CHAPTER - 1

INTRODUCTION

Objective:-
My objective is to learn and given experience from industrial training and to apply my
learning in the future for the development of India.

1.2 Why I choose JK Tyre?

I want to learn the process and the basic functioning of the] industries related tyre and tube
sector and I want to see the execution of the theoretical part related to production which I
studied in my previous semesters that is why I choose JK TYRE Industries for industrial
training.

1.3 Company Details:-

JK TYRE is one of the divisions of JK INDUSTRIES LTD. The foundation stone of KTP
was laid on May 08,1975. The plant was commissioned in a record time and commercial
production started on 1 jan 1977 after having entered into technical collaboration with the re
known tyre manufacturers in the world M/S General Tyre International Co. USA with an
initial capacity of 5 lac tyres per annum. When the first tyre rolled out of the Kankrolityre
plant in 1977, well known international and domestic brands had already laid dominance over
the market. However through excellent product development and aggressive marketing, JK-
TYRE today commands on enviable chunk of the market share in the passenger car, jeep,
LCV, farm & truck tyre segments. The present installed capacity is 16. 41 lac tyres, 14.81
Lac tubes and 2.72 lac flaps per annum. It has continuously upgraded plant and machinery in
order to stay ahead of its competitors and has many technological firsts to its credit.
The Kankrolityre plant has recently undergone business process reengineering. For efficient
functioning of the organization the whole plant has been divided into business units and
service support units.

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering

1.4 Group Companies of JK Tyre:-

JK TYRE Industries Ltd. 9 Plants in India and 3 Plants in JK Tornel

Mexico.
JK PAPER Ltd. Market leader in Branded Copier Paper
JK LAKSHMI CEMENT Ltd. Formidable presence in Northern &
Western India cement markets.
JK Risk Managers & insurance Brokers Provides insurance advisory & placement
Ltd. service to both retail & corporate clients.
JK Agri Genetics Ltd. Leading agri biotech hybrid seed company

UMANG DAIRIES Ltd. Produce and markets skimmed milk

powder, butter etc.
JK Lakshmipat University The various school and colleges running
under the Lakshmipat foundation.
JK Fenner Ltd. Manufactures industrial and automotive
V-Belts, Oil seals Engineering products.
Table 1: Group Companies Of JK Tyres.

1.5 Plants of JK Tyre:-

Figure 1.5.1: JK tyre office, Kankroli

Figure 1.5.2: JK TYRE, Rajsamand

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 Figure 1.5.3: JK Research centre

Figure 1.5.4: JK Fenner

Figure 1.5.5:

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1.6 Products of company:-

Figure 1.6.1: JK Tyre Ranger TL 215/75 Figure 1.6.2: LCV TYRE – JET RIB

Figure 1.6.3: JK Tyres – JET STEEL JDE Figure 1.6.4: SCV Tyre – jumbo jumbo Ace

Figure 1.6..5: JK Tyre – HCV Jet R Miles Figure 1.6.6: JK Tyres– Tubes

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering

 Figure 1.6.7: JK Tyre Jumbo Magic, Tyre, Tube & FlapsJK Tyres

Figure 1.6.8: Elanzo Supra Tubeless Tyre

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering

1.7 Customer Exports:-

JK Tyres is focusing on expanding its export footprint using its plant in Mexico to drive
volumes in the car segment as part of which some New York cabbies are have now started
using the Indian brand for the time. The tyre market leader has been exports in effort to make
up for the slowdown in the domestic car, market, said top company officials.

