minutes. MH system like crane and EOT used to transport powder

3rd stage is compacting Process of pressing the powder in die Stage where the powders attain shape of product

Density of product is determined by tonnage used

Presses of tonnages 400T, 200T & 145T used Die for compacting is made from tooling section Spark cutting, wire cutting etc are used to cut

Sintering: After compacting the product is heated Heating stars at 350C and ends at 1250C. Heating is gradual After heating the product is passed to vibro de-burring system Extra fins are removed by vibrating material along with marble like granules. After de-burring the product is sized These products are sent for heat treatment.

HEAT TREATMENT

Heat treatment of sintered product is carried out. Rotary furnace is used to carry out heat treatment of sintered product

Parts are arranged in trays

Placed inside underground chamber from where it is heated

FURNACES

PRODUCTION & ASSEMBLY

Aluminum factories

casting

brought

from

other

Casting are finished and made dimensionally correct using CNC machines Gears for pumps are procured from PM plant Assembling is carried out in assembly line

Parts are brought into assembly line are entered in register

Man and machine together assemble the components

Compressed air operated screwdrivers are used

Each and every part cleaned by jet of compresse air Entire room air conditioned to prevent dust

Assembled products are checked for flaws

Certified products are packed Packed products send to store Dispatching section is attached to store

QUALITY ENGINEERING
Quality

of product is checked frequently

Randomly
Products

selected samples send to QE

are tested based on standards

Inspection
Calibration

grade slip gauges are kept here

of shop floor measuring insturment carried out

Instruments used at QE

Digital Superficial Rockwell Hardness Testing Machine

Vickers Hardness Testing Machine

Brinnel Hardness Testing Machine Case Hardening Process Tester Micro Vickers Hardness Testing Machine Coordinate Measuring Machine

Profilometer

THANKS TO
Mr. RA JASEKHARAN
HEAD PDE PUMPS ,PRICOL

M r s . D I V YA R
S E N I O R O F F I C E R ,T R A I N I N G , P R I CO L

MR. GERALD
DESIGN ENGINEER,PRICOL

M r. S E N T H I L
SUPERVISOR, PRICOL