ITREPORT1

BY,
DHANANJAYAN.K
SOORYAJITH
DIBIN RAJAN
CHRYSTOPHER K BABU
JISHNU E J
ENGINEERS’ TRAINING CENTRE
INERNSHIP REPORT
[STUDY REPORT ON SIFL]

CHAPTER1
1.1 INTRODUCTION
Steel & Industrial Forgings Limited (SIFL) is an ISO 9001:2008 certified,
Public Sector Undertaking fully owned by Government of Kerala. Incorporated in 1983 and
Started commercial production in 1986. With a realistic production capacity is 5000
MT/annum of closed die forgings, SIFL specializes in the medium and heavy range of
forgings of Alloy steel, Super alloys, Aluminium and Titanium.
Untiring efforts of two decades has saddled SIFL firmly in the Forging Industry of
India and abroad with best ratings for its products and services. Forgings with exquisite
designs and shapes, flawless forms and contours, broad bands and spectra of metals like alloy
Titanium and
Aluminium, all in wide range of weights and unmatched quality have made SIFL the most
sought after forging company in the country for critical components.
1.1.1 Company Profile
Steel & Industrial Forgings Limited (SIFL) is an ISO 9001:2008 certified, Public
Sector Undertaking fully owned by Government of Kerala. Incorporated in 1983 and started
commercial production in 1986, SIFL rapidly forged ahead to become a name to reckon with.
They are masters in Titanium and Special alloy forgings.
Untiring efforts of two decades has saddled SIFL firmly in the Forging Industry of India and
abroad with best ratings for its products and services. Forgings with exquisite designs and
shapes, flawless forms and contours, broad bands and spectra of metals like ALLOY STEEL,
SUPER ALLOYS, ALUMINIUM and TITANIUM. All in wide range of weights and
unmatched quality have made SIFL the most sought after forging company in the country for
critical components.
SIFL's diverse product mix caters to a wide range of sectors. These include complex and high
precision Aerospace forgings, Specialized Forgings for Defence, Heavy Forgings for
Commercial vehicles, Railways and other components for automobiles etc.
Dept. Of Mechanical , Engineers’ Training Centre , Thrissur
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1.1.2 Quality Standards
An ISO 9001:2008 certified organization, their strength and prime aim is strict
adherence to quality standards. At SIFL, they believe that their success depends entirely on
delivering the quality customer demands. Their policy is to always attain and wherever
possible exceed the standards expected by the valued customers. This is achieved by
continuous improvement programme in process discipline, manufacturing methods and
Quality Systems. Their success is in regular interactions with National Laboratories, premier
forging institutes and of course, long term association with their prestigious customers.
SIFL cater to a wide range of Industries in Defense, Automobile, Heavy engineering,
Aerospace, Railways, Earthmoving Equipments, Agriculture etc. They draw strength from
their team of experienced professionals and workforce committed to quality and timely
delivery. The support from prestigious public and private sector together with guidance from
Government of Kerala makes them one among the best performing State Public Sector Units
in Kerala.
SIFL continued with landmark development, during the last quarter also. The company has
been recommended for AS9100 certification. The remarkable products developed includes
seven items for Arjun Mark-II, main battle tank being developed by CVRDE for INDIAN
ARMY. This includes Integral axle arms which are indigenized for the first time in the
country and are of very complex in design.
Another technological feat which was successfully completed is the development of stainless
steel valve body (S410) for BHEL, Trichy. This is the heaviest forging done by SIFL so far
and weighs 550KG/piece.
The company has became a partner in the prestigious Brahmos missile development program
by obtaining an order from M/s Brahmos Aerospace Ltd, Hyderabad. This involves
indigenization of forgings in Titanium, Aluminium and Stainless Steel Alloys.
1.1.3 Clients
The company caters mainly to the needs of Automobile, Heavy Engineering,
Defence, Railways, Oil and Aerospace sectors. Their major customers are giants of Indian
Industries from Indian Railways, BEML, BHEL, HAL, ISRO, Ordnance factories and other
Defence establishments of the Public Sector, L&T Komatsu, Caterpillar, Hindustan Motors,
Elgi Equipments, Ashok Leyland etc. from the Private Sector. The company also exports
forgings to the Middle East, Indonesia and Korea. Their competence and willingness to take
up forgings in special alloys and materials of unique chemistry has stood them in good stead
for assuring a niche market in the above weight range for a variety of complex forgings. SIFL
have so far developed more than 700 different forgings for various applications. SIFL is now
in the threshold of exploring new avenues to widen scope and extent of their operations and
are poised for a quantum leap with a vision stretching to the year 2020.