Figure 1.7: CUSTOMER EXPORTS OF JK TYRES

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering

 CHAPTER - 2

LAYOUT AND DEPARTMENTS

2.1 Plant Layout:-

Figure 2.1.1: Plant Layout

2.2 Departments of Company:-

 Management
 Personal and accounts department
 Quality department
 Research and development department
 Process engineering department
 Utility department
 Main store

2.3 Function of departments:-

2.3.1 Production department:-The production function undertake the activities necessary to

provide the organization products or services. Its main responsibilities are:-

 Production planning and scheduling

 Control and supervision of the production workforce
 Managing product quality
 Maintenance of plant and equipment
 Control of inventory
 Deciding the best production methods and factory layout

2.3.2 Research and Development Department:-The Research and Development (R&D)

function is concerned with developing new products or processes and improving existing
products/processes. R&D activities must be closely coordinated with the organization’s

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering

marketing activities to ensure that the organization is providing exactly what its customers
want in the most efficient, effective and economical way.

2.3.3 Purchasing Department: -The Purchasing function is concerned with acquiring goods
and services for use by the organization. These will include, for example, raw materials and
components for manufacturing and also production equipment. The responsibilities of this
function usually extend to buying goods and services for the entire organization (not just the
Production function) including for example, office equipment, furniture, computer equipment
and stationery. In buying goods and services, purchasing managers must take into account a
number of factors – collectively referred to as ‘the Purchasing Mix’, namely, Quantity,
Quality, Price and Delivery.

 Quantity - Buying in large quantities can attract price discounts and prevent
inventory running out. On the other hand, there are substantial costs involved in
carrying a high level of inventory.
 Quality - There will usually be a trade-off between price and quality in acquiring
goods and services. Consequently, Production, R&D and Marketing Functions will
need to be consulted to determine an acceptable level of quality which will depend on
how important quality is as an attribute of the final product or service of the
Organization.
 Price - Other things being equal, the purchasing manager will look for the best price
deal when procuring goods and services, although price must be considered in
conjunction with quality and supplier reliability, in order to achieve best value, rather
than lowest price only.
 Delivery - The time between placing an order and receiving the goods or services, the
lead time, can be critical for production planning and scheduling and also has
implications for inventory control. Suppliers must therefore be evaluated in terms of
their reliability and capability for on time delivery.

In short, the ‘purchasing mix’ can be considered as making sure that the organization has the
right amount, of the right quality, at the right price, in the right place at the right time.

2.3.4 Marketing Department: - Marketing is concerned with identifying and satisfying

customers’ needs at the right price. Marketing involves researching what customers want and
analyzing how the organization can satisfy these wants. Marketing activities range from the
‘strategic’, concerned with the choice of product markets (and how to compete in them, for
example, on price or product differentiation) to the operational, arranging sales promotions
(e.g., offering a 25 per cent discount), producing literature such as product catalogues and
brochures, placing advertisements in the appropriate media and so on. A fundamental
activity in marketing is managing the Marketing Mix consisting of the ‘4Ps’: Product, Price,
Promotion and Place

 Product - Having the right product in terms of benefits that customers value.
 Price - Setting the right price which is consistent with potential customers’
perception of the value offered by the product.

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering

  Promotion - Promoting the product in a way which creates maximum customer
awareness and persuades potential customers to make the decision to purchase the
product.
 Place - Making the product available in the right place at the right time – including
choosing appropriate distribution channels.

2.3.5 Human Resources Department: - The Human Resources function is concerned with
the following:

 Recruitment and selection - Ensuring that the right people are recruited to the right
jobs.
 Training and development - Enabling employees to carry out their responsibilities
effectively and make use of their potential.
 Employee relation - Including negotiations over pay and conditions.
 Grievance procedures and disciplinary matters - Dealing with complaints from
employees or from the employer.
 Health and Safety matters making sure employees work in a healthy and safe
environment.
 Redundancy procedures administering a proper system that is seen to be fair to all
concerned when deciding on redundancies and agreeing redundancy payments.

In recent years, the Human Resources function has attained a more important status as there
has developed an increasing need (especially in service organizations) to ‘get the most’ from
employees, in terms of customer service, for the benefit of the organization.

