Internship Report of 15days Internship at Esmech Equipments Pvt. Ltd. Wada

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ESMECH EQUIPMENT PVT. LTD.
Engineering Excellence...
INTERNSHIP REPORT
NAME OF STUDENT:
Kalpesh Gurunath Pawar
NAME OF COLLEGE:
Bharat College Of Engineering
B.E. (Mechanical Engineering)
NAME OF GUIDE:
Mr. Harish Sharma
DGM- Esmech Equipment Pvt. Ltd.

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ACKNOWLEDGMENT
I am highly indebted to Mr. Harish Sharma Sir, DGM-Assembly
department for their guidance and constant supervision as well as
for providing necessary information regarding the internship and
also for their support in completing the internship. I would like to
express my gratitude towards member of organization for their kind
co-operation and encouragement with help me in completion of
this internship.

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CERTIFICATE
This is to certify that Mr. KALPESH G. PAWAR have satisfactorily
completed this summer training in the FAB, MACHINE &
ASSEMBLY workshop at “ESMECH EQUIPMENT PRIVATE
LIMITED. WADA” during period from 20th
June to 7th
July, 2015
Mr. Harish Sharma Mr. Mukesh Kapoor
DGM VP
Esmech Equipments Pvt.Ltd. Esmech Equipments Pvt.Ltd.

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Table of Contents
1 Company Overview 5
2 Introduction About Project 6
3 Planning Dept. 7-9
4 Fabrication Shop 10-11
5 Machine Shop 12-15
6 Assembly Shop 16
7 Reflection of Internship 17
8 Conclusion 18

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COMPANY OVERVIEW
Esmech Equipment is a Joint Venture between SMS Siemag AG
(Germany) and HB Esmech Pvt. Ltd (India), and is the leading manufacturer
of World Class Cold Rolling Mills and Strip Metal Process Line equipment.
Esmech Equipment is a subsidiary of SMS Siemag AG, and is
therefore a proud member of the SMS Group. Esmech Equipment’s mission is
to combine SMS’s World Class Technology with Esmech’s low cost
manufacturing ability to give its customers an unbeatable advantage !
Esmech Equipment is headquartered in Thane, India (adjacent to
Mumbai). Esmech has its manufacturing facility in two locations Thane and
Wada.
Esmech Equipment has a very long reputation of quality supplies and has a
Reference List of over 275 Lines.
Esmech’s product Range Includes:
● Cold Rolling Mills (Single stand and Twin Stand-compact Mill)
● Skin Pass Mill
● Galvanizing Lines
● Color Coating Lines
● Pickling Lines
● Cut-To-Length Lines
● Recoil Lines
● Electrolyte Cleaning Lines
● Slitting Lines
● Tension Leveling Lines
● Blanking Lines
● Rewinding (Recoiling) and Trimming Lines

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INTRODUCTION OF PROJECT
In this project, we can understand the Manufacturing Process of various
parts of design structures/flat products in Fabrication shop. In Machining
department, various M/C processes done on fabricated parts. At last the
fabricated & machined parts of M/C assembled in assembly shop.
In Planning Dept. the planning of Project Manufacturing Process takes place.
In Fabrication Dept. with the help of M/C such as cutter, driller, CNC, Grinder,
Welding M/C components are to be fabricated. Various checking parameters
& inspection done with respect to Quality purpose & then structures/flat
products are passed to Machine shop.
In Machine Dept. of an Industry; carries out various kinds of processes to
finalize the assembly of a structure.
In Assembly Dept.; Assembly modeling, technology, and methods used by
computer aided design & product visualization software.

