Mechanical Engineering Practices in Industry A Beginner s Guide 1st Edition by Dhruba J Syam ISBN 9781032516103 1032516100

1. Prologue

2. Industrial Organizations: Operational Characteristics

2.5 Inter-Functional Role Appreciation And Managerial Co-Ordination

2.6 Industrial Relation Matters

2.6.1 Personnel Policies

2.6.2 Participative Style of Management

2.6.3 The Employee Participation Process, by and large, may get into practice through the following approaches:

2.6.4 Besides the above mentioned processes, certain other approaches, as mentioned below, circumstances demanding, can also be put into practice*

2.6.5 The Participative Approaches mentioned above may help in achieving effective results by way of:

2.6.6 Extra-Ordinary Performance Recognition and Reward Schemes

2.7 Away- Centres And Subsidiaries

2.8 External Linkages And Relationships

3. Mechanical Engineering and Design Aspects: Familiarization with Fundamental Approach

3.1 Mechanical Engineering And Design Activities

3.1.1 Mechanical Project Design Activities

3.1.2 Mechanical Structural Designs (Using Steel/Alloy Steel, other Metallic Components)*

3.1.3 Mechanical Machine Design/Component Design

3.2 The Fundamental Approach In Mechanical Design

3.3 Mechanical Designs For Drives And Mechani- Cal Power Transfer Devices

1 Drives/Prime-movers

3.4 Mechanical Design Of Machine Tools

3.5 Design Of Tools, Jigs And Fixtures To Be Used On/With Machine Tools

3.6 Mechanical Design Of Furnaces/Ovens

3.7 Mechanical Design Of Boilers (For Steam Generation)

3.8 Design Of Heat Exchangers And Pressure Vessels

3.9 Design Of Mechanical Services For Ventilation, Air Conditioning Systems

3.10 Mechanical Design Of Hydraulic And Pneumatic Systems

3.11 Mechanical Design Of Material Handling Systems

3.11.1 Mobile Cranes/ Gantry Cranes/ Tower Cranes

3.11.2 EOT Cranes, Self-Standing Jib Cranes, Stacker cranes, Wall-mounted jib/cantilever cranes, suspension type cranes, lifting beams etc.

3.11.3 Intra-Bay and Inter-Bay transfer trolleys

3.11.4 Fork lifter, Frontend Loaders

3.11.5 Conveyor Belt Systems

3.12 Mechanical Design Of Transportation System

3.13 Design Of Foundry Equipment (Used For Man- Ufacture Of Castings And Forgings)

3.14 Mechanical Designs for Power Station Equipment

3.15 Mechanical Design of Prime Movers

4. Mechanical Work-Shop Practices for Manufacturing and Also for Plant Maintenance and Repair Services

4.1. Workshop Practices

4.2.

4.3 Metal Working Processes

4.4 Workshop Practices

4.4.1 The Workshop Practices can be broadly grouped under the following activities:

4.5 Thermal Cutting of Metals

4.6 Machining Processes For Metal Cutting, Metal Forming/Working In Engineering Industries

4.7 Portable Hand Tools And Auxiliary Workshop Devices

4.7.1 Electrically Operated Hand Tools

4.7.2 Pneumatic Hand Tools

4.7.3 Hydraulically Operated Portable Tools and Devices

4.7.4 Engine Driven Portable Tools

4.8 Fitting And Assembly Process; Fits, Tolerances And Limits, Engineering Measurement And Dimensional Metrology, Application Of Relevant Standards

5. Machining Technologies and Machine Shop Practices (Metal Cutting/Stock Removal, Metal Forming/Working, Wood-working)

5.0 Machining Technologies

5.1 Metal Cutting Processes

5.1.1 Commonly Practised Machining Processes in the Manufacturing work-shops (which may include those for Capital Repair jobs/making Replacement Spares) are listed under:

5.1.3 Types of Machining Operations

5.2 Metal Forming Technology and Metal Working Processes

5.2.1 Metal Forming/Metal Working by Pressing, Rolling, Bending etc.

5.2.2 Metal Forming/Metal working by Forging and Extrusion Process

5.3 Wood Working Machines

5.3.1 Usage of Wood in Industry

5.3.2 Wood Working Machines

6. Techno-Organizational Aspects of Production and Manufacturing Management in Engineering Industries

6.0 Production and Manufacturing Aspects

6.1 Role of the Production Technologists/Shop Process Engineers

6.2 Production Planning and Control (PPC) Group

6.3 Shop Planning Group

6.4 Quality Control And Stage-Wise Inspection

6.5 Product-Design and Engineering Support

6.6 Production/Manufacturing Management

6.7 Other Production Support Services That Mechanical Engineers Should Get Familiarized With For Enriching Their Competence As Up-Coming Business Administrators

6.7.1 Industrial Engineering (IE), Productivity Services (PS) Functions

6.7.2

6.7.3 The IE department normally deals with traditional IE-functions like

6.7.4 Productivity: A Comprehensive Concept That Helps in Attaining Operational Excellence

6.7.5 Plant Maintenance and Services (PMS) Functions

6.7.6 Industrial Safety

6.7.8 Tool Room Practices

7. Fits, Limits, Tolerances, Engineering Measurements/Dimensional Metrology

7.1 Fits, Limits, Tolerances

7.1.1 Application of Concepts of Fits, Tolerances and Limits

7.1.2 Engineering Measurements and Dimensional Metrology

7.1.3 Terminologies Relevant to ‘Fits and Tolerances’ ‘Engineering Measurements’ ‘Dimensional Metrology

7.2 Fitting And Assembly Processes In Manufacturing Shops

7.3 Works-Testing Of Products

7.4 Surface Treatment And Packing

7.5 Inspection Methodology For Mechanical Components

8. Selection of Machine Tools

8.1 Selection Of Machine Tools

8.1.1 For Selecting Machine Tools for Manufacturing Activities in the Existing Shops

8.2 For Selecting Of Machine Tools For Fresh Procurement (Purchase From The Market)

8.3 Use Of Nc/Cnc Machine Tools

8.3.1 Historical Background of Development of Numerical Control (NC) Machines

8.3.2 Application of NC Machine Tools

8.3.3 CNC (Computer Mumerical Control) Machines

8.4 Selection Critetia For Cutting Tool For Metal Cutting Machines

8.5 Erection and Commissioning of Machine-Tools

9. Facility Planning for Industrial Enterprises

9.1 Facility Planning For Industrial Enterprises

9.1.1 The First Category comprises of Capital/Fixed Assets type facilities

9.1.2 The Second Category of Facilities

9.1.3 The Capital Facilities

9.1.4 Facility Planning

9.1.5

9.1.6 The Facility Planning Activity

9.1.7 Modernization of Manufacturing Facilities through Reconditioning and Retrofitting

9.1.8 The Facility Planning Task Group

9.2 Facility Engineering Activities In Industrial Units

9.3 Technology Development Efforts In Industrial Operations

10. Mechanical Supporting Equipment and Services Systems in Engineering Industries

10.1 Mechanical Supporting Equipment And Services System For Engineering Industries

10.1.1 Pumps

10.1.2 Compressors

10.1.3 Power Presses

10.1.4 Hammers (Pneumatic)

10.1.5 Furnaces and Ovens

10.1.6 Boilers

10.1.7 Material Handling Equipment

10.1.8 Transportation Equipment:

10.1.9 Earth Moving Equipment

10.1.10 Mechanized Ventilation Systems

10.1.11 Fans and Blowers

10.1.12 Air Conditioning Systems

10.1.13 Refrigeration

10.1.14 Humidity Control

10.1.15 Piping Systems

10.1.16 Incinerators (For Waste Disposal)

