CHAPTER – I

1. INTRODUCTION

Internship training is one in which applying the existing skills in an organization to

a specified period of time to learn about a particular activity. It involves a supervision
component that is mentoring and educational and includes career related experiences. It also
have a reflection and evaluation process at the conclusion of the internship.

Internships provide real world experience to those looking to explore or gain the
relevant know ledge and skills required to enter into a particular career field. Internships are
relatively short term in nature with the primary focus on getting some on the job training and
taking what's learned in the classroom and applying it to the real world. Interns generally have
a supervisor who assigns specific tasks and evaluates the interns overall work. Completed the
internship to gain relevant experience in this particular career field as well as to get exposure.

Internship report was made after having internship with INTEGRA

AUTOMATION PRIVATE LIMITED particularly in Human Resource Department from
03/08/2023 to 31/08/2023. This chapter contains the following Background of internship;
Background of the Company; Location; Mission; Company structure; and other main activities
carried out by the company.

Integra Automation is a one stop solution provider for Grey Iron, SG Iron castings
in the form of components and also sub-assemblies.

Integra Automation owns a world class machine shop which along with its foundry
caters to renowned Customer in the Automotive, Power generation, Tractor, Locomotive,
Printing machinery, Valves, Pump and other engineering industries in India and Abroad.

1
COMPANY MISSION:

To make citizens aware about the need of trees for the survival and protect natural resources
for generations to come.

They passionately work for the environment through a series of nature-related activities. By
working at the source, viz., planting trees, they Endeavor to ensure that afforestation helps to
bring back the lost natural resources.

They can say that planting a tree is almost Elemen’Tree’ because it has an impact on
all the five elements. Its role in giving us Air, Water, Fire, Wind and space is
indispensable, which is why it is essential that they plant trees.

Primary objective:

To study the organizational structure and departments of the company

Secondary objectives:

To get a real-life exposure to human resources management, marketing techniques and

financial management, knowledge, this gained through management studies.

• To get awareness about the overall culture of the company to ascertain the process

of each department and structure of each department

• To ascertain the organization structure

• To know the function of each department

• To give suggestions to the for improvement

• Getting practical experience regarding the organizational working

• To improve the management and research aptitude

2
 CHAPTER – II

2. INDUSTRIAL PROFILE

The Indian pump and valve industry contributes significantly to the country’s
growth, given its role as basic equipment in almost every sphere including infrastructure and
agriculture.

The Indian pump and valve market can be segregated on the basis of end use. The
main sectors in which pumps and valves are used are agriculture/irrigation, building services,
water, waste water/sewage management, and industrial uses (power, oil and gas, metals and
mining, etc.). Pumps are generally classified into positive displacement and dynamic pumps
based on the type of operating principle. Displacement pumps can be sub-classified as rotary
and reciprocating pumps, while dynamic pumps can be centrifugal and special effect pumps.

Expanding the domestic market

The Indian pump and valve segment has registered significant growth in the past
few years. Notably, the sector provides one of the highest net value additions (over 20 percent)
in the engineering sector. It has matured significantly and domestic sales are increasing at the
rate of 16-18 percent per annum. According to industry estimates, India produces about 4.5
million pumps per annum. As per the Indian Pump Manufacturers’ Association, the pump
industry has a turnover of about ₹200 billion. The segment has around 800 manufacturers
making pumps of different capacities.

Indian pumps and valves are exported to more than 100 countries across the globe.
The present market scenario suggests that export growth is likely to double in the next two
years. India’s key export markets include the Middle East, North Africa, the US, Germany,
Russia, China, and Latin America.

3
 With regard to imports, Indian pumps and valves are sourced from the US, China,
and France. The availability of low-cost models makes local manufacturers competitive and
this has limited the inroads by Chinese products, especially in the agricultural sector. Also, the
lack of adequate aftersales service has restricted the acceptance of Chinese supplies by
industrial sectors.

The industry’s structure is characterised by a high level of market fragmentation with

the presence of a few big players and a large number of medium- and small-sized players. There
are over 800 domestic pump and valve manufacturers, and the industry employs over 1,20,000
people. Pumps perform two key functions — the transfer of liquids from one system to another
and the circulation of liquids within a system. Some of the key components that determine the
configuration of pumping systems are pumps, prime movers (electric motors, diesel engines or
air systems), piping, valves (to control flows in the system), other fittings, controls and
instrumentation, and end-use equipment.

Most of the pump market (about 95 percent) comprises centrifugal pumps, while the
remaining 5 percent are positive displacement pumps. Agriculture and building services
account for the major portion of demand at 46 percent of the market in terms of value, while
the rest of the infrastructure sector together accounts for the remaining 54 percent. This
segment of the pump market is technologically intensive and hard for small and medium
enterprises (SMEs) to penetrate. Almost 95 percent of the country’s demand is met by domestic
pump manufacturers and about 5 percent through imports. Thus, both Indian and foreign
players play a role in the local market.

The pump industry comprises a few large players — both Indian and multinational
companies (MNCs) — and many SME players. Some domestic SMEs have entered foreign
markets such as Egypt, the US, West Asia, Greece, and Italy, while MNCs have either entered
into joint ventures or made direct investments in the Indian market.

4
Recent developments in technology to improve pump and valve efficiency

From an electric motor perspective, motor technology is changing gradually. The

induction motor has almost hit its design limit in terms of efficiency. Therefore, other motor
types such as Permanent Magnet and Synchronous Reluctance motors are being used to help
increase motor efficiencies. Martin Richardson, Water Framework Manager, ABB said, “These
are different technologies, so they have different challenges, but certainly can help increase the
efficiency from the electromechanical perspective.”

To take it further, Daniel Griffiths, Operation Manager, WEG Motors said,

“Improvements in motor efficiencies, control and process analysis and the inclusion of
IoT/Industry 4.0 will all assist the system designers in creating adaptive and efficient pump and
valve systems.” The efficiency gains now being made can only be marginal, as hydraulic design
is well-engineered from old-school engineers and well-developed in terms of software.

