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World Class Manufacturing Practices for achieving Zero Defects

Seminar on

World Class Manufacturing Practices for achieving Zero Defects

16-17 February 2017
IMTMA Gurgaon

In today’s competitive environment and increased level of globalization, Indian industries need to adopt World-Class Manufacturing Practices for achieving zero defects in a consistent manner. World-Class manufacturing strategies focus on product quality, JIT Production techniques, eliminating waste, workforce management, agility in meeting customer requirements and lean cum learning organisation. Implementing world class manufacturing practices will enable the company to be one of the best in each field viz. Quality, Price, Delivery speed, Delivery reliability, Agility and creativity.

Keeping this in view, Indian Machine Tool Manufacturers' Association (IMTMA) organized a 2 day programme on World Class Manufacturing Practices for achieving Zero Defects on 16 - 17 February 2017 at Gurgaon.


The key focus areas of the program were as follows

  • Zero defect program planning
  • Importance of Basic Applied Industrial Statistics for zero defects, Normal Distribution
  • Process, Process Mapping 7M s
  • Competency Mapping, Multi Skilling, Bench Marking, X bar & 6s control Chronic & Sporadic defects handling
  • Matrix Diagram - Critical characteristics
  • Improvement of FMEA, doing FMEA link to shop floor and how to get good results
  • Set up Approval of Process & Loss Function
  • Statistical Process Control and Process Stability, Capability Cpk ST, LT
  • Drawing Tolerance and Product Approval
  • Cost of Quality and its relevance to Manufacturing
  • PDCA - Importance of SDCA Parameters, Locking of Parameters, Continual Improvement Process
  • PPAP - process, products acceptance, five batches
  • Measurement Systems, Metrology, Customer and Organization measurements
  • Mistake Proofing-Levels and .Master Audits
  • Zero Defect Tool usage in manufacturing line
  • FPY - First Pass Yield
  • Root Cause Analysis, 3P methodology
  • Machine Capability Study Short term study-Cmk
  • Control of Visual defects, Missing, Mix up of defects
  • Plant Lay out, Storage plan and its importance
  • W C M Parameters Guide lines

This faculty for this program was Mr. Srinivasan V, retired from Bosch Limited as Manager Quality. He has over 40 years of rich experience and has worked with companies like Siemens, HMT and Bosch in the areas of Quality, Production and Training. He is Lead assessor on ISO 9001; 2000, Six sigma champion, certified Statistical Quality Control Engineer from Indian Statistical Institute and a Post graduate in Business Administration. He is currently in to Training, Hand holding and Implementations programs for various manufacturing companies including Supplier development.

The programme was highly interactive and participants were able to solicit guidance on specific technical issues from the expert faculty. Delegates from A2Z Filtration Specialties Pvt Ltd, Bajaj Auto Ltd, Bilz Tool Pvt Ltd, DY Auto India Pvt Ltd, Kobelco Cranes India Pvt Ltd, ROOP Automotive Ltd, Sigma Electric Manufacturing Corporation Pvt Ltd & Subros Ltd attended the seminar.

Practical Approach to Gears & Gear Design – Spur & Helical Gears

Seminar on

Practical Approach to Gears & Gear Design – Spur & Helical Gears

10-11 January 2017
IMTMA Gurgaon

Power transmission is very important aspect in many industries. Gears drives are most important drives used in transmitting mechanical power. Gears and Gear drives are also one of the key components of all kinds of vehicles, machine tools, aircrafts, household appliances as well as a broad variety of industrial equipment.

Study of Gears, Gear terminology, correction, Quality, Strength calculations, Errors & its Measurement is a fairly complex data. Proper understanding about all these topics and selecting gears with required quality to the required application gives better productivity, long life and noise less drive for the industries.

Keeping this in view Indian Machine Tool Manufacturers' Association (IMTMA) organized a 2 day programme on Practical approach to Gears and Gear Design - Spur and Helical Gears on10 - 11 January 2017 at Gurgaon


After attending the programme the delegates were able to

  • Select type of gear for a particular application.
  • Have an overview of types of gears, Gear Profile, Gear parameters, gear quality.
  • Able to design Spur and Helical gears for a given application and calculate their parameters.
  • Estimate gear correction, contact ratio and Backlash.
  • Select materials for gear to required application.
  • Understand Gear quality, gear errors and method of measurement.

This Program was conducted by Mr. P. Aruna Kumar. He is a Post graduate Mechanical Engineer with Machine tool specialization. He comes with over 36 years of domain expertise in Machine tool design, Assembly, Inspection and Testing. He retired as DGM, Designs and development, HMT Machine tool division, Bangalore. He has a rich experience in Gear design, Gear cutting machine design, Gear metrology and also other Machine tool Design. He has also worked in the field of assembly and testing of machine tools.

The programme was highly interactive and participants were able to solicit guidance on specific technical issues from the expert faculty. Delegates from Bajaj Auto Ltd, ISGEC Heavy Engineering Ltd, Mahindra Heavy Engines Ltd, Mahr Metrology India Pvt Ltd, Micro Turners Ltd, Onkar Dies Pvt Ltd & Rotomag Motors & Controls Pvt Ltd attended the seminar.

Heat Treatment Processes in Metal Working

Seminar on

Heat Treatment Processes in Metal Working

2-3 December 2016
IMTMA Gurgaon

Heat Treatment is a core manufacturing process carried out under controlled application of temperature and atmosphere to optimize certain physical and mechanical properties of metals/alloys. Heat treatment is an enabling process that can improve product performance by increasing its strength or other desirable characteristics such as machinability, formability, ductility, etc. The process of heat treatment has a major bearing on the quality of the end product and finds a wide application in many industries such as Automobile & Auto Components, Dies & Mould, Machine Tools, Aerospace, and General Engineering & so on. Keeping this in view, Indian Machine Tool Manufacturers' Association (IMTMA) organized a two day programme on Heat Treatment Processes in Metal Working on 2-3 December 2016 at Gurgaon.


