The objectives achieved after completing industrial training are

1. Learning the working of the organization Cooper Corporation Pvt.Ltd.

2. Developing Soft Skills i.e. Communication, Presentation
3. Developing Life Skills i.e. Time management, Safety, Innovation, Entrepreneurship,
Team building, etc.
4. Getting Hands-on Design, Implementation. O & M and Quality Assurance aspects.
5. Learning importance of Mechanical Branch in real life.
6. Developing skills for development of real life projects.

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 Chapter 1
Organization and General Layout

The Cooper Corporation employs over three thousand people, making it one of the
largest employers in the area. An ultra-modern workspace along with in-house staff training
programmes, excellent pay rates and staff and family benefits has Cooper enjoying high-levels
of staff retention rates, with many of the employees even completing 20 to 30, and recently
even 33 years’ of service with the company.

Experienced and well-qualified workforce backed by best quality equipment and the
latest delivery systems enable Cooper to continue building its reputation as an innovative, high-
quality and cost-effective engineering products' manufacturer.

Fig. General Layout of Industry.

Address- Cooper Corporation Pvt. Ltd.
"Nariman House" M60/1,
Additional MIDC, Post-Kodoli,
SATARA, Maharashtra – 415 004 India
Weekly Off: Tuesday
Contact: +91 - 2162 - 240413, 240272, 240273, 240702, 240703,
Fax: +91 - 2162 - 240271, 240023.
Email: [email protected]

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 Chapter 2
Introduction of industry

Cooper is now a name to be reckoned with in the foundry, engine components and
engine industry with exports across the globe.However, the company saw its share of lows
before reaching its present status. It hit an all-time low following the untimely deaths of both,
Nariman D. Cooper and Sir D. B. Cooper in quick succession in 1944 and 1947 respectively.
During the interim period of 1947 to 1960, the late Homai Nariman Cooper took the mantle on
herself to look after all the assets and properties in Satara till such time Satara Industrial Work
started.
From 1968 to 1982, our primary business was machining of cylinder liners and crankshafts,
and since we did not have a foundry, the growth and prospects of the company were limited.
Hence, we decided to start the foundry in 1982 to become an independent, autonomous,and
cost-effective business entity.Satara Industrial Works became Cooper Metals Pvt. Ltd. and later
on the 29th of January 1982, Cooper Foundry Pvt. Ltd. was incorporated by Mr Farrokh N
Cooper.

Since then, for the last five decades, under the leadership of Mr. Farrokh Cooper, Cooper
Corporation (formerly Cooper Foundry) has grown to become a prominent engineering
company, manufacturing and supplying to world’s renowned manufacturers a wide range of
automotive products and acting as OEM supplier of centrifugally cast cylinder liners, sleeves,
cylinder heads, compacted graphite castings, aluminium castings and machined large engine
crankshafts. The company took a big leap forward in 2007 and started manufacturing 2, 3, 4
&6 cylinder gaseous and diesel engines and generating sets in the range of 5 kVA to 500 kVA.

Now Cooper Corporation is a group of eleven manufacturing sites engaged in researching,

designing, manufacturing and supplying precision engineered products worldwide.At Cooper
Corporation, we are continually evolving and building on our strengths.Over the last three
years, we have self-financed 64% of Cooper Corporation's growth by re-investing company
capital.

We have our own government-recognised Research and Development Centre studying

component design, process and tooling improvements, material improvements and production
process equipment development.We have the support of highly qualified technical consultants
based in India, England and Germany. Our manufacturing and production lines utilise
Computer, Gantry and Robotic technology. Our foundry and machining tooling are
manufactured, calibrated and maintained in-house. All critical inspection gauges are built and
calibrated by independent specialist companies.