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PROJECT PLANNING DEPARTMENT
The Planning Dept. plays the role of Brain for the industry body.
Every Project in company starts from Project Manufacturing Process Planning
in Planning Dept.
Each Project has a Unique Identification NO.(UIN) given by the planning Dept.
A single project contains a no. of sub-assemblies (for Ex. For a single slitting
line has 49 Assemblies.)
In Design Dept. there is a folder contains particular assembly drawing,
drawing no., Assembly part list, part code, Such detail of assembly which den
transfer to Planning for further process.
In the Dept; Manufacturing Process Planning starts from raw material.
Requirement of Raw material is given by planning Dept.
RAW Material: Bill of Material (BOM)
Part List by Assembly Drawing
Drawing Reading.
Req. Raw material by Quantity
The list then transfer to Fabrication OR Machine shop according to the
operation.
M/c Shop: Hacksaw Cutting-
pins, shafts/drum shafts, spacer.
Fabrication: Cutting List Drawing, FAB Drawing
STORE: Hardware, Baring, Hex-bolt, Hex-nut.
Cutting parts after Fabrication Process send for the process in M/C shop.
Inspection is done by the Quality Control Dept.
And components go for Assembling.
Planning Dept. maintain the schedule as per target date of the dispatch of
Project Assembly.
System ACR- All Component Readiness; to check whether component ready
within target date or not.
Dispatch of Project Assembly is then done according to Project Order.
IMP steps in Planning:
Drawing Reading:
Process Sequence (depends on requirement of product.):
Cutting
Finishing/Grinding
Fabrication
Turning
Milling

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ERP PROCEDURE
Enterprise Resource Planning (ERP)
Raw Material ISSUE :
 Master data management—transaction--project assembly--UIN no---
copy.(drawing no--product no)
 Procurement management—transactions--RM Issue--new-paste
 Save-lines--new--product--key--paste--search--double click-
 Storage bin--wip--enter--save & new-product--key--fab key
 Paste--with store--select—ok--moment quantity--save --header
 RM Issue completed --Document no
INTERNAL CHALLAN :
 Internal challan--new--business pa--Wada –-save--lines--new
 Product--paste--with stock--search-moment quantity--storage bin--enter--wip
select--new storage bin--IBP –enter--save
 Challan line activity--new--sequence--ex--fabrications--save
 Header-- challan send to approve--ok

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GOOD RECIEPT :
 New --is internal challan --business partner--name--% esm %--All--search--
4no Wada select-save--creates line from--order--warehouse position--7 no
Wada -–save-ok—line--supplier challan –quantity--weight--save--header--
complete—ok
PRODUCTION MANAGEMENT :
 Batch planning--planning--search record--product--key paste--search--select--
ok.--Po & Wo & Iwo--Good receipt--select sequence--fabrications--save--good
r. process--ok
REQUISITIONS :
 Productions management--transactions-- req--non--project item--new--save--
lines--new—product--key--name—search—description--quantity--save--
header--completed--ok--print.

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FABRICATION SHOP
Raw Materials: Max length 6m.
 Plates: As per thickness MS/C45/S355
 I-Beam
 C-Channels
L-Angle: As per angle 35/50/65/75/80/100 upto 250
Equal Angle (h=w)
Unequal Angle (h=/w)
 Box(Square Tube): As per Length and Width
Equal Box(Square box)
Unequal Box(Rectangular box)
 Bar(Round Bar): As per Diameter D25/50
Metal Cutting:
 Hand Cutter: Directly cut over marking on structure.
 Profile Cutting M/C: Gas Cutter(consist Nozzle) contains
LPG+O2
 CNC Cutting M/C: Cuts only Plates. Capacity thickness max.
75mm.
 PUG Cutting M/C: Moves on Rails
Straight Cut
Angular Cut
Metal Grinding/Finishing:
 Handle Grinder/Angle Grinder: Uses Grinding Wheel
 Shot Blasting: M/C in which small metal balls hits surface
of structure.

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Welding:
 A union of material produce by heat & pressure.
 A welding procedure is a systematic method. Heat is used to
repeatedly produce sound welds.
 There is over 100 recognized welding or thermal joining processes.
 ARC (MMA) welding: Uses Rectifier, sometimes transformer.
Dia of Rod 2.5/3.15/4/5/6
 GMAW(MIG/MAG) Welding: Wire spool
Filler Wire 0.8/1/1.2/1.6
Fabrication:
 With the help of fabrication Drawing structures are Fabricated after Metal
Cutting, Welding & Grinding.