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1.2 ORGANIZATION CHART OF STEEL & INDUSTRIAL FORGINGS
LIMITED
Fig. 1.1 Organization chart of Steel & Industrial Forging Limited
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CHAPTER 2
2.1 DAY 1: ORIENTATION
On the first day of our industrial training I had to complete many formalities
regarding the training that I am going to undertake. I was directed to meet the Human
Resource department. There I did some paper works regarding our personal data and our
academic side.
After that I proceeded to their conference hall. There one of the officials gave a
presentation regarding the history of the company, their production, plants, and goals and
about their future ventures.
The first day ended with presentation and I was instructed to meet the production
manager of the plant to start off our training the next day.
2.2 PRODUCTION DEPARTMENT
Production system plays a very important role in achieving organizational
excellence. But the lack of proper planning, coordination and control often affects the
capabilities of this system because of which these systems are not utilized fully and
effectively leading to many undesirable situations forcing many organizations to become less
competitive. A number of organizations worldwide have achieved and sustained excellence
by effective production management.
Effective production management involves understanding of the characteristics of
various types of production system, identification of the dynamics of the different phases of
the management process, realizing the potential of different analytical tools, learning nuances
of the implementation of these tools, visualizing the impact of various uncertain situation and
developing the ability to react under various scenarios to achieve consistently excellent
business result. There is evidence to show how a number of organizations achieved world
class status by effective management of their production system. These organizations
achieved superior quality, higher productivity, perfect delivery performance, customer
satisfaction and enterprise excellence all with lower cost. Production is the basic activity of
all industrial units. All the other activities revolve around this activity. The end product of the
production activity is the creation of goods and services for the satisfaction of human wants.
The production activity is nothing but the step-by-step conversion of one form chemically or
mechanically. This is done in factories with house manufacturing. The basic inputs of
production process are men, machine, plant services and methods. The product of farm, sea
forest and mine are used as raw materials on which the processing is done to create or
5

enhance the firm utility it should be noted that the finished product by one manufacturing unit
does not always furnish a readymade product for the ultimate consumption.
Production management deals with decision making related to production process so
that the resulting goods or services is product to specification, in the amounts and by the
schedule demanded and at minimum cost.
Fig 2.1 Organogram of Production Department
The Production department consists of two divisions, the forge shop and the
Materials Preparation division which is headed by a Senior Manager and an Asst. Manager.
Based on the monthly and weekly plans, jobs are allocated and recorded in forge shop. The
process owners are the primary head of production department and a secondary shift in
charge. There are 69 skilled and 15 unskilled labourers.
The Production Manager is responsible for day-to-day production within the
forge shop. He supervises, motivates, and supports the staff daily, applying a team approach
and maintaining open communication. The Production Manager plans, schedules, strategizes,
and oversees all production activities while continually building sales and maintaining
profitability. The Production Manager performs essential functions to ensure overall customer
satisfaction and quality service, and establishes and maintains effective communication with
employees and clients. The Production Manager is responsible for the effective and efficient
planning and scheduling of personnel and equipment to reduce bottlenecks and problems.
2.2.1.1 Functions
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● Planning daily production according to annual target.
● Monitoring actual production & checking any deviation.
The entire production activities of the company are under this department. SIFL
has a well-established production planning and control system. This section deals with the
issue of work order, materials issue from store, dispatching, loading and scheduling
production progress and material planning. The existing production system in SIFL is a
better one as total is concerned.
2.2.2 Procedure for Production
1. Planning and Control
2. Monthly and weekly plans are communicated to the production head by planning. Based on
the plans, the production head will communicate to the shift in-charge about daily plan. Jobs
are then allocated and recorded in forge shop job and cum shift wise production report.
3. Setup verification is done before starting the work order and is recorded. After the approval
of set up, bulk production is started. Corrective actions are initiated for process non-
conformances.
4. Analysis of set up NCs is done daily for implementing corrective actions. Shift in-charge
monitors the process and the inspections are carried out by the QA. Route card cum work
order is issued and it is updated by the shift in-charge for the required process and the work
order is updated and moved along with the material till the completion of all process, which
is referred for traceability.
5. If any rejection is found in the process, the same will be updated in the NC register and the
route card and the material is identified with rejection tag for disposition action.
6. Components are offered to QA for final inspection. After production, die should be cleaned
and handed over to the die shop.
2.2.1.2 Production Process
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Fig 2.2 Production Process
2.2.1.3 Die Design & Development
SIFL's design & engineering capabilities are ably backed by a well equipped Die
Shop, set up along modern lines with Double Spindle Copy Milling Machines, Electrical Die
Sinking Machine, CNC Die Sinking Machine, CNC Turning Centre, Radial Drilling
machines, Heavy Duty Plano miller, Lathes, Tool & cutter grinders, etc. The design and
development of the die holds the key to blemish-free forgings.
