MALNAD PRIME MACHINING

TECHNOLOGIES PVT . LTD .

( No 36A, Shimoga – Bhadravathi Industrial Area, Machenahalli, Shimoga, Karnataka, INDIA.)

Internship Report Submitted by:

HARSHAVARDHAN C SARATE 4JN19ME021

Submitted in partial fulfilment for the award of Bachelor of Engineering in

MECHANICAL ENGINEERING
Of Visveswaraya Technological University, Belagavi during the year 2022-23

Under the guidance of:

Dr. SATHYA PREMA
BE, M.Tech, MBA, PhD Professor,
Dept. of Mechanical Engineering,
JNNCE, Shivamogga

Department of Mechanical Engineering

Jawaharlal Nehru New College of

Engineering Shimoga-577204,2022-2023
 Acknowledgement:
We express our deepest gratitude and respect to our internal-guide Mr. H R
Raghavendra, Professor in Department of Mechanical Engineering, JNNCE,
Shivamogga us valuable guidance and encouragement while doing this
internship training successfully. We would like to express our special thanks to
external-guide Mr. Mahaveer jain, process Engineer, Malnad Alloy Casting
pvt. Ltd. for giving an opportunity to undergo internship training and for their
full support and providing their valuable knowledge in completing this
internship training successfully. We also thankful to management of Malnad
Alloy Casting Pvt. Ltd. for providing us an opportunity to carry out this
internship training in their organization and all the workers for their co-
operation. We are grateful to Dr. E.Basavaraj, HOD and Dr. P Manjunath,
Principal for their advice and suggestions at various stages of the work. We also
extend our thanks to the Management of JNNCE for having provided good
laboratory and library facilities. We remain grateful to the co-operation and the
help rendered by the internship coordinator and, teaching and non-teaching staff
of the department.
 CONTENTS

Chapter – 1
About the company:

1.1.1 History 1
1.1.2 Vision, Mission and strength 2
1.1.3 MACPL Progress 3
1.1.4 Products 4-7
1.1.5 Suppliers of Raw Materials 7-8
1.1.6 Process of flow charts 9-12
1.1.7 Environment focus 12
1.1.8 Achievements and Awards 12-13
1.1.9 Quality policy 14
1.1.10 Maland group companies 14
1.1.11 Major customer 15

Chapter – 2

Safety precautions and casting:

2.1 Safety 16
2.2 Introduction to casting 17
2.3 Foundry processes:
2.3.1 Pattern shop 18-19
2.3.2 Types of pattern 19
2.3.3 Pattern material 19-20
2.3.4 Patter allowance 20-21
2.3.5 Patter inspection 21-22
2.3.6 Methoding 22
2.3.7 Inspection and rework 23-24
2.3.8 Manufacturing Practices 24
2.4 Moulding:
2.4.1 Introduction to Moulding 24
2.4.2 Sand preparation 24-26
2.4.3 Moulding Practices 27-28
2.5 Melting:
2.5.1 Introduction to Melting 28
2.5.2 Lining and sintering 28
2.5.3 Melting temp of common Metals 29
2.5.4 Melting Practices 29-30
2.6 Pouring:
2.6.1 Steps Before pouring 31

2.7 Fettling:
2.7.1 Introduction to Fettling 31
2.7.2 Fettling Practice 31
2.8 Shot blasting and Color coding:
 2.8.1 Shot blasting 32
2.8.2 Color coding 32-33

2.9 Heat treatment:

2.8.1 Introduction to Heat treatment 34
2.8.2 Normalizing 35
2.8.3 Water quenching 35-36
2.8.4 Hardening 36
2.8.5 Tempering 36
2.8.6 Acid pickling 37
2.8.7 Passivation 37

Chapter – 3

Lab testings:
3.1 Incoming Sand inspection and testing 38
3.2 Destructive testings 38
3.2.1 Optimum emission Spectrometer 38-39
3.2.2 Mechanical Testings 39-42
3.3 Non-Destructive testings 43-44

Chapter – 4

Machine shop:

4.1 Introduction to Machine shop 45

4.2 Machines tools in MACPL 45
4.3 Operations Performed 45-51

Chapter –

Quality check and dispatch:

