REPORT ON

SUMMER VOCATIONAL TRAINING

At
Federal Mogul Goetze Ltd.
A TRANING REPORT SUBMITTED
IN PARTIAL FULFILLMENT OF THE REQUIREMENTS
FOR THE AWARD OF DEGREE OF

BACHELOR OF TECHNOLOGY
In
Mechanical Engineering
SUBMITTED BY
Name: Rajat Sharma

Roll Number: 2314785

SUBMITTED TO

Department of Mechanical Engineering

Ambala College of Engineering and Applied Research,
Ambala
(Affiliated With)
Kurukshetra University, Kurukshetra
July 2015

Scrap Reduction in Moly Coated Indica KV1

Material
Piston Rings
At
Federal Mogul Goetze Ltd.
A TRAINING REPORT SUBMITTED
IN PARTIAL FULFILLMENT OF THE REQUIREMENTS
FOR THE AWARD OF DEGREE OF

BACHELOR OF TECHNOLOGY
In
Mechanical Engineering
SUBMITTED BY
Name: Rajat Sharma

Roll Number: 2314785

SUBMITTED TO

Department of Mechanical Engineering

Ambala College of Engineering and Applied Research, Ambala
July 2015

CANDIDATE'S DECLARATION
I, Rajat Sharma, Roll Number: 2314785, hereby declare that the work which is
being presented in the Training Report entitled, Scrap Reduction in Moly Coated
Indica KV1 Material Piston Rings in partial fulfillment of requirement for the award
of degree of B.Tech. (ME) and submitted in the Department of Mechanical
Engineering, Ambala College of Engineering and Applied Research, Ambala,
Kurukshetra University, Kurukshetra, is an authentic record of my own work carried
by me under the supervision of Dilmohan singh (M/c Shop, & Federal Mogul Goetze
Ltd. ).The matter presented in this Training Report has not been submitted in this or
any other University / Institute for the award of B.Tech Degree.

Rajat Sharma
Roll Number: 2314785

Dated:

ACKNOWLEDGEMENTS
(It is just a format for hierarchy of the acknowledgement and can be extended/ reduced
accordingly)

The Training work is an important aspect in the field of engineering, where

contribution is made by many persons and organizations. The present shape of this
work has come forth after contribution from different spheres.

Give acknowledgement to all those persons who have helped during training
at industry.
Give acknowledgement to H.O.D

I would also like to thank my parents who helped me in my Training.

I express my sincere gratitude to Ambala College of Engineering and Applied
Research, Ambala and Kurukshetra University, Kurukshetra for giving me the
opportunity to work on the Training during my final year of B.Tech.

Signature of the Student

(Rajat Sharma)

Roll Number:2314785

INTRODUCTION
To
The Company

1.1 History
1899 1940: Founded on Innovation
1941 1956: Diversifying for Success
1957 1974: Going Global
1975 2005: A Bright Future
Federal-Mogul Corporation is an innovative and diversified $6.3 billion global supplier of
quality products, trusted brands and creative solutions to the automotive, light commercial,
heavy-duty truck, off-highway, agricultural, marine, rail and industrial markets. The 45,000
people of Federal-Mogul located in 35 countries drive excellence in all they do.

Companys globally networked engineering and technical

centers in the U.S.,
Europe and Asia enable to bring customers breakthrough in advanced technology
and innovation.

Federal Mogul is a premier supplier of products, services and solutions to original equipment
manufacturers that use quality components in their vehicles and automotive systems, and to
aftermarket customers who sell companys world-renowned brand-name replacement parts
through repair shops and retail outlets. As partner with a global network of suppliers whose
commitment to excellence and on-time delivery is crucial to company success.

For more than a century, Federal Mogul has developed the innovative products, which
customers need to produce the next generation of vehicles. Federal-Mogul has been creating
value through innovation and leading technology for more than 100 years. Today, the
company is a key player in the global marketplace, serving industries that range from
automotive and commercial vehicles to railroad and aerospace. Customers know they can rely
on Federal-Moguls quality excellence in products, trusted brands and creative solutions.
This company started with a bold idea, with a global workforce thousands strong. The
Federal-Mogul team has celebrated countless victories and worked hard to overcome the
inevitable challenges.
The company utilizes its engineering and materials expertise, proprietary technology,
manufacturing skill, distribution flexibility and marketing power to deliver quality products
and services, and leading brands. Federal-Mogul is focused on driving global profitable
growth and creating value to satisfy customer, employee and stakeholder expectations.
Headquartered in Southfield, Michigan, the Company, which reported sales of $6.3 billion in
2005, employs 42,000 people worldwide. Federal-Mogul was founded in Detroit in 1899. The
Companys principal customers include many of the worlds foremost original equipment
manufacturers of automotive, light commercial, heavy-duty truck, agricultural, marine, rail
and industrial vehicles and equipment as well as the worldwide aftermarket.
Federal-Mogul employees throughout the organization create value for their stakeholders and
continuously strive to exceed their customers expectations by following these core values:

We are a team first.