SIFL designs both single-impression and multi-impression dies. The design, of course, is
related to the forging drawings. And the decision on the type of die to be used is based on the
specific requirement of each case. The care that goes into the design of each die also goes
into the selection of raw materials and the sequence of operation that follows. To facilitate
uninterrupted operations, SIFL is equipped with standby Power Generators. Forging dies are
usually made of high-alloy or tool steel. Dies must be impact resistant, wear resistant,
maintain strength at high temperatures, and have the ability to withstand cycles of rapid
heating and cooling.
To keep pace with hi-tech developments, SIFL has equipped itself with CAD, CAM facilities
like DELCAM for three dimensional modelling of Product, Die & Tool design etc. thereby
minimizing the development cycle time. All these qualities have helped SIFL grow quickly
into a premier forging unit, capable of producing forgings with close dimensional tolerances.
DAY 2: 2.2.2 DIE SHOP
On the Second day of our in-plant training we were allowed to enter the Die shop and
interact with the engineers and workers.
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We met the manger P.Kochukrishnan sir and assistant engineer Sukumaran sir who
showed us around and described various machines.
The die shop is a section where dies are manufactured for forging components as per
the design submitted by the clients. Huge die blocks made of forged steel are imported from
Germany. Then dovetails are cut on it at an angle about 10 degrees for the purpose of
inserting the key and holding it firmly in the ram of the press during forging process. Holes
are drilled on the lateral surfaces of the block and rods are inserted for the purpose of lifting it
using a crane for carrying it from one site to another.
The 7.5 ton crane made in Mumbai is used for moving around the heavy die blocks
inside the die shop.
A template is prepared for each drawing of the component to be forged and a mould
of it is made in plaster of Paris.
The various machines in the die shop are as follows:
1. Copy milling or Trace milling machine which was bought in 1984, but is not in use today.
It is a machine designed for milling profiles (slabbing) or relief contours (three-dimensional
milling) on articles made of various materials by means of a cutting tool (milling cutter),
which reproduces on the article the surface or contour of a master device—for example, a
master cam in the shape of a flat template, a three-dimensional model, or a contour drawing.
The master device is mechanically, pneumatically, or hydraulically connected to a
servomechanism, which directs the cutting tool. The servomechanism acts on an amplifying
device on the one hand and, on the other hand, on an actuating device. Hydraulic,
electromagnetic, or electro-optical relays are used in the amplifying devices of such
machines. The actuating member may be a screw, a slide valve, an electromagnetic coupling,
a solenoid, a differential, or some other device, and it may be driven by an electric motor or a
hydraulic power cylinder.
2. Heavy Duty Lathe used for holding jobs up to 3 tons and can rotate at a maximum speed of
250 rpm. The holders are fabricated for each die to be machined.
3. Electric discharge machining (EDM) which has a graphite cathode. It was used for
producing threaded holes on inside of chuck for inserting chuck key. It is sometimes
colloquially also referred to as spark machining, spark eroding, burning, die
sinking or wire erosion,[1]
is a manufacturing process whereby a desired shape is obtained
using electrical discharges (sparks). Material is removed from the workpiece by a series of
rapidly recurring current discharges between two electrodes, separated by
a dielectric liquid and subject to an electric voltage. One of the electrodes is called the tool-
electrode, or simply the ‘tool’ or ‘electrode’, while the other is called the workpiece-
electrode, or ‘workpiece’.
4. Vertical Milling Machine with tracing unit on top. It was German made and 1965 model. In
the vertical mill the spindle axis is vertically oriented. Milling cutters are held in the spindle
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and rotate on its axis. The spindle can generally be extended (or the table can be
raised/lowered, giving the same effect), allowing plunge cuts and drilling. There are two
subcategories of vertical mills: the bed mill and the turret mill.
▪ A turret mill has a stationary spindle and the table is moved both perpendicular
and parallel to the spindle axis to accomplish cutting. The most common example
of this type is the Bridgeport, described below. Turret mills often have a quill
which allows the milling cutter to be raised and lowered in a manner similar to a
drill press. This type of machine provides two methods of cutting in the vertical
(Z) direction: by raising or lowering the quill, and by moving the knee.
▪ In the bed mill, however, the table moves only perpendicular to the spindle's axis,
while the spindle itself moves parallel to its own axis.
5. Planer Machine modified to do milling process. A planer is a type of
metalworking machine tool that uses linear relative motion between the workpiece and
a single-point cutting tool to machine a linear toolpath.
6. CNC Milling machine for workpiece up to 3 ton: It contains a slot for inserting the card
containing CNC programs. Delcam software or other 3d modeling softwares are used for
generating the codes. A milling machine is a machine tool used to machine solid materials.
Milling machines are often classed in two basic forms, horizontal and vertical, which refers to
the orientation of the main spindle. Both types range in size from small, bench-mounted
devices to room-sized machines. There was another CNC Milling Machine for machining
heavier dies upto 4.5 ton.