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History of Industry-
The Cooper family has been in Satara for more than a 100 years now and has established its
name in many diverse fields, ranging from agriculture, education, social reform, politics to
liquor, engineering, and other industries. Sir Dhanjisha B Cooper, the first entrepreneur in the
family, came from a very humble background. His father was a carpenter in charge of
repairing barrels at a distillery and hence, the family name, Cooper.

However, D B Cooper broke free from the family profession and started a liquor business by
extracting toddy from palm trees in a plantation that he maintained. Simultaneously, he ran
many liquor shops throughout the former state of Bombay Presidency. Being an entrepreneur,
he utilised his profits in starting a small company on Satara Road that manufactured ploughs,
agriculture equipment, and years later, diesel engines. Eventually, the company went on to be
known as Cooper Engineering Limited.In those days of the British Rule, it was difficult for
an Indian to establish an industry anywhere in the country. However, Cooper was one of the
three - others being Kirloskar and Ogale - who chose to set up their own factories along the
railway line.

Over the years, Cooper Engineering continued to grow under the joint ownership with the
Walchand's into a multi-faceted engineering company making diesel engines, machine tools,
looms etc.

Back then, Sir D. B. Cooper was also ably assisted by his only son, Nariman D. Cooper, who
despite being an agriculture graduate, took to looking after the daily operations of Cooper
Engineering. Sir D. B. Cooper, eventually, sold Cooper Engineering to the Walchand group
who continued to run the company as Cooper Engineering Limited for over a decade, in
recognition of Sir D B Cooper's contribution to the organisation.

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 Chapter 2

Types of Products and services

Types of Products And Services –
Equipped with state-of-the-art plant and machinery, we have the technology and expertise to
manufacture the entire range of cylinder liners and sleeves for tractors, jeeps, automobile and
stationary industrial applications as per international standards.

We have carved a niche for ourselves in the domestic as well as the overseas markets. In fact,
Cooper is among the top three manufacturers of cylinder liners worldwide and a trusted
source for crankshaft machining for OEMs.

Our capabilities in components also include Centrifugal Casting, Sand Casting, CNC &
Robotic Machining Lines, Crankshafts Machining, Engineering, Product and Material
Development.

Apart from cylinder liners and crankshafts, our component portfolio consists of cylinder
heads and cylinder blocks, valve seat inserts, flywheels and pulleys, crankcase insert,
aluminium parts, pistons and anti-polishing ring.

Our futuristic infrastructure supports our capabilities and progressive goals for delivering the
highest quality components to our clients world over.

1.Liners

Cooper Corporation converted a

pressed liner design to Cooper Grip
Design and started manufacturing
the Cooper Grip Liner in cast iron
and bainitic iron. We take pride in
the Cooper Liner which is being
delivered to customers across the
globe. Find out more about the
Cooper Liner in the 'Component
Portfolio'.

The most critical part of the engine where actual combustion takes place. The liners are
typically manufactured from cast iron in grades FG20 to FG55.

Inside diameter and its surface finish are the most critical parameters of a cylinder liner, and

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we specialise in manufacturing them through a highly evolved process.
Fig.2.1.1.Cylinder Liners Essential performance properties of cylinder liner
are wear and tear, anti-galling and extended life.

We now produce 8,000 tonnes of cylinder liners per month, thus, earning a place amongst the
Top Three Manufacturers of cylinder liners in India.

Our research division has developed centrifugally cast cylinder liners manufactured with our
own formula alloy cast iron. The use of this alloy cast iron gives phenomenal wear and
corrosion resistance with optimal durability and resistance to scuffing.

All cylinder liners are finely ground and bore machined to the last micron for that unique
'Cooper Grip' finish.

Cooper Corporation cylinder liners are used in locomotives, earth-moving equipment, the
Automotive industry, in tractors, the Oil and Gas industries, power plants, gensets and other
domestic and industrial applications.