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MACHINE SHOP/DEPT.
Machine Shop of an Industry; carries out various kinds of processes to finalize
the assembly of a structure.
Raw material/ Rough material from in-house workshop/outside vendor comes
at Machine Shop for Processing.
Mostly Fabricated/Forged/Casting/Hardened parts are in Raw Materials of
Machine Shop.
Various Operations/Processes at M/C Shop:
 Milling: To cut a shape with Rotating tool/Grind in a mill.
Plano Milling M/C
Vertical Milling
Horizontal Milling
There are four types of Milling M/C are used.
 Turning: In which cutting tool non-rotary tool bit describes a helical tool
path by moving more or less linearly while work piece rotates. Tool
axes of movement may be linearly a straight line, may be along some
set of curves or angles.
Can be used for boring hole or drilling M/C.
 Boring: When same essential cutting action as turning‖ when applied to
internal surface is called as boring.
The phrase ―turning and boring‖ categorized the large family of
(essentially similar) processes.
The cutting faces on work piece (i.e. surface perpendicular to rotating
axes) whether with turning and boring tool called ―Facing‖.
Boring can be done manually on lathe or CNC (Computer Numerical
Control).
Single point boring
Multipoint boring
 Drilling: It is a cutting process that uses drill bit to cut or enlarge the
hole circular cross section in solid material.
The drill bit is rotary cutting tool.

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MACHINES SPECIFICATIONS
BORING MACHINE:
Sr.
No.
Machine Name
(Company)
Spindle Dia. Table (LxW) Spindle
Stroke
Remark
1 Boring-Conventional
(KARAM) INDIA
Ø100 1100x850 400 For Smaller
Operations
2 Boring (STIM) ITALY Ø100 1250x1250 1000 Comparatively Large
Structure.
3 Boring RUSSIAN Ø160 1800x1600 900 For Smaller
Operations.
4 Boring-Conventional
(BUCUREST) AFM 150
Ø150 2500x2000 1000 For Large Structures
but slower in
operations.
5 Boring (C & E) UK Ø130 1800x1600 1000 For Large Structures-
comparatively Faster
in operations.
6 CNC Milling & Boring
(UNION) GERMANY
Ø130 1600x1250 1600 Large Structures.
Computer Numeric
Control-Ease in
Operations.
7 CNC PRECITEC Ø150 - - Covers a Large
working area.
8 CNC Boring (DOOSAN)
KOREA
Ø130 2000x1800 700 For Heavy Machining.
9 STARRAG HECKERT - - 875 For Continuous
Process of Operations.
Pallets to load jobs.
PLANO-MILLER & FTB MACHINE:
Sr.
No.
Machine Name
(Company)
Spindle Dia. Table (LxW) Spindle
Stroke
Remark
1 Plano-Miller (LIBERTY)
USA
HORZ-180 2800x5500 800 Ideal For Large
Streuctures.
2 Plano-Miller (TITAN)
GERMANY
Ø180 1000x4210 1000 For small
Structures
3 Plano-Miller (TITAN)
GERMAN
Ø180 1000x4210 1000 For small
Structures

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HORIZONTAL MILLING MACHINE:
Sr.
No.
Machine Name
(Company)
SpindleTaper. Table (LxW) Spindle
Stroke
Remark
1 Milling (FMT 700) ISO 50 2000x600 450 Horizontal
Milling
Operations.
2 Milling (TOS) KARAM
CZECK
ISO 50 2000x450 - Horizontal
Milling
Operations.
VERTICAL MILLING MACHINE:
Sr.
No.
Machine Name
(Company)
SpindleTaper. Table (LxW) Spindle
Stroke
Remark
1 Milling (WMW)
GERMANY
ISO 50 1590x400 - Vertical Milling
Operations
2 Milling (TIGER) ITALY ISO 50 1600x400 - Vertical Milling
Operations
3 Milling (VF3) ISO 50 2130x350 - Vertical Milling
Operations
4 CNC Milling (ZYER) ISO 50 5000x1000 - Vertical Milling
Operations,
Dovetails, Max
Capacity.
5 CNC Milling (MTE
COMACT)
- 1700x750 2Tone Vertical Milling
Operations,
Dovetails, Less
Capacity
DRILLING MACHINE:
Sr.
No.
Machine Name (Country) Table (LxW) Remark
1 HMT RM 61 (INDIA) 1200x640 Smaller Operations
2 HMT RM 63 (INDIA) 1600x750 Smaller Operations
3 HMT RM 65 (INDIA) 2200x850 Large Operations

