SUMMER INTERNSHIP AT EM TECH

FABRICATORS
A SUMMER INTERNSHIP REPORT

Submitted by

KAVISH DESAI

200170119010

In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING

In

MECHANICAL DEPARTMENT

Vishwakarma Government Engineering College, Chandkheda

 Gujarat Technological University, Ahmedabad

VISHWAKARMA GOVERNMENT ENGINEERING COLLEGE

CERTIFICATE
This is to certify that the project report submitted along with the project

entitled Summer internship at EM Tech Fabricators has been carried out

by KAVISH DESAI , 200170119010 under my guidance in partial

fulfillment for the degree of Bachelor of Engineering in Mechanical

Department 7th Semester of Gujarat Technological University,

Ahmadabad during the academic year 2023-24.

Internal guide Head of department

Prof. Mohammedyasin M. Modan Prof. Pragnesh K. Brahmbhatt

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 Vishwakarma Government Engineering College

DECLARATION

We hereby declare that the Summer Internship report submitted along with

Summer Internship at EM Tech Fabricators submitted in partial fulfillmentfor

the degree of Bachelor of Engineering in Mechanical Department to Gujarat

Technological University, Ahmedabad, is a Bonafide record of original project

work carried out by me at EM Tech Fabricators and no part of this report has

been directly copied from any student’s reports or taken from any other source

without providing due reference.

Name of the student Sign of Student

KAVISH DESAI

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 ACKNOWLEDGEMENT

I take this opportunity to thank EM TECH FABRICATORS for giving

me the opportunity to do a summer internship here. It gives me

immense pleasure to acknowledge all those who have given me data, time

and energy to supply all the valuable facts and opinions that have helped

me in gaining some technical knowledge in MANUFACTURING

industry during this internship. I express my profound sense of gratitude

to DEVANG DESAI (DIRECTOR, EM TECH FABRICATORS),

MINESH DESAI sir(Manager, EM TECH FABRICATORS) who have

rendered constant guidance, advice and help me when needed to

complete t h i s i n t e r n s h i p s u c c e s s f u l l y . I a l s o e x p r e s s

my gratitude to the company employees who have helped me during this

time.

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 ABSTRACT

- To learn about METAL FABRICATION in manufacturing processes

- To learn about WELDING processes in Plant.

- Tolearn about DRILLING and LATHE machining processes

involved in making tank components from raw materials.

-To gain practical knowledge in the field of MACHINING,

MANUFACTURING, and ASSEMBLY.

-To observe the employee work in the industry and know about the
working of a manufacturing industry through interaction with
company employees.

- Tostudy about plant Maintenance the objective of plant

maintenance is to achieve minimum breakdown and to keep the
plant in good working condition at the lowest possible cost.

- Tolearn about Quality Control parameters and Process pre-

requisites.

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5
 INDEX

1. Overview Of Company....................................................................... 07
2. Heat Exchangers................................................................................. 10

3. Fabrication Procedure.......................................................................... 11

4. Welding............................................................................................... 12

5. Assembly............................................................................................. 14

6. Wastes and Saves Of Manufacturing................................................... 15

7. Photos................................................................................................... 24

8. Conclusion............................................................................................ 25

9. References............................................................................................. 26

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 1.0 : OVERVIEW OF COMPANY

1.1 INTRODUCTION
Established in the year 1997, at Navsrai (Gujarat, India), we, “EM. Tech Fabricators”, are
known as the renowned service providers engaged in providing premium quality MS Plate
Cutting Service and Profile Cutting Service etc. The offered services comprise Profile Plate
Cutting Service, MS Profile Cutting Plate Service, Template Cutting Service, MS Heavy
Structural Fabrication Service, Mild Steel Industrial Fabrication Service, SS Fabrication
Service etc. We render these services as per the variegated needs of our precious clients. Highly
appreciated among clients for their accuracy, flexibility, timely execution and client centric
approach, these services are widely used in various industrial applications thereby increasing
the demand in the industry. We function with some of the highly skilled engineers who utilize
their in-depth knowledge and strong sense that provides clients the best services.