Brian Conway, Director, Pumps & Systems Ltd said, “The solution is to run a
pump or multiple pumps at best efficiency point (BEP), or very close to it. It requires a good
understanding of system demand variation, if any, and a detailed process description, followed
by intelligent selection of a pump, or multiple pumps to operate at BEP. There is now a great
opportunity for data gathering and the facilities for AI cloud-based systems, but there are very
few providing real-time intelligent control to maintain assets at their optimum.”

Challenges caused by inefficiency of pumps and valves

Inefficiencies in pumping systems ultimately cost money. The obvious cost is

energy, but the inefficient running of a pump or system also has an impact on asset life,
maintenance intervals, reliability, and risk of failure. Richardson said, “Whilst costs are
important for users and operators of pumps, the environmental impact of running inefficiently
should not be ignored. On a global level, a huge proportion of the world’s electrical energy is
consumed by pumps and they are the single biggest user of electricity in the EU, so the
opportunity to make a difference in CO2 savings and energy reduction is massive.”

5
 Poor selection, control and maintenance are key areas which present the most
challenges to pump users, as the plant equipment can often be in remote or inaccessible
locations or have such a wide and changing requirement that it can be difficult to keep a pump
system running at its optimum. Griffiths said, “These factors often result in expensive, rushed
repairs and an overreaction for highly sophisticated control and monitoring solutions.” Even
pumps designed and installed more than 50 years ago are very efficient, and if they are selected
correctly for the system, they will provide and maintain almost as-new efficiency and long-
term reliability of wearing and non-wearing components.

To which Conway elaborated, “When a pump is taken outside of its preferred

operating zone, then you are inviting increased stress, vibration, wear, recirculation, etc. as
compound interactive issues, which will increase maintenance costs and reduce reliability. If
we look outside of the effect on the pump, the annual energy cost over the life of the pump is
a hidden cost, often not seen within the budgets of those that can affect it.”

Solutions to enhance efficiency

Society generally sees technology as the solution and there is no doubt that
technology is advancing. It is allowing us to increase efficiency at a component level, but we
sometimes are obsessed with ‘new stuff’ and tend to focus on that rather than utilising the tools
that we already have. According to Richardson, “I think the biggest gains in terms of gaining
efficiency from pumping systems actually come down to how these systems are really operated
and used. The interaction of components and how individual items can be combined to increase
efficiencies is important, but designers often have limited control over how the system actually
operates after it is commissioned.”

Further Griffiths says, “A simplistic and practical approach to any pump

solution is often the most effective at maintaining an efficient system, asking good questions
about the requirements of the pump system, planning for expansion, redundancy and duty
control and understanding the demand profile are vital to creating an efficient control system
which matches the requirements of the system.”

6
 Pumps are almost at their peak in terms of efficient design, but there is a long
way to go in terms of a sustainable, optimised and reliable system. The pump needs to match
the system, either through confident engineering methodology, or practical system testing and
analysis, and intelligent operation.

Conway says, “Being able to understand the interaction of pump characteristics

with system characteristics enables intelligent design, control and operation.” Many in the
industry who operate pumps do not understand what they are operating because they haven’t
been given the right training. Investment in training will provide enormous benefits to
intelligent, operational pump efficiency and enable greater development of the market.

The India pump market size was valued at USD 2.2. billion in 2020 and is expected to reach
USD 3.3 billion in 2026, growing at a compound annual growth rate (CAGR) of 7% during
2020-2026. 16% of India's pump manufacturing potential is export-oriented and is projected to
expand further.

Growth factors for Indian pumps include:

• Increase in population and higher dependence on agriculture

• Industrialization
• Growing public awareness of the safety of drinking water
• Declining quality of water
• Lower levels of water
• Environmental pressure on pollution disposal from government entities

7
 CHAPTER – III

3. COMPANY PROFILE

Integra Automation Private Limited

Established in 1989, Integra Automation , rapidly became the leader of high quality Ductile
and Gray Iron castings.
The company distinguishes itself by its High level performances in the precision Ductile and
Gray iron casting industry because of the team work, the meticulous quality control, the
capacity of production, the skills of the Technicians and specialized engineers and also the state
of the art equipment. One of the major advantages is that Integra has an in-house sophisticated
CNC and conventional machine shop. They are capable of providing the castings in finished
condition.
Integra currently caters component requirements to Automotive, Engineering, Power, Tractor,
Locomotive, Printing machinery, Valves, Pump and other industries, both in India & across
the globe.

NEW DIRECTION FOR CASTING &

MACHINING
Integra Automation is a one stop solution provider for Grey Iron, SG Iron castings in the form
of components and also sub-assemblies.

Integra Automation owns a world class machine shop which along with its foundry caters to
renowned Customer in the Automotive, Power generation, Tractor, Locomotive, Printing
machinery, Valves, Pump and other engineering industries in India and Abroad. Integra
Automation has facility for painting components which caters to primary coating that can meet
acceptable Customer standards and supports casting Preservation, in addition, Integra
Automation can also provide heat treatment services in-house where required by the Customer,
in addition both painting & heat treatment services can also be outsourced to meet critical
product specific requirements. Integra Automation has the capability to undertake more

8
complex and intricate machining solutions with its world class facilities and proven solution-
focused approach, to enhance time and cost.

Integra Automation takes pride in being certified for the following Management System
Standards, IATF 16949:2016 & ISO 9001:2015 standards that demonstrates compliance to
international standards in addition to meeting demanding Customer Specific requirements.

Integra Automation has been strategically initiating efforts to compete with world class
manufacturing facilities by introducing Robotics and Automation in the manufacturing
processes, supported by focused advancement in the IT infrastructure to become a Industry
V4.0 compatible company by 2020.