7. CNC lathe having a 3 jaw chuck partially funded by ISRO
8. A furnace for producing dies by shrink fit method
9. Surface plate with measuring instruments for taking accurate dimensions.
2.2.3 FORGE SHOP
On day 3 of our training we visited the forge shop and learned the following from
the assistant engineers there.
2.2.3.1 Manufacturing of Forgings
Forging is a manufacturing process involving the shaping of metal
using localized compressive forces. Forging is often classified according to the temperature at
which it is performed: "cold", "warm", or "hot" forging. Forged parts can range in weight
from less than a kilogram to 580 metric tons.
Forged parts usually require further processing to achieve a finished part. Main
production machinery of SIFL comprise closed die forging hammers of 10 Ton (16000 ft.lb)
and 6 Ton (10650 ft.lb) capacity. Open die forgings requirements are met with a 1Ton clear
space hammer. Other supporting facilities include shot blasting machines, Pneumatic
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trimming press of 1000Ton and 500 Ton capacity, Hydraulic trimming press of 1200 Ton
capacity, Billet shearing machines and a number of oil-fired and electric furnaces for soaking
as part of forging process. There is a modern heat treatment plant equipped with number of
furnaces both LDO fired and electrically heated and a charging machine which takes care of
loading and unloading of heat treatment charges.
2.2.3.2 Drop Forging
Drop forging is a forging process where a hammer is raised up and then
"dropped" onto the workpiece to deform it according to the shape of the die. There are two
types of drop forging:
open-die drop forging and closed-die drop forging. As the names imply, the difference is in
the shape of the die, with the former not fully enclosing the workpiece, while the latter does.
Open-die forging is also known as smith forging. In open-die forging, a
hammer strikes and deforms the workpiece, which is placed on a stationary anvil. Open-die
forging gets its name from the fact that the dies (the surfaces that are in contact with the
workpiece) do not enclose the workpiece, allowing it to flow except where contacted by the
dies. Therefore the operator needs to orient and position the workpiece to get the desired
shape. The dies are usually flat in shape, but some have a specially shaped surface for
specialized operations. For example, a die may have a round, concave, or convex surface or
be a tool to form holes or be a cut-off tool.
2.2.3.3 Open-Die Drop Forging
Open-die forging lends itself to short runs and is appropriate for art smithing and
custom work. In some cases, open-die forging may be employed to rough-shape ingots to
prepare them for subsequent operations. Open-die forging may also orient the grain to
increase strength in the required direction.Cogging is successive deformation of a bar along
its length using an open-die drop forge.It is commonly used to work a piece of raw material
to the proper thickness. Once the proper thickness is achieved the proper width is achieved
via edging.
Edging is the process of concentrating material using a concave shaped open die.
The process is called edging, because it is usually carried out on the ends of the workpiece.
Fullering is a similar process that thins out sections of the forging using a convex shaped die.
These processes prepare the workpieces for further forging processes.
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Fig 2.3 Forging Operation
2.2.3.4 Impression-Die Drop Forging
Impression-die forging is also called closed-die forging. In impression-die
forging, the metal is placed in a die resembling a mold, which is attached to the anvil. Usually
the hammer die is shaped as well. The hammer is then dropped on the workpiece, causing the
metal to flow and fill the die cavities. The hammer is generally in contact with the workpiece
on the scale of milliseconds. Depending on the size and complexity of the part the hammer
may be dropped multiple times in quick succession. Excess metal is squeezed out of the die
cavities, forming what are referred to as flash. The flash cools more rapidly than the rest of
the material; this cool metal is stronger than the metal in the die so it helps prevent more flash
from forming. This also forces the metal to completely fill the die cavity. After forging the
flash is removed, their annual capacity is around 7500 Metric Tons. They manufacture closed
die forgings in the weight range of 5 kg to 450 kg and open die forgings within 1kg to 75 kg
net weight per piece and ring rolling up to 650mm OD. The company has got the capability to
manufacture forgings out of Carbon steels, Alloy steels, Stainless steels, Managing steels,
Aluminium alloys, Titanium alloys etc.
2.2.3.5 Forging & Heat Treatment Facilities
The billets for forging are heated in oil fired or electric furnaces, closely
controlling the temperature to reduce the scale formation and overheating so that the
metallurgical properties are ensured in the final product. In addition, in-process inspection is
carried out at all stages and 100% inspection for visual defects after forging. The accepted
forgings are duly heat treated to ensure its mechanical properties. By providing heat treatment
services in-house, SIFL is able to maintain greater control over heat treating process. The
facility comprise batch furnaces both oil fired & electrical, continuous electrical heating
furnaces, solution treatment etc. to carry out annealing, normalizing, hardening, tempering,
isothermal annealing, solution treatment etc. or other operations as specified by the customer.
