INDEX

CHEPTER – 1 COMPANY INTRODUCTION

1.1 COMPANY PROFILE
1.2 PREFACE
1.3 ORGANISATION STRUCTURE
1.4 RESPONSIBILITY CHART
CHEPTER – 2 PRODUCT INTRODUCTON

2.1 PRODUCTS

2.2 MANUFACTURING

2.3 MANUFACTURING PROCESS

2.4 APPLICATIONS OF THE PRODUCTS

2.5 EQUIPMENTS/MACHINE USED IN THE MANUFACTURIG THE
PRODUCT
2.6 PROCESS CHAIN OF COLD FORGING

CHAPTER -3 VARIOUS COMPONENT

3.1 VARIOUS COMPONENT

CHAPTER -4 QUALITY MANAGEMENT

4.1 QUALITY MANAGEMENT

CHAPTER -5 ADVANTAGES OF COLD FORGING & RAW

MATERIAL

5.1 ADVANTAGES OF COLD FORGING

5.2 RAW MATERIAL

5.3 CONSUMABLE MAT

CHAPTER -6 LIST OF FORMATS

6.1 MASTER LIST OF FORMATS

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6.2 DISTRIBUTION CHANNEL

6.3 PUBLIC RELATIONS

6.4 PLANNING OF MARKETING DEPARTMENT

6.5 EMPLOYEES SERVICES

CHAPTER – 7 LIST OF THE PROBLEMS & SOLUTIONS

7.1 LIST OF THE PROBLEMS

7.2 POSSIBLE SOLUTIONS OF THE PROBLEMS

CHAPTER-8 CONCLUSION

8.1 CONCLUSION

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 CHEPTER - 1

COMPANY INTRODUCTION

3
1.1 COMPANY PROFILE

Raajratna Fasteners Pvt. Ltd. is India’s Leading Fasteners manufacturing company located at
Ahmedabad – Mehsana highway , Gujarat. To get the better demand in the market it receive
ISO 9001 certification, which assure customers of highest quality products at par with
National & International standards. Raajratna Fastener Pvt. Ltd. has range of Fasteners are
widely acclaimed for quality and consistency. We are committed to strive constantly and
innovate the entire range of fasteners to provide exciting and feasible solutions to customers.

MANAGEMENT BODIES

Managing Director: - Nareshbhai B. Sanghvi

Directors: - Arvindbhai D. Sanghvi

Babubhai D. Sanghvi

Tarachand D. Sanghv

Bankers: - Standard Charted Bank

Axis Bank

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1.2 PREFACE

As part of Diploma (Mech.) program ,we have assigned some practical project work or
training. So I have prepared a comprehensive project report on all over industry with
the help and guidance of Production Manager: Mr. V. M. Patel of Rajratna Fasteners
Pvt. Ltd.

The purpose behind industrial visit and preparation of project report to study the
particular co. form the view point of its history and development and functional
departments like ,
Production dep., Marketing dep., HRM dep., and Finance dep.

“This practicing training give a chance to know how efficiently one can use theoretical
knowledge in practical world of management “

So I have chosen Raajratna Fasteners Pvt. Ltd.

It is one of the biggest and reputed co. in Fasteners.

Due to practical training in Raajratna Fasteners Pvt. Ltd.

I came to know about various aspects of the co. It is indeed a golden opportunity for
me in the management study and a matter of esteem by itself.

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1.3 ORGANISATION STRUCTURE

Director

Sales Prod. Admin

Executive Manager Manager

Coordinator
Coordinator Production
In charge

Supervisor

Operator

Workers

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1.4 RESPONSIBILITY CHART

Marketing marketing management

Administration management factory management
Purchase Purchase I/C
New Development Engineering
Production Production Manager management
I.S.O. – M.R. Factory management
Stores Store I/C
Maintenance Maintainence I/C management
Quality Assurance Q.C.Incharge
Outside work factory management
House keeping (work shop) factory management
Human resources factory management
Communication factory management
House keeping (office) factory management
Resource management factory management
Dispatch Packing I/C

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 CHEPTER - 2

PRODUCT INTRODUCTON

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2.1 PRODUCTS

Raajratna Fasteners Pvt. Ltd. established with a view to done product named as
under:--

Machine Screw

Self Tapping Screws

Self Drilling Screws

Wood Screws

Socket Head Cap Screws

Hex Head Flange Screws

Hex Head Screws

Dry Wall Screws

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 Chipboard Screws

Hex Head Bolts

C’Sk Socket Screws

Carriage Bolts

Rivets

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2.2 MANUFACTURING

Requirements of Fasteners are initiated by the Sales Section who forward a

copy of requirement as per Customer orders.

Based on the requirements, Production and Delivery Plans are prepared.