2.3.6 Accounting and Finance Department: - The Accounting and Finance function is
concerned with the following:

 Financial record keeping of transactions involving monetary inflows or outflows.

 Preparing financial statements (the income statement, balance sheet and cash flow
statement) for reporting to external parties such as shareholders. The financial
statements are also the starting point for calculating any tax due on business profits.
 Payroll administration Paying wages and salaries and maintaining appropriate
income tax and national insurance records.
 Preparing management accounting information and analysis to help managers to
plan, control and make decisions.

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering

 CHAPTER - 3

MACHINERY TECHNOLOGY

There are different types of machines and Technologies used in different departments.

3.1 Calendering machine - compounds are processed with multi roll Calender to produce
different semi finished products. Calendars are used in rubber industries for two purposes.

 To prepare a rubber sheet.

 To coat rubber over fabric
In Calendering process dual let off is used with accumulator to maintain the continuity. The
dipped fabric are joined using cement, which contain rubber compound. The fabric passes
through a tension control rolls and passes to air bleeding section. Here bleeder threads are
applied, the sheet of the fabric is prickled at constant intervals. Then the fabric is wound o a
dual wind up after passing through a wind up accumulator.

Equipment name: 4-roll Calender

Function: Dipped fabric skim coating with a thin film of rubber on both sides

Input: Dipped fabric rolls, rubber compound.

Output: Calendered fabric rolls wrapped in PP liner

Uses: Ply roll and green tyre

Resource required: Steam, Hot water, and Cold water.

No of rolls produced per shift: 50 to 55

DESCRIPTION: The four roll Calender is mainly used for Calendring the fabric on both the
sides. The four rolls of the Calender have a Z configuration of 24 inch *68 inch dimensions.
The rolls are driven by two 100 HP and two 125 HP D. C. motors. The maximum linear
speed of the Calender is 60 rpm. The 1st and the 4th roll runs at 40 rpm and the 2nd and the 3rd
roll at 60 rpm. The different parts of the Calendring unit are:

LET OFF ZONE: The fabric is let off from a dual let off stand. A steam heated splice press
join the ends of 2 rolls. The curing time is 40 seconds. The fabric is pulled from the let off
roll by the let off pull rolls. It creates tension of 400psi in the accumulator. The let off
accumulator allows smooth running. When the roll is changed or ends are spliced.

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering

DRYING ZONE: Here the temperature is about 800C and is used to dry the fabric. The zone
is heated by hot air. This zone is 50 yards long.

CALENDERING ZONE: After the drying zone, the fabric enters the Calendring zone. The
fabric is pre tensioned to about 320 kg/cm2 by pre Calender tension pull rolls. It pulls the
fabric from the feed pull rolls to maintain a constant accumulator tension. The last part holds
back the fabric to create the necessary pre Calender tension. The fabric then passes through
the nip of the inclined Z Calender to get itself coated on both sides. Then it passes through a
post Calender tension pull roll where the tension of 550 kg/cm2 is applied. The Calendered
fabric is then cooled by passing through a series of cold water circulated hollow cylinders.

WINDING UP ZONE: After cooling the fabric reaches the wind up accumulator. It is then
passed under 2 perforated rolls, having a large number of blunt needles to punch the
Calendered fabric. This assures the removal of air. It is then passed wind up pull roll, which
exerts a tension of 100 psi. The Calendered fabric is then passed through the spreader roll,
which relives it of any increases.