Close temperature control and process monitoring with the help of temperature recorders
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ensures uniform properties duly supported by evaluation of metallurgical properties through
representative test pieces.
2.2.4 HEAT TREATMENT OPERATIONS
On the fourth day we were instructed to visit and learn the heat treatment operations
that are being conducted on the parts that are manufactured. The common heat treatment
operations that are carried out in the heat treatment department are:
1. Quenching: is the rapid cooling of a workpiece to obtain certain material properties. It
prevents low-temperature processes, such as phase transformations, from occurring by only
providing a narrow window of time in which the reaction is both thermodynamically
favourable and kinetically accessible.
2. Annealing: is a heat treatment wherein a material is altered, causing changes in its properties
such as hardness and ductility. It is a process that produces conditions by heating to above the
critical temperature, maintaining a suitable temperature, and then cooling. Annealing is used
to induce ductility, soften material, relieve internal stresses, refine the structure by making it
homogeneous, and improve cold working properties.
3. Tempering: Tempering is the process of reheating the steel leading to precipitation and
spheroidisation of the carbides. The tempering temperature and time are generally controlled
to affect the final properties required of the steel. The benefits resulting are the increase in
the metal toughness and elongation. The negative effects are the reduction of the martensite
(BCT) structure and the progression towards a spheroidal carbide + ferrite matrix structure.
4. Normalising: Normalising involves heating the steel to about 40o
C above its upper critical
limit. The steel is then held at this temperature for a period of time and is then cooled in
air.. It is desirable that the temperature of the steel shall be maintained for a time period more
than 2 minutes per mm of section thickness and shall not exceed the upper critical
temperature by more than 50o
C. The structure produced by this process is pearlite (eutectoid)
or pearlite in a ferrite matrix (hypoeutectoid) or pearlite in a cementite matrix
(hypereutectoid). Because the steel is cooled in air the process results in a fine pearlite
formation with improved mechanical properties compared to the full annealing process .
2.2.4.1 Testing/Inspection Facilities
Surface conditioning is done by shot blasting/grinding and final inspection is
carried out once again to ensure quality requirements. Non-conformities are taken care of by
timely corrective and preventive action. Calibration of electrical furnaces of SIFL is done by
NABL accredited laboratories like HAL, STIC, CUSAT etc.
SIFL has set up a system of total quality control consisting of an array of state-of-the-art
speciality equipments where the products go through a series of rigorous tests, the destructive
test including tensile, jominy and impact testing, wet analysis, carbon-sulphur determination,
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in situ metallography (where microstructure can be observed without destroying the job) and
non-destructive tests using Spectrometer, Microscope, Magnaflux crack detection, Die
Penetrant, Ultrasonic flaw detection etc. SIFL is now equipped with a new digital ultrasonic
flaw detector which has got a range of 5mm to 5m in steel.
Setting and control of quality standards at all stages right from the receipt of raw material to
the finished product through quality plan makes them deliver superior quality forgings with
close dimensional tolerances and metallurgical properties.
2.2.4.2 Machining Unit
SIFL has set up a complete machining unit to meet its post forge operations and to
meet its customer requirements. The machining unit is equipped with modern machineries to
meet the requirements. It was set up within 6 months record time, as a Greenfield project. The
main machineries include Vertical Machining Centre, Radial Drilling Machine, CNC
Horizontal Lathe, Magnetic particle testing machine, Shot blasting machine etc.
2.3 DAY 3: QUALITY CONTROL DEPARTMENT
Fifth day was to visit quality department. Quality control department has a
responsibility to control and maintain the quality of billets and to grade it according to BIS
standards and reporting it to production department. The department has full-fledged
laboratory to do this task. During refining the samples are analyzed. The products of the
company are every time subjected to the most stringent and uncompromising test. Being
holder of a good license, company is authorized to issue certificates conforming BIS
specification.
The objectives of the department is, to ensure that good quality forging only reach
to customers and that the product meet customer’s requirements and to ensure the customers
complaint to Nil on quality.
2.3.1 Organogram of Quality control department
The Manager of Quality Assurance is charged with the responsibility for
maintaining the procedures and standards, monitoring its effectiveness and implementing a
continuous improvement program. The Manager of Quality Assurance’s authority to
overview all functions of the organization and to recommend and/or initiate improvements, is
fully supported by the General Manager. All employees are responsible for upholding and
enhancing the quality of Company’s performance through knowledge, dedication to their
tasks, awareness of the procedures, standards and regulations that govern their work and
appreciation of their role in the company-wide team.