2. Aluminium Parts-
Aluminium parts are manufactured
with processes such as gravity die
casting, low pressure die casting or
high pressure die casting. The process is decided based on the volume and criticality of the
component. We are well-equipped with the facilities needed for all the
operations mentioned above. Fig.2.2.1 Aluminium Parts

3. Cylinder Blocks

The cylinders heads are either modular or integrated and are designed as per the engine
requirement. We are making both types of heads. The entire valve assembly fits into the
cylinder head. The valve seat valve guide is the most
critical part of the head & is manufactured with
special tools & the machining process. The
combustion in the engine is mainly dependent on the
head. The cylinder heads are manufactured in cast
iron & compacted graphite iron. The cylinder heads
are manufactured from single cylinder to multiple
cylinders. The cylinder block is the main part of the
engine, on which all the parts get fitted.

The blocks are designed based on the engine

requirements, and they are manufactured from single
cylinder to multiple cylinders, they are manufactured
from cast iron grades ranging from FG25 to FG35,
COMPACTED GRAPHITE IRON. The crank shaft
bore, camshaft bore, cylinder liner bore, HLA bore are the most critical parameter of the block.
The block are manufactured on the specialized equipments & tooling. At Cooper Corporation

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we produce all types of Cylinder Heads and Cylinder Blocks to customer Fig.2.3.1
Cylinder Blocks

specifications. These are manufactured on an imported Moulding Line with strict controls on
the core to ensure leak proof Cylinder Heads with clean water passages. We supply Cylinder
Heads fully machined, pressure tested and assembled with valve seat inserts, valve guides and
yoke guides

4.Pistons

Piston is either manufactured from aluminium or cast iron. This part fits into the cylinder liner
using the piston rings. The combustion in
the engine is mainly dependent on the
piston. We manufacture
pistons for large bore liner in cast iron
with tin plating.

Fig.2.4.1 Pistons

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 Chapter 3
Types of machines used in indusrty
At Cooper, our manufacturing process is continuously updated to comply with the latest
global standards and customer specifications. The production process is constantly monitored
to ensure consistency in quality, and we use high-performance machine tools in each phase of
the process to achieve the desired surface finish through optimised machining operations.

Our manufacturing plants are equipped with precision casting, machining and honing facilities.
All critical machines are imported from renowned global manufacturers such as Junker,
WMW, Mori Seiki, Hommelwerke and Nagel.
For Machinig -
• 280 CNC Turning Lathes
• 12 Horizontal Machining Centres
• 15 Vertical Machining Centres
• 4 Horizontal Boring Machines
• 4 Vertical Boring Machines
• 9 Honing Machines
• 6 Grinding Machines (Cylindrical & Centreless)
• 50 Heavy Duty Turning Lathes
• 2 –5 Axis CNC Machines
• 2 VTL Machines
• 36 Robots for Machining Lines

For Casting-
• 18 Six-head Carousel Centrifugal Casting Machines
• 22 Inductotherm Induction Furnaces, ranging from 500 to 2200 kilograms
• 2 Eight-head Carousel Centrifugal Casting Machines
• 2 Robots for handling Eight-head Centrifugal Casting Machines
• 10 Single Centrifugal Casting Machines
• 8 Shot Blasting Machines
• 7 Stress-relieving Furnaces

For Inspection-
• CMM – Zeiss/Mitutoyo
• Hardness Testing
• Tensile Testing
• Eddy Current Testing

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• Ultrasonic Testing
• Auto Gauging System
• Radioactive Radiation Detection
• Profile Projector
• Spectro Analyzer
• Image analyser
• Millipore Analysis
• Microscope

Heavy Duty Lathe

Parting off is mainly
performed in bar feed
machines, often used in
mass production. The
parting off operation is
usually only a small part
of the component's total
machining time and
therefore not usually seen
as a target area for time
savings. However, after the parting sequence, some components still have additional features
to be machined while in the sub spindle. If chips wrap around the component they can prevent
the clamping of the next component in the sub spindle. If this occurs, the machine will either
produce scrap or stop. Chips wrapping around the finished component can cause problems in
consecutive operations (heat treatments, deburring, assembly, etc.) and destroy the surface
finish. Since parting off is usually one of the
last operations to perform on the
component, security is of great importance.
If the tool breaks during parting, the
component is usually Fig.3.1
Heavy Duty Lathe
scrapped. This may lead to long machine
stoppages.