PRACTICAL WORK

4 ROLL CALENDER

OPERATOR SIDE NON OPERATOR SIDE

MAIN 1 2 3 4 MAIN 1 2 3 4
BEARING BEARING

54.8 60.8 61.3 53.7 56.7 57.8 56.8 57.4

BENDER 1 2 3 4 BENDER 1 2 3 4

BEARING 55.9 58.5 61.2 57.6 BEARING 52.9 55.6 57.1 56.3

Table 2: 4 ROLL CALENDER

Three Roll Calender:

FUNCTION

Inner liner calendring& squeeze application on ply

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PARTS

1. Cold feed extruder

2. 3 roll calendar

OUTPUT

Inner liner

Squeezee application on ply

Calendered roll

Diagram of Calender Machine

Figure 3: Calender Machine

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3 ROLL CALENDRING

MAKE

1. 3 ROLL CALENDER-: FALK VISCONSIN,USA

2. EXTRUDER-: BAINITE

FUNCTION

Inner liner calendring& squeeze application on ply

PARTS

1. Cold feed extruder

2. 3 roll calendar
3. Cooling drums

OUTPUT

Inner liner

Squeezee application on ply

Calendered roll

PROCESS FLOW DIAGRAM

COMPOUND

EXTRUSION

CALENDERING

BOOKING

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PRACTICAL WORK { TEMPERATURE IN 0C }

3 ROLL CALENDER

MILL BUSH GEAR BOX

FW FD RW RD ID I.ND INT.D INT. O.D O.ND

ND

FEED 45 44.4 46 48.4 55.7 61.4 55.4 59.1 54.5 57.9

MILL

CR. 41.1 45 40.1 40.3 58 66.7 54.9 57.6 54 56.2

MILL

Table 3: 3 ROLL CALENDER

3.2EXTRUSION

INTRODUCTION

Extrusion is a process by which the un-vulcanzed rubber compound is transformed into

definite continuous shape through a particular die opening under pressure & temperature.
Extruders are machines which force rubber compound through a die under controlled
conditions of temperature & pressure, rate and homogeneity to give a continuous length of
material having shape of fitted die.

TYPES OF EXTRUDER

 Hot feed extruder

 Dual extruder
 Multipurpose extruder
 Cold feed extruder
 On line filler extruder
 ‘T’ head extruder

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DIAGRAM OF EXTRUDER MACHINE

Figure 3.2: Extruder Machine

DUAL EXTRUDER:

Dual extruder is mainly used for extruding treads & some time for tread and sidewall. It
consists of two different extruders 8-1/2inch &10 inch screw diameter with single head. Dual
extruder is used because the tread is made of three different compounds.

1. CAP

The cap constitutes 60% of truck tread and therefore it’ is extruded by 10”diameter extruder.

2. BASE

The base constitutes 40% of the truck tread and so it is extruded from the 8-1/2” extruder.

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering

3. CUSHION COMPOUND

A thin cushion compound is applied at the bottom of the tread from a two Roll Calender.
Mechanical pressure is applied by a number of thin metal plates clamped together traversely
to the tread to enable better adhesion of the cushion compound. This is an online process
done before skiving & cooling.

OBJECTIVE

Treatment of rubber compound to make tread.

INPUT MATERIAL

 Cap compound
 Base compound
 Cushion compound

OUTPUT
Tread

TREAD

Tread is the outer most part of Tyre. It is contact with road. So it needs more strength,
abrasion resistance &uniformity to carry load.

PARTS OF DUAL EXTRUDER

 Sub base conveyor

 Pull out conveyor
 Cushion through weighing scale
 Overhead cooling conveyor.
a. Extruder &conveyor.
b. Center conveyor
c. Extension conveyor No. 1&2
 Discharge to decline.
 Decline.

STEP OF WORKING

1. Master compound is mixed thoroughly in the mixer.

2. Then warmed up or heated in warm up mill. It is then fed in the extruder, separately
according to the compound required for cap and base.

3. Both the 10-inch and 8-1/2 inch screws extrude the cap and base respectively through a
common head.
4. The extrudate then passes through the die where the cap and base are attached together to
form tread.

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering

Then cushion is applied at bottom to extruded compound, and then it passes through
machined chamber to shrinkage. After that required size & dimension cut.

3.3 Slitting Machine

Slitters are used to slit chafer and flipper fabrics. This will make strips of the required width
after cutting in the bias cutter and spliced into continuous length.