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Fig 3.1 Organogram of Quality Control Department
2.3.2 Functions
1. Inspect raw materials available.
2. Test the quality of scrap.
3. Checking the quality of billets.
4. Checking the quality and size of rolled items
5. Analyze the heat
Control of the elements such as carbon, manganese, silicon, sulphur and phosphorus
etc. are also the functions of this department. The quality reports of the raw materials are sent
to the deputy production manager and all other departments. In shift, chemist will analyze the
sample and its chemical content is reported to the production department, so that they can add
or reduce each component in order to get a high quality product. The shift chemist analyzes
final billets samples and the result will be given to the production department. Each and every
billet are thoroughly checked by shift chemist in order to give code and colour according to
the quality standards laid down by BIS. Billet yard supervisor will assist him.
2.3.3 Quality of Inputs
In fact, SIFL's ISO 9001:2008 quality system covers the whole ground,
● Acceptance plan and testing of 100% raw material supplies.
● Setting and control of quality standards for forging as per quality plan.
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● Corrective and preventive actions are implemented promptly for minimizing defects to a zero
level.
● Certification of facilities by IBR, EIL, IRS and other inspection agencies.
● In-depth testing and research, based on specific customer requirements.
● Continuous vendor evaluation.
● Strict implementation of established processes.
● Calibration and maintenance of testing, measuring and thermal control equipment.
● Constant and continuous consultation with customers and suppliers on all technical aspects.
● Maintenance of high vendor rating with customers.
2.4 DAY 4: MAINTENANCE DEPARTMENT
After Quality control department we went to visit Maintenance department. The
term “maintenance” means to keep the equipment in operational condition or repair it to its
operational mode. Main objective of the maintenance is to have increased availability of
production systems, with increased safety and optimized cost. Maintenance management
involves managing the functions of maintenance. The responsibility of maintenance
department is to keep the entire shift always ready for action. For the smooth and effective
functioning of company it is necessary to maintain the system properly. The motto is to
minimize the downtime, keep the machineries in good condition, maximize the utilization of
equipments and to achieve required level of quality.
2.4.1 Organogram of Maintenance Department
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Fig 4.1 Organogram of Maintenance Department
Maintenance organization structure can be considered as being made up three necessary and
interdependent components.
● Resources: men, spares and tools
● Administration: a hierarchy of authority and responsibility for deciding what, when and how
work should be carried out.
● Work Planning and Control System: a mechanism for planning and scheduling the work
and feeding back the information that is needed for correctly directing the maintenance effort
towards defined objective.
The manager is responsible for the safe maintenance, repair or replacement of plant
equipment and systems, to ensure maximum production quantity and quality, while
supporting the policies, goals and objectives of the company.
2.4.2 Functions
● Breakdown maintenance
● Calibration
● Preventive maintenance
● Machine Capability Test
2.4.2.1 Breakdown Maintenance
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There is a section which undertakes the job of maintaining, repairing the parts of
machinery where breakdown or disasters had happened. This section is helpful to maintain
such problems by them temporarily and thus the production function will conduct smoothly
without delays. The department authority gets intimation who then attends the status of the
particular equipment in maintenance register. The site is inspected, and the logbooks are
updated. The problems are recorded in machine history book and monthly review is
performed.
2.4.2.2 Calibration
Thermocouples are identified and calibrated once in 3 months. Non-conforming
thermocouples are disposed. Furnaces are calibrated by using calibrated thermocouples. They
are maintained at 100°C. Certificate is issued after calculation.
2.4.2.3 Preventive Maintenance
Maintenance of furnaces:
Furnaces are provided with thermocouples after ensuring the validity of thermocouples.
Furnaces are maintained at a temperature of 100°C. The performance is checked and they are
handled over for production process. The furnaces are inspected once in 30 days. eg: lining
failure, coil failure (major breakdown).
Equipments other than furnace: The 10T and 6T hammer and compressors involves
replacement/modification, the necessary spares are made available. If unavailable, the parts
are sketched. Before assembly of new spares, components are verified with sketches. Records
are maintained for 3 years.
2.4 DAY 5: MATERIALS DEPARTMENT
On the next we visited Materials department. Materials input is very important
as excess material as inventory causes costs to the company and shortage of material results
into stoppage of conversion process and subsequently shortage of finished goods leading to
customer dissatisfaction. Out of 5Ms, that are inputs to a conversion process, material is
substantial in terms of its contribution to product cost, and current assets. Management of
materials is crucial in a Just in Time Company. Production process needs very strong
materials management support to gear up to face challenges of current market. Materials
Management provides information about availability of new products and services in the
market which leads to cost efficient changes in the process.
2.4.1 Organogram of Materials Department
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Fig 5.1 Organogram of Material Department
2.4.2 Functions
● Materials Planning & Control
This is the primary function of Materials Management. The market forecast is
converted into production schedules by production planning and control. Materials
management prepares the materials plan to meet the production schedule. The plan is then
implemented and controlled.