The drawings define the sequence of production. The activities follow through the
workmanship guidelines sheets within suitable working environment.

Individual operator carries out in-process monitoring. Records are maintained and
if there is any non conformance observed it is reported and logged. The
Operators notify supervisor for any problems or any deviation and receive
instructions for corrective actions.

Daily Production Report is logged by all operators.

Identify each Batch as unique number for identification and Traceability.

Ensure Daily Maintenance of all identified equipments.

The production sequence for Screws and bolts are as defined

a. Cold forging

b. Cleaning [ Wooden Tumbling ]

c. Rolling

d. Oil Removal

e. Pickling

f. Water Rinse

g. Drying

h. Packing

The production sequence for Threaded Studs and bars are as defined

a. Receive finished size bars

b. Rolling

c. Packing

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2.3 MANUFACTURING PROCESS

The production process shall be planned and carried out through the following
Processes and Sections

1. Engineering Process

2. Stores Section

3. Manufacturing Process for

Screws and bolts

Threaded Studs and bars

4. Maintenance Process

1 Engineering Processes

The Engineering team shall plan and initiate all activities for any new product
development or modification. This shall include special Customer Requirements.
Current Addition of Applicable standards shall be used to select specification of

the fasteners. Tool drawing shall be prepared for each stage of manufacturing.
Part drawing shall also be prepared.

Master list shall be maintained having information of the Part description,

Identification Code, Quantity and Current Revision number of the drawing. All
original drawing shall bear a Red stamp “Master" at the rear side of the copy.
Controlled issue shall be done and the information of Revision number shall be
logged. A Red stamp marking “Controlled" shall be placed at the front side of the
copy. All old drawings shall be promptly destroyed. The Engineering section shall
participate with Quality and Production Section for validation of the tooling and
approval of the First part production processes.

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 2. Stores Section

Stores Operation shall be done through two separate sections.

One - For SS Wire Coils / Bars and Packaging material.

Inward receipt of material shall be logged , verified for Physical Condition ,

Weight , Quantity and receipt of test reports where applicable. The requirements
of material shall be verified with reference to Open Purchase Orders.

Tags shall be placed for identification. Separate identified area is maintained for
all Production related Material. With Colour Code on the raw material coil.

Two - For Tooling and Maintenance parts.

Inward receipt of Tools shall be logged , verified for Physical Condition , and
receipt of Inspection reports. Quality Control Section shall be informed of the
receipt of Tools. Inspection or verification shall be carried out in accordance with
Inspection Plan and Drawings. Based on the Inspection tools shall accept or
rejected. For new tooling First Part Qualification shall be done and the records of
such shall be maintained.

Stores shall have unique storage location for tools and each shall have location
identification.

Records of Tool issue , return and condition verification shall be maintained.

For Consumables and Maintenance items, Inward receipt of material shall be

logged, verified for Physical Condition, Weight and Quantity. Indenting Section
shall be informed of the receipt of Material. Inspection or verification shall be
carried out and based on the decision material shall accepted or rejected.

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2.4 APPLICATIONS OF THE PRODUCTS

1. vehicle
2. marine industries
3. bulding
4. furniture
5. bridge
6. chemical industries

2.5 EQUIPMENTS/MACHINE USED IN THE MANUFACTURIG THE

PRODUCT

Machine photo:-

Nut & bolt formar

Coil stand die&punch die&punch

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 2.6 Process chain of cold forging

Raw Heat Surface Cold Formed

Material Treatment Treatment Forming Part

Metal Heat Metal Finished

Removal Treatment Removal part

Open Extrusion & Traps extrusion

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 CHAPTER -3

VARIOUS COMPONENT

16
 3.1 VARIOUS COMPONENT

DIE {HEX}

• PUNCH
• TEPAR
• RING GAUGE
• PLUGE GAUGE
• DIE ASSEMLY
• PUNCH ASSEMLY

BOLT FORMER MACHINE WORKING 4- STAGE

sT
1. AFTER CUT OFF, IN 1 STATION “HEAD IS CONICAL SHAPE”.
nd
2. IN 2 STAGE “HEAD IS CIRCULAR SHAPE”.
rd
3. IN 3 STAGE “POINTING IS HELD IN EXTRUSION PROCESS”

4. AND IN LAST STAGE “HEAD IS IN HEX SHAPE THROUGH

TRIMMING DIE”.