MAIN PARTS OF THE SLITTER

LET OFF ASSEMBLY- to take away the fabric from the liner for slitting.

CUTTING ODEVICE- It consists of a motor driven roll on which a few number of rotor
blades are fixed at desired distance apart.

TAKE OFF CONVEYOR- The slitted fabrics are taken through these conveyors and
continuously wind up on liners. There are 2 slitters here, one for slitting chafer/flipper and the
other for breaker.

Diagram of sliiting machine

Figure 3.3: Slitting Machine

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering

3.4 Compressor

Ingersoll Rand offers an expensive offering of centrifugal air &gas compression solutions,
powered by MSG, Turbo Air Plant air compressor as well as process air and gas compressor.
In addition to equipment, Ingersoll Rand also offers a variety of compressed air services
including installations, system upgrades, compressed air system assessments and audits, and
planned or emergency maintenance.

MSG TURBO AIR 2000 Centrifugal Air Compressor

The MSG TURBO AIR 2000 was built on a standard frame, featuring a wide arrangement of
air flow components designed for easy, low cost installation operation The MSG TURBO
AIR 2000 was designed with a built in after cooler that eliminates the need for a separate
pipeline type cooler, and a packaged check valve for faster installation and easier
maintenance.

Diagram of MSG TURBO AIR 2000 Centrifugal Air Compressor

Figure 3.4: MSGTURBO AIR 2000 Centrifugal Air Compressor

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering

MSG TURBO AIR 3000 Centrifugal Air Compressor

The MSG TURBO AIR 3000 was built on a standard frame, featuring highly engineered air
flow component. It is designed for easy, low cost installation operation The MSG TURBO
AIR 3000 was designed with a built in after cooler that eliminates the need for a separate
pipeline type cooler, and a packaged check valve for faster installation and easier
maintenance.

Figure 3.4.1: MSG TURBO AIR 3000 Centrifugal Air Compressor

3.5 Banbury Machine

The banbury mixer is an internal, intensive, batch mixer capable of mixing viscous materials
in very short time. The following definitions will enhance understanding ofthis product.

 INTERNAL refers to the mixing action of specially shaped counter rotating rotors
inside a closed chamber.
 INTENSIVE means that a large amount of energy imparted to the material in a short
period.
 BATCH indicates that machines mix a fixed volume of material during each mixing
cycle.
There are 5 banburies in the whole plant.
Banbury 1 : Situated in BU1. It is mostly used for final batch .
mixing.

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering

Banbury 2 : Situated in BU1. It is mostly used for master batch m
mixing.
Banbury 3 : Situated in BU1. It is mostly used for master batch compound mixing.
Banbury 4 : Situated in BU1. It ismostly used for master compund mixing of NR/SR and
butyl based component .
Banbury 5: situated in BU1. It is mostly used forfinal batch mixing.

Diagram of Banbury

Figure 3.5: Banbury Mixer

MAIN PARTS OF THE BANBURRY MIXER

HOPPER ASSEMBLY
Hopper consists of two sub- assemblies.
HOPPER ITSELF
For loading the raw stock and the compounding ingredients.
THE AIR OR HYDRAULICALLY OPERATED FLOATING WEIGHT
Forces the material into the mixing chamber and maintains pressure on the material during
the mixing cycle.

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering

MIXER BODY
A mixing chamber contains
ROTOR
The place where the actual mixing is taking place. The rotors are generally of two types two-
wing rotor, four-wing rotor.
HYDRAULICALLY OPERATED DISCHARGE DOOR
It forms the bottom of the chamber and allows batch discharging.
BED PLATE
It forms the foundation of the entire mixer. It supports the latch assembly, which locks the
discharge door closed during the mixing cycle.
DUST STOPS
There are four dust stops on each mixer, one at each mixer, one at each point where a rotor
shaft passes through the end frames. Their function is to prevent material leaking out of the
mixing chamber around the rotor shafts. Proper lubrication is necessary for satisfactory
operation of dust stops.

