submitted to: MRS SHAUKAT

dAWOOD UNIVERSITY OF ENGINEERING AND TECNOLOGY

submitted by: Students of DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGYDepartment Industrial Engineering & Management 3rd year. 13 batch. GROUP MEMBERSMuhammad Asim aslam (D-13-IN-06)Muhammad Husnain Siddiqui (D-13-IN-07)Muhammad Ahsan (D-13-IN-10)Mairaj saleem (D-13-IN-18)

Internship Duration Start Date: 09-june-2015 End Date: 24-june-2015

ContentsINTRODUCTION TO PMTF02DESIGN OFFICE03PRODUCTION PLLANING.03PRODUCTION CONTROL.04TOOL DESIGN.05TOOL ROOM05CNC SHOP06LIGHT PARTS .06HEAVY PARTS.07MACHINE ASSEMBLY AND STORE07SPECHIAL MANUFACTURING..08FORGING08HEAT TREATMENT..09DIE-CASTING. 09

INTRODUCTION OF PMTF.Pakistan Machine Tool Factory (Pvt.) Ltd. (PMTF)is a precision engineering goods manufacturing enterprise in Pakistan, established in technical collaboration with M/s. Oerlikon Buhrle & Co. of Switzerland who are the world's renowned manufacturers of Machine Tools. The factory came into regular production in 1971.It is located Off National Highway, about 35 Km from Karachi City near Landhi Industrial Estate and spread over an area of 226 acres out of which 17 acres are occupied by works. The factory employs about 1900 engineers, technician, workers and other service staff. The layout of the factory is according to the best European standards. This factory is a unit of State Engineering Corporation of Pakistan and is engaged in the production of Machine Tools, Automotive Transmissions and Axles Components, Gears for Locomotives, Pressure Die Cast parts and other products.PMTFhas rich experience in Designing and Manufacturing of precision engineering goods and its facilities include Designing, Machining, Forging, Heat Treatment, Assembly, Die Casting etc.PMTFis certified to ISO 9001.Quality Assurance System and has excellent Quality Control and Testing facilities to meet the international quality requirement.

DESIGN OFFICE:In design office we saw various things we saw PMTF standards books like zero standard book in which so many detail about any basic standard of designs and lines and we also saw a 1 standard book in which detail description about material and we saw and read other standards book of PMTF. We learn how design person work on AUTOCAD software .In PMTF mostly drawings are converted from one unit to another or we can say that PMTF convert every drawing on PMTF standards units.PRODUCTION PLANNINGProduction Planning may be said to be a technique of forecasting ahead every step in the long process of production, taking them at right time and in the right degree and trying to complete operations at the maximum efficiency.The production planning department of PMTF consist of three section: Cost estimation Production pre-planning MethodologyCost Estimation.The production planning department estimate the manufacturing cost of the product which includes material cost, rejection cost, forging cast, normalizing cost and machine hour rate.Production pre-planning.Production pre planning section prepare the manufacturing lay-out which include all the operation required to make the final product. Also give the operation instruction O.I where necessary. Then make the material warrant to issue the material.Methodology.Methodology section does the time and motion study to estimate the production time. Calculate the standard time and obtain time and difference between them.

Production controlProduction control is the process that keeps a watchful eye on the production flow and size of resources along with the location, of any deviation from the present action and to arrange for the prompt adjustment so that the production may run according to the original or revised schedule.AREAS OF PRODUCTION CONTROL Sub-dividing the master schedule into manufacturing and subsidiary orders Routing Scheduling Dispatching Expediting Inspection RoutingRouting is determining the exact path which will be followed in production. It is the selection of the path from where each unit have to pass before reaching the final stage. The stages from which goods are to pass are decided in this process.SchedulingScheduling is the determining of time and date when each operation is to be commenced or completed. The time and date of manufacturing each component is fixed in such a way that assembling for final product is not delayed in any way.DispatchingDispatching refers to the process of actually ordering the work to be done. It involves putting the plan into effect by issuing orders. It is concerned with starting the process and operation on the basis of route sheets and schedule charts.ExpeditingExpediting is that branch of production control procedure which regulates the progress of materials and part through the production process.

Inspection Inspection is the process of ensuring whether the products manufactured are of requisite quality or not. PMTF has material testing lab to inspect the material supply by the supplier to ensure that the material quality (hardness, tensile strength, toughness, etc.) is as per requirement. Material testing lab also tests the chemical composition of material. TOOL DESIGN:Tool design dept. design every new tool and kept record of old tools .Tool design dept. play an important role in PMTF .They make four types of tools Machine tools Transmission Tool Armaments Tools Die casting ToolTool design dept. work on these four types of tools and these four types further divided in many types. PMTF purchase dies from KTDMC. They make design of fixtures, jigs and gauges, broaching and hoboing tool are purchased from outside. TOOL ROOM:Tool Room dept. divided in many sections. Milling machines Lathe machines Sharpen machines Grinding machines EDM(Electric discharge machine) machine Drilling machineIn milling section there are different types of milling machines like shrill machine which is used to cut the surface, copy milling machine is used to copy the given design form the original copy generally use to make dies. In lathe section we saw different operation like turning, boring and facing of tools. In grinding section many types of grinding machines like internal, cylindrical and surface grinding .In EDM section PMTF has two machines for EDM operation. In re-sharpen section mostly hob and brooch and tools of lathe and milling machine sharpen. In drilling section various types of drill machine like simple drilling machine and gang drill machine for many drilling operation at a time.