● Procurement
Procurement function begins with sourcing the supply after short listing
suppliers. An effective method is to rate the vendors on the basis of performance and choose
the best. Purchase order is placed on the source and the material is procured from the source.
Procurement activity includes preparation placement of purchase order, follow up,
transportation and handling.
● Handling
The material which reaches the company premise is to be unloaded, moved and
positioned as per the storage plan.
● Storage & Preservation
The procured material is to be stored and preserved against internal and external
deterioration and theft. Against the authorized demand the material from the store is retrieved
and issued.
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● Inventory control
Inventory control function controls the inventory levels to ensure shortage free
and excess free stock to check the costs and ensure customer satisfaction
● Vendor development
The company makes the chosen vendors effective and efficient by providing
necessary inputs of training and information. The suppliers systems are audited to ensure
adherence. A good vendor is an asset as he makes his customer more effective and efficient.
● Vendor rating
Vendor rating is used as a tool for narrowing down the supplier base for productive
management of materials function. The same system is used continuously to assess strengths
and weaknesses of short listed vendors for their effective development.
● Waste control
Procuring standard material and continuously trying to improve yield is waste
reduction and control function. When a product is processed two types of wastes are
generated. One type of waste is called as standard scrap. This is accepted as unavoidable.
Product that is not right first time is scrap and thereby wastes. Non moving
obsolete material is another waste that cripples organization. Material management should
address these wastes and not only should control but reduce the wastes. The wastes thus
generated are transferred to the Steel Complex for further processing.
2.5 DAY 6: STORE & PURCHASE DEPARTMENT
Items purchased, are broadly meant for managerial activity, which cross the
boundary of single act of buying. It is a dynamic activity which includes administration,
accurate forecasting, effective planning, developed capacity research and development for
selection of materials and resources from which those may be brought follow up to issue
proper delivery and forms to enable the purchase department to carry out the standard public.
This department is concerned with purchase of each and every article for SIFL. At SIFL, the
raw material required for any forgings are bought only from prime manufacturers in the
country viz. SAIL, VISL, JSW, MUSCO etc. These prime manufacturers have been approved
as vendors based on our evaluation of their capability and quality systems. All the die blocks
are imported from the prime die manufacturers viz. M/s EDELSTAHLWERKE BUDERUS
A.G, Germany. The furnace oil and High Speed Diesel (HSD) which is required before and
after production are supplied as per the contract with IOC. The stores department has two
sections: for raw material and for general consumables. Each of this department is
responsible to handle the activities of corresponding work. The areas of responsibility of the
Purchase Manager include price negotiation, planning, production, inventory control, quality
control and factory control. The authority proactively improves Purchasing processes,
supplier selection and development to support above. Oversees the preparation of tenders,
20

analysis of bids and the award of contracts and manage Supplier performance and create
action plans to address those that underperform. There is one junior manager for store and
sufficient number of subordinates and staffs.
2.5.1 Functions
In SIFL the store and purchase department perform the following functions;
● Supply the needed materials.
● Procure quality materials at minimum cost. Try to procure maximum materials from the
manufacturer's itself.
● Ensure quality of materials
● Issuing and raising the materials
● Maintain the stock
● Annual stock verifications
● Check and maintain the stock of minor items
● Stock and consumption return for every month
SIFL is equipped with a load from weighing machine and it is under stores
department. One qualified operator is appointed for its operation. The machine is
computerized. It has the capacity up to 40 tons. The components of weighing machine
are load cell, displaying screen and computer. The normal steps for weighing a vehicle
are:
● Weighing the empty vehicle
● Weighing with load
● Comparing with bill
The deviations are recorded. Standard deviation will be omitted when scrap is arrived in
containers; it will be weighed from outside since the weighing machine can't occupy the
length of containers. The weighing machine is used for company purpose only and its
maintenance is contracted to outside parties.
2.5.2 Sources of Scrap
SIFL purchases minor items from home country and major items are imported from foreign
countries. Advertising regarding the needs of SIFL assist to achieve the procurements easily.
Indigenous materials are got mainly from manufacturers and through dealers.
Import of Scrap: Import of scrap is mainly on the basis of open general license (OGM)
Following is the steps of import:
1. Scrap arriving bulk in containers
2. Arranging customs clearance, loading etc.
3. Arranging supervisions. Containers are opened only after supervision.
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4. The details of arrived materials are entered in ledgers.
The major suppliers of the scrap are
● Lioyets global trade-Dubai
● Ahumudi Generator trade in Dubai
● Middle east metal trading Dubai
2.5.3 Inventories
Raw materials including raw materials in process, semi finished goods, finished goods and
stores and spares are valued and carried at lower of cost or Net Realizable Value. Slow-
moving inventory of raw materials and finished goods are valued at cost or Net Realizable
Value, whichever is lower. Loose tools are carried at cost which is lower than Net Realizable
Value. The above are valued adopting FIFO Cost Formula. In relevant cases the Machinery
spares in stock are devalued below cost to realistic Realizable Values and to zero value in the
case of obsolete/unusable spares.