We respect, trust and help each other.

We act with integrity.
We are driven to be the best in all we do.
We create value through innovation.
We celebrate our success.

1.2 FEDERAL MOGUL GOETZE (INDIA) LTD.

BAHADURGARH, PATIALA

(History)

Goetze (I) Ltd., Bahadurgarh, Patiala was set up in 1954 with the collaboration of M/s.
Goetze Werke, Germany which started its production of Piston Rings for automobile industry
in 1957. The plant is situated at Bahadurgarh, about 10 kms. from Patiala on the PatialaRajpura Road.
Considering the need of complete Piston assembly, Escorts Ltd. ventured into manufacturing
of Pistons in 1958 with the collaboration of M/s. Mahle GmbH, Germany, which delivered
the
Indian
automobile
industry
its
Pistons
in
1960.

Escorts entered in collaboration with M/s. SUKO GmbH, Germany for Piston Rings in 1967
and manufacturing started in 1968. To meet the increasing demand of market, in 1977, a
parallel unit for manufacturing Pistons and Piston Pins was set up in Bangalore.
From 1 October 1996, Escorts Ltd. entered into joint venture with M/s. Mahle GmbH,
Germany with the formation of the new company Escorts Mahle Ltd. in 1998, Goetze also

became a part of Federal Mogul, a well-known group of USA. In June 2000, both Escorts
Mahle Ltd. and Goetze have become QS-9000 certified companies.
The present capacity of the plant is 285.09 lacs nos. Piston Rings and 52.68 lac nos. Pistons
(on 302 working days). The total capital employed as on 31 March 2004 is 134.46 crores in
Ring Activity and Piston Activity. The workforce including managers and supervisors is 1131
nos. in Ring Activity and 1304 in Piston Activity as on 31 March 2004. The turnover of the
Patiala Plants is 159 crores excluding Excise (combined in Ring Activity and Piston Activity)
as on 31 March 2004.

BRANDS

2.1 Federal-Mogul Goetze (India) Limited

Manufacturer of world-class pistons, piston rings, sintered parts and cylinder liners

covering a wide range of applications including two/three-wheelers, cars, SUVs,

tractors, light commercial vehicles, heavy commercial vehicles, stationary engines
and high output locomotive diesel engines.
Widest range of piston rings and pistons varying from 30mm to 300mm diameter.
The most modern production facilities at Bangalore, Patiala and Bhiwadi are certified
TS 16949, ISO14001 and OHSAS 18001.
Market leaders both in OEM and aftermarket. Exports to many countries.
Goetze and Goetze Brico provide leading-edge technologies and competitive
solutions for original equipment manufacturers and the automotive aftermarket.

Production Capacity:

Piston rings

55 Million

Pistons

13 Million

Turnover:

April 05 -March 06

INR 5124 Million

Net Profit (after tax):

April 05 -March 06

INR (505) Million

MILESTONES
1954 Incorporated as a JV with Goetze Werke
1957 Ring & liner production

Patiala
1958 Piston production as escorts (Automotive Division) (Collaboration:Mahle)

Patiala
1960 Cast iron / Forged piston production started

Patiala
1968 Pins / ring carrier production started

Patiala
1977 Piston / ring production started

Bangalore
1982 Steel rings / Large bore locomotive piston

Bangalore
1985 Light alloy products

Patiala
1989 Auto thermic pistons production

Bangalore
1990 Moly coated / IKA / chrome oil rings

Patiala
1992 Large bore rings / pistons for battle tanks

Bangalore
1994 Composite pistons / new ring foundry

Bangalore
1996 Escorts (Automotive Division) hived off into joint venture with M/S Mahle, Germany

1997 Goetze TP (India) Ltd. - Manufacturer of steel rings

2001 Merger of Federal-Mogul sintered products Ltd. with Goetze (India) Ltd.
2003 Merger of Escorts pistons activities with Goetze (India) Ltd.
2004 Introduction of chrome-ceramic rings
2004 Technical collaboration for pistons with Federal-Mogul Corporation
2006 Majority stakeholding acquisition by Federal-Mogul Corporation
2006 Name changed "Goetze (India) Limited" to "Federal-Mogul Goetze (India) Limited"

Management
Board of directors
Chairman

Name
Mr. Charles B.Grant

Vice Chairman, Managing Director

& C.E.O.