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 decreasing the diameter of the blank by pushing it through a smaller hole
 reduces size without yield loss
 Cold Forging:
 generic term describing the combination of cold heading with cold
extrusion
 Cold Forging machines - by the number of dies and
blows
 for example:
 1 Die/2 blow
 2 Die/3 blow
 2 Die/4 blow

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19
 CHAPTER -4

QUALITY MANAGEMENT

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4.1 QUALITY MANAGEMENT:-

Inward Inspection - Raw Material

Raw Material shall include Wire Coils, Bright Bar and Packaging Material. All incoming
Material receipt shall be tagged and logged. Inspection shall be carried out by the
Production coordinator as per Inspection Plan. Ensure the receipt of the Supplier Test and
Inspection reports . The same shall be verified and the record shall be maintained.

Records of Receipt , Inspection activity, acceptance , non-conformities or rejection are

kept wide log register.

Accepted material shall have approval tag and stored at the storage location. Non
Conforming material shall be shifted to the identified Area.

As when required the material shall be picked up and used for production.

Inward Inspection - Tooling

All tools developed by Suppliers shall have identification and on receipt shall logged.
Ensure the receipt of the Supplier Test and Inspection reports . The same shall be verified
and the record shall be maintained.

Inspection shall be carried out by Tool Store coordinator as per Inspection Plan.

Controlled Engineering Drawings shall be used for inspection.

Records of receipt, Inspection activity, acceptance or non-conformities are kept wide

Inspection Report.

As when required the tooling are issued to production and logged wide Tool Issue Slip.

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First Part Inspection and Qualification

First part manufactured by each new tool shall be inspected by Tool Store Coordinator ,
Quality person along with person from Engineering.

Controlled engineering drawing shall be used for inspection.

Records of Inspection, acceptance or non-conformities are kept wide Inspection Report.

If the part inspected is conforming to requirements, the tooling is declared qualified.

If any non conformance is found, the nonconformance is analysed and necessary correction
on tooling is planned and carried out .

Inward Inspection - Other Material & Consumables

All material receipt shall logged. Inspection for verification of Quantity and receipt
without any damage shall be carried out by Store coordinator. Further confirmation shall
be done by the indenting person before accepting the material .
Inpocess Inspection

Individual operator carries out in-process inspection as in accordance to the requirements

of the Drawing. Records of verification by the supervisor are maintained .

Controlled Engineering Drawings shall be used for inspection.

Accepted material is tagged and forwarded for next process.

Non-conformities are logged , reviewed and action for rework or scrap is decided.

Final Inspection

Final inspection shall be carried out by Quality Control Engineer as per Inspection plan.

Controlled Engineering Drawings shall be used for inspection.

Records of Inspection, acceptance or non-conformities are kept wide Inspection Report.

Non-conformities are logged , reviewed and action for rework or scrap is decided.

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Final packaging inspection

Final packaging inspection shall be carried out by the Packaging Section as per Inspection
plan.

No Records of Inspection are kept.

Non-conformities are logged, reviewed and action for rework or scrap is decided.

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 CHAPTER -5

ADVANTAGES OF COLD FORGING

&
RAW MATERIAL

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5.1 Advantages of Cold Forging

• Design Versatility
• High strength parts from non-heat-treatable alloys
• Most cost effective way vs. milling, machining, hobbing and chemical etching
• High production rates
• Metallurgical Effects
• Grain flow
• Improves strength, hardness, toughness & fatigue resistance
• Material Savings

5.2 RAW MATERIAL

 AISI – S.S. 302 HQ

 AISI – S.S. 304
 AISI – S.S. 304 MD
 AISI – S.S. 304 L
 AISI – S.S. 304 HC
 AISI – S.S. 316
 AISI – S.S. 316 L
 AISI – S.S. 316 LA
 AISI – S.S. 317
 AISI – S.S. XM7

5.3 CONSUMABLE MAT.

 Carbide & Steel Tooling

 Pickling Chemical
 Wooden Powder
 Forging Oil
 Corrugated Boxes ( Plain )
 Corrugated Boxes ( Printed )
 Labels
 BOPP Tape
 Wooden Pallets
 PP Strap