1.2 COMPANY PROFILE

We are backed by rich expertise of our professionals, who possess immense years of experience in
this domain. Our team members use excellent quality raw material that are sourced from some of the
reliable vendors of the industry, along with advanced technology, to render these services in
conformity with the set universal standards. Apart from this, they plan and implement these services
as per the instructions laid down by the clients keeping in mind their budgetary constraints. Our
experienced team is an essential part of our organization, through which we have gained a strong
goodwill and strengthened our position in the industry. The professionals working with us are highly
qualified and skilled and possess vast industry experience. They work with dedication to render the
most intricate projects with high precision. Our dexterous engineers, trained workers, researchers and
other industrial professionals work in coordinated manner to cater to the ever growing demands of the
clients. We also conduct various training sessions and learning programs in order to keep our team
updated with the market developments.

Our prime objective is to attain the utmost level of client satisfaction by providing premium quality
services. We have selected an adroit team of quality controllers who evaluate the quality of our
offered 7
services at each stage of planning and execution to ensure that the international standards are
successfully met. To render highly reliable services to the clients, our team members utilize only high
grade raw material that are procured from the most reliable and certified vendors and modern
technology in the best possible manner. We direct all our endeavors to exceed the expectations of
clients by offering them optimum quality services as per their specifications within their monetary
constraints. Our team members work in close coordination with the clients to minutely comprehend
their each and every detail and render suitable services that meet their varied demands in the most
efficient way. In addition to this, we follow ethical business policies and crystal clear transparency in
all our business dealings to maintain healthy relations with our clients.

1.3 VISION AND MISSION

1.3.1 Vision

Being among the top manufacturers in the world.

1.3.2 Mission

To become a world famous Metal fabrication and manufacturing company through excellent
service quality and more processes.
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1.4 SAFETY

First our guide told me regarding the safety and safety measures/ equipment in the
industry. Some of those are:-
 Fig. 1.2 Safety equipment

• Safety shoes :- This are meant to provide protection to the feet under extreme
conditions such as to avoid shocks, abrasion resistance, oil resistance, heat resistance and
others.

• Safety goggle:-It is meant for protecting eye from chemicals, dust and from the
radiations coming from high temperature sources.

• Ear plug:-An earplug is a device that is meant to be inserted in the ear canal to protect
the user’s ear from loud noises or the intrusion of water, foreign bodies, dust or excessive
wind.

• Dust mask:-It is a flexible pad held over the nose and mouth by elastic or rubber straps to
protect against dusts encountered during the handling of raw material in batch house.

• Safety helmet :- It is a type of helmet predominantly used in workplace environments such

as industrial or construction sites to protect the head from injury due to falling objects, debris,
rain, and electricity.

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 2.0 : SHELL and TUBE HEAT EXCHANGERS

Em Tech Fabricators specializes in providing high-quality custom fabrication of shell and tube heat
exchangers that meet customer specifications, industry codes and standards (ASME, TEMA, HEI),
and accepted industry practices. As a leading heat exchanger manufacturer in India, we consistently
delivers with competitive pricing and dependable, on-time delivery.

From the initial consultation, Em Tech Fabricators engineers work directly with customers through
the entire heat exchanger fabrication process, from thermal analysis and mechanical engineering to
detailed CAD drawings and fabrication. Utilizing state-of-the-art software, Em tech engineers model
various shell and tube heat exchanger configurations to meet specified thermal requirements. This
includes single-pass, multi-pass units, as well as standalone and multi-unit configurations in parallel
or series. As a part of heat exchanger manufacturer in Ahmedabad, Gujarat,, some examples of the
variety of shell and tube heat exchangers include:

➢ Condensers

➢ Vacuum Condensers

➢ Evaporators

➢ Rising Film Evaporators

➢ Re-boilers

➢ Heaters

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 3.0 : Fabrication Procedure

1. Design and Engineering: The first step in precision fabrication is to create a detailed design of the
component to be fabricated. This design is then reviewed by engineers to ensure that it meets all the
necessary specifications, including size, shape, and material properties. This involves defining Quality
Assurance Plan (QAP), Weld Plan, WPS, PQR and other necessary quality control procedures.

2. Material Selection: The choice of material for the component is a critical step in precision
fabrication. The material must be strong, durable, and capable of retaining its shape and size over
time, even under extreme conditions.