3.6 Bias Cutting Machine

In this section, Calendered fabric rolls are cut into plies having definite width and angle. Such
bias cut plies are booked in Cotton liners and supplied to the Tyre Building Sections.

TYPES OF BIAS CUTTER

In JK Industries, there are two types of Bias Cutters are used:

 Low Table Bias Cutters (LTBC)

 High Table Bias Cutters (HTBC)

INPUT :Calendered Fabric

OUTPUT :Plies of cutting angle

Figure 3.6: Bias Cutter Machine

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PROCESS :The Calendered rolls are brought to bias cutter section. The rolls are loaded to
the machines. The width & angle are set as per technical specifications in the machine. The
cutting operation is started and automatically the cutting of the fabric will be done. Photocell
will control the conveyor speed as well as ply width. The bias cut roll is booked in cotton
liners. Cut pieces of Calendered rolls are called plies. The plies have definite width & angle.

Low table Bias cutter has more number of splicing tables than HTBC. So the productivity is
much higher in LTBC. It is used for cutting the plies. HTBC is used for cutting Chaffer &
Flipper cutting.

ADJUSTMENTS

Two basic adjustments are provided for the cutting operation.

a. The angle of cut, and

b. The perpendicular distance between the cuts which determines the ply width.

ANGLE OF CUT
The assembly containing the cutter head and it’s drive system adjustable about a circular arch
centered on the centerline of the table. The bias angle range of adjustment on the m/c is 450 to
900.

This adjustment may be obtained either by manually by means of a hand crank or by motor
drive.

PLY WIDTH

It is obvious that the ply width will be determined by the distance between the path of the
cutter wheel and stepping point of the fabric as determined by the position of the scanner.

Thus in order to vary the ply width it is necessary to vary the ply width it is necessary to vary
this distance, either by maintaining the scanner is fixed position and moving to cutter or vice-
versa, by holding cutter fixed and adjusting the scanner by ply width capacity are generally
within the range 11” & 53” on HTBC.

3.7 Automated screw driver – Automated screw driver is used to tighten the screw. It has
different torque setting according which torque is applied on the screw for tightening of the
screw

3.8 Batch marking machine - This is also worked on pneumatic principle. When the switch
reaches this machine it senses the position and a trigger gun engrave the key number on the
body. It is fully automated and need no human assistance.

3.9 Emergency Lamp – These lamp contains sensors and works according to line when the
line have some problem or fault it automatically indicate by blinking red light

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering

 CHAPTER – 4

Project assigned during training

Objective -

To determine the defects in tire.

The most common tire defects include:

1. Tread separation
2. Tread and steel belt separation
3. Tire made without all specified components
4. Improper puncture repair
5. Tires made without the know separation prevention design features
6. Tire not suitable for vehicle
7. Retread failure
8. Tire damaged during the mounting process
9. Manufacturing defects
10. Tires that look good but are old

These are serious defects. For instance, if the tread separates, it is often followed by a
complete blowout. Unfortunately, this could be due to a design defect or any number of
manufacturing defects such as certain elements being present or left out during the
manufacturing process.

Methods of Avoid Tire Defect

Checking Tire Pressure

Although checking tire pressure is the last thing most drivers want to do, it is critical. In fact,
it is probably the most important step to take. A tire 20 percent below optimal pressure is
actually considered a flat tire. And industry research has shown that 90 percent of tire
blowouts are a result of underinflation.

It’s no fun, but checking tire pressure and making sure your tires are not at all underinflated is
a necessary part of your pre-inspection routine. Then, you can get behind the wheel without
having to worry about it.

Proper Alignment
Maintaining alignment is necessary to reduce the wear in your tires. But it also helps your
control of the truck as the driver. Proper alignment allows maximum handling ability,
reducing the risk of accidents or other issues on the road.