CNC Turning Lathe Machine

CNC Turning is a manufacturing process in

which bars of material are held in a chuck
and rotated while a tool is fed to the piece to
remove material to create the desired shape.
A turret (shown center), with tooling
attached is programmed to move to the bar
of raw material and remove material to create the programmed result. This is also called
“subtraction machining” since it involves material removal. If the center has both tuning and
milling capabilities, such as the one above, the rotation can be stopped to allow for milling out
of other shapes.

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 • The starting material, though usual round, can be other shapes such as squares or
hexagons.
• Depending on the bar feeder, the bar Fig.3.2 CNC Turning Lathe
length can vary. This affects how much
handling is required for volume jobs.

• CNC lathes or turning centers have tooling mounted on a turret which is computer-
controlled. The more tools that that the turret can hold, the more options are available
for complexities on the part.
• CNC’s with “live” tooling options, can stop the bar rotation and add additional features
such as drilled holes, slots and milled surfaces.
• Some CNC turning centers have one spindle, allowing work to be done all from one
side, while other turning centers, such as the one shown above, have two spindles, a
main and sub-spindle. A part can be partially machined on the main spindle, moved to
the sub-spindle and have additional work done to the other side this configuration.
• There are many different kinds of CNC turning centers with various types of tooling
options, spindle options, outer diameter limitations as well as power and speed
capabilities that affect the types of parts
that can be economically made on it.

Honing Machine

Honing is an abrasive machining process that

produces a precision surface on a metal
workpiece by scrubbing an abrasive stone
against it along a controlled path. Honing is
primarily used to improve the geometric form of
a surface, but may also improve the surface
texture.
Typical applications are the finishing of cylinders for internal combustion engines, air
bearing spindles and gears. There are many types of hones, but all consist of one or more
abrasive stones that are held under pressure against the surface they are working on.
In terms of sharpening knives, a honing steeldoes Fig.3.3 Honing Machine
not actually hone knives, but simply realigns the
metal along the edge

Dial Bore Gauge

A dial bore gauge is a special tool, calibrated in .001

inch (.0025 centimeter) or .0001 inch (.00025
centimeter), which is used to accurately measure the
inside diameter of a hole, cylinder or pipe. In
conjunction with a micrometer, a bore gauge will give you the exact reading of a bore size. A
typical bore gauge is comprised of a shaft with a dial indicator at the top and a measuring sled
at the base. The measuring sled consists of three guides and an Fig.3.4 Dial Bore
Gauge
actuating plunger. Dial bore gauges give you quick
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and accurate readings on the size, less than perfect roundness or wear

Go-No/Go Snap Gauge

Snap gauges are often used when a large quantity of
work pieces must be inspected.[4]The snap gauge
has four anvils or jaws, the first one or pair
(outermost) are set using the upper limit (tolerance)
of the part and the inner set adjusted to the lower
limit of the part. A correctly machined part will pass
the first set of jaws and stop at the second—end of
test. In this manner, a part may be checked in one
action, unlike the plug gauge that needs to be used twice and flipped to access the second gauge.
The first go/no-go snap gage for checking thread rolls was Fig.3.5 Go Snap Gauge
invented in 1943 to speed production of parts during WWII.

Brinell Hardness Tester Machine

The Brinell hardness test method as used to
determine Brinell hardness, Most commonly it
is used to test materials that have a structure
that is too coarse or that have a surface that is
too rough to be tested using another test
method, e.g., castings and forgings. Brinell
testing often use a very high test load (3000
kgf) and a 10mm diameter indenter so that the
resulting indentation averages out most surface
and sub-surface inconsistencies.

