Acknowledgement

It is my pleasure and fortune to have training in such a good and well managed
company Super Circle Pvt. Ltd. I want to express my sincerest thanks to all the
peoples who encourage me and give proper guidance at every step.
I will always remain indebted to them for shaping not only this training report but also
knowledge of machines and other process.

A special work of thanks to Mr.Singhal & Mr. Sandeep Bharadwaj for their
constant co- operation, encouragement, confidence and affectionate guidance at every
step and help me out to complete my training report.

Neeraj
Contents
1. Acknowledgment
2. Profile of the company
3. Departments
4. Products
5. Product Wise Applications
6. Manufacturing
• Flow Diagram of production process
• Types of Finishes
1. Description of production lines of plant
➢ Annealing Pickling Line
➢ Reversible Cold Rolling mils
➢ Bright Annealing line
➢ Tension Leveler
➢ Degreasing Line
➢ Slitting Line
➢ Skin pass Machine
1. General Safety precautions at the plant
Profile of the Company

The Company

SUPER CIRCLE manufactures a wide range of high quality, precision engineered

automotive parts. With over four decades of production expertise, the company is a
leading name in Friction Products like Disc Brake Pads, Brake Linings, Roll Linings, Brake
Shoes, Backing Plates & Brake Shoe Metals and Engine Parts like Piston Rings, Cylinder
Liners, Connecting Rods, Pistons, Engine Bearings, etc. A high degree of quality control,
fine tuned customised production and the ability to stay in step with changing global
requirements have ensured that the company is associated with quality and reliability
the world over.

The Market

Over 65% of the company's production is exported to more than fifty countries
worldwide in Europe, North and South America, Australia, Asia and Africa. In India, the
company's products are associated with up-market automobiles like Toyota, Honda,
Ford, Hyundai, Opel, Daewoo, Mitsubishi, Hindustan, Premier, Tata, Leyland, Massey
Ferguson, New Holland, Zetor, Eicher, Escorts, Bajaj, TVS and Others. Furthermore, the
company has long standing contracts with various government and defence
departments.

Infrastructure

The company has eight manufacturing units with high-end production facilities, situated
on prime industrial locations in and around the nation's capital. Each of them receives
the benefits of qualified and experienced technical supervisors and a motivated labour
force. The resolve for quality, combined with a vast and well-knit marketing and sales
network, interactive customer support services and a thirty year old track record of
product reliability and market stability, have made SUPER CIRCLE a name people trust.

The Promise

The company has shown tremendous growth potential - a result of maintaining the most
exacting of international standards and delivering high technology at low cost. The
company has adopted ISO9001, ISO/TS16949 quality management standards, ISO14001
environmental management standards and OHSAS18001 health & safety management
standards. With progressive management techniques, the company ensures that your
most demanding specifications are met and deadlines adhered to.
DEPARTMENTS

PRODUCATION DEPARTMENT
MAINTENACE DEPARTMENT
HUMEN RESOURSES DEPARTMENT
QUALITY CONTROL DEPARTMENT
PACKAGING DEPARTMENT

Production Department:-

Aims and functions of production department

Production is the functional area responsible for turning inputs into finished outputs
through a series of production processes. The Production Manager is responsible for
making sure that raw materials are provided and made into finished goods effectively.
He or she must make sure that work is carried out smoothly, and must supervise
procedures for making work more efficient and more enjoyable.
Some production sub-functions:-

In a manufacturing company the production function may be split into these sub-
functions:

1) The production and planning department will set standards and targets for each
section of the production process. The quantity and quality of products coming off
a production line will be closely monitored. In businesses focusing on lean
production, quality will be monitored by all employees at every stage of
production, rather than at the end as is the case for businesses using a quality
control approach.

2) The purchasing department will be responsible for providing the materials,

components and equipment required to keep the production process running
smoothly. A vital aspect of this role is ensuring stocks arrive on time and to the
right quality.

3) The stores department will be responsible for stocking all the necessary tools,
spares, raw materials and equipment required to service the manufacturing
process. Where sourcing is unreliable, buffer stocks will need to be kept and the
use of computerized stock control systems helps keep stocks at a minimal but
necessary level for production to continue unhindered.
A key aspect of modern production is ensuring quality. The term quality means fitness
for purpose i.e. a product, process or service should do exactly what is expected of it.

Maintenance Department:-

The Maintenance Department Works as a Back Bone of the System of the Changing raw Material in to the
finished Product. The department keeps up the machine ready for use. The Maintenance department always
works for the giving running conditions to all the Machines and remove all the hindrance from the production
process.