MILESTONES
Establishment of Integra Automation with a CNC‐ EDM wire cutting machine

1989
First Auto-customer Hyundai throught ILJIN Automotive

1998
Integra unit II in Coimbatore & started exports to Mitsubishi, Japan

2001
TS 16949:9001 Certification

2006
Established 1500 MT Foundry division

2007

9
 Established Real time X Ray machine from XLON Germany

2014
Commissioned Belloi flask line for bigger castings

2016
Robotic cell for Brake drum machining

2018
Established 2000 MT Foundry division

2020

THE PRODUCTS
They manufacture the following products to the customers

• Passenger Vehicle
• Hydraulic
• Locomotive
• Tractor
• Printing & Machineries
• General Engineering
• Commercial Vehicle
• Power Transmission
• Valves & Pumps

10
COMPANY POLICY

• IATF 16949 : 2016 ( certification from TUV Nord)

• ISO 9001 : 2015 ( certification from TUV Nord)

The Mission
Managing the environment managing Ourselves
To make citizens aware about the need of trees for the survival and protect natural
resources for generations to come.

They passionately work for the environment through a series of nature-related

activities. By working at the source, viz., planting trees, they Endeavor to ensure that
afforestation helps to bring back the lost natural resources.

They can say that planting a tree is almost Elemen’Tree’ because it has an impact on
all the five elements. Its role in giving us Air, Water, Fire, Wind and space is
indispensable, which is why it is essential that they plant trees.

Plant a tree and plant a hope for future…

In-plant production of bricks containing waste foundry sand.

Waste recycling is very important for environmental conservation and sustainable
development. The most important reason for waste collection is the protection of the
environment and the health of the population.

11
AWARDS & RECOGNITIONS
Best Supplier Award

• Best Supplier Award from ILJIN Automative in 2009

• Awarded for Best Quality Systems in Coimbatore Cluster by Institute of Indian
Foundry men in August 2010
• Awarded as Best Supplier for Quality Performance in the year 2012 by AVCL

The Strengths
• Capacity – 3500 MT / month

• Weight range 3 – 200kg / piece in high pressure mould line

➢ Pattern Making and Engineering

➢ Core Shop

➢ Moulding

➢ Melting

➢ Laboratory

➢ Sand Plant

➢ Finishing

➢ Heat Treatment

➢ Painting

➢ Machine Shop

➢ Quality

➢ Wire cut

12
Company Details

CIN U30007TZ1989PTC029822

Company Name INTEGRA AUTOMATION PRIVATE LIMITED

Company Status Active

RoC RoC -Coimbatore

Registration Number 29822

Company Category Company limited by Shares

Company Sub Category Non-govt company

Class of Company Private

Date of Incorporation 26 September 1989

Age of Company 33 years, 10 month, 26 days

Authorised Capital ₹50,000,000

Paid up capital ₹39,581,500

Director Details

DIN Director Name Designation

07231050 VIKRAM SOKKALINGAM Wholetime Director

00364372 SOKKALINGAM MANGAYAR THILAGAM Director

00364273 SOUNDAPPA CHETTIAR SOKKALINGAM Managing Director

13
Address:

Integra Automation Pvt Ltd

S.F.No. 238, Kurunalli Palayam Village Kinathukadavu Taluk,
Coimbatore - 642120, Tamilnadu, India

Phone: 9843244350

E-mail: [email protected]

14
 CHAPTER - IV
4. ORGANIZATIONAL CHART

An organizational chart is a visual chart that represents the structure of a company. It highlights
how teams and departments are organized, the reporting relationships across the organization,
and every individual’s role and responsibilities. An up-to-date organization chart template
serves several important functions for your organization.

15
 5. VARIOUS DEPARTMENT FUNCTIONS

This company has two types of departments one department is for consultancy in
this department they will take care of the activities of managing the data within the organization
and they will give consultancy services to their customers and the other department is for
sales and services in this department they will take care of sales and the after sales services to
their customers it is the centralized control where the authority and orders are coming from the
one source.

The different departments included in the organization is as follows:

• Production Department

• Marketing / Sales Department

• Finance / Accounts Department

• Human Resource (HR) / Personnel Department

The production department in a business organization is responsible for the

manufacturing or production of goods for the business organization. The production
department is headed by the production manager. Other workers in this department include
technicians, engineers, designers, machine operators etc. The production department
manufactures goods for the business which are then sold in order to bring revenue for the
business.

16
 5.1 PRODUCTION DEPARTMENT

Production Planning And Control

The production planning and control functions of production and operations

management ensure that the organisation’s production activities are coordinated and aligned
with its overall objectives. It includes developing and maintaining production schedules,
coordinating materials and resources, and monitoring production progress.

Production planning and control aim to ensure that the organisation’s production
activities are efficient and effective and that they promptly meet customers’ needs. To do this,
production planners and controllers must have a good understanding of the organisation’s
overall objectives, as well as the specific goals of the production department. They must also
be familiar with the various processes and activities involved in production to identify potential
bottlenecks or areas of inefficiency.

Production planning and control is a complex task, and it is essential to have

systems and procedures in place to ensure that it is done effectively. A manufacturing execution
system (MES) is one essential tool that can support production planning and control. MES
software provides a centralised platform for managing all aspects of production, from
scheduling to materials management to quality control.

By using an MES, organisations can improve communication among all

stakeholders involved in production, including engineers, managers, operators, and suppliers.
It can lead to better coordination of resources and improved overall efficiency.

17
Supply Chain Management

Supply chain management (SCM) is a process that starts with procuring raw
materials and ends with delivering finished products to the customer. Several steps are required
to transform the raw materials into a finished product.

The first step in SCM is procurement, which is acquiring the raw materials needed
for production. The next step is manufacturing, which is transforming raw materials into
finished products. Finally, there is distribution, which delivers the finished products to the
customer.