The Brinell method applies a predetermined

test load (F) to a carbide ball of fixed diameter
(D) which is held for a predetermined time period and then removed. The resulting
Fig.3.6.1Brinell Hardness Tester
Impression is measured with a specially Machine
designed Brinell microscope or optical system across
at least two diameters – usually at right angles to each other and these results are averaged
(d). Although the calculation below can be used to
generate the Brinell number, most often a chart is then
used to convert the averaged diameter measurement to
a Brinell hardness number.

Test Method Illustration

D = Ball diameter

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 d = impression diameter
F = load
HB = Brinell result Fig3.6.2 BHN Test Method

Chapter 4
Manufacturing Process along with production planning &control methods.

Machining Process –

The casting are shot blasted and are sent to the machine shop for machining operation,
the first operation is the roughing operation where casting skin is removed, this operations is
performed on a custom designed vertical high speed
turning cum boring
machine. The machined liner is then turned on a CNC Turning Centre where all and lengths
are maintained, for Dry liners the next sequence of operations would be

Fig.4.1 CNC Turning Lathe

1.Rough honing
followed by Plateau honing and Finish grinding whereas for Wet Liners after CNC turning,
fine boring followed by rough honing, fine CNC turning and plateau honing would be
performed. Honing has been and will remain to be in the foreseeable future the only process
available that could provide both the required surface roughness and the cross-hatching in
cylinder liners. The cross-hatching lay direction is needed to provide means for retaining
lubricants. A cylinder liner has fairly intricate surface requirements due to its complicated
functions. It has to provide adequate surface roughness to resist wear and to store and retain
lubricants during high temperatures, in addition to liner hardness, geometric dimensioning and
tolerance to ensure other proper functions.

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2.Fine Boring
Boring is the process which gives the final look of inner diameter. We perform boring
operation on vertical machining center. This is fully computerized control machine. We also
use special purpose boring machine which maintains dimension accuracy, taper, ovality and
surface finish.

3.Outer Diameter Turning

It perform outer diameter of liner on Lathe machine, which is manually operated machine,
gives high accuracy in dimensional parameters, surface roughness parameters and geometrical
parameters. A main benefit of OD CNC Turing is to minimize cycle time, repeatability of
quality and consistency product.

4. Grinding
Grinding is the process where super surface finish can be maintained on products. We have
two type of grinding process center less grinding and cylindrical grinding.
Grinding controls dimensional parameters, surface parameters and geometricalparameters.

5.Honing
Honing is the process where required hex pattern can be maintained in finish inner diameter.
We use Plato honing process. The main benefits of Plato honing process is to achieve required
quality parameters like surface finish.

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 Chapter 5
Testing raw material & finished products along with Quality assurance

Inspection Facilities

Each product from Cooper undergoes stringent levels of quality testing. Our well-equipped
laboratory has a trained workforce that conducts Chemical analysis, Microstructure analysis,
Tensile Strength inspection, Elongation tests, Modulus of Elasticity examinations and other
maintenance processes - from quality control to assurance.

Our in-house facilities for regular testing and analysis of parts also includes Emission
Spectrometer (for analysis of chemical composition), Hardness Testing machines (BHN &

HRB) and Metallurgical Microscopes with CCTV

camera for evaluation of microstructure.

Testing and analysis are also carried out at NABL-approved laboratories for third-party
evaluation of tensile strength and modulus of elasticity.

Fig.5.1 Eddy Current Testing Machine

Quality Assurance -
We practice stringent quality control measures for all our products. In the Cooper
Corporation Quality Control laboratories, products undergo Chemical Analysis with an

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Emission Spectrometer, and Microstructural Analysis using CCTV camera equipped
Metallurgical Microscopes and BHN/HRB Hardness Testing Machines. The products are
further depth measured and tested for Tensile Strength, Elongation, Modulus of Elasticity,
Surface Quality and Internal Defects.