5.1 Quality check 52
5.2 Instruments used for inspection 52
5.3 Colour coding after inspection 53
5.4 Dispatch 53
5.5 Packing procedure 54
Chapter – 6

Conclusion and reflection notes:

6.1 Conclusion 55-56
6.2 References 56
List of Figures:

Fig 1.1 Company Pitcher 1

Fig 1.2 Valve Components 4
Fig 1.3 Hydraulic Components 4
Fig 1.4 Pump Components 5
Fig 1.5 General Engineering Equipment 5
Fig 2.1 Sample pattern 23
Fig 2.2 Molten metal pouring to ladle 30
Fig 2.3 Molten metal pouring to ladle 30
Fig 2.4 Blasting 32
Fig 2.5 Arc cutting 33
Fig 2.6 Gas cutting 33
Fig 2.7 3&7,5 ton furnace 35
Fig 2.8 Mechanized quenching 35
Fig 2.9 Heat treatment Process 37
Fig 3 Spectrometer 39
Fig 3.1 UTM machine 39
Fig 3.2 Charpy impact test 41
Fig 3.3 Brinell Hardness test 42
Fig 3.4 MPT test and UT test 44
Fig 4.1 Lathe 46
Fig 4.2 Vertical Milling Machines 47
Fig 4.3 Hydro leak testing Machine 48
Fig 4.4 CNC Machine 48
Fig 4.5 Vertical turning lathe 49
Fig 4.6 Horizontal Milling Machine 49
Fig 4.7 Vertical Milling Center 50
Fig 4.8 Radial Drilling Machine 51
Fig 4.9 Painting 53

List of Tables:

Table1.1 Some of the grade manufactured by MACPL 8

Table 2.1 Calibration of different mixers 26
Table 2.2 Furnace Capacity 28
Table 2.3 Knocking time 30
Table 2.4 Aiming chart for some material 30
Table 2.5 Pouring temperatures 31
Table 2.6 Color coding and type of cutting 32
Table 2.7 Heat treatment furnace Capacity 34
Table 2.8 Acid Pickling solution
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CHAPTER – 1
ABOUT THE COMPANY
1.1 HISTORY
The Malnad Alloy Castings Private Limited (MACPL) has established in the year of
1983 and the company is located in Machenhalli industrial area Shivamogga. The foundry
started commercial production in the year 1985 and is managed by the team of highly
experienced foundry professionals headed by Mr. H C Ravindranath who has more than 35
years of experience in foundry in various capacities.
The company that started off with the 175KW furnace in the year of 1985 has
explored with many equipment’s and machineries over the years. The decades of experience,
diligent work system and expertise over techniques, tools, and equipment’s makes the
company a much trusted name in the bracket of heavy machinery industry. This ISO 9001
Certified Company has received the foundry status form the prestigious Indian Boiler
Regulations (IBR) in 1993. A team that works meticulously over different projects brings
forth greater name to the company and would continue to do into view. Future developmental
ideas comprise of obtaining ISO-14001 AND Norsok and OSHA’s approval in 2014. Also in
the pipeline is Thermal Reclamation Plant installation for 100% foundry and reclamation.

Fig-1.1

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1.2 VISION, MISSION & STRENGTH

Vision:
"Become global leader for the supply of finished cast components in wide range of
materials with highly committed and socially responsible employees"

Mission:

To meet the casting requirements of the country using latest state of the art-
technology in wide range of materials at competitive cost.
Provide stable employment and develop highly skilled technical manpower and
develop wide vendor base.
Adopt environmentally sound and safe technology and create awareness on energy
conservation.
Serve the community around through welfare schemes.

Strength:

State of Art Omega Semi-Automatic Mold Carousal for consistent mold quality for
small & medium casting production with 120 molds/shift capacity.
Mechanised Quenching system for Heat treatment Process.
10 WPS-PQR Certified Operators for various grades witnessed by TUV,Lloyds &
DNV.
10 Qualified Welders for handling the welding activities of various grades More than
15,000 Patterns with 6000 patterns live!. Traceability through ERP maintained
location system and Product code.
Exclusive storage arrangement for preservation of patterns.
50 to 60 New Products being developed every month.
More than 750 fully machined cast components exported / month.