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 CHAPTER -6

LIST OF FORMATS

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6.1 MASTER LIST OF FORMATS

⇒ QUOTATION
⇒ ORDER VERIFICATION
⇒ DESPATCH ORDER
⇒ CUSTOMER SATISFACTION SURVEY
⇒ CUSTOMER COMPLAINT
⇒ INTERNAL AUDIT PLAN
⇒ NON CONFERMITY ( AT PROCESS STAGE )
⇒ NON CONFERMITY ( AT CUSTOMER STAGE )
⇒ BREAKDOWN REGISTOR
⇒ MAINTENANCE CHECK SHEET
⇒ DOCUMENT DISTRIBUTION
⇒ TRAINING LOG REGISTOR
⇒ EMPLOYEE’S DATA
⇒ SKILL MATRIX
⇒ MACHINE DOWN TIME REPORT
⇒ LINE INSPECTION REPORT ( FORGING )
⇒ LINE INSPECTION REPORT ( ROLLING )
⇒ DAILY REPORT FOR PICKLING
⇒ INWARD REGISTOR ( RAW MATERIAL )
⇒ RAW MATERIAL ISSUE SLIP
⇒ PURCHASE ORDER
⇒ SUPPLIER EVALUATION
⇒ CALIBRATION PLAN
⇒ TOOL INSPECTION REPORT
⇒ IN HOUSE CALIBRATION REPORT
⇒ FINAL INSPECTION REPORT
⇒ TOOL CONSUMPTION REPORT
⇒ TOOL CARD
⇒ INWARD REGISTOR ( TOOLING )
⇒ EMPLOYEE’S TRAINING RECORD
⇒ INTERNAL AUDIT REPORT
⇒ COMMERCIAL CUM TECHNICAL SHEET
⇒ INVOICE ( INTERNATIONAL )
⇒ INVOICE ( DOMESTIC )

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6.2 DISTRIBUTION CHANNEL

CLIENTS SALES

PRODUCTION CO-
ORDINATION

DESIGNE

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6.3 PUBLIC RELATIONS

There are many clients in this company .so most of international & domestic
publicity very well knows that the company produces highly reliable products at cheap
rates.
It is public company, so relations are easy increased by company at national or
international level.

A Partial List of
Our International Business

 France
 Germany
 Turkey
 U. K.
 Sweden
 U.S.A.
 Greece
 Brazil
 Spain
 Italy
 Polland
 South Africa
 Nederland
 Switzerland
 U.A.E.
 Czech Republic
 Shri lanka
 Austria

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6.4 PLANNING OF MARKETING DEPARTMENT

 Customer complaint shall be attended in ten days from the receipt of the complaint
 100% of the complaint shall be attended in time
 Sales of Fasteners shall pick up by 15% international market & 5% Domestic market by
the end of financial year 2007-08

 By the end of year 2007-08, fifteen new international customers would be developed.
 By the end of year 2007-08, ten new domestic customers would be develop

6.5 EMPLOYEES SERVICES

The employee benefit and service refers to the invectives, which are provided to the employee
so that are unarranged and motivated. It consists of recreational facilities, Wages, Bonus, and
many other facilities like that.

Raajratna Fasteners Pvt. Ltd. co. also gives a facility to its employees as per the good rules and
revaluation under below.

♦ MEDICAL FACILITES

♦ UNIFORM

♦ LOAN FACILITIES

♦ HOUSING FOR EMPLOYEES

♦ MILK TEA OFFICE

♦ INSURANCE FACILITES

♦ COUNSELING

♦ CULTURAL ACTIVITY

♦ TRANSPORTATION

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 CHAPTER - 7

LIST OF THE PROBLEMS & SOLUTIONS

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7.1 LIST OF THE PROBLEMS FOUND DURING THE MANUFACTURING
PROCESS OF THE PRODUCT.

During the manufacturing of the Nuts and Bolt by Cold forging process following numbers of
the problems.
• In the continuous manufacturing process of the product in the cold forging machine it
is necessary to supply the oil continuously to minimize the temperature. This
Processing Oil is continuously reused in the process so chances of the filter chock up
are more.

• Motor pulley foundation bolt become loose.

• Pulley grooves and belt profile miss-match.

• Due to the continuous working of the machine the belt of the gear and pulley becomes
hot which resulted in the elongation of the bolt.

• Improper selection of the Raw material which break the Die & Punch.

• Improper clearance between Die and Punch.

• Rough surface and unmatched profile of the Die,

• The Hardness range of the Die material is very high or less.

• Die tempering is not proper so chances of the stress on die.

• Die setting not proper die & punch gap very less.

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7.2 POSSIBLE SOLUTIONS OF THE PROBLEMS

• Tight belt sufficiently not to tight or loose

• Pulley grooves and belt profile always matching require.

• Check daily foundation bolt either loose or not.

• Raw material tensile maintain has requirement only

• Maintain die & punch gap minimum 0.5mm to avoid heating problem

• Die surface mirror polish require

• Die hardness Continues manufacturing process for schedule Timely clean oil

• maintain 60-62 BHN.

• Do tempering properly ½ hrs at 400 temperatures and keep room temperature

• Maintain die& punch gap minimum 0.5mm to avoid heating problem

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CHAPTER-8

CONCLUSION

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CONCLUSION

After undertaking This industrial training, I can conclude that of management.

Because such industrial training help the student in matching theoretical
knowledge with its practical implementation.

As far as the co. “RAAJRATNA FASTENERS PVT. LTD.” is concerned,

I can that it is good market value in India & Across the world.

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