Each of these steps requires different skills and knowledge to be completed

successfully. For example, procurement involves an understanding of the market and an ability
to negotiate prices with suppliers. Manufacturing requires an understanding of production
processes and an ability to troubleshoot problems that arise during production. Distribution
involves an understanding of logistics and an ability to ensure that products are delivered on
time and in good condition.

Operations management ensures that all of these steps are completed efficiently
and effectively. This includes designing efficient production processes, developing effective
procurement strategies, and planning efficient distribution routes. It also includes monitoring
all aspects of SCM to identify potential problems and implement solutions to improve
performance.

18
 5.1.1 DEBURRING

Deburring is a secondary operation of a machining process that enhances the final

quality of the product by removing raised edges and unwanted pieces of material, known as
burrs, left by the initial machining processes. Burrs are created from shearing, bending, cutting,
piercing, and compressing materials. These are mostly seen on soft and ductile materials.
Deburring machines are used to remove burrs by mechanical, electrochemical, and thermal
methods.

The cost associated with deburring processes is about 30% of the manufacturing
cost for high precision parts used in aerospace applications. In automotive applications, the
deburring costs about 15 to 20% of the manufacturing expense. This increment in
manufacturing cost is significant considering that deburring does not add intrinsic value to the
product.

Deburring is done in a variety of methods that depend on the material, part geometry,
size and location of burrs, product volume, and cost. Manual and mechanical deburring
operations are conventional methods for deburring. Electrochemical, thermal energy, and
cryogenic are non-conventional methods for specific deburring applications.

Below are common deburring processes and the advantages and applications of each.

Mass Finishing:

This method is utilized when there is a large quantity of parts/components that need
to be finished, which can be run as batch systems or as continuous systems and can be
performed as dry or wet processes (depending on the material of the products being finished).
Mass finishing requires an initial investment of time and materials to determine the exact mass
finishing recipe required for your needs, but will save time, money, and manual labour in the
long run.

19
Manual Deburring:

This method refers to deburring operations that use hand-held or mechanized tools
which use tools such as deburrers, grinders, brushes, files, sanders, and so forth. This process
is "localized"--meaning it does not affect the entire part. This is employed in locations where
there is a high tolerance for dimensional variations since the parameters for manual deburring
cannot be defined perfectly. In-house time standards have been developed by most fabricators
and manufacturers. However, these do not solve the problem regarding the consistency of the
process. This process is slow and is generally done at the end of the production line making
any mistake costly for the manufacturer. Below are some of the types of manual deburring
methods.

Brushing:

Brushes made of metal filaments or thin wires attached to a rotating disc are used to
scrape off burrs along the edges of the cut. This is a fast and relatively low-cost method but is
limited by the consistency of the deburring action. Intensity depends on filament diameter, free
length configuration, texture, density, material type, disc width, angular velocity, and contact.

Sanding or Bonded Abrasive Finishing:

This method uses abrasives such as aluminium oxide, silicon carbide, and zirconia
compounds bonded into sheets, belts, pads, wheels, and discs. Mechanized reciprocating or
rotating action of the abrasives removes materials that are raised from the surface of the
workpiece. Abrasives can vary grades from coarse to exceptionally fine depending on the
dimensions of the material to be removed, desired surface finish, and application.

Sheet Metal Edging:

Sheet metal edging machines have small grinding wheels or pinch rolls that smoothen
edges of sheet metal with various thicknesses ranging from 0.025 to 0.25 inches. Sheet metal
edging machines are stationary where sheet metal is fed manually or automatically. Some
machines can deburr the top and bottom surfaces and can also create chamfers or fillets. For a
set of multiple rollers, the pressure exerted at each roller pair progressively forces the burrs and

20
raised edges over, under, or into the sheet metal. However, compressive forces must be
carefully controlled especially on soft and malleable materials since these can warp or buckle
under roller pressure.

Robotic Deburring:

This involves a chamfering, grinding, or deburring tool mounted on a robotic arm.

Since the main disadvantage of manual deburring is inconsistency, slow turnover, and labor-
intensiveness, robotic deburring solves these problems by eliminating the human factor. Robots
can perform repeatable movements consistently and rapidly. CNC programming allows
operators to input predefined movements and other parameters such as force and tool speed.
Despite the bigger initial cost, robotic deburring is beneficial in the long term because of the
reduced operating costs. Moreover, robotic systems are a much safer process than manual.

Mechanical Deburring:

Mechanical deburring employs machines to perform a general deburring on the

workpiece. The operator has less control over the aggressiveness and localization of the
deburring action, as compared to manual deburring. Manual, robotic, and waterjet deburring
are also considered as mechanical due to the nature of abrasion application. Examples of
mechanical deburring machines are as follows.

Barrel Tumbling:

Barrel tumblers are one of the most economical deburring machines in regards to
operating costs. This equipment not only removes burrs, but it also polishes the surfaces of the
part. The machine works by loading a part or several parts into a chamber or "barrel" along
with the abrasive media. Special compounds are also added depending on the material and
surface finish. This is usually a batch operation, but in-line batch processing and single-pass
processing are also available. Barrel tumbling can be divided into wet and dry tumbling.

21
Wet Tumbling:

In wet tumbling, water is loaded which acts as a lubricant and helps wash out
residues to improve deburring efficiency. The level of water affects the speed of processing and
fineness of the surface finish. Compounds designed to work with ceramic or plastic media are
also added to the water. These compounds impart corrosion resistance, cleanliness, cosmetic
finish, shine, and other additional surface qualities. Compounds also improve the deburring
operation by removing oils, lengthening the life of the abrasive media, and eliminating foaming
from plastic and synthetic media.

The use of water and liquid compounds proves to have a lot of benefits. However, there are
also downsides such as wastewater contamination and uncontrolled reactions with fluids used
in upstream operations.