This department make records of the all the spare parts and having a teams which provide the regular
overhauling of the all machines in the plant.

Humen Resources Department:-

Human resource management (HRM) is the strategic and coherent approach to the
management of an organization's most valued assets - the people working there who
individually and collectively contribute to the achievement of the objectives of the
business. The terms "human resource management" and "human resources" (HR) have
largely replaced the term "personnel management" as a description of the processes
involved in managing people in organizations. In simple sense, HRM means employing
people, developing their resources, utilizing, maintaining and compensating their
services in tune with the job and organizational requirement.
Functions:-

The Human Resources Management (HRM) function includes a variety of activities, and
key among them is deciding what staffing needs you have and whether to use
independent contractors or hire employees to fill these needs, recruiting and training
the best employees, ensuring they are high performers, dealing with performance
issues, and ensuring your personnel and management practices conform to various
regulations. Activities also include managing your approach to employee benefits and
compensation, employee records and personnel policies.

Quality Control Department:-

Quality control department insures the quality of the products of the company. Main
function of the Department is to setup the quality policy of the company and providing a
best quality products to the customers of the company.

Regular checking of the Sample of the Finished products and performing the test on
the samples of the products.

Consumer satisfaction and maintain a standard of the company in the market is the
main goal of the Department.

Packaging Department:-

Packaging Department provide a Best and economical handling of the finished products.

Inside the company there is a separate portion for packing of the different sizes
products of the company according to the order provided by the consumer.
Proper Packaging ensures a risk full handling of the company’s product from the factory
gate to the Consumer.

Necessary Notation like the type of brake pads, break shoes and the grade of friction
material the other details are written on the packaging material and arranged them in
the Dispatching area in a systematic manner.

Products:-
Disc Brake pads :-

SUPER CIRCLE has an export oriented unit to manufacture disc brake pads. The
company has developed special asbestos-free materials that maintain high performance
standards. Asbestos-free disc brake pads are made in low metal, high metal and organic
compositions for cars, commercial vehicles and bi-wheelers.

The laboratory is equipped with sophisticated equipments including full scale inertia
dynamometer to check the friction characteristics as per international standards. The
company is supplying disc brake pads and its components as original equipment.

With more than 300 references already being manufactured and many more being
developed every month, SUPER CIRCLE offers a wide range of disc brake pads for the
European, Japanese, Korean, American and Indian vehicles.
Formulation (HM55)

HM55 is an asbestos-free material of metal fibres, synthetic fibres, friction modifiers and
stabilizers. It has low to medium co-efficient of friction and is specially designed for
heavy duty applications. It shows no fade even at very high temperatures and maintains
exceptionally good wear resistance properties.

Density (gm/cc) : 3.20

Hardness (L Scale) : 80
Max. Continuous Operating Temperature : 600°C
Max. Transient Operating Temperature : 700°C

Brake Shoes:-

SUPER CIRCLE manufactures high performance brake shoes for cars, tractors and bi-
wheelers. The brake shoes are bonded with rigid or rubberised linings as per the
requirement. The company offers both lined and unlined brake shoes. As the kinetic
energy of a moving vehicle is converted into heat energy during braking, the special
adhesive used for bonding is capable of absorbing the high temperature created. With
continuous investment in the development of tools, the range is increasing very fast
every month. The unique features and unmatched quality have made the company's
brake shoes very popular.

Brake Lining:-
From luxury cars to tractors, and 50cc mopeds to heavy commercial vehicles, SUPER
CIRCLE makes linings, blocks and billets that are designed to suit the needs of the
customer. One of the largest suppliers to State Road Transport Undertakings all over
India, the company manufactures brake linings in asbestos-free rigid moulded
compositions.

The company offers brake linings for a variety of trucks like Mercedes Benz, Scania,
Volvo, Ford, Mack, DAF, Bedford, Tata, GM, Nissan, Isuzu and Leyland etc.

Manufacturing:-
Here we discuss about the Manufacturing process of the Brake shoes and Disc brake
pad manufacturing

Flow Diagram:-
 Mixing
A predefined grade of the friction material compositions. And store them in different cont

Area
And
Friction
Material
Formati

Back Plates (Semi

finished) Punching
Of Batch
Number

Shot
Drying Of Back
Plates and
Blasting
Brake Shoes
 Degreasing Line

Adhesive Coating

Molding
Process

Bakin

Rough Grinding and Slitting

FinalPrinting
Label Grindingand and
Chamfering
Accessories Fitting
 Rubber Coating

Packing and Dispatching

Punching Of Batch Number:-

Under this section the process of punching batch no. on the Back plates. So, that
a effective lot of the no. of products can be combined.
Inside the batch no. information like the day, Month and year and batch of the
product punched.