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1.3 MACPL Progress:

1985-Started with 175 KW furnace & 30 MT/Month capacity. 1991- Addition of

250KW furnace & Capacity Enhanced to 100 T/Month.
1993-Well known foundry status from IBR
1995- Implemented QMS & Certified for ISO 9001. 1996-Implemented integrated
ERP system.
1998- Certified by AD 2000 MarkBlatt. 1999-Enhanced Furnace capacity from 250 to
350 KW & 150T/Month capacity.
2000-Qualified for PED icate. 2004- Direct Export Business Started.
2006 -Enhanced Furnace Capacity from 350 to 450 KW increasing production to
275T/Month.
2006- Added Machine shop. 2007-Started LEAN
activities. 2009-Approval by BV Marine Division.
2012- Added testing facilities like PMI, Height Master & Surface tester.
2012-Separated processing of stainless steel and carbon steel in different
areas. 2013-Added 750KW Furnace increasing production to 625T/month
2013-MAGMA Simulation Software installed 2014-Lloyds Foundry
Approval. 2015-Certified EMS-OHSAS; Highest sales; DNV Foundry
Approval
2016-NORSOK Certification for 4A, 5A and 6A Grades
2016 Upgraded ISO 9001-2008 to 2015 Version 2016-Solar Roof Top Cells 100 KW
Capacity Installed
2016-Mechanized HT Quenching System to facilitate quenching within 50 sec.
2016 IBR Well Known Foundry status & certified for Carbon & Alloy Steel up to
2400 Kg single piece.
2017-ISO 14001-2004 upgraded to 2015 Version.
2018-Thermal Reclaimation plant 2018- NABL approved Mechanical & Chemical
Lab
2018- Automatic Scrap Baling Machine

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1.4 PRODUCTS:
Malnad Alloy Castings Pvt. Ltd is a trustworthy name as the manufacturer of alloy
steel, stainless steel, and nickel base alloys.The company has created its own niche over the
passage of decades through uncompromised dedication to work, client satisfaction, and
employee-friendly policies. Starting from pattern development to production machining,
MACPL efficient engineering team delivers the necessary result with effective management
of time. The goodwill of the company has now spread not only to various parts of the
country but also to foreign nations due to its impeccable work standard and quality. It holds
latest and sophisticated machineries for pattern development, production, testing, and quality
assurance of finest castings.

MACPL produce:

Valve components

Fig-1.2

Hydraulic components

Fig-1.3

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Pump components

Fig-1.4

General engineering equipment’s

Fig-1.5

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Sales

Valve components

5 5 5 5 Pump components

10 Hydraulic components

70 General engineering

Turbine components

Defence components

1.5 SUPPLIERS OF RAW

MATERIALS: Scraps
1. SS430 SCRAP (M.S Metals &Steel)
2. SS410 SCRAP (M.S Metals)
3. LPLS SCRAP (Bharat IND)
4. LPLS INGOT (Kalyani)
5. LPLS SCRAP (Sunflog Iron & Steel)
6. SS316L SCRAP (Steel & Scrap)
7. SS444 SCRAP (Shree Steel)
8. SS430 SCRAP (M.S & Steel)
9. C12A SCRAP (Steel &
Scrap)
10. CRMO Nickel SCRAP
11.SS304 SCRAP

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The sample grades that are manufactured in MACPL are given in table 1:

Steel

Low alloy WCC, WCB, WCA

LC9, LC4, LC3, LC2-1,LC2,

LC1, LCC, LCB, LCA

C12A, C12, C5, WC11, WC9, WC6,

WC5, WC4, WC1

CA6NM, CA15

CN3MN, CN7M
Austenitic
CG3M, CG8M, CF3M, CF8M, CF3,
CF8

Stainless CK3MCuN, CN7M

CD4MCun/1A, CD3MN/4A,
Duplex CE8MN, CD6MN,
CD4MCu-1A/A494, CD4MCuN-1B

CE3MN/5A, CD3MWCuN,
CD3MWCuN-6A, CD3MCuN-
1C
M35-1,CZ100,N7M,CW6M
Nickel & Cobalt Alloys CW2M,CX2MW, CW6MC, CY40

Table 1.1Some of the grades manufactured by MACPL

Other than these grades MACPL also produce Monel grade castings.