Dry Tumbling:

As the name suggests, this process only uses dry media such as sand and dried
organic materials. Using sand does not only improve polishing but also acts the same way like
water in wet tumbling. Sand carries the residues and prevents them from embedding onto the
surface of the part. Organic material, on the other hand, is more absorbent than sand which can
remove dirt and oils. Organic materials used are corn cob grits, walnut shell grits, and wood
pegs.

Vibratory Corn Cob Dryer

Using dry media does not have the disadvantages of wet tumbling
compounds; however, the process is relatively slow. Heavier abrasive composition tends to
have a shorter processing time. Dry abrasives are lighter than their liquid counterparts and
generally take about two times longer to produce the same deburring effect. Because of this,
dry tumbling is not usually applicable to large-volume production.

22
A special configuration of a barrel tumbler is a centrifugal tumbler. This consists of an array of
two or four tumblers mounted on a turret. The turret rotates in one direction which causes the
barrels to rotate in the opposite direction. Each complete rotation of the turret represents one
rotation of the barrels. Turning the turret fast enough causes centrifugal forces greater than
gravity to be applied on the barrels. This creates greater abrasive forces resulting in faster
deburring times.

Vibratory Deburring:

Vibratory deburring machines are similar to deburring barrel tumblers where the parts
are loaded into a chamber along with the abrasive media and other additional compounds. Their
main difference is the movement of the chamber. While tumblers rotate to generate agitation
inside the chamber, this type of machine vibrates to generate motion. The chamber is mounted
on springs or dampers which isolates its movement from the foundation. An off-center
revolving weight is attached which shakes the contents of the chamber. Various configurations
are available such as tubs, circular bowls, or trough machines. Choosing the configuration
depends on the geometry of the part and its application.

Waterjet Deburring:

This process utilizes the impact force of high-velocity water jets to erode burrs and
debris from the workpiece. Water jets are CNC controlled, similar to tooled robotic systems.
Waterjet deburring uses lower pressures compared to waterjet cutting to prevent damaging the
part. Thus, it only removes thin and loosely attached burrs. Larger burrs cannot be easily
removed without damaging the edges. The main advantage of using water jets is that it can
reach features that are inaccessible to ordinary deburring systems. Also, the resulting product
is free of oils and debris.

23
Electrochemical Deburring:

This is a deburring process that utilizes the principles of electrolysis. Electrolysis is

accelerated in areas with small interelectrode gaps. Meanwhile, it is prevented in areas with
insulation between electrodes. The cathodic tool is shaped as a negative of the workpiece. This
is used to focus electrolysis on regions where burrs are located. The workpiece is attached to
the circuit and acts as an anode. To complete the circuit, an electrolyte is added which transfers
charge between the tool and workpiece. Portions of the tools are insulated to prevent dissolving
other surfaces. This method is suited for deburring difficult to machine geometries and poorly
machinable but conductive materials. Also, there is no tool wear. A disadvantage for this
process, however, is the difficult wastewater treatment since it uses environmentally harmful
chemical compounds.

Thermal Deburring:

This process is also known as thermal energy method. In this process, the
workpiece is exposed to hot corrosive gases for a very short period. A thermal shockwave is
generated which quickly vaporizes the burr. The rest of the workpiece is unaffected because of
its low surface-to-mass ratio and short exposure time. Small amounts of metals such as burrs
and raised edges sublimate since they are unable to dissipate the intense heat to the surrounding
parts. Thermal deburring is effective on materials with low thermal conductivity that can easily
oxidize.

Cryogenic Deburring:

Cryogenic deburring is mostly done on precision plastic parts which possess

inherent impact toughness. In this process, liquid nitrogen is flashed into a chamber containing
the parts to be deburred. The flashing process cools the chamber near the glass transition
temperature of the part material. This embrittles the burrs and flashes but is not enough to
change the properties of the rest of the parts. The part, along with the abrasive media, are
tumbled in the chamber.

24
 5.1.2 PACKING

Packaging is the science, art and technology of enclosing or protecting

products for distribution, storage, sale, and use. Packaging also refers to the process of
designing, evaluating, and producing packages. Packaging can be described as a coordinated
system of preparing goods for transport, warehousing, logistics, sale, and end use. Packaging
contains, protects, preserves, transports, informs, and sells.[1] In many countries it is fully
integrated into government, business, institutional, industrial, and personal use.

Packaging types

Primary packaging is the material that first envelops the product and holds it. This usually is
the smallest unit of distribution or use and is the package which is in direct contact with the
contents.

Secondary packaging is outside the primary packaging, and may be used to prevent pilferage
or to group primary packages together.

Tertiary or transit packaging is used for bulk handling, warehouse storage and transport
shipping. The most common form is a palletized unit load that packs tightly into containers.

These broad categories can be somewhat arbitrary. For example, depending on the use, a shrink
wrap can be primary packaging when applied directly to the product, secondary packaging
when used to combine smaller packages, or tertiary packaging when used to facilitate some
types of distribution, such as to affix a number of cartons on a pallet.

Packing process is the process of packing all the items for an order into an
appropriate container before shipping it to the customer. It is the second step in order
fulfillment, right after the picking process. The packing process takes place in the warehouse
and typically consists of choosing appropriate materials and an appropriate container to pack
the products, weighing the package, and labelling it with the relevant invoice or packing slip.

25
 5.1.3 WELDING

Welding, technique used for joining metallic parts usually through the application
of heat. This technique was discovered during efforts to manipulate iron into useful shapes.
Welded blades were developed in the 1st millennium CE, the most famous being those
produced by Arab armourers at Damascus, Syria. The process of carburization of iron to
produce hard steel was known at this time, but the resultant steel was very brittle. The welding
technique—which involved interlayering relatively soft and tough iron with high-carbon
material, followed by hammer forging—produced a strong, tough blade.

There are a wide variety of welding processes.