Quality Policy:

At Cooper Corporation, Quality Policy has been designed to achieve the following
objectives:

• Maintain a quality system in line with ISO 9001:2008, ISO/TS 16949:2009 and ISO
14001:2004
• Improve processes and reduce cost on a continuous basis through the extensive
application of statistical techniques
• Empower employees through varied training opportunities
• Follow high standard housekeeping tasks to provide best-in-class working environment

Quality Process:
Documentation and evaluation of all the critical manufacturing steps - from material
composition to final inspection before dispatch - ensures that we consistently produce top
quality products that meet international standards. Design and development of new products
are also routed through the APAQ Process Quality, integrated into the manufacturing process
through:

Fig.5.3 Quality Award Fig.5.4 Quality Award

• Process monitoring and operating instructions

• Control plans and checklists
• Set-up approval
• Process capability evaluation

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A robust packing system has been developed at Cooper which allows parts to be shipped across
the ocean or stored in the warehouse while remaining fresh and ready-for-use without any oil
accumulation. This also makes it a preferred choice for aluminium die casting.

Quality Certifications:
Cooper Corporation has been awarded the following Quality Certificates:

• ISO 9001:2008
• ISO:TS 16949:2009
• ISO 14001:2004

Fig.5.4 Quality ISO Certificates

We ensure perfect synchronisation between our manufacturing and engineering

operations. Both are performed at the company plant in Satara, Maharashtra and the
engineering activities complement manufacturing by designing all the dies, fixtures, tooling
and preparing control plans and specifications.

Most of the tooling is made and calibrated in-house while critical inspection gauges are
outsourced to other manufacturers. The blend of in-house work and outsourcing is extended
to laboratory facilities for regular testing and analysis of parts. This process delegation helps
in substantially reducing the lead time in tailor-made production, either made to customer
specifications or engineered for their applications.

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All equipment for casting, machining and quality control has been sourced from leading
suppliers in India and overseas to ensure very high levels of efficiency and reliability.

Chapter 6.
Major material handling product

Material handling equipment is

mechanical equipment used for the movement,
storage, control and protection of materials, goods and products throughout the process of
manufacturing, distribution, consumption and disposal. The different types of handling
equipment can be classified into four major categories: transport equipment, positioning
equipment, unit load formation equipment, and
storage equipment.
A conveyor system is a common piece of
mechanical handling equipment that moves materials
from one location to another. Conveyors are
especially useful in applications involving the
transportation of heavy or bulky materials. Conveyor
systems allow quick and efficient transportation for a
wide variety of materials, which make them very
popular in the material
handling and packaging industries
Fig 6.1 Conveyor System.
Cranes are used to transport loads over variable (horizontal and vertical) paths within
a restricted area and when there is insufficient (or intermittent) flow volume such that the use
of a conveyor cannot be justified. Cranes provide more flexibility in movement than conveyors
because the loads handled can be more varied with respect to their shape and weight. Cranes
provide less flexibility in movement than industrial trucks because they only can operate within
a restricted area, though some can operate on a portable base.

Fig .6.2 Cranes

Storage equipment is used for holding or buffering materials over a period of time.
The design of each type of storage equipment, along with its use in warehousedesign,
represents a trade-off between minimizing handling costs, by making material easily
accessible, and maximizing the utilization of space.

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 Industrial trucks are used to move materials over variable paths and when there is
insufficient (or intermittent) flow volume such that the use of a conveyor cannot be justified.
They provide more flexibility in movement than conveyors and cranes because there are no
restrictions on the area covered, and they provide vertical movement if the truck has lifting
capabilities.

Chapter 7
Safety Procedures Followed
Industrial safety are the policies or precautions put in place to ensure plant and factory worker
protection from hazards that could cause injury. Industrial safety is important as it safeguards
human life, especially in high risk areas such as manufacturing industries, where a fatal mistake
can be catastrophic. Safety procedure includes the use of safety gadgets during the working
time. Thus, the use of safety gadgets is important and compulsory for protection purpose.