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The first flow chart till pouring is common for every grade. Firstly MACPL receives the
drawing from the customer at the same time MACPL receives particular pattern from sub
vender. Received pattern will be inspected for the major dimension and allowances if the
pattern is ok then it go further for mounting and moulding. If it is not ok then it will be
reworked and send it to inspection again otherwise it will be scrapped. Once the pattern is
received to moulding section planning department will release the BOM. The mould and core
will be prepared and inspected; if it is ok it is sent to further process otherwise scrapped. At
the same time charge calculation, ladle preparation is done in the melting section. The
painting and lighting the mould spray and it will be assembled for pouring. Once the melt is
ready it will be poured to mould cavity.

In the second flow chart from pouring to dispatch is shown. After pouring the assembly is
knocked out. To remove the sand present in the surface of the casting it will be shot blasted.
1st stage inspection of the casting is done after shot blasting and color coding is done to
identify the returns and if it is ok it goes to dispatch followed by heat treatment, testing, post
weld treatment and final clearance.

1.6 ENVIRONMENT FOCUS:

As MACPL produce heavy industry products that involve certain amount of pollution,
we have also implemented machineries to save the environment. They are as follows:

High chimneys:
` It helps to ensure that the harmful pollutants are dispersed at higher altitude and
do not cause health issues to life.

Water scrubbers:
It washes out various acid gas and other pollutants which are considered harmful for
the atmosphere.

Bag filters:
It enhances the quality of air that is released in the atmosphere from the various
production processes.

Plantation of tress:
It is a natural process through which pollution can be controlled as we all know. More
trees means greener, and healthier environment.

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1.7 ACHIEVEMENTS AND AWARDS:

Certificates & Awards

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1.8 QUALITY POLICY:

MACPL is committed to excel in all sphere of management with the active
participation of all persons within or working on behalf of the organization as a part and
parcel of the organization objective.

The Leadership has reaffirmed its commitment to the customers and other
stakeholders:

To meet their needs and expectations to their continued satisfaction.

To satisfy applicable requirements.
To continually improve the Quality Management System.

1.9 MALNAD GROUP COMPANIES:

1. Malnad Alloy Castings Pvt Ltd since 1985:
Scop: Manufacture & Supply of Raw, Machined and Hydro tested Castings in
Ferrous, Nickel and Cobalt based alloys

2. Shimoga Precision Castings Pvt Ltd since 1996:

Scop: Manufacture and Supply of Alloy Steel, Stainless Steel, Nickel Alloy Steel,
Cast Iron and Cobalt Alloy Steel Castings By Investment and Sand Casting Process

3. Malnad Prime Machining Technologies since

2010: Scop: Manufacture of Precision Machined
Components

4. Malnad Alloy Castings Pvt Ltd (Laboratory Division) since

2018: Scope: NABL Accredited Mechanical and Chemical Testing Lab

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1.10 MAJOR CUSTOMERS:

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CHAPTER 2
SAFETY PRECAUTIONS AND CASTING

2.1 SAFETY:
It is said to be the condition of being protected from or unlikely to cause danger, risk
or injury.

HAZARD:
A Hazard is something that has the potential to cause injury or disease to people in
the workplace.

RISK:
Risk is the likelihood that a hazard will cause injury or disease in the workplace.

PERSONAL PROTECTIVE EQUIPMENT (PPE)

It is anything used or worn by a person to minimize risk to the person's health or safety at
work place. They are
Goggles (Eye protection)
Ear Plug (Ear Protection)
Mask (Respiratory
Protection) Hand Gloves
Helmet (Head Protection)

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CASTING

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CHAPTER-4
MACHINE
SHOP

4.1INTRODUCTION TO MACHINE SHOP:

Machining is a process in which a material (often metal) is cut to a desired
final shape and size by a controlled material-removal process. Once the drawing of the product
is sent to the machine shop for the further process, the job card will be developed by using the
information present in the drawing. Machining will be done wherever required and also customer
requirement. Machining allowance should be given for the machining in the pattern shop.