Forge welding

This original fusion technique dates from the earliest uses of iron. The process was
first employed to make small pieces of iron into larger useful pieces by joining them. The parts
to be joined were first shaped, then heated to welding temperature in a forge and finally
hammered or pressed together. The Damascus sword, for example, consisted of wrought-iron
bars hammered until thin, doubled back on themselves, and then rehammered to produce a
forged weld. The larger the number of times this process was repeated, the tougher the sword
that was obtained.

Arc welding

Shielded metal-arc welding accounts for the largest total volume of welding today.
In this process an electric arc is struck between the metallic electrode and the workpiece. Tiny
globules of molten metal are transferred from the metal electrode to the weld joint. Since arc
welding can be done with either alternating or direct current, some welding units accommodate
both for wider application. A holder or clamping device with an insulated handle is used to
conduct the welding current to the electrode. A return circuit to the power source is made by
means of a clamp to the workpiece.

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Thermochemical processes

One such process is gas welding. It once ranked as equal in importance to the
metal-arc welding processes but is now confined to a specialized area of sheet fabrication and
is probably used as much by artists as in industry. Gas welding is a fusion process with heat
supplied by burning acetylene in oxygen to provide an intense, closely controlled flame. Metal
is added to the joint in the form of a cold filler wire. A neutral or reducing flame is generally
desirable to prevent base-metal oxidation. By deft craftsmanship very good welds can be
produced, but welding speeds are very low. Fluxes aid in preventing oxide contamination of
the joint.

Resistance welding

Spot, seam, and projection welding are resistance welding processes in which
the required heat for joining is generated at the interface by the electrical resistance of the joint.
Welds are made in a relatively short time (typically 0.2 seconds) using a low-voltage, high-
current power source with force applied to the joint through two electrodes, one on each side.
Spot welds are made at regular intervals on sheet metal that has an overlap. Joint strength
depends on the number and size of the welds. Seam welding is a continuous process wherein
the electric current is successively pulsed into the joint to form a series of overlapping spots or
a continuous seam. This process is used to weld containers or structures where spot welding is
insufficient. A projection weld is formed when one of the parts to be welded in the resistance
machine has been dimpled or pressed to form a protuberance that is melted down during the
weld cycle.

Electron-beam welding

In electron-beam welding, the workpiece is bombarded with a dense stream of

high-velocity electrons. The energy of these electrons is converted to heat upon impact. A
beam-focusing device is included, and the workpiece is usually placed in an evacuated chamber
to allow uninterrupted electron travel. Heating is so intense that the beam almost

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instantaneously vaporizes a hole through the joint. Extremely narrow deep-penetration welds
can be produced using very high voltages—up to 150 kilovolts. Workpieces are positioned
accurately by an automatic traverse device; for example, a weld in material 13 mm (0.5 inch)
thick would only be 1 mm (0.04 inch) wide. Typical welding speeds are 125 to 250 cm (50 to
100 inches) per minute.

Cold welding

Cold welding, the joining of materials without the use of heat, can be accomplished
simply by pressing them together. Surfaces have to be well prepared, and pressure sufficient to
produce 35 to 90 percent deformation at the joint is necessary, depending on the material.
Lapped joints in sheets and cold-butt welding of wires constitute the major applications of this
technique. Pressure can be applied by punch presses, rolling stands, or pneumatic tooling.
Pressures of 1,400,000 to 2,800,000 kilopascals (200,000 to 400,000 pounds per square inch)
are needed to produce a joint in aluminium; almost all other metals need higher pressures.

Friction welding

In friction welding two workpieces are brought together under load with one part
rapidly revolving. Frictional heat is developed at the interface until the material becomes
plastic, at which time the rotation is stopped and the load is increased to consolidate the joint.
A strong joint results with the plastic deformation, and in this sense the process may be
considered a variation of pressure welding. The process is self-regulating, for, as the
temperature at the joint rises, the friction coefficient is reduced and overheating cannot occur.
The machines are almost like lathes in appearance. Speed, force, and time are the main
variables. The process has been automated for the production of axle casings in the automotive
industry.

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Laser welding

Laser welding is accomplished when the light energy emitted from a laser source is
focused upon a workpiece to fuse materials together. The limited availability of lasers of
sufficient power for most welding purposes has so far restricted its use in this area. Another
difficulty is that the speed and the thickness that can be welded are controlled not so much by
power but by the thermal conductivity of the metals and by the avoidance of metal vaporization
at the surface. Particular applications of the process with very thin materials up to 0.5 mm (0.02
inch) have, however, been very successful. The process is useful in the joining of miniaturized
electrical circuitry.

Diffusion bonding

This type of bonding relies on the effect of applied pressure at an elevated temperature
for an appreciable period of time. Generally, the pressure applied must be less than that
necessary to cause 5 percent deformation so that the process can be applied to finished machine
parts. The process has been used most extensively in the aerospace industries for joining
materials and shapes that otherwise could not be made—for example, multiple-finned channels
and honeycomb construction. Steel can be diffusion bonded at above 1,000 °C (1,800 °F) in a
few minutes.

Ultrasonic welding

Ultrasonic joining is achieved by clamping the two pieces to be welded between an

anvil and a vibrating probe or sonotrode. The vibration raises the temperature at the interface
and produces the weld. The main variables are the clamping force, power input, and welding
time. A weld can be made in 0.005 second on thin wires and up to 1 second with material 1.3
mm (0.05 inch) thick. Spot welds and continuous seam welds are made with good reliability.
Applications include extensive use on lead bonding to integrated circuitry, transistor canning,
and aluminium can bodies.

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Explosive welding

Explosive welding takes place when two plates are impacted together under an
explosive force at high velocity. The lower plate is laid on a firm surface, such as a heavier
steel plate. The upper plate is placed carefully at an angle of approximately 5° to the lower
plate with a sheet of explosive material on top. The charge is detonated from the hinge of the
two plates, and a weld takes place in microseconds by very rapid plastic deformation of the
material at the interface. A completed weld has the appearance of waves at the joint caused by
a jetting action of metal between the plates.