The programme focused on

  • Fundamentals & Purpose
  • Basic Heat treatment processes (Annealing, Normalising, Hardening, Quenching, Tempering, Case Carburising & hardening, Case Nitriding, Sub - zero treatment, Induction Hardening)
  • Advanced techniques (Vacuum hardening, Toughtriding)
  • Process problems and solutions; Techniques of distortion control
  • Successful drawing requirements
  • General Quality plan of H/T for acceptance / rejection
  • Industry practices
  • Understanding of case depth determination (Carburising, Nitriding & Induction hardening particularly in case of components like gear, Shafts Plane & spline); Common failures and remedies

This programme was conducted by Shri. A Dasgupta, a topper in Metallurgical Engineering from Calcutta University in the year 1974-1975. He worked at Central Manufacturing Technology Institute (CMTI) for 30 years and became a Scientist - Divisional Head of Materials. During his tenure in CMTI, he helped many industries to resolve their technical problem associated with materials - Heat-treatment–Metallurgical & Mechanical Testing & Evaluation. He had developed Vibratory stress relieving Equipment and Hardness Standardized Blocks, after conducting applied research & study.

The programme was highly interactive and participants were able to solicit guidance on specific technical issues from the expert faculty. Delegates from Advertising & Display Services India Pvt Ltd, AK Automatics, ACMA, Bharat Gears Limited, HMSI, Sansera Engineering Limited, SUBROS Limited, Surmela Tools Pvt Ltd, Technico Industries Ltd & Toyo Springs Ltd attended the seminar.

Design of Fixtures Specialization

Training on

Design of Fixtures Specialization

The six-day training program on Design of Fixtures Specialization was conducted in Gurgaon by IMTMA Design Institute from February 13-18.

The course was structured with introduction to Fixture Design basics to final design. Design of fixture is key to effective utilization of machine tools. Basics of fixture design if not implemented correctly results in poor productivity & quality problems. Set-up time and cycle time reduction, increased accuracy on components, deskilling the job setting operation are the obvious advantages of a good fixture. Competence in right fixture differentiates excellent organizations.

During the six days, a complete process of fixture design was carried out from concept to finish design. Pre-design activities like design input, conceptualization, process planning, accuracy consideration, cycle time estimation, POKAYOKE, 3D modeling of parts and assembly, using popular design CAD tools and preparing the final manufacturing drawings. Design for Accuracy, Manufacturing and Assembly will be addressed during the course. It was highly interactive and hands on training session and covers entire 360° view on all types of fixture design aspects.

Topics Covered

1st Day - Mr. S.K Gupta – Consultant Topics delivered by him were Introduction to Jigs and Fixtures, Types of Fixtures, Process related eg. Machining, Welding, Assembly, Types of Fixtures – Manual, Hydraulic, & Pneumatic. Key factors and Technical features, Basics of fixture design, design process for Fixturing, Basic elements of fixtures, Materials and Manufacturing process for the elements.

2nd Day - Mr. S.K Gupta and Mr. Rahul Vylen – Topics delivered – Modular Concepts of Fixtures, Standard elements of Fixtures, safety features, Cost effectiveness while designing, Trouble shooting of fixtures, Machining Process and elated CNC Machines Case Studies / Training of Solid works.

3rd and 4th Day - Mr. Rahul Vylen and Mr. Deepak Kumar Ravilla – Topics Covered Introduction to Fixture Clamping elements and selection process, application, advantage etc. Further a Hydraulic Fixturing was designed considering an automobile component as a case study.

5th Day – Participants were taken to Industry visit in Tokai Engineering Private Limited – Where participants were have closely observed – Assembly Fixtures, Inspection Fixtures, Welding Fixtures and Machining Fixtures.

6th Day – Mr. Avinash Khare - Topics covered - Introduction and conceptualization to BIW, Assembly, Welding and Inspection fixtures along with case studies.

A total of 10 candidates nominated from Artech Welders, Global Autotech Limited, Lucy Switchgear FZE, Rolls- Royce India Pvt Ltd, Tata Hitachi Construction Machinery Co. Pvt. Ltd, Tata Motors Limited, Variational Technologies Pvt. Ltd. attended the training program.


Delegate Speak

  • It has been a very enriching experience covering a wide range of fixture design specialization.
  • The Faculty members have been quite friendly and encouraging and have kept us upto date with the recent advancements. – Mr. Danduram Soren
  • Training was very helpful to upgrade my knowledge – Mr. Prashant Bele

Machine Tool Design - MECHANICAL

Training Programme on

Machine Tool Design - MECHANICAL

In the second batch of the 48-day training programme was held from Nov. 14, 2016 to Jan 10, 2016 and 26 budding engineers were trained in designing of a turning center, at the IMTMA Design Institute, BIEC, Bangalore.

The training programmes were conducted by more than 25 industrial experts, who supported the trainees and enhanced their skills in their respective areas of expertise.

    

A visit to Ace Designers and Ace Foundry was also arranged during the program and was a value addition to their course.

Camworks, an evolved software an extension of SolidWorks by Geometric ltd, was sponsored to Design Institute, was of extreme support to evolve the prototype - turning center as per customer specifications.

With the candidates primarily being fresh graduates, 70% of the candidates were offered placements by various companies, stating from SSI to MNCs. They were inducted into companies like, Strategy Automation, Ace Designers, Craftsmans’ Automation, Conceptia, Shesha Tool and others.