4.2 MACHINES IN MACPL:

1. Lathe Machine
2. Milling Machine
3. Hydro leak testing Machine
4. Computer Numerical Control (CNC) Machine
5. Vertical Turning Lathe
6. Horizontal Milling Machine
7. Vertical Milling Centre
8. Drilling Machine
9. Co-Ordinate Measuring Machine (CMM)

4.3 OPERATIONS PERFORMED:

1. Lathe Machine:
A lathe is a machine tool that rotates a work piece about an axis of rotation to perform
various operations such as cutting, sanding, knurling, drilling, deformation, facing,
and turning, with tools that are applied to the work piece to create an object
with symmetry about that axis.
Lathes are used in metalworking, metal spinning, thermal spraying, parts
reclamation. Lathes can be used to shape pottery, the best-known design being
the Potter's wheel. Most suitably equipped metalworking lathes can also be used to
produce most solids of revolution, plane surfaces and screw threads or helices.
Ornamental lathes can produce three-dimensional solids of incredible complexity. The
work piece is usually held in place by either one or two centers, at least one of which
can typically be moved horizontally to accommodate varying work piece lengths.
Other work-holding methods include clamping the work about the axis of rotation
using a chuck or collet, or to a faceplate, using clamps or dog clutch.

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Side flange surface finish

◦ GRADE: WCC,WCB

2. Milling Machine:
The milling machines are also known as the multi-tasking machines (MTMs) which
are multi-purpose machines capable of milling and turning the materials as well. The milling
machine has got the cutter installed up on it which helps in removing the material from the
surface of the work piece. When the material gets cooled down then it is removed from the
milling machine.

Types of Milling Machines:

The two main configurations of the milling machining operations are the types of
milling machines. These are the vertical mill and the horizontal mill.

1. Vertical Milling Machines:

The vertical mill has a vertically arranged spindle axis and rotates by staying
at the same axis. The spindle can also be extended and performing functions such as
drilling and cutting. Vertical mill has got two further categories as well: turret mill
and bed mill.

The turret mill has got a table that moves perpendicularly and parallel to the spindle
axis in order to cut the material. The spindle is, however, stationary. Two cutting
methods can be performed with this by moving the knee and by lowering or raising
the quill.

The other is the bed mill in which the table moves perpendicular to the axis of the
spindle and the spindle moves parallel to its axis.

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2. Horizontal Milling Machines:

The horizontal mill is also the similar cutter but their cutters are placed on a
horizontal arbor. A lot of horizontal mills have got rotary tables that help in milling in
various angles. These tables are called the universal tables. Apart from this all the tools
that are used in a vertical mill can also be used in the horizontal mill.

Drilling, boring, Slotting, threading, face

milling.
Grade: CF8M, WCB, WCC, CF15

Fig 4.2 - Vertical Milling Machines

1. Hydro leak testing

Machine:
Hydrostatic (Hydro) Testing is a process where components such as piping systems,
gas cylinders, boilers, and pressure vessels are tested for strength and leaks. Hydro tests are
often required after shutdowns and repairs in order to validate that equipment will operate
under desired conditions once returned to service.

Although hydrostatic testing is considered to be a nondestructive testing method, equipment

can rupture and fail if the inspection exceeds a specified test pressure or if a small crack
propagates rapidly.

Hydrostatic testing is a type of pressure test that works by completely filling the component
with water, removing the air contained within the unit, and pressurizing the system up to 1.5
times the design pressure limit the of the unit. The pressure is then held for a specific amount
of time to visually inspect the system for leaks. Visual inspection can be enhanced by

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applying either tracer or fluorescent dyes to the liquid to determine where cracks and leaks
are originating.

Leakage Testing
Check for oil & water
testing Capacity
20MT -> 0.5” to 3”
40MT -> 4” to 6”
100MT -> 3” to 12”
Grade: All Grade

2. Computer Numerical Control (CNC) Machine:

The term CNC stands for 'computer numerical control', and the CNC
machining definition is that it is a subtractive manufacturing process that typically
employs computerized controls and machine tools to remove layers of material from a
stock piece known as the blank or work piece and produces a custom-designed part.
A CNC machine is a programmable machine that is capable of autonomously
performing the operations of CNC machining.
While subtractive processes remove layers of material from the work
piece to produce custom shapes and designs, additive processes assemble layers of
material to produce the desired form and formative processes deform and displace
stock material into the desired shape. The automated nature of CNC machining
enables the production of high precision and high accuracy, simple parts and cost-
effectiveness when fulfilling one-off and medium-volume production runs.