Weldability of metals

Carbon and low-alloy steels are by far the most widely used materials in welded
construction. Carbon content largely determines the weldability of plain carbon steels; at above
0.3 percent carbon some precautions have to be taken to ensure a sound joint. Low-alloy steels
are generally regarded as those having a total alloying content of less than 6 percent. There are
many grades of steel available, and their relative weldability varies.

Aluminium and its alloys are also generally weldable. A very tenacious oxide film on
aluminium tends to prevent good metal flow, however, and suitable fluxes are used for gas
welding. Fusion welding is more effective with alternating current when using the gas-tungsten
arc process to enable the oxide to be removed by the arc action.

Copper and its alloys are weldable, but the high thermal conductivity of copper makes welding
difficult. Refractory metals such as zirconium, niobium, molybdenum, tantalum, and tungsten
are usually welded by the gas-tungsten arc process. Nickel is the most compatible material for
joining, is weldable to itself, and is extensively used in dissimilar metal welding of steels,
stainless, and copper alloys.

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 5.2 HUMAN RESOURCE DEPARTMENT

A human resource department manages a company's human resources, otherwise

known as its employees. The human resource department is responsible for the effective
hiring, training, developing, compensating, and management of these employees.

FUNCTIONS OF HR DEPARTMENT
• Performance measurement and evolution
• Recruitment
• Training and development
• Compensation and benefits
• Legal issues and personal policies

MANPOWER PLANNING

Manpower Planning is essentially the process of getting the number of qualified employees
and seek to place the right employees in the right job at the right time, so that an organization
can meet its objectives. Manpower Planning or Human Resource Planning is a forward looking
function. Migrating the employees to other units of the same organization at the time of need
in human resources.

WAGES AND SALARY

Salary is a fixed amount paid or transferred to the employees at regular intervals for their
performance and productivity, at the end of the month whereas wages are hourly or daily-based
payment given to the labour for the amount of work finished in a day.

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RECRUITMENT POLICY

Recruitment can be defined as the process of attracting right talent with right skills, right
attitude and right experience. It is one of the very important and most discussed topics of
human resource. It includes various terms with it, those terms are selection and induction.

As per recruitment and selection policy the process of talent acquisition starts from recruitment
and is processed further with selection and continue till induction. We can explain the term
selection as well as induction. Selection is the process of choosing the best person for a given
position.

Recruitment is attraction and selection for choose. Induction means introducing the person to
position. In other words, we can say success of the company is based on right recruitment to a
very large extent as the process of recruitment is based on proper strategies.

An organization to survive well must have a concise Recruitment and Selection Policy so that

it can have the best talent from a pool of candidates. Having a robust recruitment policy is the

first demand of an efficient hiring process. The company must follow the recruitment policy

and procedure.

INCENTIVES AND OTHER BENEFITS

The employees in the company receive incentives which are given on the basis of quarterly
production. That means the employees who produce more without any rejection will be
awarded more in addition to the salary. Some of the benefits given to the employees are

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 • Bonus
• Gratuity
• Provident Fund

The Company follows all the terms and conditions and provide all sorts of Perks allocated by
the Government to the Employees.

One of those were NAPS. I had closely watched the performance of the NAPS process while
crediting the Salary to the Employees account by the 15th of every month.

The Government of India directly credited the Amount of 1500/- to the employees account
during the Salary process.

The charges may differ according to their Qualification.

This process is mainly done by the HR Department of the Organization. They are responsible
to check those were performing in a right way.

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 5.3 FINANCIAL DEPARTMENT

Finance is the lifeline of any business. However, finances, like most other
resources, are always limited. On the other hand, wants are always unlimited. Therefore, it is
important for a business to manage its finances efficiently. As an introduction to financial
management, in this article, we will look at the nature, scope, and significance of financial
management, along with financial decisions and planning.

Financial management may be defined as the area or function in an organization

which is concerned with profitability, expenses, cash and credit, so that the "organization may
have the means to carry out its objective as satisfactorily as possible;" the latter often defined
as maximizing the value of the firm for stockholders. Financial management is generally
concerned with short term working capital management, focusing on current assets and current
liabilities, and managing fluctuations in foreign currency and product cycles, often through
hedging.

ROLE OF FINANCIAL MANAGERS

Financial managers perform data analysis and advise senior managers on profit-
maximizing ideas. Financial managers are responsible for the financial health of an
organization. They produce financial reports, direct investment activities, and develop
strategies and plans for the long-term financial goals of their organization.

Financial managers typically:

• Prepare financial statements, business activity reports, and forecasts,

• Monitor financial details to ensure that legal requirements are met,

• Supervise employees, who do financial reporting and budgeting,

• Review company financial reports and seek ways to reduce costs,

• Analyse market trends to find opportunities for expansion or for acquiring

other companies,

• Help management make financial decisions.

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The role of the financial manager, particularly in business, is changing in response to
technological advances that have significantly reduced the amount of time it takes to produce
financial reports.

Let’s define financial management as the first part of the introduction to financial management.
For any business, it is important that the finance it procures is invested in a manner that the
returns from the investment are higher than the cost of finance.

In a nutshell, financial management –

• Endeavours to reduce the cost of finance

• Ensures sufficient availability of funds

• Deals with the planning, organizing, and controlling of financial activities like
the procurement and utilization of funds

Finance statement is primarily for decision making. It is an organized

collection of dataaccording to logical and consistent accounting procedures.

Information provided in the financial statement are immense use is

making decision through analysis and interpretation of financial analysis is the process
of identifying the financial strength and weakness of the firm by property establishing
relationship between the item of balance sheets and profit and loss account.

Finance is the life blood of an organization. Without finance we can’t do

anything. Finance is only part which brings together various segments of an
organization which helps to attain organizational goals. Finance manager is the top
authority in financial work. He has equalrights and responsibilities in general matters
like the managing director of the company.