10.1.17 Hydraulic-Powered Operating Systems

10.1.18 Pneumatic Systems

10.1.19 Oxygen Gas (O2Generating Plant)

10.1.20 Acetylene Gas Generating Plant

10.1.21 Producer Gas Plant

10.1.22 Other Mechanical Working Systems

10.1.23 Energy and Power Supply System for Industrial

10.1.24 Industrial X-Ray and Gamma Ray Equipment

10.1.25 Material (Metal and Non-Metal) Strength Testing Equipment

10.2 Prime-Movers: The Moving-Force Devices That Drive Industrial And Transport Operations

11. Engineering Materials, Engineering Drawings

11.1 Engineering Materials

11.1.1 Metals and their Composition

11.2 Engineering Drawing Practices

12 Power/Energy Supply for Industrial Units

12.0

12.1 Heat Energy

12.2 Electrical Energy

12.3

12.4 Electrical Power Supply System For Industrial Units

13. Selected Miscellaneous Topics

13.1 Systems and Methods Instructions and Procedures

13.2 Practicing Excellence In Factory Management: Adopting The 5S Working Culture

13.3 Jishu Hozen’ (Autonomous Maintenance): A Tactical Concept of Plant Maintenance

13.4 Legal Framework System for Business and Industry: A Brief on Legal References/Relevant Laws/Acts: Commonly Applicable And Known To Trade, Commerce, Business And Industry (An Awareness Brief)

14. Application of Standards in Business and Industry

14.1 Application Of Standards

14.2 Standardization and Regulating Bodies

14.3 Environmental Management System (Ems) Standards

15. Trouble Shooting for Mechanical Working Systems in Industrial Units

15.0 15.0 Mechanical Working Systems Commonly Deployed in Industrial Units

15.1 MECHANICAL STRUCTURES IN INDUSTRIAL UNITS (excluding building structures which fall in the domain of Civil Engineering activities ).

15.1.1 Static Structures

15.1.2 Moving, Sliding, Rotating Structures

15.2 Mechanical Plants and Machinery (Commonly Deployed in Manufacturing Industries)

15.2.1 Machine Tools

15.2.2 Pumps

15.2.3 Air/Gas Compressors

15.2.4 Power Presses

15.2.5 Pneumatic Hammers

15.3 Furnaces And Ovens

15.3.1 Furnaces

15.3.2 Ovens

15.4 Boilers

15.4.1 Unfired Boilers

15.4.2 Fired Boilers

15.5 Heat Exchangers

15.6 Industrial Fans and Blowers

15.7 Mechanized Ventilation System

15.8 Air Conditioning Systems

15.8.1 Air Conditioning In Low-Temperature Zones

15.8.2 Summer Air Conditioning (Cooling)

15.9 Refrigeration Plant

15.10 Humidity Control

15.11 Pipe Lines Of Mechanical Services

15.12 Hydraulic And Pneumatic Operating Systems

15.13 Material Handling Equipment

15.14 Material Transportation Equipment

15.15 Welding Machines And Welding Technology

15.15.1 In case of Gas Welding Machines

15.15.2 In case of Electrical Resistance Welding Machines

15.15.3 In case of Electric Arc Welding Machines

15.16 Industrial X-Ray Equipment

15.17 Industrial Gamma-Ray Equipment

15.18 Material Testing Equipment

15.18.1 Gauges, Calipers, Micro Meters, Dial Gauges, Torque wrenches, RPM Counters;

15.19 Earth Moving Equipment

15.20 Diesel Engines

15.21 Oxygen Gas Plant

15.22 Acetylene Gas Plant

15.23 Producer Gas (Coal Gas) Plant

15.24 Trouble Shooting On Portable Hand Tools And Work-Shop Devices

Annexure 1 Quantities and Units

Definition of Base Units (Considerably Simplified in Part)

Selected Derived Units and Terms

Annexure 2 Energy Terms and Definitions

Annexure 3 National Laboratories and Institutes (A selected listing)

Annexure 4 Some Important Industrial/Business Directories

Annexure RB List of Books for Supplementary Reading