There are three main industrial safety systems followed by the industry;

• Process Safety System or Process Shutdown System.

• Safety Shutdown System: This system includes emergency shutdown of all the facilities
to a safe state in case of an emergency situation, thus protecting personnel, the
environment and asset. Safety Shutdown System shall manage all inputs and outputs
relative to emergency shutdown functions. This system might also be fed by signals
from the main fire & gas system.
• Fire & Gas System: The main objective of this system is to protect personnel,
environmental and plant. This system shall achieve these objectives by detecting at an
early stage, presence of flammable gas.
The plant can make some improvements in safety during the work, they are mentioned as
follows;

1) Inform supervisors of unsafe conditions.

2) Use equipments, machines and tools properly.
3) Wear safety equipments or gears (PPE).
4) Prevent slips and trips.
5) Keep work areas and emergency exits clean.
6) Eliminate fire hazards.
7) Avoid tracking hazardous materials.
8) Prevent objects from falling.
9) Use correct postures when lifting.
10) Take work breaks from time to time.

• Safety Gears used:

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 Various safety gadgets are used by workers in the plant. These safety gadgets are
compulsory to wear during the working time. These gadgets prevent or protect from any
harmful asset. These safety gadgets are;
1) Safety Shoes
2) Helmet
3) Safety Goggles
4) Rubber Hand Gloves or Cotton Hand Gloves
5) Lather Apron
6) Earplug
7) Face Shield
8) Mask
These safety gadgets are used at every section of the plant. Some gadgets are common to
use such as safety shoes, helmet, lather apron, cotton hand gloves and the remaining gadgets
are used as per the work in different sections or departments.

Chapter 8:
My Experience during Industrial Training
It is my great pleasure to express my thoughts on the things that I have experienced during the
passed month and half during the Industrial Training.
When I was placed for training in Satara,I was really excited about the training and for
new experience in Cooper Corporation Pvt.Ltd .Really speaking at the start when we were
ready to go training I felt that this is just waste of our holidays, this is just wasting our time as
their no interest for industrialist in teaching us.
But when I reached organization after first day I came to know that I was wrong because
of the teaching skills of Mr.Ashish Ghanawat sir. He was a great man I will near forget his
teachings in my whole life. He never put any burden on us.
My training program was very enriching and enabled me to gain knowledge about
Cylinder Liners, Pistons & Machines . The main skill learnt were the Communication. Due to
training I personally was encouraged for being a entrepreneur. Before training I also assumed
that industrial job I very stressful, dress code, have overcome losses, stress to make profit due
to change in market conditions. But Mr.Ashish Ghanawat Sir taught how the industry is
managed efficiently and how to gain profits.
It was because my industrial training and Cooper Corporation Pvt.Ltd.I changed my
thoughts towards the industries. At last I want to say that it was just an awesome experience
for me and I wish I would gain chance to have more such experience in my upcoming life.

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 Speaking on thoughts on Industrial Training, it is and in future it will prove very helpful
for students to experience and understand what the industries really expect from them.

Chapter 9
Description of the project
Some of the basic thing were taught during the training by the employees of
organization along with Ashish Ghanawat sir. Some project activities were also carried out by
me. These things are
Time Study
Time study may be defined as “the art of observing and recording the time required to do
each detailed element of an industrial operation”.
The term industrial operation includes manual, mental and machining operations, where:
(i) Manual time is divided into three types of operations, i.e. handling of tools, machines
and materials.
(ii) Mental time includes time taken by the worker for thinking over some operations.
(iii) Machining time includes time taken by the machines in doing its share of work.
Thus time study standardizes the time taken by average worker to perform these
operations.
It can also be defined in the following words “work measurement” is the application of
techniques designed to establish the time for a qualified worker to carry out a specified
job at a definite level of performance.
Methods of Time study
Time study can be performed by the following methods, depending upon the accuracy
re-quired:
1. Stop Watch Method