If in the future problem regarding the product faced by the consumer than the
problem of that product can be easily fined by these information and necessary
step are taken to remove such problems by improving the process and Making
the design changes.

Shot Blasting:-
Shot blasting is a process in which iron shots are sticks with the back plate to clean the
surface and reduce the scale formation on it.

Shot Blasting material:-

These type of iron balls known as iron shots are used in this Process.

Degreasing Line:-
Degreasing is the process of clearing the surface of any material by the action of
chemicals to remove the dust particles.
Specifications:-

• Chemical used: - DCE ( Di Chloro Ethene )

• Temp range: - 80 Deg. C

• Air pressure: - 3 to 4 kg/cm2

• Time period: - 10 minutes

Working:-

1. First of all the tank is filled with DCE . Inside the tank heaters are provided to
maintain a temp range of 80 deg C.

2. Evaporation of the thinner gets started.

3. The loading of the pieces of Brake pads are inserted on the platform which is
have up and down motion and operated by air pressure.
 4. By the evaporation dust particle are settled down in the form of mud at the
bottom of the tank.

5. Cooling system is also providing to prevent the escaping of thinner from the tank.

6. After 10 mantes the pieces are taken out from the tank and then adhesive
coating processes on them.

Adhesive coating:-

Adhesive coating is a process of making a layer of adhesive on the one surface

of the back plate to adhesion the friction material on them in the molding
process.

It has to types:-

A. Manual Coating

B. Machine Coating

Manual Coating:-

This type of coating is used for the brake shoes because of the complicated
shapes of the brake shoes.

In this process the brake Shoes are dipped inside the tank of the adhesive
material manually. After it the are keep for drying.

Machine Coating:-

This process is followed for the brake pads.

This machine contains a convey belt and a adhesive tank. The roller which is
wetted by adhesive from tank is continues apply the adhesive on the surface of
the brake pad.

Drying:-
• After coating Natural drying of pads followed at room temp.
• The brake pads are drying for 6 hour time period after coating and the brake
shoes are drying for 24 hours after dipping.
• The pads and shoes are arranged on the stands separately.

Molding:-
Under this process the two types of molding processes are followed.

➢ Pre forming molding

➢ Hydraulic press molding

Performing molding:-

 Under this process a hydraulic ram and punch die system is provided.

 First of all the the die is fixed on the plate form.

 There are two types of materials in which one has only Friction properties and
other has friction as well as adhesive properties.

 Now these material are weight on weighing machine and filled in the cavity in the
ratio 25 : 62 gms.

 Now pressure applied on the punch by the hydraulic ram.

 Now the molded shape ejected from the cavity and store.
Hydraulic Press Molding:-

Hydraulic press machines are used in this process.

Specification:-
Let’s take a example here.

We have to make a final Pad of thickness 15mm.

But here we have a tolerance for this 15.40 - 16.20.

 Temp range :- 145 to 155 deg C

 Pressure :- 1600 psi
 Time period: - according to the types and thickness of friction material used.
 Cycles :- 90 cycle

Operation:-

➢ Press contains a Fixed Platform and a moveable platform.

 ➢ On the moving platform the arrangement of performs along with the back plate
are placed.

➢ Now the Moving plate moves upwards and by the action of pressure and temp.
the performs takes a shape of the die and fixed on the back plates.

➢ Hence unfinished brake pad is formed here.

➢ After this the pads are sending to the baking section.

Baking Process:-

• To have proper bonding between the friction material and back plate baking
process is used.

• For this process heating furnace is used. Where heating is provide by the 3 sided
Electric heaters.

• The brake pads are kept inside the furnace for a time period at a temp. 105 deg
C.

Finishing Process:-
• Rough grinding and slitting.

• Powder Coating
 • Final grinding and chamfering.

• Rubber Coating.

Rough Grinding and Slitting:-

In this process grinding machines are used for making the size of the brake pad near to
the final size of the product.
In this process slitting is also provide in the pad by the slitting cutter.

Slitting means to divide the friction surface in two or three parts.

Slitting has importance in the braking system. Whenever the brake of vehicle is applied
than due to the friction between the pad and disc heat generates than slitting provides
between the pads helps in cooling of pad and resist the variations.