3. Fabrication: The component is then fabricated using high-precision process typically involves
multiple stages, including cutting, grinding, welding, and shaping, to produce the final component.

4. Quality Control: The final step in precision fabrication is to inspect and test the component to
ensure that it meets all the necessary specifications and tolerances. This may include visual inspection,
NDT, dimensional analysis, and performance testing.

Hence, precision fabrication is a complex and highly specialized manufacturing process that requires a
high level of expertise, technical knowledge, and specialized equipment. As a market leading
precision fabrication manufacturer in India, our goal is to produce high-quality, consistent, and
accurate components that meet the needs of a wide range of industries and applications.

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 4.0 : WELDING

Welding is a fabrication process that joins materials, usually metals or thermoplastics, by using
high heat to melt the parts together and allowing them to cool, causing fusion. Welding is distinct
from lower temperature techniques such as brazing and soldering, which do not melt the base metal
(parent metal).

In addition to melting the base metal, a filler material is typically added to the joint to form a pool of
molten material (the weld pool) that cools to form a joint that, based on weld configuration (butt, full
penetration, fillet, etc.), can be stronger than the base material. Pressure may also be used in
conjunction with heat or by itself to produce a weld. Welding also requires a form of shield to protect
the filler metals or melted metals from being contaminated or oxidized.

Many different energy sources can be used for welding, including a gas flame (chemical), an electric
arc (electrical), a laser, an electron beam, friction, and ultrasound. While often an industrial process,
welding may be performed in many different environments, including in open air, under water, and
in outer space. Welding is a hazardous undertaking and precautions are required to
avoid burns, electric shock, vision damage, inhalation of poisonous gases and fumes, and exposure
to intense ultraviolet radiation.

4.1 : Gas welding

The most common gas welding process is oxyfuel welding, also known as oxyacetylene welding. It is
one of the oldest and most versatile welding processes, but in recent years it has become less popular
in industrial applications. It is still widely used for welding pipes and tubes, as well as repair work.
The equipment is relatively inexpensive and simple, generally employing the combustion of acetylene
in oxygen to produce a welding flame temperature of about 3100 °C (5600 °F). The flame, since it is
less concentrated than an electric arc, causes slower weld cooling, which can lead to greater residual
stresses and weld distortion, though it eases the welding of high alloy steels. A similar process,
generally called oxyfuel cutting, is used to cut metals.

4.2 : Arc welding

These processes use a welding power supply to create and maintain an electric arc between an
electrode and the base material to melt metals at the welding point. They can use either direct
current (DC) or alternating current (AC), and consumable or non-consumable electrodes. The welding
region is sometimes protected by some type of inert or semi-inert gas, known as a shielding gas, and
filler material is sometimes used as well.
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The process is versatile and can be performed with relatively inexpensive equipment, making it well
suited to shop jobs and field work. An operator can become reasonably proficient with a modest
amount of training and can achieve mastery with experience. Weld times are rather slow, since the
consumable electrodes must be frequently replaced and because slag, the residue from the flux, must
be chipped away after welding. Furthermore, the process is generally limited to welding ferrous
materials, though special electrodes have made possible the welding of cast iron, stainless steel,
aluminum, and other metals.
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 5.0 : ASSEMBLY

The assembly operation is the second basic type of manufacturing, where components are joined
together using permanent or semipermanent methods.

• Permanent methods of joining components together are used in applications where the
components are required to remain together and not easily disconnected. These permanent
methods can be a single or combination of methods such as adhesive bonding, brazing,
soldering, and welding.
• Semipermanent methods of joining components together are performed using a combination of
mechanical operations and components such as screws, bolts, and other threaded fasteners.
These traditional mechanical assemblies allow for easier disconnection of the assembly if
needed.