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 2. Time Recording Machine, and
3. Motion Picture Camera.
Procedure of Time Study
(a) Analysis of Work:
(b) Standardisation of Methods:
(c) Making Time Study:
Methods of Rating:
Following are the important methods used for performance rating:
1. Speed Rating.
2. Westinghouse System of Rating
3. Synthetic Rating.
4. Objective Rating.
5. Physiological Evaluation of Performance Rating.
Allowances:
To get the standard time, a proper allowance must be added considering the working
conditions.
While deciding the quantum (generally in terms of percentages) of allowance to be added to
the normal time, following types of allowances are considered:
1.Relaxation Allowance:
2. Interference Allowance:
3. Process Allowance:
4. Contingency Allowance:
5. Special Allowance:
Cycle Time:
Cycle time is defined as the time duration from starting point of a job to the starting point
of the next job. This time is established from the observation data of an operator while
working at a certain pace.
Basic Time:
Basic time of an job is determined by multiplying rating factor to the observed time
(cycle time). Basic time is also expressed as Normal time.
Basic time = (Observed time X Performance Rating)/100
Standard Time:

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 Standard time is the time allowed to an operator to carry out the
specified task under specified condition and defined level of performance. This is a
standard definition for standard time.
Use of Time Study:
(i) It is useful in determining the standard time for various operations, which helps in
fixing wages and incentives.
(ii) It is useful to estimate the cost of a product accurately.
(iii) It helps in production control.
(iv) It helps in predicting accurately as to when the work will be completed and hence
customers can be promised to take delivery on a fixed date.
(v) Using the time study techniques, it can be found that how much machines an opera-tor
can run.

Chapter 10
Challenging Experiences

It is my great pleasure to express my thoughts on the things that I have experienced

during the passed month and half during the Industrial Training.
When I was placed for training in Satara,I was really excited about the training and for
new experience in Cooper Corporation Pvt.Ltd.Really speaking at the start when we were ready
to go training I felt that this is just waste of our holidays, this is just wasting our time as their
no interest for industrialist in teaching us.
But when I reached organization after first day I came to know that I was wrong because
of the teaching skills of Mr.Ashish Ghanawat sir. He was a great man I will near forget his
teachings in my whole life. He never put any burden on us.
My training program was very enriching and enabled me to gain knowledge about
Cylinder Liners, Pistons & Machines . The main skill learnt were the Communication. Due to
training I personally was encouraged for being a entrepreneur. Before training I also assumed
that industrial job I very stressful, dress code, have overcome losses, stress to make profit due
to change in market conditions. But Mr.Ashish Ghanawat Sir taught how the industry is
managed efficiently and how to gain profits.
It was because my industrial training and Cooper Corporation Pvt.Ltd.I changed my
thoughts towards the industries. At last I want to say that it was just an awesome experience
for me and I wish I would gain chance to have more such experience in my upcoming life.
Speaking on thoughts on Industrial Training, it is and in future it will prove very helpful
for students to experience and understand what the industries really expect from them.
It was not much difficult kind of training for me, but there were some challenging
experiences to during the training. It was challenge to involve in the organization within very
short period of time. The major challenge was in manufacturing of Liners. Another challenging

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experience was taking interview and gathering the requirement of the products from the
production manager of Cooper Corporation Pvt.Ltd.

Conclusion

Industrial Training was very interesting part of diploma learning. It was really a very
good experience. Industrial gave us opportunity to learn new concepts and experience the
working of the industry. It was a pleasure for me to be a part of such training. I conclude that I
have understand all the concepts taught during the industrial training.
I conclude that I have successfully completed the training and completed all the
activities and assignments which were told during the training. I also conclude that all the
concepts that were taught during have successfully understood to me.

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