2.5.4 Major Raw Material Suppliers
1. Steel Authority of India Ltd. (SAIL)
2. Jindal Steel Works(JSW)
3. Visweswaraya Iron & Steel Ltd. (VISL)
4. Super Forgings & Steel Ltd.
2.6 DAY 7: MARKETING DEPARTMENT
Last day of our visit was Marketing department. Marketing management is
a business discipline focusing on the practical application of marketing technique and the
management of a firm’s marketing resources and activities. More than any other business
functions, marketing deals with customers. Creating customer value and satisfaction are at
energy heat of modern marketing thinking and practice. The simplest definition of marketing
is “marketing is the delivery of customers satisfaction at a profit” the two field goal of
marketing is to attract new customers by promising superior value and to keep present
customers by delivery satisfaction. Sound marketing is critical to the business of every
organization large or small, for profit or not for profit, domestic or global. The two major
aspects of marketing are customer acquisition and the retention and expansion of relation
with existing customers.
2.6.1 Functions
● Enquiry / Order Acceptance
22

● Customer Satisfaction Survey
● On Time Delivery
● Handling Customer Complaints
2.6.2 Product Profile
SIFL's critical forgings are supplied to various sectors like Aerospace sector,
Defence sector, Railway sector, Heavy Engineering sector, Earth Moving sector, Agriculture
sector, and Automobile sector. SIFL is equipped to manufacture high pressure application
forgings like Gate/ Valve Bodies, Choke Bodies etc. in Carbon and Alloy steel material, to
meet the requirements of Oil Field Equipment manufacturers, Thermal Power Stations,
Refineries, Petrochemical Industries and Nuclear Plants. The company has made significant
contribution in Aerospace/ Aeronautical sector by way of developing complex forgings for
various Aero engines, the latest of which involves the supply for project CHANDRAYAN by
ISRO. So far the company has developed about 800 different types of forgings and the
development of new components are continued. Forgings are also being exported to countries
like USA, Indonesia, Malaysia and Middle East.
2.6.3 Quality Standards
● Certification from DGQA, DGAQA, Ministry of Defence, Govt. of India.
● Assessed and approved by NQA Quality Systems Registrar against the quality assurance
system standards ISO-9001:2008 for manufacture and supply of forgings.
● Facilities certified by premier inspection agencies viz.: IBR, Indian Registry of shipping,
Engineers India Ltd.
● Best vendor award from BEML.
● Evaluated by the Central Boilers Board and has been granted recognition as a "Well Known
Forge".
● RDSO, ISRO, Certifications/Approval.
● SIATI 2003 Award for excellence in Aerospace indigenization.
● Kerala's Best PSU Award Winner - 2006 - 2007, 2007- 2008.
● Special Award for notable achievement in Enterprise Performance, 2008-2009, 2009-2010 &
2010-2011
23

2.6.4 Products of SIFL
24

Table 1.1 Products of SIFL
CHAPTER 3
25

EVALUATIONS
In this industry, I proposed to conclude the study report by highlighting important
findings of the study. The important findings has led to some suggestions for improving the
profitability of the concern
● As a government company SIFL enjoys the leadership status in the market.
● It produces high level quality steel and negligible number of defective products.
● Company makes arrangements to avoid overcrowding in the production unit near the
machine.
● SIFL is paving the seeds of changes in its way. Stability in its production is production is
possible now in SIFL.
● Due to liberalization the company need not suffer to import the raw material necessary for
production.
● The main strategy of SIFL is aiming at gaining a sustainable advantage over competition
through quality and reduced price.
● SIFL trying to improve its position m the mind of the customers by following up and
attending any complaints.
● Proper timekeeping system is there in SIFL.
● SIFL is strict in quality of products and quality checking can be done through modern
technique of spectroscopy.
● There is proper control and coordination in the company.
● The company has facilities such as canteen, rest room etc.
● The company appointing general helpers to help different department.
● Water and power is supplied for whole day.
● There is a sales depot to sell the steel.
LEARNING EXPERIENCE
The in-plant training at Steel and Industrial Forgings Limited has enhanced our
knowledge about the technical concepts of manufacturing and provided exposure and
practicability of subject in the industry. It gave us an understanding as to how an organization
operates and an idea as to how the hierarchical structure of an organization is and helped me
understand the chain of command and authority. The study was a significant endeavour in
analyzing overall functions of various departments within the organization. It has provided us
with valuable insight into the technical aspects of manufacturing and the amount of hard
work put in by the managers, engineers and workers in manufacturing a component.
26

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