The five types of manufacturing processes are:

1. Repetitive manufacturing: Involves dedicated assembly lines that produce the same product
24/7. This process requires minimal setup and has minimal change-over.
2. Discrete manufacturing: This process utilizes dedicated assembly lines; however, it
involves a variety of setups and changeover frequencies and usually applies to products
that vary in design.
3. Job shop manufacturing: This process utilizes production areas instead of assembly lines
to produce smaller batches of custom made-to-order or made-to-stock products.
4. Process manufacturing (continuous): This process is used to produce raw materials such as
gases, liquids, powders, and slurries.
5. Process manufacturing (batch): This process produces batches of product based on
customer demand.
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 6.0 : 8 WASTES AND 5’S OF
MANUFACTURING IN INDUSTRY

Fig.6.1 8 Wastes Of Manufacturing

6.1 THE 8 TYPES OF WASTE IN INDUSTRY

• Transport

• Inventory

• Motion

• Waiting

• Over Production

• Over processing

• Defects

• Skill not used

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1.1 Transport :-

The transport waste is defined as any material movement that doesn’t directly support
immediate production. An improper facility layout, poor production planning, poor
scheduling can generate transport waste. Another example is poor workplaceorganization,
which results, in unnecessary additional material transport.

6.1.2 Inventory :-

The inventory waste refers to any supply in excess of process requirements necessary to
produce goods or services in a Just-in-Time manner. Causes of inventory waste include
inaccurate forecasting systems, inefficient processes or suppliers, long changeover times,
unbalanced production processes, or poor inventory management and tracking.

6.1.3 Motion :-

The motion waste is defined as any movement of people that doesn’t contribute added value
to the product. Examples include moving equipment, reaching or bending, or gathering tools
more than necessary, as well as unnecessarily complicated procedures. The Motion waste is
often caused by ineffective plant layouts, lack of visual controls, poor process documentation,
or poor workplace organization.

6.1.4 Waiting

The waiting waste refers to as any idle time that occurs when codependent events aren’t
fully synchronized. Examples of this waste include idle operators waiting for equipment,
production bottlenecks, production waiting for operators, and unplanned equipment
downtime. Waiting can be caused by inconsistent work methods, lack of proper equipment or
materials, long setup times, low man/machine effectiveness, poor equipment maintenance,
or skills monopolies.

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6.1.5 Over Production:-

Overproduction is defined as producing more than is needed, faster than needed, or before it’s
needed. This form of waste is most commonly seen in a "push system" supply chain.
Automation in the wrong places, lack of communication, local optimization, low uptimes,
poor planning, and a just-in-case reward system can cause overproduction waste.

6.1.6 Over Processing

Over-processing refers to any redundant effort in production or communication that does

not add value to a product or service. Over-processing waste includes endless product or
process refinement, excessive information, process bottlenecks, redundant reviews and
approvals, and unclear customer specifications. It is caused by decision-making at
inappropriate levels, inefficient policies and procedures, lack of customer input concerning
requirements, poor configuration control, and spurious quality standards.

6.1.7 Defects

The defect waste is defined as the loss of value do to the scrap, repair, or rework of a product
that deviates from specifications. Excessive variation in production processes, high inventory
levels, inadequate tools or equipment, incompatible processes, insufficient training, or
transport damage due to poor layouts and unnecessary handling can all lead to quality defect
waste.

6.1.8 Skill Not Uses

The waste of unutilized talent refers to underutilizing or engaging employees in a process.

This could take the form of employees performing unnecessary work when their talent could
be utilized in activities that add greater value, or not utilizing employees’ critical thinking
abilities and feedback in processes. Unutilized talent also includes allowing employees to
work in silos, which prevents them from sharing their knowledge.

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6.2 INTRODUCTION TO 5’S OF MANUFACTURING
5’S is a five step methodology for creating a more organized and productive workspace:Sort,
Straighten, Shine, Standardize, and Sustain. 5’S serves as a foundationfor deploying more
advanced lean production tools and processes.

S is often summarized by the philosophy “a place for everything and everything in its place.”

You may have heard of “KonMari,” a home organization system propagated by Marie Kondo.
The KonMari method transforms cluttered homes into tidy and simplified living spaces. The
5’S principles are similar to KonMari. However, saying that 5’S is just about tidying is like
saying yoga is just about stretching. In other words, there is much moredepth. So, let’s
explore the true intent and meaning of 5’S.

Fig. 6.2 5’S of Manufacturing

5’S originated as 5 Japanese words: Seiri, Seiton, Seisou, Seiketsu, and Shitsuke.
In English these have come to be known as:

• Sort: Eliminate that which is not needed.