Types of CNC Machining Operations:

Facing, Turning, OD, ID,

Turning, Hubend
Grade: CF8M, WCB, WCC, CF15
Programming: Galaxy

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3. Vertical Turning Lathe:

Threading, Surfacing,
Bonnet
boring
Grade: CF8M, WCB, WCC,
CF15 etc
Programming: ACE

4. Horizontal Milling Machine:

Milling, Boring, Threading, Tapping, Facing

Grade: CF8M, WCB
Programming: Mazak

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5. Vertical Milling Centre:

Facing, Boring, Chamfering, Bonnet

drill and Tapping, Milling, Treading
Grade: CF8M, WCB, WCC, CF15 etc
Programming: Mazak

6. Drilling Machine :

Drilling Machine, device for producing holes in hard substances. The drill is
held in a rotating spindle and is fed into the work piece, which is usually clamped in
a vise resting on a table. The drill may be gripped in a chuck with three jaws that
move radially in unison, or it may have a tapered shank that fits into a tapered hole in
the spindle. Means are always provided for varying the spindle speed and on some
machines for automatically feeding the drill into the work piece.

Drill presses for occasional use in general-purpose machine shops usually have only
one spindle. For drilling several holes successively or simultaneously in a work piece,
machines with multiple spindles are available. When large quantities of identical
mechanical components are required, special-purpose drilling machines, with spindles
arranged in a variety of positions relative to the work piece, can be constructed.
Although drill presses are used mainly for drilling holes, they can also be used for
enlarging holes with a boring tool or finishing holes with a reamer. With the aid of a
special tapping attachment and a tap, they can produce threads in a hole. See
also boring machine.

Types of Drilling Machines:

Radial drilling machine.
Upright drilling machine.
Automatic drilling
machine.
Multiple Spindle drilling
machine. Deep hole drilling
machine.
Sensitive drilling machine.
Portable drilling machine.
Gang drilling machine

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In MACPL there are using Radial drilling machine.

Backspot,

-
made tool used to control the
location and/or motion of parts or
other tools.

reduction in error by holding a

component firmly on a table

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CHAPTER-5
QUALITY CHECK AND DISPATCH

5.1 QUALITY CHECK:

Quality control involves testing units and determining if they are within the
specifications for the final product. The purpose of the testing is to determine any needs for
corrective actions in the manufacturing process. Good quality control helps companies meet
consumer demands for better products.

Calibration
In measurement technology and metrology, calibration is the comparison
of measurement values delivered by a device under test with those of a calibration standard of
known accuracy.

To improve the quality of the calibration and have the results accepted by outside
organizations it is desirable for the calibration and subsequent measurements to be
"traceable" to the internationally defined measurement units. Establishing traceability is
accomplished by a formal comparison to a standard which is directly or indirectly related to
national standards (such as NIST in the USA), international standards, or certified reference
materials. This may be done by national standards laboratories operated by the government or
by private firms offering metrology services. Quality management systems call for an
effective metrology system which includes formal, periodic, and documented calibration of
all measuring instruments. ISO 9000 standards require that these traceable actions are to a
high level and set out how they can be quantified.

5.2 INSTRUMENTS USED FOR INSPECTION:

Vernier caliper both digital and

analogue vernier Height Gauge
inside micrometre
micrometre
plug gauge
bevel protractor
Telescopic gauge
Height Gauge
Boar Gauge
CMM

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5.3 COLOUR CODEING AFTER INSPECTION:

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5.4 DISPATCH:
Chemical treatment applied to steel parts that creates a thin adhering layer of iron,
zinc, or manganese phosphates, to achieve corrosion resistance, lubrication, or as a
foundation for subsequent coatings or painting. It is one of the most common types of
conversion coating.

Fig – Painting

5.5 PACKING PROCEDURE:

Check the size and quality of casting.