Another thing to avoid is mixing and matching tires, especially tires across an axle. This will
help expand the lifecycle of your tires and maintain their integrity.

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering

Minimizing Heat
Heat actually accelerates the aging process in a tire. An underinflated tire that is exposed to
heat loses integrity in its casing. Avoid the damage by avoiding exposure to heat.

Minimizing Cold
In extreme cold, it’s necessary to check tire pressure in a controlled environment. A
temperature above freezing is optimal. This will make sure that you get an accurate measure
of tire pressure.

It’s also a good idea to avoid extreme cold because it can damage the tire compounds and
make them brittle. This hurts the integrity of the tire, and causes it to wear a lot faster.

Avoiding Road Hazards

This is hard to do sometimes, and in some cases it’s unavoidable. But often, potholes and
serious road hazards can be fatal to tires. When it doesn’t kill the tire on the spot, it can
sometimes cause internal damage that will speed up the aging, sending the tire to its death.

It’s a good idea to avoid driveway lips, potholes, curbs, and obviously any hazards on the
road.

Diagram

Figure 4: Defect of tyres

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering

 Chapter –5

Learning And Outcomes

This training provided me a good opportunity to learn many skills like; managing skills,
operating skills, and communicating skills, i.e. how to communicate with the seniors and the
workers and the other member. Through this training I also get the power to visualize the
things going on, and through this training I learned the many technical knowledge and
industrial knowledge. In this training I learned how to manage and to make the work effective
and properly working within the specified time. Through this industry I came to know that for
them safety is first, then the production because if they will take precautions then only the
production can take place, company has some of the tag line used inside the company at time
of production, i.e.

“FIRST SAFETY, THEN PRODUCTION”

Other thing which I learned in industry is that how work on different factors, i.e. this
company work on the: 5’ S, 3’ G, 3’ M. These were the different factor in which the company
work and they are necessary to follow by every member part of this company.

5.1 3G <Three G> Principle and activities:-These are quality terms which is used in the
organization to get better quality product .Working of these is described as:

5.1.1 Genba - "The actual place". This is where work takes place and value is created for the
customers. Note that work and value are not always aligned.

5.1.2 Genbutsu - "The thing". This could be a piece of equipment, a product, etc. It is the
target of one's focus for improvement. "The facts". What is happening in the area of the area
of kaizen, a work cell, etc.

5.2 5S <Five S> Principles and the activities:- 5S activities are practiced in a real
participatory movement to improve the quality of both the work environment and service
contents delivered to your clients

 Sort: - what is not needed. Use the red tag system of tagging items considered not
needed and then give everyone a chance to indicate if the items really are needed. Any
red tagged item for which no one identifies a need is eliminated (sell to employee, sell
to scrap dealer, give away and put into trash.
 Set: - what must be kept. Make things visible. Put tools on peg board and outline the
tool so its location can be readily identified. Apply the saying "a place for everything
and everything a place’’.
 Shine: - Next is to get everything cleaned and functioning properly. The goal is to
remove all the dirt and the grime and to keep it that way on daily basis. You want to
get it clean and keep it clean.
 Standardize: - The clean/check routine. When others see the improvements in the
Kaizen area, give them the training and the time to improve their work area.
 Sustain: - Self-discipline. Established a cleaning schedule. Use downtime to clean
and straighten area.

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering

 Chapter - 6
Conclusion

I have learnt a lot of things from this industrial training, mainly to control and handle the
assembly line in industry. By this training we get a good exposure of industrial world. This
training program will help us to learn the concepts relating to the machine, material, process,
quality, startup & shutdown, problem solving, material handling and the terminology
associated with the product development. We are really thankful to our HOD of Mechanical
Engineering Department and JK Tyre company to provide this opportunity

Poornima Group Of Institutions, Jaipur B.Tech, Mechanical Engineering