• Straighten: Organize what remains after sorting.
• Shine: Clean and inspect the work area.

• Standardize: Write standards for 5’S.

• Sustain: Consistently apply the 5’S standards.

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At their core, 5’S activities build the discipline needed for substantial and continuous
improvement by creating (and sustaining) efficient and effective work areas.

6.3 LIST OF 5’S OF MANUFACTURING

6.3.1 Sort

The Sort step separates items in your workspace that you know you need from those that
you do not need or may not need by moving the latter to a “red tag” holding area.

Need of Sort

Sort enables you to have a more productive workspace by removing unneeded clutter (and
eliminating distractions). It also is a first step towards opening up space that can be used for
other things.

Example of Sort:-

• Remove waste (or muda) from your workspace.

• Discard broken or old parts using 5’S red tags.

• Responsibly recycle materials and papers.

• Separate everyday tools from special-case tools.

• Avoid overfilling your workspace with excess materials.

• Create an overflow area outside of workspace for duplicate materials, tools, and

parts.

6.3.2 Straighten

The Straighten step thoroughly organizes the items that remain after sorting, such that
frequently used items are easy to access and every item has a clear and easyto-find home.
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Need of Straighten

Straighten enables every item to have a specific home where it can be easily found and to
which it can be easily returned. It reduces the waste from excess motion as items are placed
in more ergonomic locations. It is also the second step towards opening up space that can
be used for other things.

Some Examples of Straighten

• Give every item a distinct “home.”

• Use color as a way of organizing and creating meaning.
• Separate everyday tools from special-case tools.
• Dedicate a surface or area entirely to shadow boxes and tool storage.
• Dedicate another surface or area entirely to working.

6.3.3 Shine

The Shine step elevates the work area by thoroughly cleaning and inspecting tools,
equipment, and other items. It also can include routine maintenance on equipment, which
is one of the ways it flows directly into TPM.

Need of Shine
Shine creates a work environment that engages and empowers operators by giving them more
responsibility and agency over their work area. It also helps them to identify problems before
they interfere with production. For example, in a clean work environment, it is much easier
to spot emerging issues such as fluid leaks, material spills, metal shavings from unexpected
wear, hairline cracks in mechanisms, etc.

Some Examples of Shine

• Wipe down equipment.

• Examine the wear of your tools.
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 • Disassemble larger objects to inspect the state of their parts.
• Investigate a recurring unclean spot or mess.
• Make sure to follow proper cleaning procedures to prevent damage to equipment.

6.3.4 Standardize

The Standardize step is a bridge between the first three steps (Sort, Straighten, Shine) and the
last step (Sustain). In this step your goal is to capture best practices for 5’S as standardized
work for your team.

Need of Standardize

Standardize makes 5’S repeatable. It transforms 5’S from a one-off project to a reproducible
set of activities.

Some Examples of Standardize

• Write down your 5’S practices.

• Create “implementation” checklists and “audit” checklists.
• Create “kits” that contain the materials needed to perform a specific task.
• Use photos and other simple visuals as part of your training materials.
• Build a schedule for tasks.

6.3.5 Sustain

The Sustain step assures that 5’S is applied on an ongoing basis. It transforms your
standardized 5’S processes into regularly completed tasks.

Need of Sustain

Iterative 5’S processes lock in your gains and ensure further and continued progress.
How Do You Implement Sustain?
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Once you’ve standardized, it’s time to continually act upon those standards. We
recommend you

Some Examples of Sustain

• Hold a demonstration meeting to explain complex or multi-step processes.

• Perform periodic check-ins after initial training.
• Teach employees to run 5’S audits.
• Respond to mistake

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7.0 : Photos

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 8.0 : Conclusion

Though the industrial training lasted just for 2 weeks only, I learned quite a lot in these few
months. I had the privilege to participate as an assistant in a sizeable number of maintenance
work, production work, quality department works, job change, learning new things, attending
seminar hall industry fair, and many more things. The material fabrication industry is one of
its kind of industry with a lot of potential, I am grateful that I got the opportunity to do the
internship in such a wonderful company.

I suggested my solutions for the various problems I found, and the guides appreciated my
work and enthusiasm and that made it the best experience ever.

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 9.0 References

[Link]
[Link]

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