Decide the size of box with 19mm plywood sheet based on weight size of the casting.
Cut Box with minimum waste.
Prepare pallet arrangement at bottom for entry with 150 mm wooden logs.
Assemble the box using metallic clamp and nails.
Place cotton path to avoid damage.
Place sufficient size vcg paper inside the box so that it acts as a protective layer.
Before placing wraps each casing will bulb shot and apply AP oil or any other anti-
resistance.
Sufficient gap between each casting is avoiding damages due to rubbing put
waste paper between partition gaps.
For alloy casting silica pouch used in a corner and top centre of packing to avoid
oxidation due to moisture.
Pull and cover VCI paper on all the casting and supplied to ends of paper properly
afterwards use racking adhesive paper for closing the entire gap.
Put all the reports and documents and test reports if any in the box.
Place that top plywood cover and Nile clamping in the entire corner firmly.
Use ball slip clamp to hold the packing in good shape.
Stick destination address and all other details on front side of box.

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CHAPTER 6
CONCLUSION AND REFLECTION NOTES

6.1 CONCLUSION:
The Internship at Malnad Alloy Castings Private Limited for 4 weeks which gave us
the practical exposure towards the foundry practices. This internship helped us to gain
practical knowledge, skills and also experience in the various departments like pattern shop,
moulding, melting, heat treatment etc.
This internship helped us to know how various departments are interdependent to
satisfy the customer needs and how the manufacturing practices are carried out in various
department of the organization. We have been put to various department of the organization
and in the time of this training we have worked with them to know the manufacturing
practices in each department.
Internship helped us to enhance our problem solving ability by seeing managers using
various methods, ideas and plans come of the problems in different situation. Every
organization before carrying out any task has to perform managerial functions such as
Planning, Organizing, Directing, Controlling etc. besides usual functions such as
administration and manufacturing.
To get and to win the faith of the customers management skills are must. Observing
the management we learnt the way of communication and the punctuality plays a vital role in
the industry to keep up the good name and fame in the market. We got the knowledge about
the procedures that are sequenced during the production. Manufacturing includes the steps
like preparation of the purchase order, acceptance order, drawing of the required product,
preparation of job card etc., proper management is required to check the procedures so that
no rooms are provided for the mistakes.
Respecting others ideas make every effort to understand each other, take
responsibility and do our best to build mutual trust. The professional experience stimulated
personal and professional growth, the opportunities of development and maximize individual
and team performance. A healthy relationship with the co-workers must be maintained to
form the unity which will reflect the discipline and success of the company. The internship
experience allows the students to put our gifts to practical use in preparation of leadership
quality and service to the society. We were able to reflect on the internship experience and
make connections between what we understood and the needs of the profession, the students
is exploring through the internship experience.
By communicating with the managers we got develop our communication skills
which is must to impress the customers and also to know about the demands of market.
Through completing the assignments and by working in the different department of foundry,
we got the knowledge about the standards that is followed according to requirement.
The main goal of the internship is to provide the place to apply the technical
knowledge gained during the course. We gained the exposure to a practical knowledge and
we were able to learn from observing the professional behavior of the managers, supervisors
as well as through interaction with customers or clients.
By observing the organizational culture and following the rules and regulations we are
able to learn about the punctuality, time management, innovations and how to deal with the
difficulties in the professional field.
Decision making plays a very vital role in the work structure. Maintaining the
accuracy in the production is much important to satisfy the customer completely. To achieve

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 INTERNSHIP IN MPMTPL
that preparing the proper planning is must so that which can be done only if decision made
with no mistakes.
We were able to develop the skills to interact with my co-workers which are very
important to keep the healthy environment in the organization. Evaluating the performance of
an individual’s which is the self-studied learning agreement must be satisfactory to the guide.
With the help of our technical knowledge we were able to reach the expectation.
At the beginning of the work assignment, primarily we made a methodology to
complete the work then we were able to assess us capacity to meet the expected work from
our guide and got learn from our mistakes.
The main advantage of internship was it provided an opportunity for the students to
receive professional practical knowledge which helps us when we start our career in the
production field.

6.2REFERANCES:

Standard operating procedure- Ref no. - SOP-01, SOP-07C

www.MalnadAlloyCastings.com
http://paniit.iitd.ac.in/~ pmpandey
www.Foundry.com
http://nptel.ac.in/courses.php?disciplineId=112

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