Powder coating:-

The back plate is made of mild steel. During the uses of the brake pad in the
vehicle the brake pad have to face the environment due to which corrosion
occurs on it and chance of brake failure is occurs.
For prevent this corrosion resistance material like paint is provide on the brake
pad.
The process followed is known as powder coating.

Under this process paint in powder form is used. After heating is melts down and
cover the surface of the brake pad and provide a protective layer on it.

The pieces are placed on the moving belt. This goes to a chamber where spray
guns are providing to spray powder form paint on the brake pads. Than the pads
moves to the heating section where a temp. of range 225 deg C is maintain.
Under this temp. The powder melts down and covers the pad uniformly.

For Brake shoe:-

The adhesive coating provides on brake shoe serves the purpose of the paint itself.
Same machine is used in this process. There is no need of power spray on the parts.
But here a variation in the heating temp. The range of temp. Used here is 190 deg C.
For 15 minutes.

Final grinding and chamfering

 Due to the powder coating process the whole brake pad is painted out.

 We did not want to provide paint on the frictional surface. Because it will
decrease the efficiency of braking system.

 To remove this paint from the frictional surface and provide final thickness to the
brake pad the final grinding is provided.

Chamfering:-

➢ The frictional surface having a change in the thickness at the corner.

➢ For providing the uniform thickness the chamfering is done on the pads at the
chamfering machine.
Rubber Coating:-
Rubber coating is providing to the back side of the back plate. Because when this back
plate used in the braking system than vibrations are produced during braking. To
reduce these vibrations rubber coating is used because rubber have tendency to absorb
vibrations.

Liquid rubber is applied on the surface by the rubber coating machine and then after it
to dry this rubber the brake pad is heated in the furnace at a temp. 180 deg c for half
an hour.
Printing and accessories fitting:-
Here in this process company logs and the necessary information like the Type
of product are printed on the surface of the brake pad using printing machine.

Accessories:-
The brake pads and brake shoes are assembled in the braking system with the
help of necessary accessories according to the design of the company vehicle.
Like clips, springs etc.

Now the production of the Brake pad and brake shoes are get completed. And
these products are send to the packaging department.

Packaging & Dispatching:-

 ➢ First of all a set of 4 pieces of the Break shoes or the Brake pads are packed in
the plastic rappers.

➢ Now these sets are sending to the skink rapping machine.

➢ Where by the action of the hot air the rapper shrink and take the form of the
product and tightly hold the products.

➢ After this these are packed in the different boxes according to the size.

➢ Than they are put in the master cartons and then sends to the dispatching area.

➢ Where they are arranged according to the local market and export sections.

Lab Testing:-

For checking the hardness of the friction material and bonding strength of the
frictional material two types of test.

 Rockwell hardness test

 UTM Test.

Under the company standards if the Bonding strength is more than 80%. Than
it is OK for the use. Otherwise necessary steps are taken to improve these
factors.

General Safety Precautions at the Plant or Work

place:-
1) Always wear SAFETY HELMET in the Plant.

2) Do not set up or operate any machinery unless an instructor is in the Plant

3) Do not operate any machine unless authorized to do so by an instructor or

under an instructor's supervision.
4) Use the proper tool for the job. Many cuts in the shop occur because a
tools slips and a hand hits a sharp cutting tool.

5) Check tools before use to assure they are safe to use.

6) Do not leave tools or work on the table of a machine even if the machine is
not running. Tools or work may fall off and cause a toe or foot injury.

7) Put tools away when not in use.

8) Place all scrap pieces in the correct containers.

9) Never handle Scraps with your hands or fingers. Scraps are extremely
sharp and can easily cause cuts.

10)Never wear gloves or use rags to clean any part of a machine that is
running.
Rotating tools or parts can grab gloves and rags and pull you into the
machine.

11)Never use compressed air to clean any machine.

12)Never use compressed air to clean your clothes or yourself.

13)Get first aid immediately for any injury.

14)Get help for handling large, long, or heavy pieces of material or machine
attachments.
Store materials in such a way that they cannot become tripping hazards.

15)Keep the floor free of oil, grease, or any other type of liquid. Clean up
spilled liquids immediately; they are slipping hazards.

16)Loose clothing or long sleeves should not be worn in the shop. Machines
can easily grab loose clothing in rotating parts.

17)Do not walk behind a person operating a machine; you may bump him/her
by accident or
startle them and cause an accident.

18)Always Keep Distance from the Pickling tank because the Harmful fumes Effects the Humen
Eyes

19) Make Proper Look out of the temp ranges of the Furnace

20)Always keep the Fire Extinguisher in the Range of Workers.

21) Weld the one strip to another strip accurately