Mr. Arun Anand

Directors

Mr. Rainer Juestock

Mr. Charles H. Polzin
Mr. Mukul Gupta
Mr. Vishavjeet Kanwarapal

Corporate Leaders
Executive DirectorsSales & Marketing

Mr. Mohan Narayan

a) Original Equipment Sales

Mr. Yogesh

b) After Market Sales

Mr. Sanjeev Singh

c) Exports

Mr. G.S. Arshi

Executive Directors Manufacturing Operation

Mr. Andreaf Kolf

a) Bangalore Plant

Mr. K. Saravana

b) Patiala Plant

Mr. Sunit Kapur

c) Bhiwadi Plant

Mr. A. R. Ahuja

Financial Controller & Company Secretary Mr. Rajan Luthra

General Manager Corporate Planning

Mr. Ashish Mathur

Quality Policy
FEDERAL MOGUL GOETZE (INDIA) LIMITED commits itself to leadership in national
market for all its products and ensuring total customers satisfaction highest in industry. It
commits to develop and build an image in the international market to achieve a sustained
annual growth in exports.

Policy

We shall continue to manufacture all our products in conformity with accepted international
norms/ standards.
We shall also continue to retain our leadership in development of products through technical
know-how from our Collaborators and in-house developments. Consistent development of
human resources through training at all levels will be our major thrust area.

MR.CHARLES B.GRANT

(Chairman & Managing Director)

Mission of the Company

Steadily moving towards leadership with piston with vision strategy seeing it as the best
way to leaders in business

Vision of the Company

To be one of the worlds leading automotive solutions provider

Share Holding Pattern:

Federal-Mogul Corporation

51.0 %

Goetze India Ltd.

24.5 %

Teikoku Piston Rings Co. Ltd., Japan 24.5 %

EXPORT DESTINATION

Dubai

Bangladesh

Singapore

Egypt

Mauritius

U.S.A

Germany

Nepal

Sri Lanka

Uganda

COLLABORATIONS

A. GERMANY
o
o

Faun
Class

B. JAPAN
o
o
o

Yamaha
Kayaka
Mikni

o
o

JCB (Goetze)
Ford

C. UK

D. USA
o

HUGHES

E. FRANCE
o
o

Bosch
Dynapal

PROJECT CHARTER
Business Case
From Jan-Dec 2014, 21.95% average total machining and fdy.
Scrap in MOLY COATED INDICA KV1 Rings

Target = 17.8% at the end of July 2015

Problem Objective
To reduce the scrap of moly coated indica rings in KV1 material
from 22.95% to 17.8% by July 2015

Boundaries
From grinding process till final inspection

PROCESS FLOW OF INDICA KV1 RINGS

LISTING OF KNOWN PROBLEM IN JULY 2015

Edge Breakage observed in indica Moly KV1 rings.
Corner breakage observed in KV1 rings.

DATA COLLECTION SHEET FOR EDGE BREAKAGE

AND CORNER BREAKAGE IN INDICA KV1 RINGS IN
PROCESS AT BRUSHING
DATE

LOT
SIZE

QTY %

REMARKS

DETAIL

06/07/15

2200

230

10.45%

Edge/Corner breakage

At pg-100, At honing-50, At
gap-80

07/07/15

1500

223

14.8%

Edge/Corner breakage

At pg-123, At honing-60, At
gap-40

08/07/15

2300

200

8.6%

Edge/Corner breakage

At pg-125, At honing-55, At
gap-20

09/07/15

2400

256

10.45%

Edge/Corner breakage

At pg-156, At honing-68, At
gap-32

10/07/15

2300

245

10.65%

Edge/Corner breakage

At pg-98, At honing-100, At
gap-47

14/07/15

2500

288

11.52%

Edge/Corner breakage

At pg-168, At honing-90, At
gap-30

16/07/15

3000

350

11.66%

Edge/Corner breakage

At pg-150 At honing-90, At
gap-110

18/07/15

3000

332

9%

Edge/Corner breakage

At pg-132, At honing-60, At
gap-40

DATA COLLECTION SHEET FOR EDGE BREAKAGE

AND CORNER BREAKAGE IN INDICA KV1 RINGS IN
PROCESS AT INSP.
DATE

LOT
SIZE

AXIAL WIDTH
LESS

EDGE
FDY
BREAKAGE SCRAP

05/12/14

2200

40

120

45

06/12/14

1500

20

50

55

08/12/14

2300

50

145

65

09/12/14

2448

42

185

125

10/12/14

2300

30

125

75

PROFILE GRINDING - Breakage

PROFILE GRIND. DEFECTS-CAUSE VALIDATION OF

HIGH RANKING DEFECTS (indica)

ACTION TAKEN AGAINST THE DEFECTS

ACTION TAKEN AGAINST THE DEFECTS