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LATHE MACHINE:
Sr.
No.
Machine Name
(Country)
Chuck Dia. Table
Length
Centre
Height
Remark
1 WMV (GERMANY) Ø1500 5300 800 For shafts/Rods of
Large Size, Higher
Oprat.
2 Punjab Machinery
(INDIA) 20 FEET
Ø760 6069 500 For shafts/Rods of
Medium Size, 20‖,
Higher Oprat.
3 GRD (INDIA) Ø910 8950 610 For shafts/Rods of
Medium Size Higher
Oprat.
4 16 Foot Ø910 3600 600 Larger Chuck 16‖,
Various Operations
5 GUJRAT Ø350 2300 250 Small Lathe
6 BULGARIA Ø250 1500 200 Small Lathe
7 KIRLOSKAR (INDIA) Ø350 2750 190 Larger Chuck,
Various Operations,
Max Capacity
VTL MACHINE: Verical Turret Lathe
Sr.
No.
Machine Name
(Country)
Chuck Dia. Vertical
Travel
Cross Remark
1 VTL WMV (GERMANY) 2200 1100 2200 Turning,Boring,
Grinding

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ASSEMBLY DEPT.
Assembly is an act of combining components of Manufacturing.
Assembly modeling, technology, and methods used by computer aided design
& product visualization software.
Assembly Line, a manufacturing process in which parts are added to a
product in a sequential manner.
In Assembly Dept. no, of Sub-Assemblies of a single project are combined
together.
Fabricated/Machined parts/readymade parts from outside vendor; store
material are combined with the help of Assembly Drawing.
For a single line there are no. of subassemblies; in such condition lines are
assembled at the working/installation site of line.
Sometimes Errors arises during assembly of a project.
As much as concern, Dimensional errors are the most occurring errors at the
site of Assembly section.
These errors are classified by characteristics and solved/Manipulate by
Quality control Dept.
Fully assembled project then dispatched by Assembly Dept. as per
requirement of client.

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REFLECTION OF INTERNSHIP
In this chapter, regarding my learning goals I shortly discuss my
experiences; if I have achieved my goal, whether I experienced
difficulties and what I think I have to improve.
Learning Goals:
● The functioning and working conditions of a non-governmental
organization.
At the beginning I didn’t have any experience of working within a NGO.
Although I have seen one, I understand better the functioning like the
organization structure and setting up projects.
● The use of skills and knowledge gain in university.
It is difficult to say what skills and knowledge gained in my study I could put
in my internship.
● Organizing Projects
Within the internship I did lot a field work, because of this I have seen of what
aspects you have to think while organizing a project. Furthermore I have
learned how an education program can be set up and what things have to be
taken into account. Before the education I didn’t have any experience in
environmental education I had no idea if that would work.
● Skills and knowledge that might be improved to work in professional
environment
Although you learn and develop the necessary skills and knowledge while
working in organization, there are several things that I could improve already.
I did not have totally clear what activities I could have done to reach my
learning goals. Therefore during my stay I had some difficulties to determine
tasks what I could carry out. In advance of my internship I talked with the
organization about the project I could participate, however clear agreements
on my activities were not made. A more assertive attitude from my side could
have helped. To prevent uncertainties in future projects I will pay more
attention to my clear agreements and back-up plans.

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CONCLUSION
On the whole, this internship was a useful experience. I have gained new
knowledge, skill and met many new people. I achieved several of my learning
goals. I got inside into professional practice. I learned different facts of
working within a NGO. I experienced that assembling is an important factor
that progress of project related to my study. I learned more about the
Fabrication, Machining and Assembling. There is still a lot to discover and to
improve.
The internship is also good to find out what my strength and weakness
are. This helped me to what skill and knowledge I have to improve in coming
time. It would be better at the knowledge level of the language is sufficient to
contribute fully to project. However I could perform certain tasks better if I
practice more. It would be better at knowledge level of language is sufficient
to contribute fully to project. However I could perform certain tasks better if I
practice more. It would also better if I can present and express myself more
confidently.
At last internship has given me a new rights and motivation to
pursue a carrier in industrial background.

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SPECIALLY THANKS TO…
Planning Dept.: Mr. Rajan Raut Sir (HOD)
Mr. Nikhil Pashte
Fabrication Dept.: Mr. Deshpande Sir (HOD)
Mr. Vijay Abdar (Jr. Engg)
Mr. Manjeet Pawar (Welding Inspector)
Mr. Deepak Bagul (GET)
Mr. Arvind Shingare (CNC & Tracing)
Mr. Mahendra Pal (Jr. Engg)
Machine Dept.: Mr. Bhatt Sir (HOD)
Mr. Akshay Kumbhar (Jr. Engg)
Assembly Dept.: Mr. Harish Sharma (HOD)
Mr. Navin Rao (Jr. Engg)

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