“Financial management is that area of business management devoted to a

judicious useof capital and a careful selection of the source of capital in order to enable
a spending unit to move in the direction of reaching the goals.” – J.F. Brandley

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SOURCES OF FINANCE

1. Can borrow money this can be done privately through bank loans.
2. Our company generates money by selling part of itself in the form of
shares to investors,which is known as equity funding.

SCOPE OF FINANCIAL MANAGEMENT

Further, they are upheld by the maximization of the wealth of the
shareholders, which depends on the increase in net worth, capital invested in the
business, and ploughed-back profits for the growth and prosperity of the organization.

Financial management is an organic function of any business. Any

organization needs finances to obtain physical resources, carry out the production
activities and other business operations, pay compensation to the suppliers, etc. There
are many theories around financial management:

Some experts believe that financial management is all about providing funds
needed by a business on terms that are most favorable, keeping its objectives in mind.

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RECORDS, REGISTERS AND BOOKS MAINTAINED

✓ It prepares and maintains journals book, ledger a/c and a trial balance.
✓ To prepare trading account
✓ To prepare trading profit and loss account
✓ To prepare balance sheet
✓ Rate fixing
✓ Suppliers bill paying
✓ It makes calculation and decision regarding the funds of the company.

Finance Department deals with the financial activities of the company. It consists of
differentsection.

• Inventory section
• Costing section
• Bills section
• Companies account
• Sales tax account
• Employee account
• Trust account

OBJECTIVES:
• The basic objectives of quality control are to maintain quality standards in order
to ensure customer satisfaction and to reduce the costs associated with The
Scrapping of defective goods.
• Quality of conformance related to the extent to which the goods that are
produced conformto the condition laid down.
• This aspect of quality concerns steadiness of the product.
• There is a trade-off between the costs associated with the maintenance of
quality and the cost resulting from failures.
• Quality control involves the use of resources in the inspection process.

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 6. SUGGESTIONS

Traditional Phase-Gate Structure

In the traditional phase-gate development structure, a project is divided into

phases and separated by gates. Each gate serves as a formal decision point for
management to decide if and how the project will progress to the next phase. The
traditional phase gate provides structure to the product development process, helps
managers select the best projects and reveals major problems so they can be addressed
before further investment.

But in many cases, the traditional phase-gate structure can stifle the creativity
needed to develop innovative products. The time allocated for creativity comes early—
and only once—in the process before it shifts to the next phase. However, opportunities
to generate high-impact ideas are available throughout the entire project.

Iteration-Based Approach

An iteration-based approach combines the best elements of a phase-gate

structure—high-level structure and management review points—with an iteration
strategy. This combination enables development projects to become a series of mini-
project cycles that includes comprehensive idea-generation with a design-make-test
cycle of the complete product.

Each iteration builds on the in-depth learning, discoveries and results of

the previous iteration. The lessons learned from one iteration are used as a starting point
for the next iteration to drive improvements and spark new ideas.

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 In the early phases, these iterations are quick and typically involve creating
concept prototypes from materials such as wood, plastic, cardboard, clay or other
inexpensive quick-build materials. As the product design advances to the next iteration,
the developers build prototypes with more refined and functional features that converge
with higher resolution to the final design. When combined with a systematic way to
generate and develop ideas, the iteration-based approach becomes a powerful way to
compete based on innovation.

Holistic Iteration-Based Innovation

The opportunity to create value for both end users and pump OEMs
through new product development goes beyond what is possible through innovative
product design alone. How a product is made—the production technology—is just as
important as how a product is designed.

End users not only want a new product that saves money, but they
also want an affordable upfront price that provides quick payback and quick delivery
lead times. Pump OEMs want to hit product gross margin levels that provide quick
return on investment, and they aim to deliver quickly without inflated inventory levels.

A holistic development strategy that applies the iteration-based

innovation approach to production technology with as much rigor as it is applied to
product design leverages the value creation opportunity. This can be done without
compromising seemingly conflicting interests of OEMs and end users.

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 All the above are commonly used by all the Organizations for their
development. I observe that the Integra Automation Private Limited is facing the major
Problem at the time of their Salary distribution.

They are following NAPS scheme brought by the Government for the
Employees. In my opinion it will be better by Explaining the process of NAPS to the
Employees. This can avoid the Misunderstanding by the Employees towards the
Organization.

At the time of my Internship they allowed me for taking Training to the

Female Employees working in the Integra Automation Private Limited on the Topic of
POSH ACT 2013.

They had mentioned me as a NGO.

It was a wonderful and Mind blowing experience for me.

I got to know about the Salary process of the Organization followed. They trained me
for Entering details in the EMP Master form.

I observed all the trainings and other process gave by the HR Department to the
Employees.

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LEARNINGS :

OBSERVATION

• Integra Automation is adopting modern technology for providing quality products at

reasonable price to its customers.
• The company maintains a good relationship with employees by providing better
wages, good working conditions etc.
• Integra Automation emphasis on quality, the customers treat the products as a
Symbol of quality.
• The company provides safety training to all employees.

PROFESSIONAL SKILLS ACQUIRED

• Dealing with management
• Providing training
• Working in team
• Time management
• Coordination with staffs

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 7. CONCLUSION

Every organization needs a structure in order to operate systematically. The

organizational structure can be used by any organization if the structure fits into the nature and
the maturity of the organization.

From the detailed study of the functioning of departments in terms of various working
conditions of the organization had clearly informed that the organizational environment is very
systematic. The inner departmental communications are found to be very effective.

They have clear terms and conditions. In addition, the qualities of the products as well
as the raw materials are strictly ensured in order to attain the high-quality standard of global
market.

Integra Automation takes vital steps at right times to bring the innovation in
Technological Upgradation well as organizational improvements.

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