CNC (computer numeric control):CNC (computer numeric control) this dept. play a vital role in PMTF, here we make production quickly and easily. In CNC dept. various types of lathe and milling machine then we saw and learn the process of making spline on grob machine. And then we saw a machining center.

LIGHT PARTS:Light parts section is generally known to make light parts for the PMTF various operations have been performed with high accuracy by a skilled and great experienced worker. We saw different job was being prepared such as head stock of lath machine, Gas meter body, transmission shaft etc. We had a great experienced. Light part dept. divided in four sections Drilling Turning Grinding MillingIn grinding section, final surface finish of part and achieve accuracy and here also various types of grinding machine like center hole machine, surface grinding machine, cylindrical grinding machine. In milling section here various types of milling machines like slotting machine, face cutter machine and also many machines. In turning section here various types of turning machines only difference of size of chuck in which part fixed. In drilling section we learn and saw many terms in drilling like taping, center bore, center sink.

HEAVY PARTS:Heavy parts section deals with the heavy job comparatively than light parts. We had a chance to see the different machinery working on different jobs including lathe bed, tail stock, carriage etc. Heavy part dept. divided in three sections Boring Drilling Planning In boring section vertical boring machine which moves in x and y axis. In Drilling sections drill heavy parts and here we saw and learn one more new term reamer. In surface planning section used shrill milling machines for finish surface and various machines use for planning operation.

Machine Assembly and Store:In Machine assembly dept. assemble different parts of machine and after inspection send to dispatch. Machine assembly dept. divided in different sections like Lathe section Milling section Power saw section Paint section Drilling sectionIn lathe section assemble every little or big part of lathe machine and make C4 lathe after assemble go to paint and then final inspection. In milling section assemble milling machine and make K4 and K6 milling machine and same operation as lathe section. In power saw section assemble power hack saw. In drilling section assemble pillar drilling machine.In this dept. two types of stores Those parts manufactured in PMTF Those parts purchase outside placed in separate store.

SPECIAL MANUFACTURING:S.M section called SM-300, SM-300 divided in six sections SM-302(turning) SM-303(drilling) SM-304(Milling) SM-305(Grinding) SM-306(Gear cutting) SM-307(special turning)In this dept. we saw in detail about gears cutting from hob and broaching and different types of milling machines (square, shrill vertical) and saw many types of drilling machines and also saw hydraulic press. Gear cutting section have different types of machines gear cutting machines like (spur, spiral bevel and straight bevel) for both have different machines used .In gear making there are following process: Hobbing process Shaping process Gear shaving Gear grinding

FORGING:In forging dept. material come outside and burn in furnace make red hot coke, furnace temperature 1250-1300centigrade. And then hammering the red coke piece in hammering the pressure 300PSI and then forging , here in this dept. there are 2 forging machine both apply different pressure ( one apply 1500 PSI and other apply 300 PSI ) , forging dies different from other dies PMTF purchase forging dies and after forging cutting rough material , internal cutting called parsing and external cutting called Trimming after cutting normalizing material in furnace and if we set temp 925 degree centigrade then normalizing takes 2 hours and if we set temperature at 650 degree centigrade then normalizing takes 3 hours and in normalizing process used 5 burners after normalizing material send for short blasting to remove burn stuff .

HEAT TREATMENT:In heat treatment dept. there are two types of plant old and new in old plant manual working like in old plant pit type furnace used and arrange charge and after arrange charge in furnace then check temp then oil quenching and after quenching material testing and check HRC then send to material testing lab. In new plant sealed furnace in which material after heat treatment auto directly go for quenching and then come and other process same as old plant then material send for short blasting to remove the burn stuff and finish the material and after shot blasting material send for sand blasting and go to dispatch after final inspection.

DIE CASTING:In this dept. 11 machines for aluminum die casting and every machine make different parts.Now a days PMTF die casting dept. make SSGC components like G4, G1.6. G4 have two types of component G4 upper case G4 bottom caseOther component G1.6, in G1.6 have 4 types of components GM body Top cover Side cover front Side cover rearNow a days these two types of product making in die casting dept. aluminum melt at 660-680 degree centigrade for melting aluminum used natural gas and air pressure. In die casting machine cover block fixed and ejector block move pump pressure must be greater than 100 psi.

Report Date: 25 June 2015

Preface

This report documents the work done during the summer internship at PAKISTAN MACHINE TOOL FACTORY (Pvt.) Limited under the guidance of PMTF staff. The report first shall give an overview of the learning during the period of internship with technical details.

We have tried our best to keep report simple yet technically correct. We hope we succeed in our attempt.

Student of Dawood University

Acknowledgments

Simply put, we could not have done this work without the lots of help we received cheerfully from the whole PMTF. The work culture in PMTF really motivates. Everybody is such a friendly and cheerful companion here that works stress is never comes in way.

I would special like to thank MR. Irfan and MR. Shaukat for providing us a chance to get this great experience.

Author